Mercury 2000, 3000 & 3500 ™ Smart Programmable Encoder Systems Installation Manual and Reference Guide Taking Control of Motion Manual No.
Taking Control of Motion Don Mitchell Founder, Chairman and Chief Technology Officer MicroE Systems M icroE Systems was founded to advance encoder technology to a level never before achieved. Our objective was to design encoder systems that would be small enough to fit into densely packed OEM equipment designs, affordable enough for cost-sensitive applications and easy enough to enable installation, setup and alignment by assemblers with little training.
Table Of Contents Precautions SYSTEM ILLUSTRATION Encoder with Linear scale Encoder with Rotary scale PAGE 2 3 INSTALLATION INSTRUCTIONS Encoder System Mounting - Linear Encoder System Alignment - Linear Centering the Index & Calibration - Linear Encoder System Mounting - Rotary Encoder System Alignment - Rotary Centering the Index & Calibration - Rotary 4 5 5 6 7 7 REFERENCE SECTION Installation of Linear Scales Grounding Instructions Recommendations for Power Recommended Interface Termination Custom
Mercury 2000, 3000 & 3500 Encoder System with Linear scale System View Shown with linear scale Glass scale (shown mounted on a linear slide) Sensor (shown attached on a linear slide base with mounting bracket) SmartSignal electronics module (interpolator) Double shielded cable Expanded View Mounting screws & flat washers (2 needed per screw) Sensor mounting holes (2) Optional sensor benching pins (3) End locator pin Typical user-supplied sensor mounting bracket Index / Calibration button Center index m
Mercury 2000, 3000 & 3500 Encoder System with Rotary scale System View Shown with Rotary scale Sensor (shown attached to a customer-supplied mounting bracket) Rotary scale SmartSignal electronics module (interpolator) Expanded View Double shielded cable Mounting screws & flat washers (2 needed per screw) Mounting hole (2) Typical user-supplied sensor mounting bracket would be located here Cover: Sensor cable and connector Top reflective rotary scale Index / Calibration button Rotary scale Thumb scr
Installation Instructions Linear Encoders 1 Attach the scale to the base slide. Reference the preferred datum on the interface drawing for either end or center index orientation. 2 Install the sensor on your mounting surface referencing the appropriate datum surface as shown on the interface drawing. Use 2 washers per mounting screw. Benching pins may be used to locate the sensor if the system mechanical tolerances are adequate.
Installation Instructions Linear Encoders If benching dimensions cannot be provided, proper sensor alignment may require minor adjustments to the sensor position with respect to the scale. This can be performed easily using the LED alignment indicators, as illustrated below. IMPORTANT: Confirm that the Proper Alignment LED blinks when passing over the index. If not, readjust the sensor in the Y direction and repeat the above procedure. When alignment is completed, tighten the sensor mounting screws (0.
Installation Instructions Rotary Encoders 1 Attach your hub/scale assembly to the rotary device. Refer to the interface drawing. The reflective surface of the scale must face the sensor. CAUTION: observe precautions for handling electrostatic sensitive devices. 3 Route the sensor cable through your equipment to the SmartSignal electronics. A) Remove the three cover screws and the top half of the connector housing.
Installation Instructions Rotary Encoders The red, yellow, or green LED will light depending on sensor alignment. Slowly move the sensor by allowing it to slide on the mounting surface until the green or Proper Alignment LED, is illuminated. Optimal alignment will be displayed as a “Bright Green” LED. IMPORTANT: Confirm that the Proper Alignment LED blinks when passing over the index. If not, readjust the sensor in the Y direction and repeat the above procedure.
Reference Section Installation of Linear Scales Positioning the Scale Note: Before beginning mounting procedure, use talc-free gloves or finger cots to handle the scales. "Benching" the scale to the system means aligning the scale by means of benching pins. Pin locations are described on the appropriate interface drawing. Two benching pins are recommended on the long side of the scale and one at the end as shown . This is marked datum A on the interface drawing. the benching pins in from either end.
Reference Section Grounding Instructions for Mercury 2000, 3000 and 3500 Encoder Systems For Mercury 2000 and 3000 encoder systems to operate reliably, it is essential that the sensor and cable shield are grounded properly according to the following instructions. The diagrams below show how to make the connections when the encoder's connector is plugged into the customer's controller chassis.
Reference Section Customer Interface Cable Requirements Customer cables that interface to Mercury series encoders must have the following characteristics: • Twisted pair signal 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. Examples of acceptable cables with 24 AWG gauge wire and 4 twisted pairs are Belden 9831, 8104, and 9844 or other manufacturer's equivalents.
Reference Section SmartSignal Module Mounting Options The SmartSignal electronincs module may be mounted directly to a bulkhead connector using the integral thumb screws shown in figure A. Alternatively, the module may be used with an extension cable and mounted to a base plate using the mounting tabs as shown in figure B.
Troubleshooting Problem The Power/Calibration indicator will not come on. Solution • Make sure that the SmartSignal electronics’ 15-pin D-sub connector is fully seated and connected. • Confirm that +5 Volts DC is being applied to pin 12 on the SmartSignal electronics’ 15-pin HD connector and that pin 13 is connected to ground.
Contacting MicroE Systems Thank you for purchasing a MicroE product. You should expect the highest level of quality and support from MicroE. If you have any questions or want to download the Mercury Encoder Installation Manual, Data Sheet or Interface Drawing, browse www.microesys.com and click on the Mercury Encoder Products button, then the Standard Encoder Products Tab. You’ll find everything you need right there. Taking Control of Motion World Headquarters: 8 Erie Drive • Natick • MA 01760 www.
