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Mercury TM 2000 Smart Encoder Systems
Programmable Interpolation in Integer Steps to 0.078m
Reflective Linear and Rotary Encoder Systems
Next Generation Ruggedized Design Replaces Mercury 2100
New design for more robust performance
Resolution
Linear: 5m to 0.078m Rotary: 6,600 to 4.2M CPR
Accuracy
Linear: 1m available 3m to 5m standard Rotary: Up to 2.1 arc-sec
Output
A-quad-B and Index Pulse
Sensor the size of a dime
The New Mercury 2000 encoder represents the next level of encoder performance. With programmable interpolation, smallest sensor size, easiest alignment, and superior noise immunity, the M2000 delivers Best-in-Class performance.
Imagine what you can do with this!
The new Mercury 2000 can reduce the cost and size of your system, and improve its performance all at once! MicroE Systems' Mercury 2000 kit encoders are smaller, higher performance, faster to install, and easier to set up and align than any other encoder. The tiny sensor fits into very tight spaces and works in both linear and rotary applications.
Table of Contents
System & Sensor SmartPrecision Electronics SmartPrecision Software Scales
Ordering Information
pg 1-5 pg 6-7 pg 8 pg 9 pg 10
New features
* New metal enclosure for SmartPrecisionTM electronics Best-in-Class noise immunity for harsh environments Shorter length for smaller, tighter cabinets Frame mounting compatible for easy installation Robust metal housing with easy access locking screws * Double shielded long life cable * CE compliant
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
Standard features
* Smallest sensor- 1/3 the size of other encoders * Revolutionary bolt-in alignment for many applications * Advanced SmartPrecision electronics built into shielded D-sub connector * A-quad-B output with programmable interpolation in integer steps for resolutions to 0.078m (linear); 4.2M CPR (rotary) * LED set up indicators for sensor alignment and index location * Bi-directional index signal is repeatable to encoder resolution
System Configurations
Standard and Optional Equipment M2000 Smart Encoder Systems Standard Equipment
Encoder Sensor
M10
Same for linear and rotary scales.
Sensor Cable
The standard cable is double shielded and available in lengths of 0.5m, 1m or 2m.
SmartPrecisionTM Electronics Module New Metal Enclosure Provides Best-in-Class Noise Immunity
A 15 pin high density D-sub connector mates to the customer controller.
RS 232 Interface Adapter
The adapter provides connections to a PC, the encoder system and the controller.
M2000 Optional Equipment
SmartPrecisionTM Software
The software module enables all programmable and diagnostic features plus displays encoder output and signal strength. See page 8 for details.
Page 2 of 10
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
Fussy alignment is no longer a concern. With Mercury's patented PurePrecisionTM optics, advanced SmartPrecisionTM 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. 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.
Theta Z Alignment Tolerance
2
0.5
0.006
Mercury
Brand Y
Brand X
Alignment Tolerance Comparison**
Z Standoff Y theta X theta Y theta Z Mercury* 0.15mm 0.20mm for linear _ 0.10mm for rotary > 19mm dia. 1.0 2.0 2.0 Brand X 0.1mm 0.1mm unspecified 0.1 0.006 Brand Y 0.1mm unspecified 1.0 1.0 0.5 Mercury vs. Best Competitor Mercury is 50% better Mercury is 100% better
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
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.
Mercury
Standoff Clearance
2.4mm* 0.15mm
Brand Y
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
Brand X
0.8mm 0.1mm
0.5mm 0.1mm
* Dimensions shown illustrate encoder system standoff clearance; see Mercury Encoder Interface Drawings for correct design reference surfaces.
**Based on published specifications
Page 3 of 10
System Specifications
Resolution and Maximum Speed
Mercury 2000 systems have programmable interpolation from x4 to x256 in integer steps. Below is a table of sample values.
Linear - 20m grating pitch
Interpolation Resolution Maximum Speed*
x4 x10 x20 x50 x80 x100 x200 x250
5.000m/count 2.000m/count 1.000m/count 0.400m/count 0.250m/count 0.200m/count 0.100m/count 0.080m/count
7200mm/s 7200mm/s 7200mm/s 7200mm/s 7200mm/s 5760mm/s 2880mm/s 2300mm/s
To calculate desired linear interpolation multiplier, use the following equation Interpolation Multiplier = Grating Pitch (20m) / Desired Resolution (m/count)
Rotary - 20m grating pitch
Rotary Glass Scale Diameter Fundamental Resolution Interpolation
Note: The range of available values is x4 to x256 in integer steps; example values below.
0.472" [12.00mm]
1650 CPR interpolated resolution (CPR) interpolated resolution (arc-sec/count)** interpolated resolution (rad/count)** maximum speed* (RPM)
x4 6,600 196.4 952 13090 x4 10,000 129.6 628.3 8640
x100 165,000 7.85 38.0 10470 x100 250,000 5.18 25.1 6912 x100 409,600 3.16 15.3 4219 x100 819,200 1.58 7.7 2109 x100 1,638,400 0.791 3.83 1054
x256 422,400 3.08 14.85 4090 x256 640,000 2.03 9.8 2700 x256 1,048,576 1.24 6.0 1648 x256 2,097,152 0.618 3.0 824 x256 4,194,304 0.309 1.5 412
0.750" [19.05mm]
2500 CPR interpolated resolution (CPR) interpolated resolution (arc-sec/count)** interpolated resolution (rad/count)** maximum speed* (RPM)
1.250" [31.75mm]
4096 CPR
x4 interpolated resolution (CPR) 16,384 interpolated resolution (arc-sec/count) ** 79.1 interpolated resolution (rad/count)** 383.5 maximum speed* (RPM) 5273 interpolated resolution (CPR) interpolated resolution (arc-sec/count)** interpolated resolution (rad/count)** maximum speed* (RPM) x4 32,768 39.6 191.7 2637 x4 65,536 19.7 95.9 1318
2.250" [57.15mm]
8192 CPR
4.250" [107.95mm] 16384 CPR interpolated resolution (CPR) interpolated resolution (arc-sec/count)** interpolated resolution (rad/count)** maximum speed* (RPM)
*Maximum speed produces an encoder quadrature output of up to 28.8 million states per second. ** Resolution values shown are approximate. To calculate exact resolution values, convert from CPR (Counts Per Revolution) to the desired units. Note: Specifications assume XOR function which is available in all standard controllers. To calculate desired rotary interpolation multiplier, use the following equation Interpolation Multiplier = Desired Resolution (CPR) / Fundamental Scale Resolution (CPR) 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 10
System Specifications
System
Grating Period 20m Signal Period 20m System Resolution 5m - 0.078m in integer interpolation steps (factory set or user programmed using MicroE SmartPrecision Software) Linear accuracy* Interpolation accuracy: Better than 0.12m over any 20m movement Long-travel accuracy: 1m accuracy available - consult MicroE Better than 3m for scales up to 130mm Better than 5m for scales 155mm to 1m Better than 5m per meter for scales 1m or more
*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
*Based on ideal scale mounting concentricity
Microradians 100 63 38 19 10
Arc-Seconds 21 13 7.8 3.9 2.1
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% @ 330mA (30mA for sensor) 0 to 70C -20 to 70C 10 - 90% RH non-condensing CE Compliant 1500G 0.5 ms half sine (Sensor) 5.0g (Sensor without cable) Double shield. Maximum length 2m. Diameter: 3.6mm (0.142") Flex Life: 20 x 106 cycles @ 20mm bending radius
Mechanical Information - Sensor
.272 6.91 .166 4.22 A 19.7 [500] or 39.4 [1000] or 78.7 [2000] .50 [12.7]
A
SENSOR MTG. SURFACE SENSOR MTG SURFACE
.058 1.47 .13 3.4 .037 0.94 .083 2.11 .155 3.94 .810 20.57 .405 10.29 .24 6.2 .334 8.5 .500 12.70 .345 8.75 .080 2.03 .650 16.5 C
B .142 [3.61] CABLE DIAMETER
All Specifications are subject to change. All data is accurate to the best of our knowledge. MicroE Systems is not responsible for errors.
2X .106 2.69 THRU.
Page 5 of 10
SmartPrecision Electronics Module
The Mercury 2000 encoder system includes a SmartPrecision electronics module. This compact, fully-featured signal processing system performs the following functions: * Interpolation - up to 256X with 28.8 million quadrature states / sec. * Programmable interpolation level and output bandwidth * Accuracy optimization - sensor signals are automatically optimized to improve system accuracy and maximize repeatability * Signal strength indication - red / yellow / green LEDs assist during setup and provide diagnostics at a glance * Index centering - centers the bi-directional index output pulse for repeatability to +/-1LSB * Power-indicating LED * Computer interface - for programming and data acquisition using SmartPrecision software * Superior EMI / RFI immunity - CE compliant * Mounting options - all electronics are within the EMI-shielded connector housing and can be screwed directly into a mating connector that is bulkhead mounted, or the module may be mounted to the frame of your motion system and connected using an extension cable
TM
SmartPrecision module enclosure provides "Best-in-Class" noise immunity for high noise environments.
Programmable Interpolation
The electronics module has programmable interpolation that is selectable over the range x4 to x256 in integer steps, providing output resolutions that can be matched to your application requirements. This feature provides linear resolutions from 5m to 0.078m in convenient increments (e.g. x200 interpolation = 0.1m) and rotary resolutions from 6,600 CPR to 4.2M CPR. Specify the interpolation value at the time of ordering or select the interpolation at your site using SmartPrecision Software.
Mercury 2000 Outputs:
15-pin high density Male D-sub connector PIN FUNCTION 1 Reserved - do not connect 2 Serial programming interface -transmit* 3 Serial programming interface -receive* 4 A - quadrature 5 A + quadrature 6 7 8 9 10 11 12 13 14 15 Reserved - do not connect Reserved - do not connect Reserved - do not connect B- quadrature B+ quadrature Reserved - do not connect +5V Ground I+ index I- index
Programmable Maximum Output Frequency
For encoder applications combining high resolution and high speed, the SmartPrecision electronics module supports up to 28.8 million quadrature state changes per second**. By specifying the maximum output frequency to match your controller's capability - ranging from 900,000 up to 28.8 million quadrature state changes per second - the Mercury encoder system will never produce encoder counts faster than your controller can read them. Specify the encoder's maximum output frequency at the time of ordering or select the setting at your site using MicroE's SmartPrecision Software.
* The electronics module's serial computer programming interface can be translated to be RS-232 compatible using the MicroE SmartPrecision Computer Interface Adapter or a voltage translation circuit of your own design. ** "Quadrature state changes per second" is the reciprocal of "dwell time" or "edge separation". For example, 28.8 million states per second = 0.035sec dwell time. *** Future availability, contact MicroE. All Specifications are subject to change. All data is accurate to the best of our knowledge. MicroE Systems is not responsible for errors.
Page 6 of 10
Mechanical Information - electronics module
2.11 [53.5] 2.03 [51.5] 1.89 [48.0]
.75 [19.1] 2.18 [55.4]
2
2
1.50 [38.1]
O.13 [O3.3] PIN 5
PIN 1
.85 [21.5]
.10 [2.4]
.46 [11.6]
PIN 10 PIN 11
PIN 15
Male D connector
Maximum Quadrature Output Frequency
Output Frequency 7.2MHz 3.6MHz 1.8MHz 900kHz 450kHz 225kHz A-quad-B Output Rate 28.8M quadrature states / sec 14.4M quadrature states / sec 7.2M quadrature states / sec 3.6M quadrature states / sec 1.8M quadrature states / sec 900k quadrature states / sec Dwell Time (or edge separation) 0.035sec 0.069sec 0.139sec 0.278sec 0.555sec 1.111sec
Output Signals
Quadrature TTL Pins 4 & 5 Pins 9 & 10 A B
Signal Termination for A-Quad-B and Index
120 Cable Zo=120 Mercury 2000 encoder Customer Electronics
Pins 14 & 15*
I
*Note: The index pulse may be aligned with A- or B- at some interpolation values.
All Specifications are subject to change. All data is accurate to the best of our knowledge. MicroE Systems is not responsible for errors.
Page 7 of 10
SmartPrecision Software for Mercury 2000 and 3000 Encoder Systems
SmartPrecision Software makes Mercury the industry's easiest to use encoder. It helps you program, set up, use, and diagnose Mercury 2000 and 3000 encoders with the click of a mouse. Compatible with Windows 95, 98, ME, NT, 2000, and XP.
Program Mercury Encoder Electronics
* Set interpolation in integer steps from x4 to x256 (Mercury 2000) or x4 to x1024 (Mercury 3000) * Set maximum output frequency to match your controller
Install Mercury Encoder System
* Align sensor using Signal Level display and Encoder Signal data plot * Locate index and see when sensor is over the scale's index mark * Verify sensor output over length of scale using the Signal Strength plot
Monitor Mercury Encoder Operation
* Read encoder position in engineering units of your choice * Read the encoder's hour meter to monitor system usage * Capture alarms while system operates unattended
Diagnose Mercury Encoder Performance
The encoder signal plot, or Lissajous plot, reveals the underlying strength and uniformity of the sensor's output.
How to Order SmartPrecision Software
To Purchase the SmartPrecision Software system, use this Model Number: SSWA120 for 120 VAC, 60Hz US Standard 2-prong plug or SSWA220 for 220 VAC, 50 Hz European Std. 2-prong plug
* Capture signal data and email it to MicroE for rapid diagnostic support * Monitor alarms, view the alarm history log
System Description
The SmartPrecision Software system includes Software on CD, a computer interface adapter, computer cable, and a power adapter.
All Specifications are subject to change. All data is accurate to the best of our knowledge. MicroE Systems is not responsible for errors.
Page 8 of 10
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]
0.036 [0.9] Scale Length Measured Length is always 5 mm less then total length 0.250 [6.35] End Index Center 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]
3m standard 1m 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]
Specifications Accuracy
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] Center Index
Specifications Accuracy Material Typical CTE Index
End Index
5 m <1m 5 m/m >1m Soda lime glass 8ppm/C Center or End
Model Scale length Measured length
L155 6.102 [155] 5.906 [150]
L225 8.858 [225] 8.661 [220]
L325 12.795 [325] 12.598 [320]
L425 16.732 [425] 16.535 [420]
L525 20.669 [525] 20.472 [520]
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 9 of 10
Standard Rotary Scales
HUB THICKNESS SCALE PATTERN SCALE O.D.
HUB I.D. MOUNTING HOLES OPTICAL DIAMETER
Specifications Material Typical CTE
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 R5725 R10851
0.472 [12.00] 0.750 [19.05] 1.250 [31.75] 2.250 [57.15] 4.250 [107.95]
0.250 [6.35] 0.375 [9.52] 0.500 [12.70] 1.000 [25.40] 2.000 [50.80]
0.413 [10.50] 0.627 [15.92] 1.027 [26.08] 2.053 [52.15] 4.106 [104.30]
0.1253 [3.18] 0.1253 [3.183] 0.2503 [6.358] 0.5003 [12.708] 1.0003 [25.408]
0.040 [1.02] 0.040 [1.02] 0.050 [1.27] 0.060 [1.52] 0.080 [2.03]
1650 2500 4096 8192 16384
Custom scales available
How to Order Mercury 2000 Encoder Systems
To specify your Mercury encoder with the desired scale, level of interpolation, maximum output frequency, 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): M2000-M10-256-1-L55-C1 Example (Rotary Encoder): M2000-M10-256-1-R1910-HA
M2000 - Cable Length - Interpolation M05 = 0.5 m M10 = 1.0 m M20 = 2.0 m 4 = 4x 5 = 5x Maximum Output Frequency 1 = 7.2 MHz 2 = 3.6 MHz 3 = 1.8 MHz 4 = 900 kHz 5 = 450 kHz 6 = 225 kHz Scale Model 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
256 = 256x
How to Order SmartPrecision Software
SmartPrecision Software SSWA120 for 120 VAC, 60Hz US Standard 2-prong plug
or
SSWA220 for 220 VAC, 50 Hz European Std. 2-prong plug
* 3 clamps for linear scales up to 130mm ** 10 clamps for linear scales 155mm or longer
All Specifications are subject to change. All data is accurate to the best of our knowledge. MicroE Systems is not responsible for errors.
DS-M2000 Rev G (c) 2008 MicroE Systems
MicroE Systems - World Headquarters: 125 Middlesex Turnpike * Bedford * MA 01730 www.microesys.com * info@microesys.com * T. [781]-266-5700 * F. [781]-266-5112
Page 10 of 10

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