Mercury TM1000 Analog Output Encoder Systems For Customer Interpolation- Resolution to 0.078μm Reflective Linear and Rotary Encoders Resolution Determined by Customer Electronics Linear: 20μm to 0.078μm Rotary: 2,500 to 4.2M CPR Sensor as small as a dime Accuracy Linear: ± 1μm available ± 3μm to ± 5μm standard Rotary: Up to ± 2.1 arc-sec Output Analog Sine/Cosine and Digital Index Window The Mercury 1000 encoder system includes the sensor, double shielded cable, connector, and either a linear or rotary glass scale. Mercury’s space-saving, integrated configuration gives OEM system designers a breakthrough in performance. Imagine what you can do with this! Reduce the cost and size of your system, and increase its performance all at once. MicroE Systems’ Mercury 1000 kit encoders are smaller, higher performance, faster to install, and easier to use than any other encoder. Advanced features include SmartPrecision™ automatic offset and gain adjustments during set up to optimize accuracy. No manual adjustments are needed. The tiny sensor fits into very tight spaces, has broad alignment tolerances for fast and easy setup and works in both linear and rotary applications. The entire Mercury 1000 encoder system is EMI shielded for use in the toughest environments. With standard analog sine/cosine output, use your interpolation electronics to achieve the resolution required by your application. Standard features • Small sensor with ultra-low Z height; flush screw mounting • Sensor is 8.4mm (H) x 12.7mm (W) x 20.6mm (L) and weighs 1.6g • SmartPrecision automatic offset and gain set up • Analog Sine/Cosine output and Index window • Fundamental resolution: Linear 20µm; Rotary 2,500 - 16,384 CPR Interpolated resolution determined by customer electronics: Linear: 20µm - 0.078µm; rotary: 2,500 to 4.2M CPR • Entire system is EMI shielded • Bi-directional index signal • Index mark at the center or end of the glass scale (linear) • Alignment Tool enables fast set up (Required, see pg 2) Table of Contents System & Sensor pg 4 Scales pg 5-6 Ordering Information pg 6 Required accessories • SmartPrecision Alignment Tool Optional features • Glass scale length or diameter: Linear lengths from 5mm to 2m Rotary diameters from 12mm to 108mm • Cable length of 0.5m, 1m, 2m or custom • SmartPrecision Software for set up System Configurations Standard and Optional Equipment M1000 Encoder System Standard Equipment Encoder Sensor Same for linear and rotary scales. Controller Interface Cable 15 pin standard D-sub connector with SmartPrecision™ automatic gain and offset adjustments. SmartPrecision™ Alignment Tool - SSAT 1000 Required for set up, the built-in LED indicators make alignment fast and easy, eliminating the need for an oscilloscope. In addition, The Alignment Tool automatically optimizes the M1000’s gain and offset for increased accuracy with the push of a button. The RS232 Interface Adapter provides power to the encoder and connections to a PC. This is included with the Alignment Tool. Optional Software SmartPrecision™ Software Optional software lets you view signal strength, Lissajous plots, position data and diagnostics. Page 2 of 6 Broader Alignment Tolerances, Increased Standoff Clearance, Smallest Sensor and More Why Mercury Encoders Make It Easier To Design High Performance Into Your Equipment Eliminate the Frustration of Touchy Encoder Alignment Mercury Solves this Problem for Good Theta Z Alignment Tolerance ± 2° Mercury ± 0.5° Brand Y ± 0.006° Fussy alignment is no longer a concern. With Mercury’s patented PurePrecision™ optics, advanced SmartPrecision™ electronics and LED alignment indicators, you can push the sensor against your reference surface, tighten the screws and you’re finished. Try that with brand X or Y. Brand X This performance is possible thanks to relaxed alignment tolerances, particularly in the theta Z axis. Mercury offers a ± 2° sweet spot– that’s a 300% improvement over the best competitive encoder. And that will result in dramatic savings in manufacturing costs. No other commercially available encoder is easier to align, easier to use, or easier to integrate into your designs. Alignment Tolerance Comparison** Mercury* ± 0.15mm ± 0.20mm for linear ± 0.10mm for rotary >_ 19mm dia. ± 1.0° ± 2.0° ± 2.0° Z Standoff Y theta X theta Y theta Z Brand X ± 0.1mm ± 0.1mm Brand Y ± 0.1mm unspecified Mercury vs. Best Competitor Mercury is 50% better Mercury is 100% better unspecified ± 0.1° ± 0.006° ± 1.0° ± 1.0° ± 0.5° Mercury is 100% better Mercury is 300% better *Measured at a constant temperature for one axis at a time with all other axes at their ideal positions. **Based on published specifications Standoff Clearance Mercury Can Reduce System Size and Cost Mercury’s sensor height is 44% shorter than competitive encoders, making it easy to fit into your design. This reduction can also cut total system weight and cost by allowing the use of smaller motors and stages. Safe system operation is also enhanced thanks to Mercury’s generous standoff clearance– 200% greater than other encoders. And its standoff tolerance is 50% greater than the best alternative. This significantly relaxes mechanical system tolerances, while reducing system costs. Mechanical Dimension Comparison** Sensor Z height Standoff clearance Standoff tolerance System height Mercury Brand X Brand Y Mercury vs. Best Competitor 8.4mm 23mm 15mm 44% better 2.4mm 0.5mm 0.8mm 200% better ± 0.15mm ± 0.1mm ± 0.1mm 50% better 11.7mm 28.5mm 15.8mm 26% better **Based on published specifications Mercury 2.4mm* ± 0.15mm Brand Y 0.8mm ± 0.1mm Brand X 0.5mm ± 0.1mm * Dimensions shown illustrate encoder system standoff clearance; see Mercury Encoder Interface Drawings for correct design reference surfaces. Page 3 of 6 System Specifications Analog Output Pins 7,8,14 and 15 System 20µm Grating Period 20µm Signal Period 20µm System Resolution Fundamental resolution: Linear 20µm; Rotary 2500 - 16,384 CPR Interpolated resolution determined by customer electronics: Linear: 20µm - 0.078µm; rotary: 2,500 to 4.2M CPR Linear Accuracy* Better than ±1µm available; contact MicroE Better than ±3µm up to 130mm, ±5µm from 155mm to 1m, ±5µm per meter from 1m to 2m *Maximum peak to peak error over the specified movement when compared to a NIST-traceable laser interferometer standard, used at room temperature and with MicroE interpolation electronics. Rotary Accuracy* Scale O.D. 12.00mm 19.05mm 31.75mm 57.15mm 107.95mm Microradians ±100 ±63 ±38 ±19 ±10 Arc-Seconds ±21 ±13 ±7.8 ±3.9 ±2.1 *Based on ideal scale mounting concentricity Sensor Size W: L: H: 12.70mm 20.57mm 8.38mm 0.500" 0.810" 0.330" Operating and Electrical Specifications Power Supply Temperature Operating: Storage: Humidity: EMI: Shock: Sensor Weight: Cable: 5VDC ±5% @ 60mA 0 to 70°C -20 to 70°C 10 - 90% RH non-condensing Entire system is EMI/RFI protected 1500G 0.5ms half sine (Sensor) 2.7g (Sensor without cable) Double Shield. Diameter: 3.6mm (0.142”) Flex Life: 20 x 106 cycles @ 20mm bending radius 90° Mercury 1000 Outputs 15-pin Standard Male D-sub connector PIN FUNCTION 1 Index Window2 Index Window+ 3 Reserved - do not connect 4 Reserved - do not connect 5 Reserved - do not connect 6 Reserved - do not connect 7 Cosine+ 8 Sine+ 9 Reserved - do not connect 10 Reserved - do not connect 11 Reserved - do not connect 12 +5VDC 13 Ground 14 Cosine15 Sine - Index Window Pin 2 20µm Typical 5VDC Maximum Speed Scale Length/Diameter All Lengths 0.75” 1.25” 2.25” 4.25” Linear Rotary 1V pp ±15% (Differential) Across 120Ω resistor Maximum Speed* 7200mm/s 8640 RPM 5272 RPM 2637 RPM 1318 RPM 2.05 52.0 *Assumes customer electronics have adequate bandwidth Mechanical Information - Sensor and Connector .272 6.91 Note: See interface drawing for important sensor mounting information. .166 4.22 A SENSOR MTG SURFACE .13 3.4 .058 1.47 .037 0.94 B .083 2.11 .810 20.57 .405 10.29 .155 3.94 .62 15.7 .24 6.2 .334 8.5 .142 [3.61] CABLE DIAMETER .500 12.70 2X .106 2.69 THRU. .345 8.75 .080 2.03 PIN 8 PIN 15 PIN 1 PIN 9 .650 16.5 C All Specifications are subject to change. All data is accurate to the best of our knowledge. MicroE Systems is not responsible for errors. Page 4 of 6 Scale Specifications Standard and Customized Scales MicroE Systems offers a wide array of chrome on glass scales for the highest accuracy and best thermal stability. Easy to install, standard linear and rotary scales meet most application requirements. Customized linear, rotary, and rotary segment scales are available where needed. All scales include an optical index. Mercury's glass scales save time by eliminating motion system calibrations or linearity corrections required by other encoders, and provide better thermal stability than metal tape scales. Options include: • Standard linear: 18mm - 2m • Standard rotary: 12mm - 107.95mm diameter, with or without hubs • Custom linear*: special lengths, widths, thickness, index mark locations and special low CTE materials • Custom rotary*: special ID's, OD's (up to 304.8mm), index mark outside the main track and special low CTE materials • Mounting of hubs for rotary scales: MicroE Systems can mount and align standard, custom, or customer-supplied hubs • Rotary segments*: any angle range; wide range of radius values *Custom scales or rotary segments are available in OEM quantities. Contact your local MicroE Systems sales office. Standard Short Linear Scales 130mm and Shorter Key: inches[mm] Scale Length 0.036 [0.9] Measured Length is always 5 mm less then total length 0.250 [6.35] Center Index End Index Model Scale Length Measured Length L18 0.709 [18] 0.512 [13] L30 1.181 [30] 0.984 [25] L55 2.165 [55] 1.969 [50] Specifications Accuracy ±3µm standard ±1µm available Material Soda lime glass Typical CTE 8ppm/°C Index Center or End L80 L105 L130 3.150 [80] 4.134 [105] 5.118 [130] 2.953 [75] 3.937 [100] 4.921 [125] Custom scales available Standard Long Linear Scales 155mm and Longer Key: inches[mm] 0.098 [2.5] Scale Length Measured Length is always 5 mm less then total length 0.787 [20.00] Model Scale length Measured length L155 6.102 [155] 5.906 [150] Material Typical CTE Index Center Index End Index L225 8.858 [225] 8.661 [220] L325 12.795 [325] 12.598 [320] Specifications Accuracy L425 16.732 [425] 16.535 [420] L525 20.669 [525] 20.472 [520] ±5 µm <1m ±5 µm/m >1m Soda lime glass 8ppm/°C Center or End L1025 L2025 40.354 [1025] 79.724 [2025] 40.157 [1020] 79.528 [2020] Custom scales available All Specifications are subject to change. All data is accurate to the best of our knowledge. MicroE Systems is not responsible for errors. Page 5 of 6 Standard Rotary Scales HUB THICKNESS SCALE PATTERN SCALE O.D. Specifications Material Typical CTE HUB I.D. MOUNTING HOLES OPTICAL DIAMETER Soda lime glass 8ppm/°C Key: inches[mm] Model No. Scale Outer Diameter Scale Inner Diameter Optical Diameter Hub Inner Diameter +.0005/-0.0000 Hub Thickness Fundamental CPR R1206 R1910 R3213 0.472 [12.00] 0.750 [19.05] 1.250 [31.75] 0.250 [6.35] 0.375 [9.52] 0.500 [12.70] 0.413 [10.50] 0.627 [15.92] 1.027 [26.08] 0.1253 [3.18] 0.1253 [3.183] 0.2503 [6.358] 0.040 [1.02] 0.040 [1.02] 0.050 [1.27] 1650 2500 4096 R5725 R10851 2.250 [57.15] 4.250 [107.95] 1.000 [25.40] 2.000 [50.80] 2.053 [52.15] 4.106 [104.30] 0.5003 [12.708] 1.0003 [25.408] 0.060 [1.52] 0.080 [2.03] 8192 16384 Custom scales available How to Order Mercury 1000 Encoder Systems To specify your Mercury encoder with the desired scale, cable length and software, consult the chart below to create the correct part number for your order. Call MicroE Systems’ Rapid Customer Response team for more information [508] 903-5000. Example (Linear Encoder): M1000-M05-L55-C1 Example (Rotary Encoder): M1000-M10-R1910-HA M1000 - Cable Length - Scale Model M05 = 0.5 m M10 = 1.0 m M20 = 2.0 m Lxxx or Rxxxx - Scale Mounting For linear scales: T = Tape mounting C1 = 3 scale clamps* C2 = 10 scale clamps** Hubs for Rotary Scales: NH = Without Hub HE = for R1206 HA = for R1910 HB = for R3213 HC = for R5725 HD = for R10851 * 3 clamps for linear scales up to 130mm ** 10 clamps for linear scales 155mm or longer How to Order SmartPrecision Alignment How to Order SmartPrecision Software Required for M1000 setup Optional for SSAT1000 Alignment Tool Example: Alignment Tool for Mercury 1000 encoder, 120 VAC = SSAT1000-120 SSAT1000 – Voltage SmartPrecision Software SSWA-AT = SmartPrecision software on CD 120 = 120 VAC, 60Hz US Std. 2-prong plug 220 = 220 VAC, 50Hz European Std. 2-prong plug All Specifications are subject to change. All data is accurate to the best of our knowledge. MicroE Systems is not responsible for errors. DS-M1000 Rev G MicroE Systems – World Headquarters: 125 Middlesex Turnpike • Bedford • MA 01730 www.microesys.com • [email protected] • T. [781]-266-5700 • F. [781]-266-5112 © 2008 MicroE Systems Page 6