Mercury II FamilyInstallationManual revE - Celera Motion · 2015. 1. 12. · OPS-IM Sensor Installation Rev A2 ©2015 MicroE Systems. ... Z-axis distance from top of tape scale after

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RoHS

Sensor InstallationManual and ReferenceGuide

MicroE Systems • 125 Middlesex Turnpike • Bedford, MA 01730 • USA www.microesystems.com [email protected] T. 781-266-5700

O.P.S.™ Series Encoders

OPS-IM Sensor Installation Rev A2 ©2015 MicroE Systems

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Table of ContentsOPS™ Sensor Installation

IntroductionIntroduction (Precautions, Patents, Manual Revisions) ................................................................3Recommendations for Power, Installation Considerations ..........................................................4Items Required for Sensor Installation..........................................................................................4

OPS, Side Mount Configuration System Overview Diagram ..........................................................................................................5Sensor Mounting Orientation and Tolerances ..............................................................................7Sensor Head Installation ..............................................................................................................8

OPS, Top Mount Configuration System Overview Diagram ..........................................................................................................9Sensor Mounting Orientation and Tolerances ............................................................................10Sensor Head Installation ............................................................................................................11

OPS Alignment and Calibration (Side and Top Mount, Tape and Glass Scales)By OPS Alignment Tool ..............................................................................................................12By SmartPrecision Software ......................................................................................................15

AppendixA. Specifications ......................................................................................................................19B. Wiring Diagrams ..................................................................................................................20C. Interface Cable Requirements ............................................................................................21D. RS-422 Compliance ............................................................................................................22E. Troubleshooting ..................................................................................................................23F. Order Guide ........................................................................................................................24

Contacting MicroE SystemsContact MicroE............................................................................................................................25

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LASER SAFETY INFORMATION: OPS Series

This product is sold solely for use as a component (or replacement) in an electronic product; therefore it is notrequired to, and does not comply with, 21 CFR 1040.10 and 1040.11 which pertain to complete laser products. Themanufacturer of the complete system-level electronic product is responsible for complying with 21 CFR 1040.10and 1040.11 and for providing the user with all necessary safety warnings and information.MicroE encoders contain an infrared laser diode or diodes. Emitted invisible laser radiation levels have beenmeasured to be within the CDRH Class 1 range, which is not considered hazardous; however, to minimizeexposure to the diverging beam, the encoder sensor should be installed in its operational configuration in closeproximity to the encoder scale before power is applied.

• Invisible laser radiation; wavelength: 850 nm• Max power 4.8 mW CW• 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 encoder turned off.• Do not insert any reflective surface into the beam path when the encoder is powered.• Do not attempt to service the MicroE encoder.

INVISIBLE LASER RADIATION DO NOT VIEW DIRECTLY WITH OPTICAL

INSTRUMENTS (MICROSCOPES, EYE LOUPES OR

MAGNIFIERS)

PrecautionsFollow standard ESD precautions. Turn power off before connecting the sensor. Donot touch the electrical pins without static protection such as a grounded wrist strap.

Do not touch the tape/glass scale unless you are wearing talc-free gloves or fingercots. Please read this installation manual for full instructions.

1

2

RoHS OPS models are CE and RoHS compliant.

Manual Version NumbersOPS-IM Sensor Installation Rev A, issued January 2014

Rev. A1 Changes: updated output frequencies in Appendix A, 01/12/2015

Related Documents-OPS Data Sheet-OPS Interface Drawing-PurePrecision Tape and Glass Scale Installation Manual for OPS

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Recommendations for Power; Installation ConsiderationsOPS™ Sensor Installation

1.Recommendations for PowerOPS™ encoders require a minimum of 4.75VDC continuously. When designing circuits and extensioncables, be sure to account for voltage loss over distance and tolerances from the nominal supplyvoltage so that at least 4.75VDC is available to the OPS encoder under all operating conditions. Theinput voltage should not exceed 5.25VDC.

2.Installation ConsiderationsThe OPS encoder is a precision electronic instrument. It has been designed to function in a widerange of applications and environments. To take full advantage of the modular system design,considerations should be made to allow easy access to the sensor for service and/or replacement.

For optimal performance and reliability:

DO follow standard ESD precautions while handling the sensor.

DO allow proper alignment clearance for sensor head alignment.

DO follow setup instructions for the encoder system.

DO, where possible, install the scales in an “upside down” or vertical position to minimize accumulation of dust.

DO consider redundant encoders or additional feedback devices as part of an overall riskmanagement program for medical applications.

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 airbornecontaminants).

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System OverviewOPS™ Series Encoders

Items Required for OPS Encoder Installation

• Hex wrench (M3.5 for Side Mount, 5/64" or M2.5 for Top Mount)

• Alignment Tool Kit (Model AT-OPS)

• For OPS-SM

- Z height spacer shim (ships with each sensor - 1.00mm (red) for use with tape scales - 0.83mm (blue) for use with glass scales

• For OPS Top Mount

- Z height spacer shim, ZG-PP1 for tape scales (black) - Z height spacer shim, ZG-GS1 for glass scales (white)

• Optional: MK-FFA bracket kit for installation into industry-standard mounting hole patterns.

Refer to encoder model data sheets for detailed ordering guide and more information about MicroEPart Numbers.

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System Overview, OPS Side MountOPS™ Sensor Installation

OPSTM Series, Side Mount ConfigurationSystem View

Expanded View

Scale (shown mounted on a linear slide)

Sensor mounting slots (2x)

Typical user-supplied sensor mounting bracket Sensor Mounting screws15 pin Standard

D-sub connector

Bracket mounting holes (2x)

Double shielded cable

With OPS SeriesAlignment Tool

Status LED

15 pin Standard D-sub connector

Bracket mounting Screws (2x)

Center stick-on index mark

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Sensor Head Installation (Side Mount Configuration)OPS™ Series Encoders

Sensor Mounting Orientation and Tolerances

Axis diagram.

OPS Side Mount ConfigurationSensor Alignment Tolerances

Axis Alignment ToleranceX Direction of Motion

Y ± 0.20mm

Z ± 0.15mm

qX ± 1.0°

qY ± 1.0°

qZ ± 2.0°

Z

YX

qz

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Sensor Head Installation (Side Mount Configuration)OPS™ Series Encoders

2.Verify Sensor Mounting Surface Height

Refer to the OPS interface drawing for detailed dimensions.

Use Z-Height spacer shim to verify that the Z-Height distance betweenthe bottom surface of the sensor and the top of the scale is as follows:

Tape Scales:Use red spacer (1.00mm) to set the proper Z-Height forPurePrecision Marker Tape II and Laser Tape II Scales

Glass Scales:Use blue spacer (0.83mm) to set the proper Z-Height forPurePrecision Performance and Value Linear Glass Scales

See step 3 below for installation steps.

3.Installation Steps

3.2 Place shim between the bottom of the sensor headand the top of the scale and press down in the Z-axis.

Shim can be inserted either parallel or perpendicularto the scale. The shim features cut-outs to allowsignal level to be monitored during sensor mounting.

Z

YX

qz

Axis Diagram

3.1 Loosen the sensor in the Z-axis

3.4 Carefully remove the shim by rotating it off thescale with the shim’s handle.

3.3 Tighten the sensor in the Z-axis.

Rotationalmovement toremove shim.

Gently push thesensor andmounting againstthe top of thetape scale in thez-axis.

1.Install the SensorUse a wrench and M3 screws to install the sensor. Refer to interface drawing to make sure sensor is orientedproperly with reference to the scale.

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OPSTM Series, Top Mount ConfigurationSystem View

Expanded View

Sensor(shown attached on a linear slide basewith mounting bracket)

Scale (shown mounted on a linear slide)

Scale reference datum; example shown with benching pins

Sensor mounting holes (2)

Typical user-supplied sensor mounting bracket

Mounting screws

15 pin Standard D-sub connector

Bracket mounting holes (2)

Optional sensor benching pins (3)

Double shielded cable

Center index mark

With OPS SeriesAlignment Tool

Status LED

System Overview, OPS Top MountOPS™ Sensor Installation

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Sensor Head Installation (Top Mount Configuration)OPS™ Series Encoders

Sensor Mounting Orientation and Tolerances

Axis diagram.

OPS Top Mount ConfigurationSensor Alignment Tolerances

Axis Alignment ToleranceX Direction of Motion

Y ± 0.20mm

Z ± 0.15mm

qX ± 1.0°

qY ± 1.0°

qZ ± 2.0°Z

YX

qz

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Sensor Head Installation (Top Mount Configuration)OPS™ Series Encoders

1.Verify Sensor Mounting Surface HeightRefer to the OPS interface drawing for the latest dimensions.Verify that the Z-height distance between the sensor mounting surface datum “A” and the top of the scale is asfollows:Tape Scales:

Z-axis distance from top of tape scale after blue protective film is removed to Datum “A” of sensor: 3.09 mm ±0.15Z-Height Gauge (Model number ZG-PP1) can be used to verify proper Z-Height for PurePrecision MarkerTape II and Laser Tape II scales

Glass Scales:Z-axis distance from top of glass scale to Datum “A” of sensor: 2.93 mm ±0.15Z-Height Gauge (Model Number ZG-GS1) can be used to verify proper Z-Height for PurePrecisionPerformance and Value Linear Glass Scales

Use the correct gauge to check that there are no gaps between:1.1 The mounting surface of the gauge and the mounting bracket, or1.2 The bottom surface of the gauge and the scale.Place the gauge in position and use the mounting screws as guides. If the bottom of the gauge hits the scale,you will see the gap between the gauge bottom mounting surface and your mounting bracket surface.

If you hand tighten the sensor mounting screws, there should be no gap between the tape scale and the bottomof the plastic gauge tool.

Z- Height GaugesTape Scales: P/N: ZG-PP1 (Black)Glass Scales: P/N: ZG-GS1 (White)

Mounting bracketsurface

Scale top surface

2.Install SensorInstall the sensor on the mounting surface referencing the appropriate datum surface as shown on the InterfaceDrawing. Use two M2 or 2-56 screws to loosely affix the sensor.A benching edge is recommended to locate the sensor to meet the mechanical mounting tolerances. Refer to theInterface Drawing for recommended location and height of edge.

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Sensor Alignment - by Alignment ToolOPS™ Series Encoders, Side and Top Mount Configurations

Be sure the source power is off before connecting theSmartPrecision Alignment Tool to the sensor plug.

1.Connect the encoder (either Side Mount or Top Mount) to theSmartPrecision Alignment Tool.

Connect the USB cable to either a computer’s USB port or tothe DC power supply provided.

OPS Alignment Tool

Use Universal Powersupply with USB port forAlignment Tool power ifnot connecting tocomputer USB port.

Mini USB computer interface cable(plugs into either power supply orcomputer)

To OPS Seriesencoder sensor

OPS Alignment Tool

Sensor 15-pin D-Sub connector(Side and top mount configurations;side mount shown.)

OPS Alignment Tool kit, Model Number AT-OPS (Includes SmartPrecision II Software)

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Sensor Alignment - by Alignment ToolOPS™ Series Encoders, Side and Top Mount Configurations2.AlignmentConnect the USB cable to the Alignment Tool with power from either the Universal Power supply or computerUSB port.

The Alignment Tool Signal Level and Sensor head LEDs are now used for alignment. Proper alignment isindicated by green sensor head and Alignment Tool Signal Level LEDs.

3.Position the sensor over a section of the scale. Adjust the sensor's Y or qz directions until the Signal Level andsensor head LEDs are green.

4.Move the sensor across the entire length of travel. The LED should be green over the entire length of travel. Ifthe LED is Yellow or Red, adjust Y and qz and refer to the interface drawing to ensure proper mechanicaldesign. (Passing over an Index will cause the Alignment Tool Index/Limit LED to flash green.)

Green = Optimal Performance

Alignment Tool

To align the sensor move itin the Y or qzdirections

Z

YX

qz

SensorIndicator LED

OPS Side Mount

OPS Top Mount

Yellow = Marginal Performance

Red = Improper Performance

NOTE: If you are having any difficulties getting a green light overthe entire travel length, refer to the OPS interface drawingto check mechanical design. Also, check to make sure thescale is properly installed, the sensor is properly orientedwith respect to the scale, and the blue protective film hasbeen removed from the tape scales.

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1.Press the Alignment Tool Cal button to start. (Be sure the sensor has been aligned to the scale, across theentire length.)

Both the Alignment Tool Signal Level and Index/Limit LEDs will turn solid green. This starts the Gain OffsetPhase (GOP) calibration.

2.Move the sensor back and forth anywhere on the scale, 10mm or more. This movement adapts and ends theGOP calibration when the Signal Level LED turns blue, with the Index/Limit LED solid green.

3.Index calibration: move the sensor back and forth across the index until both Signal Level and Index/LimitLEDs turn blue. (At this step, the Index has been calibrated and the left limit is ready to be calibrated.)

4.Left limit calibration: move the sensor over to the “left limit” area on the scale, with both Signal Level andIndex/Limit LEDs solid blue. Push the Cal button. The Index/Limit LED will turn red. (At this step, the Left Limithas been calibrated and the right limit is ready to be calibrated.)

5.Right limit calibration: Move the sensor over to the “right limit” area on the scale with Signal Level LED solidblue and Index/Limit LED solid red. Push the Cal button. (At this step, the Right Limit has been calibrated.)

Both the Signal Level and Index/Limit LEDs will quickly flash green 5 times to indicate that calibration hasbeen completed.

(Note: to skip a step, push and hold the Cal button for 2 seconds until LEDs change color, then release button.)

Sensor Calibration - by Alignment ToolOPS™ Series Encoders, Side and Top Mount Configurations

Calibration, Index, and Limits

NOTE: Correct orientation of the scale for Left/Right Limit calibration is shown below. The“D” datum edge from the OPS Interface Drawing is designated as the “Top” of thescale. The Index/Limit track is also the “Top” track on a scale (tape and glass).

D “D” datum edge of scale = “Top” of the scale. Index/Limit Track

“Left” side of scale “Right” side of scale

Both Signal Level and Index/Limit LEDsflash green 5 times to indicatecalibration complete.

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Sensor Alignment and Calibration - by SmartPrecision™ II SoftwareOPS™ Series Encoders, Side and Top Mount Configurations

Install the OPS SmartPrecision II Software (included with Alignment Tool kit, AT-OPS):

1) Insert CD into drive. Installer should automatically start up and install SmartPrecision II software toC:\Program Files\MicroE Systems\SmartPrecision_OPS.

2) If it does not start automatically browse to CD and run setup.exe to install software.

Install the USB Driver:

Windows 2000:

1) Connect the USB cable between the host computer and the OPS Alignment Tool/OPS Sensor.2) When the electronics are on, Windows will notify you it has found new hardware prompting you with a

"Found New Hardware" wizard. Press the Next button.3) Select "Search for a suitable driver for my device (recommended)" and press the Next button.4) Select "Specify a location" under “Optional search locations:” and press the Next button.5) Press the Browse button to locate the OPS.inf driver Installation file. It is located in the directory C:\Program

Files\MicroE Systems\SmartPrecision_OPS. Once this file is selected press the OK button.6) Verify that the correct path and filename are shown and press the Next button.7) Press the Finish button.

Windows XP, Vista, 7, and 8:

1) Connect the USB cable between the host computer and the OPS Alignment Tool/OPS Sensor. 2) When the electronics are on,, Windows will notify you it has found new hardware prompting you with a

"Found New Hardware" wizard.3) The wizard may prompt “Can Windows connect to Windows Update to search for software?” Select “No, not

this time” and press the Next button. 4) Select "Install from a list or specific location (Advanced)" and press the Next button.5) Select "Include this location in the search".6) Press the Browse button to locate the MicroE_USB.inf driver installation file OPS.inf driver. It is located in the

directory C:\Program Files\MicroE Systems\SmartPrecision_OPS. Once this file is selected press the OKbutton.

7) Verify that the correct path and filename are shown and press the Next button.8) Press the Finish button.

Using the Software:

1) To Run Software, go to directory C:\Program Files\MicroE Systems\SmartPrecision_OPS. Double-click‘OPS.exe’.

NOTE:Be sure the Alignment Tool is “not” plugged in to the computer USB while installing the software.The Alignment Tool needs to be plugged in “after” the software is installed, in order to properly loadthe USB driver.

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Sensor Alignment - by SmartPrecision™ II SoftwareOPS™ Series Encoders, Side and Top Mount Configurations

Connect the encoder to the Alignment Tool before connecting USB cable. Connect the USB cable to theAlignment Tool

Run SmartPrecision II Software1. Align the sensor:

SmartPrecision II software automatically begins in Alignment Mode, with AGC off.Position the sensor over a section of the scale. Adjust the sensor's Y or qz directions until the SignalLevel is in the Optimal Green level.Move the sensor across the entire length of travel. The Signal Level should be in the Optimal Green levelover the entire length of travel. If the Signal Level is in the Yellow or Red areas, adjust Y and qz and referto the interface drawing to ensure proper mechanical design. (Passing over an Index will cause theAlignment Tool Index/Limit LED to flash green.)Check that Index LED blinks as sensor passes over index. Tighten sensor mounting screws. Sensor LED Indicator Indicates signal strength – green for optimal performance, yellow for marginal performance, and red for improper performance. Sensor LED will blink as sensor passes over index.Alignment Mode is turned off automatically when you begin sensor calibration.

NOTE: If you are having any difficulties getting a green light over the entire travel length, refer to the OPSinterface drawing to check mechanical design. Also, check to make sure the scale is properlyinstalled, the sensor is properly oriented with respect to the scale, and the blue protective film hasbeen removed from the tape scales.

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Sensor Calibration - by SmartPrecision™ II SoftwareOPS™ Series Encoders, Side and Top Mount Configurations

1. Click appropriatecheckboxes beforecalibrating:Calibrate GOPCalibrate IndexSet Left Limit(optional) Set right Limit(optional)

Note: all procedures below must be performed at ≤1m/s relative motion between the sensor andthe scale.

3. Move the sensorback and forth(Gain OffsetPhase).

NOTE: Correct orientation of the scale for Left/Right Limit calibration is shown below. The“D” datum edge from the OPS Interface Drawing is designated as the “Top” of thescale. The Index/Limit track is also the “Top” track on a scale (tape and glass).

D “D” datum edge of scale = “Top” of the scale. Index/Limit Track

“Left” side of scale “Right” side of scale

4. Move the sensorback and forthover the Indexuntil the LeftLimit blue lightturns on. (TheIndex is nowcalibrated.)

2. Click Start Calbutton.

Note: It is important that if you choose to calibrate only the limits, the sensor must beplaced in the “no limit” area of the scale (neither the left or right limit) when you click the“Start Cal” button.

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Sensor Calibration - by SmartPrecision™ II SoftwareOPS™ Series Encoders, Side and Top Mount Configurations

7. Calibrationcomplete.

6. Move thesensor to theRight Limit andclick the Setbutton.

5. Move the sensorto the Left Limitand click the Setbutton.

8. “Calibration Complete” message will disappearafter a few seconds, ending the calibration mode.SmartPrecision II will automatically revert to themode in use prior to calibration.

Note: It is important that if you choose to calibrate only the limits, the sensor must beplaced in the “no limit” area of the scale (neither the left or right limit) when you click the“Start Cal” button.

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Appendix ASpecifications

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

Shock 300G 0.5 ms half sine

Vibration 30G at 17Hz

Sensor Cable Double Shield(contact MicroE Systems for applications >5m)

Diameter 3.6mm (0.142")Flex Life 20x106 cycles @ 20mm bending radiusStandard 15 pin D-sub connector

OutputsDigital A-quad-B, 1LSB index pulse, left and right limits. A, Band I signals are differential. Limits are single ended. Index isgated to AB high.Signal LevelA/B/I (differential): RS-422 compatibleLimits: 3.3VDC max., LVTTL compatible (High>2.4VDC, Low

<0.4VDC), maximum current output (source and sink): 14mA Limits programmable as active high, active low or disabled

Alarm: Tri-state of A, B and I outputs, latched for minimum 30ms

Operating and Electrical SpecificationsPower Supply 5VDC +5% @ 120mA when used with

recommended termination, 80mA unterminated

TemperatureOperating 0 to 70oCStorage -20 to 85oC

Humidity 10 to 90% RH non-condensing

A B

I

Quadrature and Index

* With reference to the sensor‘s optical centerline (seeinterface drawings).

Limits

0.6mm ± 0.3* 0.6mm ± 0.3*

Right Limit OutPin 10

³ 5mm ³ 5mm

Left Limit Marker Right Limit Marker

Left Limit OutPin 11

Pins 14 & 6Pins 13 & 5

Pins 12 & 4

AccuracyLinear Tape Scale Typical slope error: 100ppm

- Linearity: ±5µm/m 1

- Cyclical (interpolation) error: ±40nm 2

Linear Glass Scale ±3µm/m total- Cyclical (interpolation) error: ±25nm 2

Rotary Glass Scale 3.9 arc-sec with 64mm OD scale 3- Cyclical (interpolation) error: ±0.2 arc-sec 2

1 Achievable after two-point correction in the customer’s controller.2 Repeating error over any 20µm movement and does not accumulate.3 Assumes perfect alignment of scale pattern to axis of rotation.

Note: Accuracy is the maximum error over the specified movement when

compared to a NIST-traceable laser interferometer standard used at 20oC.

Sensor Size & Weight (side mount sensor)Height Width Length

0.46 [11.67mm] 0.56 [14.30mm] 1.35 [34.25mm]

Weight 8g (without cable)

Reliability Information5 Year Expected Reliability >99.8% under normal operating conditions

Digital Output Signals

Inverse signals are not shown for clarity. Active low limit configuration is shown.

SystemOPS sensors are compatible with:- PurePrecision™ Marker Tape II and Laser Tape II- Linear and rotary glass scales

Scale Pitch 20µm

Signal Period 20µm

System Resolution 1µm, 0.5µm, 0.1µm or 50nm (specify at time of ordering)

Output Frequency (at maximum speed)OPS 200/400: 16.5Mhz per channelOPS 40: 5Mhz per channel OPS 20: 2.5Mhz per channel Note: Output frequency must not exceed maximum input frequency of customerelectronics.

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Appendix BWiring Diagrams

Connector Pin Configuration

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!��'

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� ��

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O.P.S. 15P D-SUB

P

5 Volts0 Volts

Electrically conductive mechanicalconnection (as supplied by MicroESystems).

POWERSUPPLY

INNER SHIELD: Insulated from outer shield, sensor case, andconnector housing. Connected to circuit commoninternally as supplied by MicroE Systems

OUTER SHIELD: Connected tosensor and connector housing

5 Volts0 Volts

POWERSUPPLY

Grounding ConsiderationsSensor mounted with good electrical contact to well grounded surface (preferred):

Sensor mounted to poorly grounded or non-conducting surface:

NOTE: GND and INNER SHIELD ARE INTERNALLY CONNECTED.

Max cable length: 5m. Contact MicroE Applications Engineering if longer length required.

Recommended Signal Termination

Cable Zo=120 W

OPS Series Encoder

CustomerElectronics

120 W

+

-

Digital Outputs: A, B, I

A, B, I

Standard RS-422 Line Receiver Circuitry

Jacket

AluminumPolyesterShied

BraidedShield

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Appendix CInterface Cable Requirements

OPS Series

Signal Twisted PairA+ Pair 1

A-

B+ Pair 2

B-

Index+ Pair 3

Index-

+5V Pair 4

GND

Left Limit Pair 5

Right Limit

1. Customer Interface Cable Requirements Customer cables that interface to OPS™ 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 24AWGgauge wire for a 2m length cable. Examples of acceptable cables with 24AWG gauge wire and 4twisted pairs are Belden 9831, 8104, and 9844 or other manufacturer’s equivalents.

• Single shield cable with a minimum of 90% coverage. Note that a double shielded cable may berequired in high-noise applications.

2. Signal WiringEach differential signal should be connected to a corresponding twisted pair as follows:

Fold braided shield back over jacket. Example shows double-shielded cable.Dimensions shown are for illustration only.

3. Shield Termination:The customer's cable shield should be in 360° contact with the connector shroud and the connector shell toprovide complete shielding. The connector shell should be metal with conductive surfaces. Suggested metalconnector shells for use with OPS™ encoders: AMP 748676-1 or equivalent. The shield should be terminatedas illustrated in the following diagram.

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The OPS Series is RS-422 compatible. Encoder signals are “sending end terminated.” Therefore customerreceiving terminations are not required. If you elect to use them, the supply current will increase.

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

Appendix DRS-422 Compliance

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Appendix ETroubleshooting

ProblemThe Sensor LED indicator won’t turn on.

Solution• Make sure that the OPS Series electronics’ 15-pin D-sub connector is fully seated and connected.

• Confirm that +5 Volts DC is being applied to the OPS Sensor. Refer to the OPS interface drawing forproper pinouts.

ProblemCan't get the OPS Series electronics’ "Signal" OPS better than red or yellow; or the green, “ ProperAlignment” indicator doesn't stay illuminated over the full length of the scale.

Solution• 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 thedimensions for the mechanical mounting holes (and clamps if any) to make sure that the sensor iscorrectly 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.

• Make sure that the scale is clean over its entire length or circumference.

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Appendix FOrder Guide

How to Order

All specifications subject to change.

PurePrecision™ Marker Tape IIHPMT – N – A – L – 5000 – I

I = Individual LengthsC = Continuous reel with index and

cut marks (unless otherwisespecified)

Length in mm (40mm - 30,000mm)For length >5000mm, contactMicroE for custom P/N.

OPS-SM-400 – 3 – 1

Cable Length*1 = 1.0m3 = 3.0m5 = 5.0m

Interpolation (Resolution)20 = x20 (1µm)40 = x40 (0.5µm)200 = x200 (0.1µm)400 = x400 (50nm)

L = Center Index and End LimitsI = Center Index OnlyC = Custom

PurePrecision™ Laser Tape IIHPTS – 30000 – N

Length in mm (70mm - 30,000mm)

Limit Outputs1 = Active Low2 = Active High3 = Disabled

MK-FFA

* Custom cable lengths and connectors are available.Contact MicroE Applications Engineering.

FlexFit Adaptor Mounting Kit. Referencedesign is available upon request.

SM = Side Mount(blank) = Top Mount

End Cap Kit, PurePrecision Tape ScalesEC Optional Tape Scale End Caps

Sensor Scales

Sensor Installation ToolsAT-OPS Alignment Tool Kit for OPS encoders

includes Alignment Tool, SmartPrecision II™Software, USB Cable, Power Supply (100V-240VAC, US 2-prong plug)

ZG-PP1 Z-Height Gauge, PurePrecision™ TapeScales, Top Mount Sensor

ZG-GS1 Z-Height Gauge, Glass Scales, TopMount Sensor

FlexFit™ Adaptor

Stick-on Index and Limit Markers (for Laser Tape II andPerformance and Value Linear Glass Scales)

NRIMS Qty. 8 Stick-On Index Markers NRLMS Qty. 4 Stick-On Left Limit Markers and Qty. 4

Stick-On Right Limit Markers

Rotary Glass

Contact MicroE Applications Engineering to discussyour requirements.

Performance and Value Linear Glass

PVGL – 1000 – T

Length in mm (70mm - 1,000mm)**

T = Adhesive backing

** For lengths <70mm or >1m, contact MicroE ApplicationsEngineering.

TSAT-SM-PPT Tape Applicator Tool for OPS-SM,Side Mount Sensors

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

TSAT-PPT Tape Applicator Tool for OPS, Top Mount Sensors

Adaptor for Open Collector Limit OutputsMIIA-OCL Small DB15 adaptor to convert 3.3V left

and right limit output signals to opencollector type (7407).

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Contacting MicroE

MicroE Systems is a world leader in optical encoder technology withoffices in major industrial centers around the globe.

To learn more about MicroE Systems products, visit:www.microesystems.com.

Our products have been used by thousands of companies worldwide tosolve a wide range of motion control applications. Our advancedencoder technology and application expertise has driven innovations inthe design of machinery, equipment and instrumentation in manyindustries, including medical, industrial, robotics, automation, metrology,semiconductor manufacturing, packaging equipment, entertainment,energy, military, and scientific research.

MicroE Systems125 Middlesex TurnpikeBedford, MA 01730 USAT 781-266-5700F [email protected]

© 2015 MicroE Systems

Page 1

PurePrecision™

Tape and Glass Scale Installationfor OPS Series Encoders

Installation Manualand Reference Guide

MicroE Systems • 125 Middlesex Turnpike • Bedford, MA 01730 • USA www.microesystems.com [email protected] T. 781-266-5700

OPS-IM PurePrecision Scale Installation Rev A1


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Table of ContentsPurePrecision™ Scale Installation

IntroductionIntroduction (Precautions, Patents, Manual Revisions) ............................................................................3Overview ....................................................................................................................................................4Items Required for Scale Installation ........................................................................................................4Pre-Installation Information and Precautions ............................................................................................5Design Guidelines for Side Mount and Top Mount Configurations............................................................6Mounting Surface Preparation for Side Mount and Top Mount Sensors ..................................................7Cutting PurePrecision Tape Scales ..........................................................................................................8

Tape Scale, Lengths <300mm By Hand, for OPS Side Mount and OPS Top Mount ................................................................................9

Tape Scale, Lengths >300mm By Applicator Tool, for OPS Side Mount ................................................................................................13By Applicator Tool, for OPS Top Mount ..................................................................................................19

Linear Glass Scales, OPS Top Mount Mounting Surface Preparation ................................................................................................................25Mounting Linear Glass Scales ................................................................................................................26

Stick-On Index and Limit Marker Installation (Tape and Glass Scales)Packaging, Index and Limit Strips............................................................................................................27Stick-on Index and Limit Installation ........................................................................................................28

End Cap Installation (Tape Scales)End Cap Installation ................................................................................................................................31

Final Clean, Inspection, Cure Time, and Rework ..............................................................32

Contacting MicroE Systems ..............................................................................................................33

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PrecautionsFollow standard ESD precautions. Turn power off before connecting the sensor. Donot touch the electrical pins without static protection such as a grounded wrist strap.

Do not touch the glass scale unless you are wearing talc-free gloves or finger cots.Please read this installation manual for full instructions.

1

2

OPS models are CE and RoHS compliant.

Manual Version NumbersIM-PurePrecision Scales OPS Rev A, issued January 2014

Changes: N/A

Related Documents-OPS Data Sheet-OPS Sensor Installation Manual-OPS Interface Drawing

RoHS

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Overview

This manual applies to the installation of the following scale types.

• PurePrecision Marker Tape II for OPS Series, Model HPMT-

• PurePrecision Laser Tape II for OPS Series, Model HPTS-

• PurePrecision Performance and Value Linear Glass Scales for OPS Series, Model - PVGL-T (adhesive backed)

• PurePrecision Rotory Glass Scales OPS Series, Model - RXXXX

Items Required for PurePrecision Scale Installation

You will need the following items available:

• Shears (recommend, Clauss, Item# 18003)1

• Tape Applicator Tool, for applications >300mm (not required for installations <300mm)1

OPS Side Mount Configuration tool Model Number: TSAT-SM-PPTOPS Top Mount Configuration tool Model Number: TSAT-PPT

• Finger Cots or talc-free gloves1, 2

• Acetone or isopropyl alcohol1, 2

• Lint-free cotton cloths or wipes1, 2

• Index and Limit Marker stick-on sheets or Strips1

(optional, for Laser Tape II and Precision and Value Glass scales):

- Limit Marker Strips, Model Number: NRLMS

- Index Marker Strips, Model Number: NRIMS

• End caps (optional)1

• Two-part epoxy (Tra-Con Tra-Bond 2116)1, 2

• Stick and disposable surface for stirring epoxy1, 2

Refer to encoder model data sheets for detailed ordering guide and more informationabout MicroE Part Numbers.

1Items needed for PurePrecision Tape Scales

2Items needed for Performance and Value Linear Glass Scales

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Pre-Installation Information and Precautions

Read all instructions completely before beginning theinstallation process.

The PurePrecision™ Tape Scale is a precision metrological device. Handle itwith the utmost care at all times.

Avoid bending the tape scale to a radius less than 90mm (3.5inches)

Avoid twisting the PurePrecision Tape Scale.

Do not let any sharp object touch the tape scale after the blueprotective film is removed.

The PurePrecision Tape Scale is protected by a blue film onthe top that prevents contamination and damage to the gratingpattern during installation.

Once the adhesive on the tape scale is exposed (by removingthe adhesive liner), do not touch the adhesive or allow anycontamination to come into contact with it.

PurePrecision Tape Scale, Index and Limit Markers aredesigned for one time installation only.

If removed from the mounting surface for any reason, theyshould not be used for any kind of reapplication. This will affectthe performance and reliability of the encoder system.

Minimumstorage radius

90mm (3.5 inches)

The adhesive on the PurePrecision™ Tape Scale is permanent.

Do not touch the adhesive once the adhesive liner 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.

Avoid any contamination to the adhesive. Any particulate matter or other contamination thatis trapped between the scale and the mounting surface will affect encoder performance.

NOTE: MicroE does not recommend installing PurePrecision Tape Scaleon a curved (cylindrical) surface.

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Design Guidelines

1.Verify the tolerances of the scale's mounting surface given in the Interface Drawing.

2.Verify the dimensions of the scale benching edge (groove or straight edge) given in the Interface Drawing.

3.Calculate the length of PurePrecision™ Tape Scalerequired for your application. Refer to the InterfaceDrawing.

4.Tape scales less than 300mm can be installed byhand against a straight edge. For lengths greaterthan 300mm, tape scale applicator tools areneeded:

Side Mount Configuration: Applicator tool Model Number: TSAT-SM-PPT

Top Mount Configuration:Hand Grip Applicator tool Model Number:

TSAT-PPT

5.If the tape scale is being installed into a 6mmgrove, it must be installed by hand (regardless ofscale length). Refer to the Interface Drawing.

6.If machining the mounting surface is undesirable, or not possible, a temporary straight edge can beused that meets the dimensions and tolerancesspecified in the Interface Drawing.

Two kinds of temporary straight edge can beused -

• Type I (thin)- Temporary Straight Edge of thickness 0.76 ± 0.05 mm (0.030 ± 0.002 inches). Refer to the Interface Drawing for additional dimensional requirements. A steel rule may be one of the options for this type of temporary straight edge.

• Type II (thick)- Temporary straight edge with minimum thickness 9.53mm (0.375 inches). Refer to the Interface Drawing for additional dimensional requirements.

NOTE: See the appropriate section on Tape Applicator Toolinstallations.

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Mounting Surface Preparation

1.Inspect the mounting surface for any machining irregularities. MicroE Systems recommends a surface finishof better than 1.6 micrometers Ra.

2.The straight edge (either permanent or temporary) must be sharp on the benching side in order for theApplicator Tool to use it as a guide. In order for the tape scale to be mounted close to the straight edge, themaximum radius of 0.127 mm (0.005 inches) should be used where the edge meets the bottom of themounting surface.

3.Thoroughly clean the scale mounting surface and reference edge using a cotton swab or lint-free clothdampened with isopropyl alcohol or acetone.

Remove all dust and particles.

4.Mark the starting location on the mounting surface where the tape scale will be applied. Also mark thelocations where the index and limit markers will be applied. Refer to the Interface Drawings to identify thereference points of the markers.

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Cutting the PurePrecision™ Tape Scale

1.

Uncoil the tape scale and cut it to the required length using shears.

Note: check the interface drawing to makesure the scale is cut to the right length.

Securely hold the tape scale closeto the shear (at an approximatedistance of 40mm [1½ inches])near the point of cutting.

Orient the tape scaleperpendicular 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

Shear held inclined, not perpendicular, to the tape scale

NOTE: When working with any encoderscale, it is important to use eitherfinger Cots or talc-free gloves

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Tape Scale, OPS Side/Top Mount ConfigurationsInstallation By Hand

2.Removing/peeling the bottomadhesive liner.

PurePrecision Tape Scales have 3 layers,blue protective film, steel scale, andadhesive backing.

Remove/peel back approximately 25mm (1 inch) of the bottom adhesive liner, taking

care not to touch the adhesive or allow anyparticulate contamination.

NOTE: Do not peel the blue protectivefilm off at this time.

Adhesive liner peeled off about 25mm (1 inch) from one end

D

LEFT RIGHT

1.Scale direction/orientation

Orient the scale such that the "arrowheads" on the blue protective film are pointing towards the mountingsurface reference edge “D” as shown in the interface drawings for your sensor model.

Refer to the correct model number Interface Drawing for reference edge “D” dimensions and sensororientation. Download the latest Interface Drawing at www.microesys.com/products/documentation

D = Mounting Surface Reference Edge

NOTE: For best system performance, talc-free gloves or finger cots should be worn during allsteps of tape scale installation.

Thoroughly clean the scale mounting surface and reference edge using a cotton swabor lint-free cloth dampened with isopropyl alcohol or acetone. Remove all dust andparticles.

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4.Place the PurePrecision™ Tape Scale against the mounting surface “D” reference edge.

Place the 25mm (1 inch) exposed adhesive end of the tape scale against the mounting surface “D” referenceedge as shown and press firmly on the end.

NOTE: Adhesive exposed by removing the adhesive bottom liner can touch the mounting surface only once.

3.Flip the tape over with the 25mm (1 inch) exposed adhesive surface facing down. Be sure not to touch orcontaminate the exposed adhesive surface. Be sure the orientation arrows on the blue protective film point tothe “D” reference edge.

“D” reference edge as shown in theOPS interface drawing.

Tape scale orientation arrows.

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5.Install the PurePrecision Tape Scale along the remaining length of the mounting surface.

Press the remaining tape on to the mounting surface with a sliding motion as shown below.Pull the adhesive liner out of the way during the sliding motion.

NOTE: Make sure that the tape scale is tight against the “D” reference edge.

Pull adhesive liner out of the wayduring sliding motion

Sliding motion of finger along thelength of the tape

NOTE: Be sure to keep the blue top protective film in place.

“D” reference edge as shown in theinterface drawing.

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6.Once the scale is applied to the mounting surface, and before the blue protective film is removed, it isrecommended that even pressure be applied 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 evenly andpermanently set.

7.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 blueprotective film.

NOTE: After removing the blueprotective film, the scale isready for use and willperform to specification.

The encoder will notfunction properly with theblue protective filminstalled. It must beremoved for proper encoderoperation.

NOTE: If installing index/limits(Laser Tape II and PVGLglass), go to the “Stick-OnIndex and Limit MarkerInstallation” section.

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Tape Scale, OPS Side Mount ConfigurationInstallation By Mounted Applicator Tool

1.OPS Side Mounted Tape Scale Applicator Tool (Model Number: TSAT-SM-PPT)

The mounted application tool is needed for scale lengths greater than 300mm. It is mounted in the samefixture as the OPS Side Mount Sensor.

Tool orientationarrows

Tool contact cylinder knob

Tape entrychannel

2.Tape Scale Side Mount Applicator Tool orientation to the “A” reference sensor mounting surface.

The “A” mounting surface is shown in the OPS interface drawing. The corresponding “A” reference mountingsurface of the Applicator Tool is shown below.

Applicator ToolMounting Surface “A”

Mounting Surface “A” (see the OPS interface drawing)

A

AOPS Side Mount SensorMounting Surface “A”

Sensor AlternateMounting Surface*

Applicator Tool AlternateMounting Surface*

*The OPS-SM Tape Scale Applicator Tool, is designed to be mounted on either Sensor mountingsurfaces. The proper orientation of the OPS-SM Applicator Tool in relation to the “A” mounting surfaceand “Alternate mounting surface,” is shown above.

NOTE: For best system performance, talc-free gloves or finger cots should be worn during allsteps of tape scale installation.

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

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3.Mount the Applicator Tool.Mount the Applicator Tool in the Sensor mounting holes. Use the Z-height shim to set up the approximate Z-height, to ensure proper Applicator Tool function.

4.Note tape scale orientation with arrows and the “D” reference edge.

The applicator tool is shown mounted to the OPS Sensor mount. Both Tape Scale arrows, and Applicator Toolorientation arrows need to point in the same direction for proper configuration.

Also note, the “D” reference edge is determined from the OPS interface drawing. The tape scale orientationarrows always point to the “D” reference edge. In the example below, the dotted red line shown is themeasured “D” reference edge. When the tape scale is finally installed, the orientation arrows will be pointing tothe calculated “D” reference edge.

In the example shown, the left side of the tape scale needs to go into the applicator tool entry channel first.

Tape Scaleorientation arrows

Tool orientationarrows

D

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5.Peel off a short section of bottom adhesive backing approximately 50mm (2 inches).PurePrecision Tape Scales have 3 layers, blue protective film, steel scale, and adhesive backing.

Using a sharp tool or fingernail, initiate the peeling of the adhesive liner from the end of the tape scale that willbe inserted into the applicator tool entry channel.

6.Turn Applicator Tool to the “Up” position and insert tape into applicator tool.Rotate the knob that controls the contact cylinder plunger to the UP position. This allows you to insert the firstsection of adhesive exposed tape, into the applicator tool.

Be sure that both the tape scale orientation arrows and the applicator tool arrows point in the same direction.

Tape Scaleorientation arrows

Toolorientation arrows

Plunger in UPposition

Close-up of plunger knob in the UPposition. The position of the keywaysindicates UP or Down. Rotating the knobwill both move the plunger up or down.Adhesive backing

liner

NOTE: Do not peel the blueprotective film off atthis time.

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7.Insert a short section of tape scale into the tool, approximately 50mm (2 inches).Insert the first short section of tape scale so that it emerges just past the plunger knob to a desired endlocation. Press down on this exposed 3-5mm section of tape.

Plunger in the UP positionPress down on thissmall section of tape

8.Rotate the pressure plunger knob to the “Down” position.Rotate the plunger knob so that the key-way notch is in the position shown.

Plunger knob in theDOWN position

Close-up of plunger knob in theDOWN position. Position of notchindicates that the plunger is in theDOWN position.

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9.Move the tool in a steady motion to apply the tape scale.Push the applicator tool in the direction of tape application. Be sure to pull the adhesive backer out of the waywhile the applicator is in motion.

Pull adhesive backer away fromtape applicator, while moving theapplicator tool.

Direction of motion of tapeapplicator tool.


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NOTE: After removing the blue protective film, the scale is ready for use and willperform to specification.

The encoder will not function properly with the blue protective film installed.It must be removed for proper encoder operation.

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

NOTE: Make sure you have on finger cotsor talc-free gloves.

NOTE: If installing index/limits (Laser Tape II and PVGL glass), go to the “Stick-OnIndex and Limit Marker Installation” section.

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Tape Scale, OPS Top Mount ConfigurationInstallation by Hand Grip Applicator Tool

Reference arrows for Tool andtape scale orientation

1.OPS Top Mounted Tape Scale Applicator Tool (Model Number: TSAT-PPT)

The Hand Grip Applicator Tool is needed for tape scale lengths greater than 300mm. It is designed to be handheld and to slide along either a permanent or temporary mounting edge while tape scale is applied.

Tape scale entry channel

2.Hand Grip Applicator Tool mounting surface guide edges.

The had grip applicator tool has two guide edges. One is for low guide edge configurations of thickness 0.76mm(0.030 inches) and one for higher guide edge configurations of thickness greater than 9.5mm (.375 inches).

Refer to the OPS interface drawing for tape scale reference edge “D”

Low guide edge of tool. Mountingsurface edge of thickness 0.76mm(0.030 inches)

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

Low guide edge

D

Low guide edge

NOTE: For best system performance, talc-free gloves or finger cots should be worn during all stepsof tape scale installation.

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

Adhesive backing channel

Adhesive backing exit

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2.Hand Grip Applicator Tool mounting surface guide edges (continued)

Higher guide surface of tool. Mountingsurface reference edge is higher than9.5mm (0.375 inches)

Higher guide edge surfaceTemporary straight edge

Guide surface

D

4.18 ± 0.05mm

D

D = Tape Scale Mounting Surface Reference Edge(See the OPS interface drawings)

3.Orienting the Hand Grip Applicator Tool and PurePrecision II Tape Scale

Both Tape Scale arrows, and Applicator Tool orientation arrows need to point in the same direction forproper orientation.

Also note, the “D” reference edge in the OPS interface drawing. The tape scale orientation arrows alwayspoint to the “D” reference edge. In the example below, the “D” reference edge is shown, with tape scaleorientation arrows pointing to it. The applicator tool orientation arrows are also pointing in the samedirection.

In the example shown below, the left side of the tape scale will need to go into the applicator tool entrychannel first. This tape scale end is referred to as the “correct” end.

Applicator Tool orientation arrows Tape Scale orientation arrows on blue protective film

Left side of tape scale

4.Preparing the tape scale for the applicator tool

PurePrecision Tape Scales have 3 layers, blue protective film, steel scale, and adhesive backing. The top twolayers fit under the dowel pin, while the bottom adhesive backing fits into the backing slot as shown below.

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

Entry slot for adhesivebacking

Exit slot for adhesivebacking

Determine the “correct” end of the tape scale to insertinto the applicator tool entry slot. The correct end isdetermined by the direction of the orientation arrows onboth the tape scale blue protective film and theapplicator tool arrows. Both sets of arrows have to pointin the same direction.

There are different methods to prepare and insert thetape scale and backing into the hand grip applicator toolslots. One method is shown below.

From the “correct” end of the tape scale, peel and curlback 50-75mm (2-3 inches) of the adhesive liner asshown. Take care not to touch the adhesive on thebottom of the tape scale or allow any particlecontamination.

“Correct” tape scale end. All orientationarrows point in the same direction.

NOTE: Do not peel the blue protective film offat this time.

Peel and curl back 50-75mm (2-3inches) of the adhesive liner

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5.Feed the adhesive backing into the applicator tool

Insert the backing film into the applicator tool.


6.Tape Scale Insertion

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

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

6.4 Tape scale fed past front tool roller.

5.2 Adhesive backer exiting from backer slot.5.1 Adhesive backer inserted into backer slot.

6.1 Dowel pin and entry slot. 6.2 Tape inserted.

6.3 Tape inserted with adhesive backing exiting.

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7.Applying 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.

Applicator tool correctlyconfigured for installation.

High guide edge face. Applicator tool presseddown and against highguide edge face.

Slide tool along guide edge face with a slow even pressure motion until all of the tape is installed onthe mounting surface.

Be sure the adhesive backing film does not bunch up and jam inside the tool and exits freely fromthe exit slot.

Applicator tool in motion against guideedge face.

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NOTE: After removing the blue protective film, the scale is ready for use and willperform to specification.

The encoder will not function properly with the blue protective film installed.It must be removed for proper encoder operation .

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

NOTE: If installing index/limits (Laser Tape II and PVGLglass), go to the “Stick-On Index and LimitMarker Installation” section.

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Linear Glass Scales, OPS Side and Top MountConfigurationsInstallation

1.Mounting Surface PreparationInspect the mounting surface for any machining irregularities. MicroE Systems recommends a surface finish ofbetter than 1.6 micrometers Ra and mounting surface flatness of 0.0001 inch/inch.

MicroE Systems

0.2L 0.6L 0.2L

Benching Pins

End Benching Pin (optional)

L

2.“Benching” the linear ScaleMicroE Systems' linear glass scales should be permanently affixed to the mounting surface, using epoxy andthe adhesive attached to the back of the scale.

"Benching" the glass scale to the system means aligning the scale by means of benching pins. Refer to theOPS Interface Drawings for dimensions. The “benching” pins can be set up on either side of the glass scale,but are referenced to the “D” reference edge of the glass scale as shown in the Interface Drawing.

Be sure to use the proper orientation for the “D” linear glass scale reference edge and the OPS Top Mountreference face “B” as shown in the OPS Interface Drawings.

Two benching pins are recommended on either long side of the glass scale and one at either end.

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

Be sure the benching pins do not exceed the height of the linear glass scale to prevent mechanical interferencewith the sensor or sensor mount.

Glass Scale “Benching” Diagram

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Linear Glass Scales, OPS Top Mount ConfigurationsInstallation

3.Mounting linear Glass Scales (with adhesive backing), Model Number PVGL-TMake sure that the mounting surface is dry and clean.

Align the scale by placing the edges against the benching pins.

Peel off the glass scale adhesive backing and press into place.

Apply a hard epoxy, such as Tra-Con’s Tra-Bond 2116, to the one end of the scale (at the end benching pinside, if an end benching pin is used).

Using one end secured with hard epoxy, allows thermal expansion from the benched end of the scale.

Allow the adhesives to fully cure. A cure time of 12 hours is required for the glass scale's pressure sensitiveadhesive to achieve the best performance and reliability.

End Benching Pin

Hard epoxy at one corner, end benchingpin end sideonly.

MicroE Systems

Benching pins

Glass Scale with Adhesive Backing

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Index and Limit Marker “Strip” Packaging

Index and Limit Marker InstallationStick-On Markers for PurePrecision Laser Tape II (HPTS-) and Performance and Value LinearGlass (PVGL-). (Not applicable to PurePrecision Marker Tape II Scales)

Index Marker Strips, Model Number NRIMS

Limit Marker Strips, Model Number NRLMS

Index Strip: 8 Index Markers

Limits Strip: 4-Left and 4-Right*

4-Left 4-Right

*Limit markers have different reflectivityvalues for left and right markers.

Stick-On Index and Limit Markers, Part Numbers

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1.Put on finger cots or gloves before starting theindex and limit markers installation.

NOTE: Before installing the Limit and IndexMarkers, make sure that the blueprotective film from the PurePrecisionTape Scale has been removed.

Begin by holding the Limit and Index Marker strip sothat the blue protective film is on top and the reflectivesurface is at the bottom.

Remove the marker from a perforated strip by gentlytwisting the strip in the area of the marker.

The marker will pull away from the transparentadhesive liner. Holding only the handle section, slowlypull the index marker from the perforated sheet. Thiswill expose the adhesive.

NOTE: Be sure to hold the Index or Limit Markersby the handle only. The adhesive on thehandle section can be touched. However,be careful not to touch the adhesive onthe areas of the markers that will beapplied to the scale.

Handle sectionStick-on Index

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Index and Limit Marker InstallationStick-On Markers for PurePrecision Laser Tape II (HPTS-) and Performance and ValueLinear Glass (PVGL-). (Not applicable to PurePrecision Marker Tape II Scales)

2.Attaching the Index Marker to the Scale

Place the top edge of the marker against the benching edge, holding it at a 45° degreeangle as shown in the photo. This keeps theadhesive away from the scale, until themarker is the correct location, before beingpressed into place.

If the scale is installed with an offset from itsreference edge, a temporary reference edgesurface such as a small metal block must beused for the index and limit markers.

When the marker is tight against thereference edge, press the marker onto thescale with your finger.

Benching edge (“D” reference edge)

Index Marker

USE FINGER COTS or Gloves

NOTE: Be sure to remove the blue protective film from the top of the tape scalesbefore applying stick-on index and limit markers.

For benching edge requirements, refer to the Interface Drawings forOPS. The benching edge corresponds to the “D” reference edge in theinterface drawings.

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

Carefully remove the blue protective film from themarker surface.

NOTE: Use fingernails or plastic tweezers to remove the blue protective film, but do not use a hard metal object.Using a hard metal object mightdamage the grating on thePurePrecision Tape Scale.

4.Apply the left and right limit markers, if applicable.Repeat steps 1-3.

Peel blue protective film

Stick-on marker installed

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End Cap Installation for Tape ScalesOptional

1.Epoxy Setup

• 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.

• 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.

Only apply epoxy at theends of the tape scale. Donot get any epoxy on thetape scale in themeasuring area.

• Perform Step 2, immediately while the epoxy is still in a liquid state.

2.Installing the End Caps on the Mounting Surface

• Remove the adhesive liner from end cap.

• 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.

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

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Final Cleaning, Inspection and Cure TimeBefore using the encoder for servo control, clean the tape scale, index marker and limit markers using alcoholor acetone and a lint-free cotton cloth or swab. Finally, inspect the tape scale's surface for scratches, adhesivespots or smears in the measuring length.

A cure time of 12 hours is required for the tape scale's pressure sensitive adhesive to achieve the bestperformance and reliability.

Reworking to Correct Mistakes

Once installed, the tape scale, the index marker, and the limit markers cannot be moved or removed andreinstalled. Reworking will require removal and discarding of the old tape 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 asthere is no damage to the scale’s surface. Do not use a tool made of metal or other hard material to removethe markers. Clean the scale’s surface completely of any adhesive residue before applying new markers.

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Contacting MicroE

MicroE Systems is a world leader in optical encoder technology withoffices in major industrial centers around the globe.

To learn more about MicroE Systems products, visit:www.microesystems.com.

Our products have been used by thousands of companies worldwide tosolve a wide range of motion control applications. Our advancedencoder technology and application expertise has driven innovations inthe design of machinery, equipment and instrumentation in manyindustries, including medical, industrial, robotics, automation, metrology,semiconductor manufacturing, packaging equipment, entertainment,energy, military, and scientific research.

MicroE Systems125 Middlesex TurnpikeBedford, MA 01730 USAT 781-266-5700F [email protected]
