MicroE Mercury II 5000 User Manual

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Mercury II™ 5000 Series Encoders

MicroE Systems • 125 Middlesex Turnpike • Bedford, MA 01730 • USA

www.microesystems.com

info@microesystems.com

T. 781-266-5700

F. 781-266-5112

Installation Manual and Reference Guide

Introduction

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

1.0 Introduction ...................................................................................................................................... 2

1.1 Overview ............................................................................................................................. 2

1.2 Precautions ......................................................................................................................... 2

1.3 Laser Safety Information ..................................................................................................... 2

1.4 Patents ................................................................................................................................ 3

1.5 Standards Compliance ........................................................................................................ 3

1.6 Related Documentation ...................................................................................................... 3

1.7 Manual Revisions ................................................................................................................ 3

1.8 Trademarks ......................................................................................................................... 3

2.0 Before Installation ............................................................................................................................ 4

2.1 Power Recommendations ................................................................................................... 4

2.2 Installation Considerations .................................................................................................. 4

2.3 Items Required for Installation ............................................................................................ 4

3.0 System Overview ............................................................................................................................. 5

3.1 System View ....................................................................................................................... 5

3.2 Expanded View ................................................................................................................... 5

3.3 SmartPrecision Alignment Tool ........................................................................................... 6

4.0 Sensor Installation ............................................................................................................................ 7

4.1 Sensor Mounting Orientation and Tolerances .................................................................... 7

4.2 Verify Sensor Mounting Surface Height .............................................................................. 7

4.3 Install Sensor ...................................................................................................................... 7

5.0 Sensor Alignment and Calibration ................................................................................................... 8

5.1 Using the Cal. Pushbutton .................................................................................................. 9

5.1.1 Sensor Alignment ................................................................................................... 9

5.1.2 Sensor Calibration ............................................................................................... 11

5.2 Using the Software ............................................................................................................ 14

5.2.1 Connect the Alignment Tool and Encoder ........................................................... 14

5.2.2 Use the FindMII Program to locate the Encoder .................................................. 15

5.2.3 Sensor Alignment and Calibration ....................................................................... 16

6.0 Appendix ........................................................................................................................................ 19

6.1 Specifications .................................................................................................................... 19

6.2 Resolution and Maximum Speed Tables .......................................................................... 20

6.3 Wiring Diagrams ................................................................................................................ 23

6.4 Customer Interface............................................................................................................ 25

6.5 Serial Interface Specifications ........................................................................................... 27

6.6 Index Speed Considerations ............................................................................................. 32

6.7 RS-422 Compliance .......................................................................................................... 33

6.8 Troubleshooting ................................................................................................................ 34

7.0 Order Guide ................................................................................................................................... 35

8.0 Contacting MicroE .......................................................................................................................... 39

Introduction

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

 MII5500

 MII5700

 MII5800

 MII5800Si

 MII5800Pa

1.0 Introduction

1.1 Overview

The instructions in this manual apply to the following Mercury II 5000 Series Encoders:

Refer to the Mercury II 5000 Series Encoder data sheet for additional details on ordering parts.

1.2 Precautions

1. Follow standard ESD precautions. Turn power to off before connecting the sensor.

2. Do not touch electrical pins without static protection such as a grounded wrist strap.

1.3 Laser Safety Information

This product is sold solely for use as a component (or replacement) in an electronic product; therefore, it is not required to, and does not comply with U.S. FDA 21 CFR 1040.10 and 1040.11 which pertain to complete laser products. The manufacturer of the complete system-level electronic product is responsible for complying with 21 CFR.

MicroE Systems encoders contain an infrared laser diode or diodes. Emitted invisible laser radiation levels have been measured to be within the CDRH Class 1 range, which is not considered hazardous; however, to minimize exposure to the diverging beam, install the encoder

sensor in its operational configuration in close proximity to the encoder scale before applying power.

 Invisible laser radiation; wavelength: 850 nm.  Maximum power of 4.8 mW CW for Mercury II.  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).

 All maintenance procedures such as cleaning must be performed with the MicroE

 Do not insert any reflective surface into the beam path when the encoder is powered.  Do not attempt to service the MicroE encoder.

encoder turned off.

Introduction

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

US 5,991,249

EP 895,239

JP 3,025,237

US 6,897,435

EP 1,451,933

Version

Date

Notes

IM-MII5000 Series Rev. 1

11/21/2014

Initial Release. Combines coverage for entire series of Mercury II 5000 Series Encoders.

RoHS

1.4 Patents

Mercury II 5000 Encoders design is covered by the following patents:

Additional patents and patents pending may apply.

1.5 Standards Compliance

Mercury II models are CE and RoHS compliant.

1.6 Related Documentation

 Mercury II 5000 Series Encoders Data Sheet  Mercury II 5000 Series Encoders Interface Drawings  Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference

Guide

1.7 Manual Revisions

1.8 Trademarks

Mercury II™, PurePrecision™, and SmartPrecision™ are trademarks of MicroE Systems®.

Before Installation

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Items Required for Installation

Item

Tape Scale

Glass Scale

Index and Limit Marker sheets



Hex Wrench for Sensor Mounting Screws



Finger Cots or talc-free gloves



Acetone or isopropyl alcohol



Lint-free cotton cloths or wipes



Two-part epoxy (Tra-Bond 2116 or equivalent)



Stick and disposable surface for stirring epoxy



Shears



Tape Applicator Tool*



Silicone adhesive





2.0 Before Installation

Review the items in this section prior to installing the encoder.

2.1 Power Recommendations

 Mercury II encoders require a minimum of 4.75VDC continuously.  When designing circuits and extension cables to use Mercury II encoders, be sure to

account for voltage loss over distance and tolerances from the nominal supply voltage so that at least 4.75VDC is available to the Mercury II encoder under all operating conditions.

 The input voltage should not exceed 5.25VDC.

2.2 Installation Considerations

The Mercury II encoder is a precision electronic instrument. It has been designed to function in a wide range of applications and environments. To take full advantage of the Mercury II modular system design, considerations should be made to allow easy access to the sensor (and interpolator modules where applicable) for service and/or replacement. For optimal performance and reliability:

 DO follow standard ESD precautions while handling the sensor and interpolator.  DO allow proper clearance for sensor head alignment.  DO follow setup and calibration instructions for the encoder system.  DO, where possible, install the scales in an inverted or vertical position to minimize

accumulation of dust.

 DO NOT store sensors in an uncontrolled environment.  DO NOT electrically overstress the sensor (power supply ripple/noise).  DO NOT intentionally “hot swap” the sensor if the device is energized.  DO NOT use in high contamination applications (dust, oil, excessive humidity, or other

airborne contaminants).

2.3 Items Required for Installation

In addition to the items identified in the Section 3.0 System Overview, you will need the following items available for installation:

Note*: Not required for some installations.

System Overview

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Index Marker

15-Pin Male D-Sub Connector

Double-Shielded Cable

Left Limit Marker

Scale Mounting Surface Reference Edge (Benching Surface)

Tape Scale: shown mounted on a fixed (non-moving) substrate.

Sensor: shown mounted on a linear bearing using a mounting bracket.

Sensor Connector

Mounting Screws

Typical User-Supplied Sensor Mounting Bracket

Sensor Mounting Holes

Sensor Benching Pins

Bracket Mounting Holes

Right Limit Marker

3.0 System Overview

This section identifies parts for the sensor installation.

3.1 System View

3.2 Expanded View

System Overview

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Mercury II 5000 Alignment Tool LEDs

LED

Function

Power/Cal.

Indicates power is on and when encoder is in Alignment Mode

Red Signal Strength

Indicates improper alignment

Yellow Signal Strength

Indicates improved alignment

Green Signal Strength

Indicates proper alignment

Left Limit

Blinks in Alignment Mode and when sensor is located over left limit

Right Limit

Blinks in Alignment Mode and when sensor is located over right limit



15 Pin D-Sub Sensor Connector

Left Limit LED

Cal. Pushbutton

(Recessed)

Ethernet Connector

Alignment Tool

Adapter

Right Limit LED

Power Supply

Connect

3.3 SmartPrecision Alignment Tool

The Mercury II ATMII5000 SmartPrecision Alignment Tool is required for aligning the Mercury II 5000 Series Encoders. The Alignment Tool includes the following:

 Alignment Tool  SmartPrecision II Software  USB Cable  Power Supply

For more details, see Sensor Installation Tools in Appendix 7.0 Order Guide.

Sensor Installation

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Mercury II

Sensor Alignment Tolerances

Axis

Alignment Tolerance

Direction of Motion

± 0.20mm

± 0.15mm

X

± 1.0°

Y

± 1.0°

Z

± 2.0°

Step

Action

Verify that the vertical distance between the reference surface of the sensor and the top of the scale is as follows:

 Tape scale/marker tape after blue protective film is removed: 3.09 mm +/-0.13  Linear or rotary glass scales: 2.93 mm +/-0.13

Note: Use MicroE’s Z-axis Height Gauges to easily verify this distance:

 Blue Gauge - for use with tape scales (Part Number 409-00196)  White Gauge - for use with linear and rotary glass scales (Part Number 409-00197)

Use the correct gauge to check that there are no gaps between:

 The mounting surface of the gauge and the mounting bracket, or  The bottom surface of the gauge and the scale

Check the height at a location on the scale where there are no index or limit markers.

Step

Action

Install the sensor on the mounting surface referencing the appropriate datum surface as shown in the MII5000 Interface Drawings. Use two M-2 screws to loosely attach the sensor. Note: Do not tighten the two M2 screws at this time.

Use benching pins to locate the sensor if the system's mechanical tolerances are adequate. Refer to MII5000 Interface Drawings for recommended locations and heights of pins.

Sensor Axes

Orientation

Tolerances

XY Z

To align the sensor, move it in the Y or ӨZ

directions

4.0 Sensor Installation

This section contains instructions for installing the sensor.

4.1 Sensor Mounting Orientation and Tolerances

Refer to the following specifications when installing and aligning the Mercury II 5000 encoder.

4.2 Verify Sensor Mounting Surface Height

4.3 Install Sensor

Sensor Alignment and Calibration

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Method

Description

Use the Calibration (Cal) Pushbutton: Align and calibrate the sensor head using the Calibration (Cal) pushbutton and the LED indicators on the Alignment Tool.

Continue to Section 5.1 Using the Cal. Pushbutton.

Use the SmartPrecision II Software*: Align and calibrate the sensor head using the Alignment Tool and the SmartPrecision II Software.

Continue to Section 5.2 Using the Software.

Note*: The SmartPrecision II Software is built in to the Alignment Tool AT 5000

for setup and diagnostics; only a web browser is needed (use of software is optional). See the Sensor Installation Tools in Appendix 7.0 Order Guide for details.

Access to Cal.

Pushbutton (Recessed)

Alignment Tool

LED Indicators

SmartPrecision II Main Screen

5.0 Sensor Alignment and Calibration

After installing the MII5000 encoder, use the SmartPrecision Alignment Tool ATMII5000 to align and calibrate the sensor using one of the following methods:

 Calibration (Cal) Pushbutton: if you don’t have access to a computer or are very

experienced at performing encoder alignment and calibration.

 SmartPrecision II Software: if you have access to a computer and either are new at

performing encoder alignment and calibration or want to take advantage of the graphic interface.

Select a method:

Sensor Alignment and Calibration

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Step

Action

Connect the MII5000 encoder to the SmartPrecision Alignment Tool.

Insert the 5VDC power connector to the Alignment Tool Adapter and apply power.

Result: The Power/Cal. LED illuminates a steady green. The sensor is initialized after an approximate 10 second delay.

Enter the Alignment Mode by gently pressing and releasing the Cal. pushbutton quickly (within a second) using a small screwdriver or similar tool.

Result: The two Limit LEDs will begin to blink in unison (slowly). Automatic Gain Control (AGC) is now inactive. The AGC adjusts gain to maintain a steady signal level.

Alignment Tool

5VDC Power

Alignment Tool Adapter Encoder

Sensor Connector

Alignment Tool

Power/Cal. LED

Access to Cal. Pushbutton

(Recessed)

Limit LEDs (two)

Screwdriver

5.1 Using the Cal. Pushbutton

Use the following instructions to perform sensor alignment and calibration by using the Cal. Pushbutton located on the ATMII5000 Alignment Tool.

5.1.1 Sensor Alignment

Note: Make sure that the 5VDC power input is disconnected. Encoder should never be

connected to an already energized alignment tool since equipment can be damaged.

Sensor Alignment and Calibration

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Step

Action

Align the sensor by slowly sliding the sensor on its mounting surface in the Y or Z directions until the green Signal Strength LED is illuminated*:

Note*: Optimal alignment is indicated by Bright Green.

Once the sensor is aligned, tighten the two sensor mounting screws (0.37Nm [3.3 inch-lbs.] maximum torque).

Move the sensor over the index mark and confirm that the green Signal Strength LED blinks.

Result:

 If the green Signal Strength LED blinks when the sensor passes over the index, then

proceed to the next step.

 If the green Signal Strength LED does not blink when the sensor passes over the index,

then loosen the mounting screws and repeat the alignment procedure (go back to Step 3).

Note*: Optimal alignment is indicated by Bright Green and a blink over the index.

Move the sensor over the entire length of the scale.

Result:

 If the green Signal Strength LED remains illuminated over the entire length of travel (the

yellow and red LED’s do not illuminate), then proceed to the next step.

 Otherwise, clean the scale and try Step 3 again. If cleaning the scale is not successful,

loosen the sensor mounting screws and repeat the alignment procedure (go back to Step 3).

Press and release the Cal button quickly to exit Alignment Mode. Result: The limit LED’s will stop blinking and AGC will reactivate.

Green Signal Strength LED (Proper Alignment)*



Sensor Alignment and Calibration

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Grating Type

Limit Polarity

5.1.2 Sensor Calibration

Perform calibration when installing the sensor for first time, or if the sensor is subsequently remounted, or the scale is replaced. This section contains instructions for calibrating the following:

 Linear Scales or Rotary Scales used in applications less than <360°  Rotary Scales used in applications less than >360° without Limit Markers

Confirm Settings

Confirm the following before calibration:

 Always perform calibration of the left and right limits while Limit Polarity is set to Limits

Normal mode. See the Left and Right Limits Settings in the Calibration and Align tab of

the SmartPrecision II Software in Section 5.2.3 Sensor Alignment and Calibration.

 Select correct Reflective or Non-Reflective Grating Type on Status and Setup tab.

Note: Perform all procedures below at ≤1 meter/second relative motion between the sensor and

the scale.

Sensor Alignment and Calibration

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Step

Action

To start calibration, press and hold the Cal. button for about two seconds until the Power/Cal. LED starts blinking slowly.

Move the sensor 50mm to perform Gain/Offset/Phase calibration. Move the sensor back and forth if scale has <50mm of measuring length.

Result: After calibration both limit LEDs come on steady.

Move the sensor to an area of the scale away from the index and limit markers. Press the Cal. button once quickly.

Result: The Power/Cal LED will start blinking quickly.

Move the sensor over the index up to 20 passes (one pass is a single cycle back and forth).

Result: The Left Limit LED will start blinking quickly. Note: If the sensor is positioned over the left limit marker, the Left Limit LED will come on

steady.

Move the sensor over the left limit marker and press the Cal. button once quickly. Result: The Right Limit LED will start blinking. Note: if the sensor is positioned over the right limit marker, the Right Limit LED will come on

steady.

Move the sensor over the right limit marker and press the Cal. button once quickly. Result: All LEDs will flash together twice to indicate that setup is completed.

The encoder is now ready for connection to the controller for use in servo control.

Power/Cal LED

Cal. Pushbutton

(Recessed)

Right Limit LED

Left Limit LED

Linear Scales or Rotary Scales used in applications less than <360°

Note: To skip any portion of this calibration and move to the next procedure, press and hold the

Cal. button for two seconds.

Sensor Alignment and Calibration

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Step

Action

To start calibration, press and hold the Cal. button for about 10 seconds: until the three Signal LEDs blink twice to indicate that rotary calibration has been activated.

Move the sensor 50mm to perform Gain/Offset /Phase calibration. After calibration both limit

LED’s come on steady. Move the sensor back and forth if your scale has a circumference of

<50mm. Result: After calibration both limit LEDs come on steady.

Move the sensor to an area of the scale away from the index marker. Press the Cal. button once quickly. Result: The Power/Cal. LED will start blinking quickly.

Move the sensor over the index up to 20 passes (one pass is a single cycle back and forth). Result: The Power/Cal. LED and both limit LEDs will start to blink in sets of three.

Move the sensor away from the index and press the Cal. button once quickly. Result: The Power/Cal. LED and both limit LED’s will start to blink in sets of two.

Move the sensor over the index once. Result: The LEDs will change to Power/Cal. LED and both limit LEDs blinking just once.

Make a full revolution of the rotary scale in order to go over the index again in the same direction. The two passes over the index must be at least 1000 20µm fringes apart (equivalent of 20mm linear travel), if they are not, the Alignment Tool will wait for another pass that is 1000 fringes from the first.

The encoder is now ready for connection to the controller for use in servo control.

Signal LEDs (3)

Cal. Pushbutton

(Recessed)

Rotary Scales used in applications less than >360° without Limit Markers

Note: To skip any portion of` this calibration and move on to the next procedure, press and hold

the Cal. button for two seconds.

Sensor Alignment and Calibration

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Step

Action

Verify that the Alignment Tool Adapter/SmartPrecision II Alignment Tool is not powered on. The Power/Cal. LED should be off.

Connect the MII5000 encoder, Ethernet cable, and computer as shown below.

Power up the Alignment Tool by plugging in 5VDC to the Alignment Tool Adapter.

Result: The Power/Cal. LED illuminates a steady green. The sensor is initialized after an approximate 10 second delay.

Power/Cal

Alignment Tool

Encoder

Ethernet Cable

Sensor Connector

Computer (Windows or other OS)

5.2 Using the Software

Use the following instructions to perform sensor alignment and calibration using the Alignment Tool and the SmartPrecision II Software.

5.2.1 Connect the Alignment Tool and Encoder

Sensor Alignment and Calibration

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Step

Action

To locate the correct version for your operating system, go to Software Downloads at

http://www.microesys.com/products/documentation or click on one of the following links:

For Windows operating systems:

FindMII.exe

For all other operating systems:

FindMII.jar

Double-click on the appropriate link to launch the FindMII program. Result: The FindMII program locates the encoder and allows you to use the embedded SmartPrecision II Software on your web browser.

Note: You may receive an Application Blocked by Security Settings message when attempting to load the plotApplet. Go to the Java applet in your Control Panel and try reducing the Security Level in the Security Tab (covers up to Java 7, versions beyond 7 may require additional steps). Warning: Reducing the Security Level in the Security Tab may decrease protection of your computer against malicious software.

Once located, the FindMII program displays the MercuryII Encoder Search Utility screen. The screen will list all the encoders connected to the network as seen in the following example.

Encoder found by the program

5.2.2 Use the FindMII Program to locate the Encoder

Once the encoder is connected to the computer using an ethernet cable, run the software program FindMII (Mercury II Encoder Search Utility) version 1.2.2.1 or higher.

Sensor Alignment and Calibration

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Step

Action

Double-click the name of the encoder to open the SmartPrecision II Software.

Results: The SmartPrecision II Software Screen displays.

Step

Action

Click on the Calibrate and Align tab.

Results: The Calibrate and Align screen opens.

Calibrate and Align Tab

Calibration Status

Calibration Type

Calibration Mode

5.2.3 Sensor Alignment and Calibration

Once the SmartPrecision II Software is open, perform sensor alignment and calibration by using the Calibrate and Align tab.

Sensor Alignment and Calibration

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Step

Action

Turn on Align Mode by clicking on the Align Mode Turn On button.

Results: The Turn On button will change to Turn Off. Align Mode Status will change to On (AGC Inactive). On the Alignment Tool, both Left and Right Limit LEDS will begin blinking.

Adjust the sensor position until the maximum signal strength is achieved. See the Signal Level Indicator at the top of the SmartPrecision screen.

Tighten the sensor mounting screws. Check for index indication (using the status display at the top right of the screen).

Results: The Index indication is “not at index” when the sensor is not located at the Index marker, and “index crossed” when the sensor has passed over the Index marker.

Turn off Align Mode by clicking on the Align Mode Turn Off button.

Result: The Turn Off button will change to Turn On. Align Mode Status will change to Off (AGC Active). On the Alignment Tool, both Left and Right Limit LEDS will stop blinking.

Signal Level Indicator

Align Mode Turn On/Off Button

Index Indication

Align Mode Turn On/Off Button

Limits Indication

Sensor Alignment and Calibration

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Step

Action

Perform setup by checking the Calibrate GOP, Calibrate Index, Set Left Limit, and Set Right

Limit boxes.

Note: Not all applications require all steps.

Ensure that the Calibration Type is correctly selected for your encoder (linear/rotary sector is selected above). Press the Start button in Calibration Mode to begin calibration/setup.

Results: Sensor Calibration will begin. Follow the steps in the Calibration Status box to complete setup of the MII5000 encoder. For example, in the status box above, the instructions are to move the sensor until reaching 100% complete and then the next calibration step will start.

If there is a failure, turn off the sensor and clean the scale. After cleaning, return to this section.

Start Button

Check Boxes

Appendix

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

System

Sensor Size

Scales:  PurePrecision Laser Tape scale - available in

continuous lengths up to 30m.

 Linear glass scales for high accuracy.  Rotary glass scales for rotary applications.

H: 11.03mm

W: 13.50mm

L: 38.50mm

Operating and Electrical Specifications

Grating Period

20µm

Agency Standards Conformance: In accordance with Electromagnetic Compatibility Directive 2004/108/EC: EN 55011:2007, EN 61000-4-2, -3, -6

Signal Period

20µm

SPI Interface Clock Speed: 25MHz - 50MHz Max Sample Rate: 227,272 position reads/s - 50MHz clock

System Resolution

5µm - 0.00122µm* in integer interpolation steps (factory set or user programmed using included SmartPrecision II Software.

Power Supply: 5VDC ±5%

*Value rounded for readability. Use the formula 20µm/interpolation multiplier to calculate the exact resolution in units of µm/count. Note: MII5800Pa resolution is fixed at 1.2nm.

@ @

140mA (no outputs terminated) 180mA (A, B, I, and both limits terminated) 172mA (all serial I/O connections terminated)

Accuracy/Linearity

Cyclical Error

Tape Scales: Glass Scales:

± 30nm typical over any 20µm movement ± 20nm typical over any 20µm movement

Temperature Operating: Storage:

0°C to 70°C

-20°C to 85°C

Tape Scale Linearity:

± 5µm/m

Humidity:

10 - 90% RH non-condensing Glass Scale Accuracy

EMI

CE Compliant

High Accuracy Grade:

±1µm for scales up to 130mm ±2µm for scales from130mm to 1m

Shock:

300G 0.5 ms half sine (Sensor)

Vibration:

30G @ 17Hz

Sensor Weight:

3g (Sensor without cable)

Standard Accuracy Grade:

 ±1.5µm for scales up to 130mm  ±5µm for scales from 130mm to

Cable:

Double Shield Maximum length: 10m (contact MicroE Systems for applications >5m) Diameter: 4.2mm Flex Life: 20 x 106 cycles @ 20mm bending radius

Note: Accuracy is the maximum error over the

specified movement when compared to a NIST-traceable laser interferometer standard used at room temperature. 

Rotary Accuracy*

Scale O.D.

Micro

radians

Arc-

Seconds

Reliability Information

5 Year Expected Reliability: >99.8% under normal operating conditions.

44.45mm

± 38

± 7.8

63.50mm

± 19

± 3.9

120.65mm

± 10

± 2.1

Note: *Based on ideal scale mounting concentricity.

Index: Built-in or stick-on; bi-directional, full speed. Note: After power up, the index mark must be passed once at  1 m/s for proper operation.

Limits: Separate built-in or stick-on left and right limits.

Laser-written embedded index and limits available. Contact MicroE.

6.0 Appendix

6.1 Specifications

Note: Refer to the MII5000 Interface Drawings for additional dimensional details and important notes.

Appendix

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Maximum

Interpolation

Resolution

Maximum

Speed*

Applicable

Mercury II 5000 Models

MII5000 Output Signals

6.2 Resolution and Maximum Speed Tables

Resolution and Maximum Speed Tables - Quadrature Output

Mercury II 5000 systems (MII5500/MII5700/MII5800) have programmable interpolation from x4 to x16384 in integer steps. Below are tables of sample values. For applications requiring up to 10m/s at full resolution, use the MII5800Si/Pa with high speed serial interface.

Linear – 20µ Grating Pitch

Note: †Value rounded for readability; use the following formula to calculate the exact resolution

in units of µm/count:

𝑅𝑒𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛 =

20µ

𝐼𝑛𝑡𝑒𝑟𝑝𝑜𝑙𝑎𝑡𝑖𝑜𝑛 𝑀𝑢𝑙𝑡𝑖𝑝𝑙𝑖𝑒𝑟

Appendix

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Rotary Glass Scale Diameter

Fundamental

Resolution

Interpolation

44.45mm

5000 Lines

x20

x40

x400

x1000

x4000

x16384

interpolated resolution (CPR)

20000

100000

200000

2000000

5000000

20000000

81920000

interpolated resolution (arcsec/count)**

64.8

12.96

6.48

0.648

0.259

0.0648

0.01582

interpolated resolution (µrad/count)**

314

62.8

31.4

3.14

1.257

0.314

0.0767 maximum speed* (RPM)

6000

1500

600

150

36.6

63.50mm

8192 Lines

interpolated resolution (CPR)

32768

163840

327680

3276800

8192000

32768000

134217728

interpolated resolution (arcsec/count)**

39.6

7.91

3.96

0.396

0.1582

0.0396

0.00966

interpolated resolution (µrad/count)**

191.7

38.3

19.17

1.917

0.767

0.1917

0.0468 maximum speed* (RPM)

3660

915

366

91.5

22.3

120.65mm

16384 Lines

interpolated resolution (CPR)

65536

327680

655360

6553600

16384000

65536000

268435456

interpolated resolution (arcsec/count)**

19.78

3.96

1.978

0.1978

0.0791

0.01978

0.00483

interpolated resolution (µrad/count)**

95.9

19.17

9.59

0.959

0.383

0.0959

0.0234 maximum speed* (RPM)

1830

457

183.1

45.7

11.17

Applicable Mercury II 5000 Models

5500, 5700, 5800

5700, 5800

5800

Rotary – 20µ Grating Pitch

Note: Interpolation - the range of available values is x4 to x16384 in integer steps; sample values

below.

Note: *Maximum speed produces an encoder quadrature output of 50 million states per second

(12.5MHz). See Page 24 for additional output frequencies. Maximum speeds shown above will be reduced if a lower quadrature output frequency is selected.

Note: **Resolution values shown are approximate. To calculate exact resolution values, convert from

CPR (Counts per Revolution) to the desired units.

Note: To calculate desired rotary interpolation multiplier, use the following equation:

𝐼𝑛𝑡𝑒𝑟𝑝𝑜𝑙𝑎𝑡𝑖𝑜𝑛 𝑀𝑢𝑙𝑡𝑖𝑝𝑙𝑖𝑒𝑟 =

𝐷𝑒𝑠𝑖𝑟𝑒𝑑 𝑅𝑒𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛 (𝐶𝑃𝑅)

𝐹𝑢𝑛𝑑𝑎𝑚𝑒𝑛𝑡𝑎𝑙 𝑆𝑐𝑎𝑙𝑒 𝑅𝑒𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛 (𝐿𝑖𝑛𝑒𝑠)

Note: Specifications assume XOR function which is available in all standard controllers.

Appendix

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Interpolation Multiplier

Interpolation Bits

Resolution

Maximum Speed

x 4

5.000µm/count

10000mm/sec

x 8

2.500µm/count

10000mm/sec

x 16

1.250µm/count

10000mm/sec

x 32

0.6250µm/count

10000mm/sec

x 64

0.3125µm/count

10000mm/sec

x 128

0.15625µm/count

10000mm/sec

x 256

0.078125µm/count

10000mm/sec

x 512

0.0390625µm/count

10000mm/sec

x 1024

19.53125nm/count

10000mm/sec

x 2048

9.765625nm/count

10000mm/sec

x 4096

4.8828125nm/count

10000mm/sec

x 8192

2.44140625nm/count

10000mm/sec

x 16384

1.220703125nm/count

10000mm/sec

Rotary Glass

Scale Diameter

Fundamental Resolution

Interpolation

44.45mm

5000 Lines

x1024

x4096

x16384

interpolated resolution (CPR)

20000

5120000

20480000

81920000

interpolated resolution (arcsec/count)*

64.8

0.253

0.0630

0.01582 interpolated resolution (µrad/count)*

314

1.23

0.306

0.0767

maximum speed (RPM)

6000

63.50mm

8192 Lines

x1024

x4096

x16384

interpolated resolution (CPR)

32768

8388608

33554432

134217728

interpolated resolution (arcsec/count)*

39.6

0.154

0.038

0.00966 interpolated resolution (µrad/count)*

191.7

0.749

0.187

0.0468

maximum speed (RPM)

3660

120.65mm

16384 Lines

x1024

x4096

x16384

interpolated resolution (CPR)

65536

16777216

67108864

268435456

interpolated resolution (arcsec/count)*

19.78

0.0772

0.01978

0.00481 interpolated resolution (µrad/count)*

95.9

0.375

0.0937

0.0234

maximum speed (RPM)

1830

Resolution and Maximum Speed Tables - Serial Output

Mercury II 5800Si/Pa systems have programmable interpolation from x4 to x16384 in binary steps. Below is a table of examples. Unlike A-quad-B encoders, the MII5800Si/Pa resolution does not drop off with speed.

Linear – 20µ Grating Pitch

Rotary – 20µ Grating Pitch

Note: The range of available values is x4 to x16384 in binary steps; sample values below.

Note*: Resolution values shown are approximate. To calculate exact resolution values, convert from

CPR (Counts per Revolution) to the desired units.

Note: To calculate desired rotary interpolation multiplier, use the following equation:

𝐼𝑛𝑡𝑒𝑟𝑝𝑜𝑙𝑎𝑡𝑖𝑜𝑛 𝑀𝑢𝑙𝑡𝑖𝑝𝑙𝑖𝑒𝑟 =

𝐷𝑒𝑠𝑖𝑟𝑒𝑑 𝑅𝑒𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛 (𝐶𝑃𝑅)

𝐹𝑢𝑛𝑑𝑎𝑚𝑒𝑛𝑡𝑎𝑙 𝑆𝑐𝑎𝑙𝑒 𝑅𝑒𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛 (𝐿𝑖𝑛𝑒𝑠)

Appendix

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Output Frequency (MHz)

A-Quad-B Output Rate (millions of states/sec)

Dwell Time

(or edge separation) (µsec)

12.50

50.00

0.02

6.25

25.00

0.04

3.125

12.50

0.08

1.563

6.25

0.16

0.781

3.125

0.32

0.391

1.5625

0.64

0.195

0.78125

1.28

0.098

0.390625

2.56

0.049

0.1953125

5.12

0.024

0.09765625

10.24

𝑂𝑢𝑡𝑝𝑢𝑡 𝐹𝑟𝑒𝑞𝑢𝑒𝑛𝑐𝑦 = 12.5𝑀𝐻𝑧/2^𝑛

where n = number of steps below 12.5MHz

𝑂𝑢𝑡𝑝𝑢𝑡 𝑅𝑎𝑡𝑒 = 50/2^𝑛

where n = number of steps below 50 million states per second

Mercury II 15P D-Sub Pin Outs

Quad Output

Function

Right Limit+

GND

Right Limit-

Index-

B- 6 A- 7 +5V

+5V

GND

Left Limit+

Left Limit-

Index+

B+

A+

No Connect

Maximum Quadrature Output Frequency

Note: Values shown are approximate. Exact values may be calculated using either of the

following equations:

6.3 Wiring Diagrams

15-Pin Standard Male D-sub Connector Configuration

Note: Alarm: A and B are tri-stated if the encoder signal becomes too low for reliable operation. Note: GND and Inner Shield are internally connected.

Appendix

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

5 Volts O Volts

Outer Shield: Connector to sensor and connector housing.

Mercury II

Cable Z0 = 120Ω

120Ω

Consumer Electronics

Recommended Interface Termination

Customer Differential Line Receiver – RS 422: The following diagram shows the recommended signal termination for a-quad-b, serial, index, and limits signals for the Mercury II 5000 Series Encoders. Standard RS-422 Line Receiver Circuitry:

5800Si/Pa

Grounding Considerations

The diagrams below show how to make the connections when the encoder's connector is plugged into the customer's controller chassis. If a customer-supplied extension cable is used, it should be a double-shielded cable with conductive connector shells and must provide complete shielding over the conductors contained within it over its entire length. Furthermore, the shields should be grounded at the connection to the controller chassis the same way as the encoder connectors in the diagrams below.

Note: For best performance, isolate the encoder outer shield from motor cable shields and

separate the encoder cable as far possible from motor cables.

Sensor mounted with good electrical contact to a well-grounded surface (preferred)

The encoder's connector shell must be in close, electrically-conductive contact with the customersupplied mating connector, which must be isolated from the controller's ground. If a customersupplied shielded cable connects the encoder to the controller, then the outer shield on the customer-supplied cable must be isolated from the controller's ground.

The sensor mounting surface must have a low-impedance (DC/AC) connection to ground. The encoder sensor mounting surface may have to be masked during painting or anodizing to ensure good electrical contact with the sensor.

Appendix

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Mercury II 5000

Signal

Twisted Pair

A+

Pair 1

A-

B+

Pair 2

B-

Index+

Pair 3

Index-

Left Limit+

Pair 4

Left Limit-

Right Limit+

Pair 5

Right Limit-

+5V

Pair 6

7, 8

GND

2, 9

5 Volts O Volts

Sensor mounted to poorly-grounded or non-conducting surface

6.4 Customer Interface

Cable Requirements

Customer cables that interface to Mercury II series encoders must have the following characteristics:

 Twisted pair signals wiring.  Characteristic impedance of 100-120 ohms.  Sufficient wire gauge to meet the minimum voltage requirement at the encoder. For

example: 24AWG gauge wire for a 2m length cable. Recommended cables are 24AWG gauge wire with 6 twisted pairs.

 Single shield cable with a minimum of 90% coverage. Note that a double shielded cable

may be required in high-noise applications.

Signal Wiring for A-quad-B

Each differential signal should be connected to a corresponding twisted pair as follows for the 15pin standard male D-sub connector:

Note: The Alarm signal on pin 15 is not differential and is not part of a pair.

Appendix

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Mercury II 5800Si/Pa Signals

Twisted Pair

DB15 Pins

5800Si Signals

5800Pa Signals

Pair 1

SDATA_OUT+

NC*

SDATA_OUT-

Pair 2

SCLOCK_OUT+

SCLOCK_OUT-

Pair 3

SCLOCK_IN+

REQ_SD+

SCLOCK_IN-

REQ_SD-

Pair 4

nCS+

nCS-

Pair 5

+5V

NC 8 +5V

Pair 6

GND

NC 9 GND

7.6 (.30)

Braided Aluminum

Jacket

28.7 (1.13)

Aluminum Polyester Shield not to be exposed in this area. Do not twist.

Signal Wiring for Serial Interface

Each differential signal should be connected to a corresponding twisted pair as follows:

Note: NC - No Connect

Shield Termination

 The customer's cable shield must be in 360° contact with the connector shroud and the

connector shell to provide complete shielding.

 The connector shell should be metal with conductive surfaces. Suggested metal

connector shells for use with Mercury II encoders: AMP 748676-1 or equivalent; where the dash number is dependent on the customer's outside cable diameter.

 Terminate the shield as illustrated in the following diagram.

Polyester

Shield

Note: Fold braided shield back over jacket. Example shows double-shielded cable. Dimensions

shown are for purpose of illustration only.

Appendix

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Name

Direction

Description

Name

Direction

Description

6.5 Serial Interface Specifications

Introduction

The serial interface to the Mercury II 5800Si/Pa allows a serial host (controller) to receive position and status information serially from the sensor. Serial communications between the encoder and controller permit high speed motion system operation with high encoder resolution: up to 10m/s with the 1.2nm. The serial data word consists of the following sequence:

 Position word of four start bits  Four to thirty-five position bits  Nine bits of status  Six-bit Cyclic Redundancy Check (CRC) to provide error detection  Four stop bits

The encoder’s position is sampled by the MII5800Si at the moment the host commands a sample (falling edge of nCS); the only latency in the system is the time required for the host to receive the position word. This architecture minimizes latency and eliminates jitter due to sampling uncertainty.

Serial Interface Input/Output MII5800Si (Serial Interface)

MII5800Pa (Panasonic)

The following are the pins used by the MII5800Pa Panasonic serial interface.

 Pins 2, 7, 8, 9 are the same for both MII5800Si and Panasonic  Pins 10 and 11 are different for Panasonic  All other pins for Pa are not connected (NC)

Appendix

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Parameter

Minimum

Typical

Maximum

Differential Output Voltage

500 mv

Common Mode Output Voltage

500 mv

Termination

Parameter

Minimum

Typical

Maximum

Differential Output Voltage

Common Mode Output Voltage

1.1v

1.6v

Absolute Maximum Single-Ended Voltage

-0.3V

Recommended Common Mode Voltage

1.2v

Recommended Differential Input Voltage

250 mv

Impedance

Signal

Definition

Note

 Clock frequency requirements: 30MHz to 50MHz

 Maximum position sample frequency (falling edge to falling edge): 220 clock cycles  Minimum Pulse Width (high or low): 2 clock cycles

Output Signal Specifications

 SDATA_OUT  SCLOCK_OUT

Input Signal Specifications

 SLOCK_IN  nCS

Signal Definitions

Power-Up Sequence

Power is supplied from the host to the sensor. After power is supplied, the following sequence is performed:

 The sensor waits for the serial clock to be provided by the host on the signal SCLOCK_IN

for 100ms.

 If a clock is not provided, the sensor switches to operate in the final mode (quadrature or

serial).

 Upon detecting a serial clock on SCLOCK_IN, the sensor returns the clock to the host on

SCLOCK_OUT.

 Within the first 500ms after the serial clock is provided by the host, SCLOCK_OUT may

be unstable.

Appendix

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

First Bit ------------------------------------------------------------------------------------------------------------------------ Last Bit

Start Bits

Position Word

Status Bits

CRC Word

Stop Bits

Status Bit

Definition

Index Window

Active when the sensor is over the optical index mark

Right Limit

Active when the sensor is over the right limit marker

Left Limit

Active when the sensor is over the left limit marker

Yellow Alarm

Active during marginal alignment to the main track

Red Alarm

Active during poor or bad alignment to the main track

Saturation Alarm

Active if the main track signal is too large

Communication Error

Active if there is a communication error internal to the encoder

Over-Speed Alarm

Active if the encoder exceeds 10m/s (the speed alarm threshold)*

Reserved bit is always zero

 Once it remains on continuously for at least 500ms, the sensor is ready for data transfers

and SCLOCK_OUT will remain stable.

Data Word Format

Start Bits

The data word will always start with bits one, zero, one, one.

Position Word

The 2’s complement position word has two sections and is user adjustable. The Inter-Fringe bits which determine encoder resolution are adjustable between 14 bits (1.22nrm resolution) and 2 bits (5µm resolution). The Fringe-Counter bits are increments of 20µm which determine the total travel and are adjustable between 21 bits (±21 meters) and 0 bits (±10 microns). The total number of bits (inter-fringe + fringe-counter) must be at least 4 and no more than 35. Position word length is edited via the SmartPrecision II software in the Status and Setup tab. The position word is always transmitted most significant bit (MSB) first.

Status Bits

The encoder status bits are all active high with the exception of the Right and Left Limits. Limit status is user programmable (active high or active low) by using the SmartPrecision II software in the Calibrate and Align tab.

The nine status bits are defined as follows:

Example: ØØØØ_ØØØØ_Ø = normal operation, not at the index mark. Note*: The encoder maximum operational speed is 10 meters/second, regardless of the speed

alarm setting. The alarm is a user configured feature, to be set for specific application requirements, or the bit may be ignored if desired. The speed alarm is dependent on the clock frequency, the sample rate, and the desired speed where the user would like the bit to assert high. The speed alarm register is defaulted to 3604, and may be changed using

Appendix

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

the alignment tool and Smart Precision software. The register must be set using the following formula:

Register value = (8.19E108 x ST x NC)/CF ST = the desired speed alarm threshold in m/s NC = number of clocks between samples CF = clock frequency in Hz

Register value should be rounded to the nearest integer and entered into the settings screen in the SmartPrecision software.

The speed alarm may also be disabled in the SmartPrecision software.

CRC bits

The cyclic redundancy check or CRC includes only the position and status bits. The CRC format is 6-bit polynomial:

X6 + X + 1, MSB first after preloading the CRC register with all 1’s

Stop Bits

The data word will always end with bits one, zero, one, one (1011).

Timing Diagram

Appendix

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Configurable Settings

There are a number of settings that may be configured for serial output operation:

 Index Mode: The encoder can be set to reset the position to 0 every time the index is

crossed (“Index Mode 1”) or to use the position at power up as the 0 position (“Index Mode 0”).

 Number of Fringe Count Bits: Each fringe is 20µm long on the encoder’s scale. The

number of fringe count bits can be set from 0 bits (no fringes) to 21 bits (2,097,152 fringes). Use enough fringe count bits to ensure that the position word is large enough for the expected range of motions. For example, 18 fringe count bits will make the range of position values from -2.62144m to +2.62144m (total travel of 5.24288m). The total travel in meters is calculated as follows: travel = 0.00002m * 2n, where n = the number of interpolation bits.

 Number of Interpolated Bits: The number of bits to calculate the position within a fringe,

and thus the encoder’s resolution. The number of interpolated bits can be set from 2 bits

(x4 interpolation; 5µm resolution) to 14 bits (x16, 384 interpolation; approximately 1.22 nm resolution). Using fewer fringe count and interpolation bits than the maximums can

increase the sample rate to the controller. The encoder’s resolution, in µm, is calculated

as follows: Resolution = 20µm/2n, where n = the number of interpolation bits.

 Low Pass Filter: The digital low pass filter is used to limit the bandwidth of the encoder

system if desired. It is set in terms of % of sample rates and can be set from 0.01% to 40% in 0.01% increments.

Note: Fringe count bits + interpolated bits must be ≥ 4 bits total.

Appendix

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Limit Settings

 Left and Right Limit Settings can be changed by clicking on the associated controls

(Swap, Enable/Disable, and Toggle):

o Limit Polarity: Normal - left limit marker triggers left limit signal; right limit marker

triggers right limit signal. Reversed - left limit marker triggers right limit signal; right limit marker triggers left limit signal.

o Limit Status: The limits may also be enabled or disabled. o Limit State: Active High - status bit = 1 when limits is active; Active Low - status

bit = 0 when limit is active.

See examples in Calibrate and Align screen below.

Performance Specifications

 Resolution: 5µm to approximately 1.22nm  Maximum travel before position counter rollover, with fringe count bits set to 21: 41.94304

meters

 Maximum speed: 10m/s  Maximum cable length: 10m

6.6 Index Speed Considerations

MII5000

Maximum Speed for MII5000 Index after Power-up (MII5800, MII5700 and MII5500 Models): Each time an MII5800, MII5700, or MII5500 encoder is powered up, the first pass over the index

mark must occur at a speed ≤1m/s. Once the index is initially detected, the index will function at all speeds (up to 10m/s) until the next power cycle.

Appendix

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

MII5800Si/Pa

Controller Sample Rate and Maximum Encoder Speed for MII5800Si/Pa Index: The Index Window is part of the MII5800Si’s serial word and does not latch. To detect the index

mark, the controller must issue a sample command while the sensor is over the index mark on the scale. When this happens, the Index Window bit will be high. If the sensor is not over the index mark, the IW bit will be low. Consequently, the sample rate must be at least as fast as the output from the following equation to ensure that a sample command occurs when the sensor is over the index mark:

 Index Window duration (µs) = Index Window width (µm) / encoder speed (m/s)  The Index Window’s width can be in the range from 5µm to 30µm. It is typically 20µm

after calibration. To ensure reliable index sampling, a value of 5µm can be used in the above equation for all systems.

The maximum position sample rate is 4.4µs; there is no minimum sample rate. For example:

 Index Window width = 5µm.  Speed = up to 1.1m/s.  Index Window duration = 4.55µs.  Therefore, the controller’s position sample rate must be 4.55µs or faster to read the Index

Window (at least one position word with the IW bit high).

6.7 RS-422 Compliance

The Mercury II 5000 Series Encoders are RS-422 compatible. Encoder signals are “sending end terminated.” Therefore, customer receiving terminations are not required. For more details, see

the Proper Signal Termination of 422 Data Transmission Signals Tech Note located at

http://www.microesys.com/products/technical-notes-and-white-papers.

Optional RS-422 compliant circuitry for long cable runs in harsh electronic environments is illustrated below:

Appendix

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Problem

Solution

The Power/Calibration indicator will not come on.

 Make sure that the SmartPrecision II Electronics 15-pin D-

sub connector is fully seated and connected.

 Confirm that +5 Volts DC is being applied to pin 7 and 8 on

the SmartPrecision II electronics 15-pin connector and that pins 2 and 9 are connected to ground.

Can't get the SmartPrecision II Electronics "Signal" LEDs better than red or yellow; or the green “Proper

Alignment” indicator doesn't stay

illuminated over the full length of the scale.

 Verify that the sensor is mounted in the correct orientation

with reference to the scale and scale mounting reference edge. Refer to the Interface Drawing.

 Verify that the sensor has been aligned to the scale and

that the mounting screws are tight. Check the dimensions for the mechanical mounting holes (and clamps if any) to make sure that the sensor is correctly located over the scale in the Y and Z dimensions. Refer to the Interface Drawing.

 Check that the scale is firmly mounted and can't jiggle or

move in any direction other than the axis of motion.

 Make sure that the scale is clean over its entire length or

circumference.

The green Power/Calibration indicator LED or limit LEDs are flashing unexpectedly.

 Part of the normal setup procedure is to activate the

SmartPrecision II Electronics Calibration/Setup process by pressing the recessed button in the electronics module.

 The Power/Cal. LED or limit LEDs will begin to flash until

the relevant setup process is complete. See the instructions beginning at Section 5.1.1 Sensor Alignment.

Can't complete the Calibration/Setup process - the green Power/Calibration indicator doesn't stop flashing.

 Verify that the sensor is mounted in the correct orientation

to the scale for the desired index mark. Refer to the Interface Drawing.

 Refer to Section 4.2 Verify Sensor Mounting Surface

Height to ensure proper sensor alignment and index

marker operation.

Signal Plots in Smart Precision II Software not displaying in browser window.

 Reduce the Security Level setting for Java to “Medium” by

going to the Windows Start Menu/Control Panel/Java and selecting the Security tab (covers up to Java 7, versions beyond 7 may require different steps).

 You may receive an Application Blocked by Security

Settings message when attempting to load the plotApplet.

Warning: Reducing the Security Level in the Security Tab may

decrease protection of your computer against malicious software.

6.8 Troubleshooting

Order Guide

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Sensors

MII5800, A-quad-B Output, with Resolution from 5µm to 1.22nm

MII5700, A-quad-B Output, with Resolution from 5µm to 5nm

MII5810-AB-16384-1-1-0

MII5710-AB-4000-1-1-0

Low Pass Filter Roll Off Frequency (kHz) 0=Off (full bandwidth) 1=1khz 2=2khz

100=100kHz

Low Pass Filter Roll Off Frequency (kHz) 0=Off (full bandwidth) 1=1khz 2=2khz

100=100kHz

Limit Logic 1=Active Low (fail safe) 2=Active High

Maximum Output Frequency 1=12.50 MHz 2=6.25 MHz 3=3.125 MHz 4=1.563 MHz 5=0.781 MHz 6=0.391 MHz 7=0.195 MHz 8=0.098 MHz 9=0.049 MHz 10=0.024 MHz

Interpolation (Integer Steps) 4=x4 5=x5

16384=x16384

Interpolation (Integer Steps) 4=x4 5=x5

4000=x4000

AB AB=A-quad-B output

MII58XX (Cable Length) MII5810=1m cable MII5830=3m cable MII5850=5m cable

MII57XX (Cable Length) MII5710=1m cable MII5730=3m cable MII5750=5m cable

Note: All specificationsare subject to change.

7.0 Order Guide

How to Order

Order Guide

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Sensors

MII5500, A-quad-B Output, with Resolution from 5µm to 50nm

MII5800Si, Serial Output, with Output Resolution up to 1.22nm

MII5510-AB-4000-1-1-0

MII5810-Si-14-21-1-0

Low Pass Filter Roll Off Frequency (kHz) 0=Off (full bandwidth) 1=1khz 2=2khz

100=100kHz

Low Pass Filter Roll Off Frequency (% of Sample Rate) 0=Off (full bandwidth) 1=1% of sample rate 2=2% of sample rate

40=40% of sample rate

Limit Logic 1=Active Low (fail safe) 2=Active high

Index Mode 0=No change to position of index 1=Position reset at every index

Maximum Output Frequency 1=12.50 MHz 2=6.25 MHz 3=3.125 MHz 4=1.563 MHz 5=0.781 MHz 6=0.391 MHz 7=0.195 MHz 8=0.098 MHz 9=0.049 MHz 10=0.024 MHz

Number of Fringe Count Bits* 2=2 3=3

21=21 Interpolation Bits*

2=2 3=3

14=14

Interpolation (Integer Steps) 4=x4 5=x5

4000=x4000

Si Si=Serial Interface

AB AB=A-quad-B output

MII58XX (Cable Length) MII5810=1m cable MII5830=3m cable MII5850=5m cable

MII55XX (Cable Length) MII5510=1m cable MII5530=3m cable MII5550=5m cable

Note*: Interpolation bits plus fringe bits must be

≤35 bits.

Note: All specifications are subject to change.

How to Order

Order Guide

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Sensors

Sensor Installation Tools

MII5800Pa, Serial Output, with Output Resolution up to 1.22nm

ATMII5000

*Alignment Tool Kit for MII5000 encoders includes:

- Alignment Tool

- SmartPrecision II Software

- USB Cable

- Power Supply (100V- 240VAC/50-60Hz)

US=Power supply with US standard 2-prong plug EU=Power supply with European standard 2-prong plug

MII5810-Pa-14-10-1-0

-US

-EU

Low Pass Filter Roll Off Frequency (kHz) 0=Off (full bandwidth) 1=1% of sample rate 2=2% of sample rate

ZG-PP2

Z-Height Gauge, PurePrecision Tape Scales

40=40% of sample rate

ZG-GS2

Z-Height Gauge, Glass Scales

Index Mode 0=Default (no option) Note*: Required for MII5000/MII6000 setup.

Number of Fringe Count Bits 2=2 3=3

21=21 Interpolation Bits

2=2 3=3

14=14

Adapter for Open Collector Limit Outputs

MIIA-OCL

Small DB15 adaptor to convert

3.3V left and right limit output signals to open collector type (7407)

End Cap Kit, PurePrecision Tape Scales

Optional Tape Scale End Caps

Pa Pa=Panasonic

MII58XX (Cable Length) MII5810=1m cable MII5830=3m cable MII5850=5m cable

Tape Scale Applicator Tools (use for lengths > 300mm)

TSAT-PPT

Tape Applicator Tool for applying tape scale

Note: Interpolation bits plus fringe bits must be ≤24 bits. Note: All specifications are subject to change.

How to Order

Order Guide

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

Scales

PurePrecision Marker Tape II

MT-N-A-L-9999-I

I = Individual Lengths

C = Continuous reel with index and cut marks (unless otherwise specified) Length in mm (40mm – 9,999mm)

For lengths >10,000mm, contact MicroE for custom part number

L=Center Index and Limits I=Center Index Only C=Custom

A=Adhesive

PurePrecision Laser Tape II

TS-3000

Length in mm (40mm – 30,000 mm)

PurePrecision Linear Glass Scales

(Standard accuracy grade)

MIIL-100

Length in mm (10mm – 1,000 mm)

For high accuracy grade scales, contact MicroE.

Note: Index and limit markers must be ordered separately.

Stick-On Index and Limit Markers

(for Laser Tape II and Performance and Value Linear Glass Scales)

RIMS

Qty of 8 Stick-On Index Markers

RLMS

Qty of 4 Stick-On Left Limit Markers and Qty of 4 Stick-On Right Limit Markers

Note: To use RIMS/RLMS, MII5000 must be configured for Reflective Grating Type.

PurePrecision Rotary Glass Scales

(For example: 44.45mm OD Rotary Glass Scale with Hub: MIIR4513-HI)

MIIRxxxx* - Hub

NH=Without Hub HI=for R4513 HJ=for R6425 HK= for R12151

MIIR4513 MIIR6425 MIIR12151

Note*: Custom Versions are available. Note: Rotary glass scales are shipped not mounted to hub. Hub mounting is available, contact

MicroE Systems for information.

Note: All specifications are subject to change.

How to Order

Contacting MicroE

Mercury II 5000 Series Encoders Installation Manual and Reference Guide

8.0 Contacting MicroE

To learn more about Mercury™ encoders, or other MicroE Systems products, visit:

www.microesystems.com.

To learn more about GSI Group, visit our corporate web site: www.gsig.com. MicroE Systems is a world leader in optical encoder technology with offices in major industrial

centers around the globe. As one of fourteen product brands that comprise GSI Group, we deliver enabling technology that brings advanced applications to life in the motion control, medical, semiconductor, electronics, and industrial markets.

Headquarters MicroE Systems 125 Middlesex Turnpike Bedford, MA 01730 USA Tel: 781-266-5700 Fax: 781-266-5112

www.microesystems.com

Email: info@microesystems.com

IM-MII_PurePrecision_Scales Rev. 1

™

Tape and Glass Scale Installation for Mercury II™ Series Encoders

MicroE Systems • 125 Middlesex Turnpike • Bedford, MA 01730 • USA

www.microesystems.com

info@microesystems.com

T. 781-266-5700

F. 781-266-5112

Installation Manual

and Reference Guide

Introduction

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

1.0 Introduction ...................................................................................................................................... 2

1.1 Overview ............................................................................................................................. 2

1.2 Applicable Encoders ........................................................................................................... 2

1.3 Related Documents............................................................................................................. 2

1.4 Manual Revisions ................................................................................................................ 2

1.5 Patents ................................................................................................................................ 2

1.6 Trademarks ......................................................................................................................... 2

1.7 Standards Compliance ........................................................................................................ 3

1.8 Special Conventions Used .................................................................................................. 3

2.0 PurePrecision Rotary Scales ........................................................................................................... 3

3.0 PurePrecision Laser Tape II Scale Installation ................................................................................ 4

3.1 Before Installation ............................................................................................................... 4

3.1.1 Items Required for Tape Scale Installation ............................................................ 4

3.1.2 Pre-Installation Information and Precautions ......................................................... 4

3.1.3 Flowchart for PurePrecision Tape Scale Installation ............................................. 5

3.1.4 Design Guide ......................................................................................................... 6

3.1.5 Mounting Surface Preparation ............................................................................... 7

3.2 Cut the Tape Scale ............................................................................................................. 8

3.3 Install Tape Scale ................................................................................................................ 9

3.3.1 Install Tape Scale Manually ................................................................................... 9

3.3.2 Install Tape Scale Using the Applicator Tool ....................................................... 14

4.0 PurePrecision Linear Glass Scales Installation ............................................................................. 22

4.1 Before Installation ............................................................................................................. 22

4.1.1 Items Required for Glass Scale Installation ......................................................... 22

4.1.2 Mounting Surface Preparation ............................................................................. 22

4.2 Mount Linear Glass Scales ............................................................................................... 22

4.3 Install Linear Glass Scales ................................................................................................ 23

5.0 Stick-On Index and Limit Markers Installation................................................................................ 24

5.1 Stick-On Marker Strips ...................................................................................................... 24

5.2 Remove Markers from Strip .............................................................................................. 24

5.3 Attach Markers to Scale .................................................................................................... 26

6.0 End Caps Installation ..................................................................................................................... 27

7.0 Final Cleaning, Inspection, and Cure Time .................................................................................... 28

7.1 Reworking to Correct Mistakes ......................................................................................... 28

7.2 Cleaning Scales ................................................................................................................ 28

8.0 Contacting MicroE .......................................................................................................................... 29

Introduction

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

MII5500

MII5700

MII5800

MII5800Si

MII5800Pa

MII6500

MII6700

MII6800

MII6800Si

MII6800Pa

Version

Date

Notes

IM-MII_PurePrecision_Scales Rev. 1

11/21/2014

Combined PurePrecision Tape and Glass Scales into one installation manual and updated procedures.

US 5,991,249

EP 895,239

JP 3,025,237

US 6,897,435

EP 1,451,933

1.0 Introduction

1.1 Overview

The instructions in this manual apply to the following scales for Mercury II Series Encoders:

 PurePrecision Marker Tape II, Model MT  PurePrecision Laser Tape II, Model TS  PurePrecision Linear Glass Scales, Model MIIL  PurePrecision Rotary Glass Scales, Model MIIR  Stick-On Index and Limit Markers, Models RIMS/RLMS

Refer to the encoder data sheet or installation manual for details on ordering parts.

1.2 Applicable Encoders

Use PurePrecision Tape and Glass Scales for the following Mercury II Series Encoders:

1.3 Related Documents

 Mercury II 5000/6000 Series of Encoders Data Sheets  Mercury II 5000/6000 Series of Encoders Installation Manuals and Reference Guides  Mercury II 5000/6000 Series of Encoders Interface Drawings

1.4 Manual Revisions

1.5 Patents

Mercury II encoders and scales are covered by the following patents:

Additional patents and patents pending may apply.

1.6 Trademarks

Mercury II™ and PurePrecision™ are trademarks of MicroE Systems®.

PurePrecision Rotary Scales

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

Symbol

Description

Warning or caution: potential damage to scale.

Instructions show correct method. Instructions show example of incorrect method.

Tech Note

Description

Mercury Encoders: Design Guidelines for Customer-Supplied Hubs

MicroE Systems offers standard hubs for each of our standard rotary scales. Should customers want to design a hub themselves, this document describes the key factors that should be incorporated into the hubs.

Mercury Encoders: Alignment of Rotary Scales

This document describes two different methods of aligning rotary scales: (1) optically centering the grating pattern track using a CCD

camera; and (2) using two sensors to “electrically” center the

grating.

Mercury Encoders: Design Guidelines for Customer-Supplied Rotary Scale Segment Holders

This document provides design guidelines for customers who want to design their own holders for rotary scale segments.

RoHS

1.7 Standards Compliance

Mercury II models are CE and RoHS compliant.

1.8 Special Conventions Used

The following symbols are used throughout this document.

2.0 PurePrecision Rotary Scales

For details on rotary scales, see the following:

 Encoder data sheets  Encoder interface drawings

The following Tech Notes documents also contain information for using rotary scales.

Go to the following MicroE Systems website to locate the listed Tech Notes:

http://www.microesystems.com/products/technical-notes-and-white-papers.

PurePrecision Laser Tape II Scale Installation

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

Item

Notes

Index and limit marker strips

1

Finger Cots or talc-free gloves



Acetone or isopropyl alcohol



Lint-free cotton cloths or wipes



Two-part epoxy (Tra-Bond 2116 or equivalent)



Stick and disposable surface for stirring epoxy



Shears

Tape Applicator Tool

End Caps

Minimum bending radius 90mm (3.5 inches)

3.0 PurePrecision Laser Tape II Scale Installation

Use the steps in this section to mount and install PurePrecision Laser Tape II Scales.

3.1 Before Installation

Review the information in this section prior to installing tape scales.

3.1.1 Items Required for Tape Scale Installation

You will need the following items available for PurePrecision Tape Scale installation.

Notes:

1. Optional for tape and glass scales: limit marker strips, model RLMS; index marker strips, model RIMS.

2. Recommended: Clauss Part Number 18003.

3. Model TSAT-PPT. required for applications >300mm (not required for installations <300mm).

4. Optional for tape scales.

Refer to encoder data sheets or installation manuals for details on ordering parts.

3.1.2 Pre-Installation Information and Precautions

Read all instructions completely before beginning the installation process and follow the instruction sequence throughout the installation process. The PurePrecision Tape Scale is a precision metrological device. Handle it with the utmost care at all times.

 Avoid bending the tape scale to a radius less than 90mm

(3.5 inches).

 Avoid twisting the PurePrecision Tape Scale.  Do not let any sharp object touch the tape scale after the

blue protective film is removed.

 The PurePrecision Tape Scale is protected by a blue

film on the top that prevents contamination and damage to the grating pattern during installation.

 Once the adhesive on the tape scale is exposed (by

removing the adhesive backing), do not touch the adhesive or allow any contamination to come into contact with it.

 PurePrecision Tape Scale, Index and Limit Markers are designed for one time installation

only.

PurePrecision Laser Tape II Scale Installation

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

 If removed from the mounting surface for any reason, they should not be used for any

kind of reapplication. This will affect the performance and reliability of the encoder system.

The adhesive on the PurePrecision Tape Scale is permanent:

 Do not touch the adhesive once the adhesive backing is removed.  Do not remove the tape scale from the mounting surface once it has been installed.  Do not reinstall the tape scale if it has already been installed once. If the tape scale is

removed and reinstalled again, the encoder performance will be degraded.

 Avoid any contamination to the adhesive. Any particulate matter or contamination trapped

between the scale and the mounting surface will affect encoder performance.

3.1.3 Flowchart for PurePrecision Tape Scale Installation

PurePrecision Laser Tape II Scale Installation

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

Type of Installation

Example

Machined Edge: Trench - Hand Application Only

Trench:  6.1mm trench: applicator tool is not

compatible with 6.1mm trench, and end caps cannot be used.

 Max radius of 0.13mm required

between scale benching edge and bottom of trench.

 Benching edge must be parallel to

axis of motion to within .05/100mm.

 Trench surface flatness to within

.003/10mm.

Machined Edge: Trench - Use with Tape Applicator Tool

Trench:

 12mm trench.  Max radius of 0.13mm required

between scale benching edge and bottom of trench.

 Benching edge must be parallel to

axis of motion to within .05/100mm.

 Trench surface flatness to within

.003/10mm.

Temprary Straight Edge – Use with Tape Applicator Tool

Temporary straight edge:  Use either your hands or the

applicator tool to install the tape scale against a straight edge.

 Minimum height of 9.53mm.  Benching edge must be parallel to

axis of motion to within .05/100mm.

 Trench surface flatness to within

.003/10mm.

 4.18±0.05mm: offset from tape scale

to temporary straight edge.

0.76±0.05mm

Scale Benching Edge

Trench

Scale Benching Edge

Trench

Min. 9.53mm

Temporary Straight Edge

Tape Scale/Marker Tape

6.10mm+0.10/-0.00

0.76±0.05mm

≥12.00mm

4.18±0.05mm

Surface Flatness

3.1.4 Design Guide

The following table describes the three basic mounting configurations for tape scale installation. Also, see all guidelines that follow the table.

Guidelines:

 MicroE Systems recommends using an edge as a guide to maintain straightness of the scale

during mounting. The edge can be temporary or permanent but must follow above guidelines.

 Use the applicator tool for installation of scales, especially longer than 250mm, and for all

installations against a straight edge. For shorter scales, install by hand or use the applicator tool.

PurePrecision Laser Tape II Scale Installation

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

Step

Action

Inspect the mounting surface for any machining irregularities. MicroE Systems recommends a surface finish of better than 3.2 micrometers Ra.

The straight edge (permanent or temporary) must be sharp on the benching side in order for the applicator tool to use it as a guide. In order for the tape scale to be mounted close to the straight edge, use a maximum radius of 0.13 mm (0.005 inches) where the edge meets the bottom of the mounting surface.

Thoroughly clean the scale mounting surface and reference edge using a cotton swab or lintfree cloth dampened with isopropyl alcohol or acetone. Remove all dust and particles.

Mark the starting location on the mounting surface where the tape scale will be applied (the left edge of where the scale will be applied when the scale reference edge is away from you). Also mark the locations where the index and limit markers will be applied. Refer to the encoder interface drawings to identify the reference points of the markers.

 In #3 above, the outside reference surface of the applicator tool slides against the temporary edge

and the tape scale is offset from the edge as shown (4.18±0.05mm). If this offset is too small for the application, create a spacer than can attach to the outside of the tool.

 To ensure successful tape installation: verify all tolerances listed for your installation, and verify the

dimensions of the scale benching edge (permanent or temporary).

 Calculate the length of the PurePrecision Tape Scale required for your application using the

following formula:

ML + 40 mm = Length of Tape Scale

ML - Measuring Length (refer to the encoder interface drawings)

3.1.5 Mounting Surface Preparation

Perform the following steps prior to tape scale installation.

PurePrecision Laser Tape II Scale Installation

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

Step

Action

Uncoil the tape scale and cut it to the required length using the shears provided in the installation kit.

Note: Check the interface drawing to make sure that the scale is cut to the correct

length.

Securely hold the tape scale close to the shears (at an approximate distance of 40mm [1½ inches]) near the point of cutting. Orient the tape scale perpendicular to the shear.

Cut the tape scale in a smooth, continuous motion.

Shear held perpendicular to the tape scale (NOT INCLINED)

Hand approximately at a distance of 40mm-50mm (1 1/2 inches to 2 inches) from the cutting point

Shears held inclined, not perpendicular, to the tape scale

3.2 Cut the Tape Scale

Note: When working with any encoder scale, it is important to use finger cots or talc-free gloves.

PurePrecision Laser Tape II Scale Installation

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

Step

Action

Orient the scale such that the arrowheads on the blue protective film are pointing towards the mounting surface reference edge “D” as shown in the interface drawing for your sensor model. Refer to the correct model number interface drawing for reference edge “D” dimensions and sensor orientation.

Correct: Arrowheads on the blue protective film are pointing towards the mounting surface reference edge.

Incorrect: Arrowheads on the blue protective film are pointing away from the mounting surface reference edge.

Reference Edge

Left end of tape scale

3.3 Install Tape Scale

When installing tape scale, always perform the following steps to ensure best system performance:

 Wear talc-free gloves or finger cots during all steps of tape scale installation.  Thoroughly clean the scale mounting surface and reference edge using a cotton swab or

lint-free cloth dampened with isopropyl alcohol or acetone.

 Remove all dust and particles.

The tape scale can be installed using one of the following methods:

 Manually by hand (Section 3.3.1)  Using the Applicator Tool (Section 3.3.2)

Use Section 3.1.4 Design Guide to help select the method of installation.

3.3.1 Install Tape Scale Manually

Use the steps in this section to install PurePrecision Laser Tape II Scales manually by hand.

PurePrecision Laser Tape II Scale Installation

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

Step

Action

Remove/peel the bottom adhesive backing:

1. Use a sharp tool or fingernails to start peeling the adhesive backing from the left end of the tape scale.

2. Remove and peel back approximately 25mm (1 inch) of the bottom adhesive backing, taking care not to touch the adhesive or allow any particulate contamination.

Note: Be careful not to expose the adhesive backing more than 50mm (2 inches). Do

not peel the blue protective film off at this time.

Flip the tape over such that exposed adhesive surface of the tape scale (surface from which the adhesive backing was removed) faces the desired location where the tape needs to be attached.

Place the tape scale on the mounting surface reference edge: Place the 25mm (1 inch) exposed adhesive left end of the tape scale against the mounting surface “D” reference edge at the desired starting location and press firmly on the end.

Note: Adhesive exposed by removing the adhesive bottom backing can touch the

mounting surface only once.

Adhesive backing peeled off about 25mm (1 inch) from the left end

Tape scale orientation arrow

“D” reference edge as shown in

the encoder interface drawing

PurePrecision Laser Tape II Scale Installation

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

Step

Action

Install the PurePrecision Tape Scale along the remaining length of the mounting surface:

1. With one hand pull the adhesive backing progressively away from the scale while the other hand slides evenly along the scale.

2. During the sliding motion, press the remaining tape on to the mounting surface and pull the adhesive backing out of the way.

TIP: Maintain a gap of approximately 25 – 35mm (1 – 1½ inches) between the two

hands as you progress along the length of the tape scale.

Note: Be sure to keep the blue top protective film in place. Make sure that the tape

scale is tight against the “D” reference edge.

Once the tape has been installed, discard the adhesive backing.

Pull adhesive backing out of the way during sliding. No obstruction between tape scale and mounting surface.

Sliding motion of finger progressively along the length of the tape

“D” reference edge as shown in

the encoder interface drawing

PurePrecision Laser Tape II Scale Installation

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

Step

Action

Once the scale is applied to the mounting surface and before the blue protective film is removed, apply even pressure over the entire tape scale length by sliding a glove or cotprotected finger across the scale. The applied pressure will ensure that the adhesive is set evenly and permanently.

Performing this operation more than once is not necessary but will not have an adverse effect.

Slide across scale to apply even pressure

PurePrecision Laser Tape II Scale Installation

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

Step

Action

Peel off the blue protective film: Start the peeling process using a sharp tool, being careful not to damage the scale. Pull off the remaining blue protective film.

After removing the blue protective film, the scale is ready for use and will perform to specification. The encoder will not function properly with the blue protective film installed. It must be removed for proper encoder operation.

Pull off remaining blue film

If installing Laser Tape II index/limits, go to Section 5.0 Stick-On Index and Limit Markers

Installation.

PurePrecision Laser Tape II Scale Installation

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

Left end of tool Grips for Finger Placement

Roller

Reference arrows for tool and tape scale orientation

Adhesive backing channel

Tape scale entry channel

Adhesive backing exit

Applicator Tool

Low guide edge of tool should be in contact with mounting surface edge of thickness

0.76mm (0.030 inches)

Low guide edge

Note: The low guide edge also corresponds to the “D” tape scale reference edge in the interface drawing.

3.3.2 Install Tape Scale Using the Applicator Tool

Use the steps in this section to install PurePrecision Laser Tape II Scales using the hand-held Applicator Tool. (See Section 3.1.4 Design Guide for details on scale mounting instructions.)

The Applicator Tool

The Hand-Grip Applicator Tool (Model TSAT-PPT) is needed for tape scale lengths greater than 300mm and recommended for lengths of 250mm. It is designed to be handheld and to slide along either a permanent or temporary mounting edge while the tape scale is supplied.

Applicator Tool Mounting Surface Guide Edges

The applicator tool has two guide edges:

 Low guide edge for configurations of thickness 0.76mm (0.030 inches)  High guide edge for configurations of thickness greater than 9.5mm (.375 inches)

Refer to the encoder Interface Drawings for tape scale reference edge “D.”

Low Guide Edge

PurePrecision Laser Tape II Scale Installation

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

High guide surface of tool. Mounting surface reference edge higher than

9.5mm (0.375 inches)

Entry for metal tape scale (under dowel pin)

Entry for adhesive backing

Exit for adhesive backing

High Guide Edge Surface

Tape Travel Path

The path for the tape scale through the Applicator Tool is shown in the following diagram.

PurePrecision Laser Tape II Scale Installation

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

Step

Action

Orient the applicator tool and tape scale: With the mounting surfaces reference edge away from you, insert the tape scale in the applicator tool so that arrowheads are pointing away from you as shown. The arrowheads on the applicator tool should also point away from you.

In the example shown below, the left end of the tape scale will go into the applicator tool entry channel first. Correct orientation of the applicator tool is the “MicroE Systems” label to the left and the white-colored end to the right.

PurePrecision tape scales have 4 layers: blue protective film, Inconel (metal) scale, adhesive, and adhesive backing. The top two layers fit under the dowel pin, while the bottom adhesive backing fits into the backing slot as shown below.

= Tape Scale Mounting Surface Reference Edge (See encoder interface drawings)

Applicator tool orientation arrows

Left end of tape scale

Tape scale orientation arrows on blue protective film

Entry slot for tape scale with blue protective film (under dowel pin)

Entry slot for adhesive backing

Exit slot for adhesive backing

Install Tape Scale

When orienting the tape, both tape scale arrows and applicator tool orientation arrows need to point in the same direction for proper orientation.

Note: The tape scale orientation arrows always point to the “D” reference edge in the interface

drawing.

Make sure that the applicator tool is free of any particulate contamination.

PurePrecision Laser Tape II Scale Installation

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

Step

Action

Determine the correct end of the tape scale to insert into the applicator tool entry slot. The correct end is determined by the direction of the orientation arrows on both the tape scale blue protective film and the applicator tool arrows. Both sets of arrows have to point in the same direction.

From the left end (arrows are pointing away) of the tape scale, peel and curl back 5075mm (2-3 inches) of the adhesive backing as shown. Take care not to touch the adhesive on the bottom of the tape scale or allow any particle contamination.

Note: Do not peel the blue protective film off at this time.

Correct orientation – all arrows point in same direction

Peel and cut back 50-75mm (2-3 inches) of the adhesive backing

PurePrecision Laser Tape II Scale Installation

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

Step

Action

Feed the adhesive backing into the applicator tool.

Adhesive backing inserted into backer slot

Adhesive backing exiting from backer slot

PurePrecision Laser Tape II Scale Installation

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

Step

Action

Insert the tape scale (with blue protective film) under the dowel pin and into the entry slot.

Dowel pin and entry slot

Tape inserted

PurePrecision Laser Tape II Scale Installation

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

Step

Action

Feed tape scale into the applicator tool until the end of the tape is past the front roller.

Apply tape scale with the hand grip applicator tool: Once the applicator tool is configured with the adhesive backer exiting from the exit slot and steel tape extending past the front tool roller, the scale is ready to be installed on the mounting surface.

Tape scale fed past front tool roller.

Tape inserted with adhesive backing exiting

Applicator tool correctly configured for installation

PurePrecision Laser Tape II Scale Installation

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

Step

Action

Place applicator tool along reference edge and firmly press down on mounting surface.

10.

Slide tool along guide edge face (in direction shown) with a slow and even pressure motion until all of the tape is installed on the mounting surface. Be sure the adhesive backing film does not bunch up and jam inside the tool and exits freely from the exit slot.

11.

Once the scale is applied to the mounting surface, and before the blue protective film is removed, it is recommended that even pressure be applied over the entire tape scale length by sliding a glove-protected finger or the applicator tool across the scale. The applied pressure will ensure that the adhesive is evenly and permanently set.

12.

Peel off the blue protective film: Start the peeling process using a sharp tool, being careful not to damage the scale. Pull off the remaining blue protective film. Clean the tape scale using alcohol or acetone and a lint-free cotton cloth.

13.

Precautions:

 If scale damage has occurred, the tape scale may need to be replaced.  The ends of the tape scale can be covered and secured with an end cap.  Clean the tape scale using alcohol or acetone and a lint-free cotton cloth.  Tape scales cannot be reused if removed from mounting surface.

Applicator tool pressed down and against high guide edge

High guide edge face

Applicator tool in motion against guide edge face

If installing Laser Tape II index/limits, go to Section 5.0.

PurePrecision Linear Glass Scales Installation

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

Item

Notes

Index and limit marker strips

1

Finger Cots or talc-free gloves



Acetone or isopropyl alcohol



Lint-free cotton cloths or wipes



Two-part epoxy (Tra-Bond 2116 or equivalent)



Stick and disposable surface for stirring epoxy



Silicone adhesive



Step

Action

Inspect the mounting surface for any machining irregularities. MicroE Systems recommends a surface finish of better than 3.2 micrometers Ra.

MicroE Systems recommends a mounting surface flatness of 0.0001 inch/inch.

Thoroughly clean the scale mounting surface and reference edge using a cotton swab or lintfree cloth dampened with isopropyl alcohol or acetone. Remove all dust and particles.

Step

Action

Permanently attach MicroE Systems linear glass scales to the mounting surface using epoxy and silicone adhesive.

4.0 PurePrecision Linear Glass Scales Installation

Use the steps in this section to mount and install PurePrecision Linear Glass Scales.

4.1 Before Installation

Review the information in this section prior to installing PurePrecision Linear Glass Scales.

4.1.1 Items Required for Glass Scale Installation

You will need the following items available for PurePrecision Glass Scales installation.

Notes:

1. Optional for tape and glass scales: limit marker strips, model RLMS; index marker strips, model RIMS.

Refer to encoder data sheets or installation manuals for details on ordering parts.

4.1.2 Mounting Surface Preparation

Perform the following steps prior to mounting the glass scales (for non-adhesive backed glass scales).

4.2 Mount Linear Glass Scales

Note: Use talc-free gloves or finger cots to handle the scales.

PurePrecision Linear Glass Scales Installation

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

Step

Action

Two benching pins are recommended on the long side of the scale and one at the end as shown below. “Benching" the scale to the system means aligning the scale by means of benching pins.

Position the benching pins inward from either end of the scale. 20% of the overall scale length is the recommended location from the edge.

Be sure the benching pins do not exceed the height of the scale to prevent mechanical interference with the sensor or sensor mount.

Step

Action

Make sure that the mounting surface is dry and clean.

Align the scale by placing the edges against the benching pins. Optionally, scale clamps may be used to secure the scale while the adhesive cures.

Apply a hard epoxy, such as Tra-Bond 2116, at one point on the scale. If no end benching pin is used, epoxy at the index mark is suggested. If an end benching pin is used, epoxy at the end of the scale where the pin is located is suggested. Then apply 100% Silicone RTV adhesive around the edges of the scale.

Caution: Do not allow epoxy to seep under the scale as this will affect scale flatness and

therefore, encoder accuracy.

After adhesive curing, remove the scale mounting clamps.

End Benching Pin (optional)

4.3 Install Linear Glass Scales

Use the following instructions to install linear glass scales.

If installing Laser Tape II index/limits, continue to the next section.

Stick-On Index and Limit Markers Installation

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

Step

Action

Begin by holding the Limit and Index Marker strip so that the blue protective film is on top and the reflective surface is on the bottom.

Index Marker Strips, Model RIMS

Limit Marker Strips, Model RLMS

5.0 Stick-On Index and Limit Markers Installation

This section provides instructions for installing stick-on index and limit markers for PurePrecision Laser Tape II Scales and Linear Glass Scales. The markers come in strips with the following models names:

 RIMS - Reflective Index Markers  RLMS - Reflective Limit Markers

Note: For tape scale, make sure the blue protective film is removed before installing markers.

5.1 Stick-On Marker Strips

Stick-On Index and Limit Markers for PurePrecision Laser Tape II (HPTS):

Note*: Limit markers have different reflectivity values for left and right markers.

5.2 Remove Markers from Strip

Index/limit markers must first be removed from the stick-on marker strip.

Note: Index marker is used in this procedure, but the procedure is the same for limit markers. Note: Put on finger cots before starting the index and limit markers installation.

Stick-On Index and Limit Markers Installation

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

Step

Action

Starting from the handle, slowly remove the index marker from the strip by gently twisting the strip in the area of the marker.

Note: Be sure to hold the index and limit markers by the handle only. The adhesive on the

handle can be touched, however be careful not to touch the adhesive on the areas of the markers that will be applied to the scale.

Result: The marker will pull away from the transparent adhesive backing. Holding only the

handle, slowly pull the index marker from the strip.

Handle Section

Stick-On Index

Stick-On Index and Limit Markers Installation

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

Step

Action

Place the top edge of the marker at the top against the benching edge, holding it at a 45° angle as shown below. This keeps the adhesive away from the scale until the marker is in the correct position and you press it into place.

Note: The scale is installed with an offset from its reference edge, a temporary reference

edge surface such as a small metal block must be used for the index and limit markers.

When the marker is tight against the reference edge, press the marker onto the scale with your finger.

Press your finger on the marker close to the edge of the handle. Then, with your other hand, pull up on the handle to detach it from the marker. The handle will break away from the marker.

Benching Edge (“D” reference edge)

5.3 Attach Markers to Scale

Once marker is removed from strip, attach the marker to the tape or glass scale.

Note: For tape scales, remove the blue protective film before installation of markers. Note: For benching requirement, see the encoder interface drawings. The benching edge

corresponds to the “D” reference edge in the interface drawings.

End Caps Installation

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

Step

Action

Carefully remove the blue protective film from the marker surface. TIP: Use fingernails or plastic tweezers to remove blue protective film, but do not use a

hard metal object. Using a hard metal object might damage the grating on the scale or the marker.

To apply left and right limit markers, repeat steps 1 through 4.

Step

Action

Epoxy Setup:

1. Mix the two-part epoxy and place it in a syringe or on the end of a stick. Do not use a cotton swab to apply the epoxy.

2. Put epoxy on the end of the scale. Make sure that the epoxy touches both the mounting surface and the scale across the width of the scale.

Note: Only apply epoxy at the ends of the tape scale. Do not get any epoxy on the tape

scale in the measuring area.

Perform the next step immediately while the epoxy is still in a liquid state.

Attached Marker with Handle Removed

6.0 End Caps Installation

Perform the following steps to install optional End Caps on tape scale.

Final Cleaning, Inspection, and Cure Time

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

Step

Action

Install the End Caps on the Mounting Surface:

1. Remove the adhesive backing from end cap.

2. Place the end cap on the top of the scale and epoxy so that the end of the scale is in the middle of the end cap.

3. Press down lightly to ensure adhesion and let cure for 24 hours.

Step

Action

General Particle Removal: Blow off any contamination with nitrogen, clean air, or a similar gas.

Contamination Removal: Use a lint-free cleanroom wipe or cotton swab dampened with isopropyl alcohol or acetone to wipe the surface clean. Handle the scale by the edges. Do not scrub the scale.

7.0 Final Cleaning, Inspection, and Cure Time

Before using the encoder for servo control, clean the scale, index marker, and limit markers using alcohol or acetone and a lint-free cotton cloth or swab. Finally, inspect the scale's surface for scratches, adhesive spots or smears in the measuring length.

For tape scales, a cure time of 12 hours is required for the scale's pressure-sensitive adhesive to achieve the best performance and reliability.

7.1 Reworking to Correct Mistakes

7.2 Cleaning Scales

Once installed, the scale, index marker, and limit markers cannot be moved or removed and reinstalled. Reworking will require removal and discarding of the old scale or markers, and installation of new ones.

If only the index or limit markers have to be replaced, the scale can remain in place and be reused so long as there is no damage to the scale’s surface. Do not use a tool made of metal or other hard material to remove the markers. Clean the scale’s surface completely of any adhesive residue before applying new markers.

Contacting MicroE

Mercury II PurePrecision Tape and Glass Scales Installation Manual and Reference Guide

8.0 Contacting MicroE

To learn more about Mercury™ encoders, or other MicroE Systems products, visit:

www.microesystems.com.

To learn more about GSI Group, visit our corporate web site: www.gsig.com. MicroE Systems is a world leader in optical encoder technology with offices in major industrial

Headquarters MicroE Systems 125 Middlesex Turnpike Bedford, MA 01730 USA Tel: 781-266-5700 Fax: 781-266-5112

www.microesystems.com

Email: info@microesystems.com

MicroE Mercury II 5000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

1.0 Introduction

1.1 Overview

1.2 Precautions

1.3 Laser Safety Information

1.4 Patents

1.5 Standards Compliance

1.6 Related Documentation

1.7 Manual Revisions

1.8 Trademarks

2.0 Before Installation

2.1 Power Recommendations

2.2 Installation Considerations

2.3 Items Required for Installation

3.0 System Overview

3.1 System View

3.2 Expanded View

3.3 SmartPrecision Alignment Tool

4.0 Sensor Installation

4.1 Sensor Mounting Orientation and Tolerances

4.2 Verify Sensor Mounting Surface Height

4.3 Install Sensor

5.0 Sensor Alignment and Calibration

5.1 Using the Cal. Pushbutton

5.1.1 Sensor Alignment

5.1.2 Sensor Calibration

5.2 Using the Software

5.2.1 Connect the Alignment Tool and Encoder

5.2.2 Use the FindMII Program to locate the Encoder

5.2.3 Sensor Alignment and Calibration

6.0 Appendix

6.1 Specifications

6.2 Resolution and Maximum Speed Tables

6.3 Wiring Diagrams

6.4 Customer Interface

6.5 Serial Interface Specifications

6.6 Index Speed Considerations

6.7 RS-422 Compliance

6.8 Troubleshooting

7.0 Order Guide

8.0 Contacting MicroE

Table of Contents

1.0 Introduction

1.1 Overview

1.2 Applicable Encoders

1.3 Related Documents

1.4 Manual Revisions

1.5 Patents

1.6 Trademarks

1.7 Standards Compliance

1.8 Special Conventions Used

2.0 PurePrecision Rotary Scales

3.0 PurePrecision Laser Tape II Scale Installation

3.1 Before Installation

3.1.1 Items Required for Tape Scale Installation

3.1.2 Pre-Installation Information and Precautions

3.1.3 Flowchart for PurePrecision Tape Scale Installation

3.1.4 Design Guide

3.1.5 Mounting Surface Preparation

3.2 Cut the Tape Scale

3.3 Install Tape Scale

3.3.1 Install Tape Scale Manually

3.3.2 Install Tape Scale Using the Applicator Tool

4.0 PurePrecision Linear Glass Scales Installation

4.1 Before Installation

4.1.1 Items Required for Glass Scale Installation

4.1.2 Mounting Surface Preparation

4.2 Mount Linear Glass Scales

4.3 Install Linear Glass Scales

5.0 Stick-On Index and Limit Markers Installation

5.1 Stick-On Marker Strips

5.2 Remove Markers from Strip

5.3 Attach Markers to Scale

6.0 End Caps Installation

7.0 Final Cleaning, Inspection, and Cure Time

7.1 Reworking to Correct Mistakes