Mercury™3000Si Dual Axis Averager
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Manual No. IM-M3000SiDAA Rev S4
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icroE Systems was founded to
advance encoder technology to a level
never before achieved. Our objective was to
design encoder systems that would be small
enough to fit into densely packed OEM
equipment designs, affordable enough for
cost-sensitive applications and easy enough
to enable installation, setup and alignment
by assemblers with little training. We are
pleased to say that all of these goals have
been realized with
the introduction of
the Mercury family
of encoders
M
Sensor shown
actual size
M10
Page 1
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Follow standard ESD precautions. Turn power off before connecting the sensor.
Do not touch the electrical pins without static protection such as a grounded wrist strap.
Do not touch the glass scale unless you are wearing talc-free gloves or finger cots.
Please read this installation manual for full instructions.
MicroE Systems Mercury series reflective encoders are classified as CDRH Class I and IEC Class 1M laser products.
• Invisible laser radiation (wavelength: 850 nm). Max power 1.5 mW CW.
• This product conforms to all applicable standards under 21 CFR Ch. I 1040.10.
• CDRH Class I level of laser radiation is not considered to be hazardous.
• CAUTION - The use of optical instruments with this product will increase eye hazard.
•
DO NOT VIEW DIRECTLY WITH OPTICAL INSTRUMENTS
(MICROSCOPES, EYE LOUPES OR MAGNIFIERS)
• CLASS 1M LASER PRODUCT
• IEC 60825-1 (2001)
Safety Information
1
2
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Covered by the following patents: US 5,991,249; EP 895,239; JP 3,025,237; US 6,897,435; and EP 1,451,933.
Additional patents and patents pending may apply.
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SYSTEM ILLUSTRATION PAGE
Encoder with Linear scale 2
Encoder with Rotary scale 3
INSTALLATION INSTRUCTIONS
Encoder System Mounting - Linear 4
Encoder System Alignment - Linear 5
Centering the Index & Calibration - Linear 5
Encoder System Mounting - Rotary 6
Encoder System Alignment - Rotary 7
Centering the Index & Calibration - Rotary 7
REFERENCE SECTION
Installation of Linear Scales 8
Grounding Instructions 9
Recommendations for Power 9
Customer Interface Cable Requirements 10
Serial Output Specifications 11-12
SMARTPRECISION SOFTWARE INSTALLATION 13-19
SPECIFICATIONS
Operating and Electrical 20
Output Connector Pinout 20
Serial Output 21
Operational Modes: Standard Communication 21
Serial Output Specificattion 22
Operational Modes - Trigger Approach Diagram 23
Serial Data Format 24
ENCODER TROUBLESHOOTING
Selected Topics 24
Cleaning Scales 25
Contact MicroE Systems Back Cover
Mercury 3000Si Encoder System
with Linear scale
Page 2
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Scale benching edge
End locator pin
End index mark
Sensor mounting holes (2)
Bracket mounting
holes (2) per
sensor
Optional sensor benching pins (3)
Double
shielded cables
Center index mark
Typical user-supplied
sensor mounting brackets
Top reflective linear scale
Detail A
25 pin High Density
D-sub connector
Signal - Sensor 1
SSyysstteemm VViieeww
Shown with linear scale
Glass scale
(shown mounted on a linear slide)
Sensors
(shown attached on a linear slide base with
mounting brackets)
Dual Axis/SmartPrecision electronics module
(interpolator)
Scale reference datum;
example shown with benching pins
Cover: Sensor cables
and connectors
Power/Calibration - Sensor 1
Index Calibration Button - Sensor 1 and 2
Signal - Sensor 2
Power/Calibration Sensor 2
USB interface
Mounting screws & flat
washers (2 needed per
screw)
Sensor 1
Sensor 2
Mercury 3000Si Encoder System
with Rotary scale
Page 3
Double
shielded cable
SSyysstteemm VViieeww
Shown with Rotary scale
Sensors
(shown attached to a customer-supplied
mounting brackets)
Rotary scale
Dual Axis/SmartPrecision electronics module
(interpolator)
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Rotary scale
Mounting hole (2)
Top reflective
rotary scale
Typical user-supplied
sensor mounting bracket
Mounting screws & flat
washers (2 needed per screw)
25 pin High Density
D-sub connector
Signal - Sensor 1
Power/Calibration - Sensor 1
Index Calibration Button - Sensor 1 and 2
Signal - Sensor 2
PowerPower/Calibration Sensor 2
USB interface
Sensor 1
Sensor 2
Installation Instructions
Linear Encoders - Mounting
Page 4
1
2
Install the sensors on your mounting surfaces
referencing the appropriate datum surface as
shown on the interface drawing. Use 2 washers
per mounting screw.
Benching pins may be used to locate each sensor
if the system mechanical tolerances are adequate.
See data sheet for alignment tolerances, or keep
mounting screws loose for sensor alignment if
benching pins are not used.
Attach the scale to the base
slide. Reference the preferred
datum on the interface drawing
for either end or center index
orientation.
Depending on the mounting
method, attach the scale to the
slide with adhesive. Refer to pg.
8 for details.
Be sure the grating surface of
the scale faces the sensor.
Insure that there is no contact
between these surfaces or
damage may result.
Be sure the source power is off before
connecting the SmartPrecision plug.
Connect the SmartPrecision electronics to the
controller using the pinout diagram described on the
interface drawing.
Insure proper system grounding. Refer to the procedure on pg 9.
Tighten the thumb screws.
Power up the system. The Power and Signal indicators for both sensors will illuminate.
4
3
CAUTION: observe precautions for handling electrostatic sensitive devices.
Route the sensor cables through your equipment
to the Dual Axis SmartPrecision electronics module.
A) Remove the three cover screws and the top
half of the connector housing. Do not pull on
the 25-pin D-sub connector or the circuit
board under the insulation layer.
B) Attach each sensor's 5 X 2 connector to the
mating 5 X 2 connector on the circuit board.
C) Route the sensor cables through their channels
in the center of the connector body and place
the cable's hex sleeves in the matching recesses.
Attach the top half of the connector housing
to the bottom half using the three cover screws.
Sensor 2
Sensor 1
Installation Instructions
Linear Encoders - Alignment
Page 5
5
If benching dimensions cannot be provided, proper sensor alignment may require minor
adjustments to each sensor’s position with respect to the scale. This can be performed easily
using the LED alignment indicators, as illustrated below.
For sensor 1, the Sig 1 multicolor LED will turn from red to yellow-orange to green depending
on sensor alignment. Slowly move the sensor by allowing it to slide on the mounting surface
until the Sig 1 multicolor LED turns green. Optimal alignment will be displayed as a “Bright
Green” LED. Repeat the last step, using sensor 2 and the Sig 2 multicolor LED, to align
sensor 2.
IIMMPPOORRTTAANNTT
: Confirm that the Proper Alignment LED blinks when passing over the index.
If not, readjust the sensor in the Y direction and repeat the above procedure. When alignment is
completed, tighten the sensor mounting screws (0.37Nm [3.3 inch-lbs.] maximum torque).
6
Confirm proper alignment over
the full range of motion.
The “Proper Alignment” LED
must remain green over the
entire range for both sensors.
If not aligned over the entire
range of motion, loosen the
sensors mounting screws and
repeat step 5.
x
Y
Z
θ
z
To align the sensor, move it
in the Y or θz directions.
IIMMPPOORRTTAANNTT
OOUUTTPPUUTT CCAALLIIBBRRAATTIIOONN PPRROOCCEEDDUURREE
This procedure must be completed for proper system
operation each time the sensors are aligned or if the
SmartPrecision electronics module is replaced
Position each sensor at least 7mm (1/4”) away from the index
mark on the scale. Next, for sensor 1, push the
Index/Calibration button inside the module just once. The
Power/Calibration indicator for sensor 1, will flash continuously.
Move the scale past sensor 1 in both directions so that the
index mark passes under sensor 1. When the calibration procedure is complete, the Power/Calibration indicator for sensor 1
stops flashing.
To calibrate sensor 2, push the Index/Calibration button twice. The
Power/Calibration indicator for sensor 2 will flash continuously.
Move the scale past sensor 2 in both directions so that the
index mark passes under sensor 2. When the calibration procedure is complete, the Power/Calibration indicator for sensor 2
stops flashing.
7
Improper
Alignment LED
Red:
Sensor 1
Power/
Calibration
Sensor 1
Improper
Alignment LED
Red:
Sensor 2
Power/
Calibration
Sensor 2
Improved
Alignment LED
Yellow-Orange:
Sensor 1
Power/
Calibration
Sensor 1
Improved
Alignment LED
Yellow-Orange:
Sensor 2
Power/
Calibration
Sensor 2
Proper
Alignment LED
Green:
Sensor 1
Power/
Calibration
Sensor 1
Proper
Alignment LED
Green:
Sensor 2
Power/
Calibration
Sensor 2
Sensor 1: Proper
Alignment indicator
Sensor 1:
Calibration / Index
Set Up button
Push once.
Sensor 2: Power/
Calibration indicator
Sensor 2:
Calibration / Index
Set Up button
Push twice.
Sensor 2: Proper
Alignment indicator
Sensor 1: Power/
Calibration indicator
Installation Instructions
Rotary Encoders - Mounting
Page 6
Attach your hub/scale
assembly to the rotary
device. Refer to the
interface drawing. The
reflective surface of the
scale must face the
sensors.
1
2
Install the sensors on your mounting surface referencing the
appropriate datum surface as shown on the interface drawing.
Use 2 washers per mounting screw.
Benching pins may be used to locate each sensor if the system
mechanical tolerances are adequate. See data sheet for alignment
tolerances, or keep mounting screws loose for sensor alignment if
benching pins are not used.
Be sure the source power is off before
connecting the SmartPrecision plug.
Connect the SmartPrecision electronics to the controller
using the pinout diagram described on the interface
drawing.
Insure proper system grounding. Refer to the procedure
on pg 9.
Power up the system. The Power and Signal indicators for
both sensors will illuminate.
4
3
CAUTION: observe precautions for handling electrostatic sensitive devices.
Route the sensor cables through your equipment
to the Dual Axis SmartPrecision electronics module.
A) Remove the three cover screws and the top
half of the connector housing. Do not pull on
the 25-pin D-sub connector or the circuit
board under the insulation layer.
B) Attach each sensor's 5 X 2 connector to the
mating 5 X 2 connector on the circuit board.
C) Route the sensor cables through their channels
in the center of the connector body and place
the cable's hex sleeves in the matching recesses.
Attach the top half of the connector housing
to the bottom half using the three cover screws.
Sensor 2
Sensor 1
Installation Instructions
Rotary Encoders - Alignment
Page 7
5
If benching dimensions cannot be provided, proper sensor alignment may require minor
adjustments to each sensor’s position with respect to the scale. This can be performed easily
using the LED alignment indicators, as illustrated below.
For sensor 1, the Sig 1 multicolor LED will turn from red to yellow-orange to green depending
on sensor alignment. Slowly move the sensor by allowing it to slide on the mounting surface
until the Sig 1 multicolor LED turns green. Optimal alignment will be displayed as a “Bright
Green” LED. Repeat the last step, using sensor 2 and the Sig 2 multicolor LED, to align
sensor 2.
IIMMPPOORRTTAANNTT
: Confirm that the Proper Alignment LED blinks when passing over the index.
If not, readjust the sensor in the Y direction and repeat the above procedure. When alignment is
completed, tighten the sensor mounting screws (0.37Nm [3.3 inch-lbs.] maximum torque).
6
Confirm proper alignment over the full range of motion.
The “Proper Alignment” LED must remain green over the entire
range for both sensors. If not aligned over the entire range of
motion, loosen the sensors mounting screws and repeat step 5.
x
Y
Z
θ
z
To align the sensor, move it
in the Y or θz directions.
IIMMPPOORRTTAANNTT
OOUUTTPPUUTT CCAALLIIBBRRAATTIIOONN PPRROOCCEEDDUURREE
This procedure must be completed for proper system
operation each time the sensors are aligned or if the
SmartPrecision electronics module is replaced
Position each sensor at least 7mm (1/4”) away from the index
mark on the scale. Next, for sensor 1, push the
Index/Calibration button inside the module just once. The
Power/Calibration indicator for sensor 1, will flash continuously.
Move the scale past sensor 1 in both directions so that the
index mark passes under sensor 1. When the calibration procedure is complete, the Power/Calibration indicator for sensor 1
stops flashing.
To calibrate sensor 2, push the Index/Calibration button twice. The
Power/Calibration indicator for sensor 2 will flash continuously.
Move the scale past sensor 2 in both directions so that the
index mark passes under sensor 2. When the calibration procedure is complete, the Power/Calibration indicator for sensor 2
stops flashing.
7
Sensor 1: Proper
Alignment indicator
Sensor 1:
Calibration / Index
Set Up button
Push once.
Sensor 2: Power/
Calibration indicator
Sensor 2:
Calibration / Index
Set Up button
Push twice.
Sensor 2: Proper
Alignment indicator
Sensor 1: Power/
Calibration indicator
Move the scale past both
sensor s so that the index
mark passes under both
sensors as described in
step 7.
Improper
Alignment LED
Red:
Sensor 1
Power/
Calibration
Sensor 1
Improper
Alignment LED
Red:
Sensor 2
Power/
Calibration
Sensor 2
Improved
Alignment LED
Yellow-Orange:
Sensor 1
Power/
Calibration
Sensor 1
Improved
Alignment LED
Yellow-Orange:
Sensor 2
Power/
Calibration
Sensor 2
Proper
Alignment LED
Green:
Sensor 1
Power/
Calibration
Sensor 1
Proper
Alignment LED
Green:
Sensor 2
Power/
Calibration
Sensor 2
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