Newport ESP6000 User manual

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ESP6000
UNIDRIVE6000
U SER ’ S M ANUAL
Motion Controller/Driver
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i
ESP6000 UNIDRIVE6000
Motion Controller/Driver
USER’SMANUAL
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ii
Warranty
Newport Corporation warrants this product to be free from defects in
material and workmanship for a period of one year from the date of ship-
ment. If found to be defective during the warranty period, the product will
either be repaired or replaced at Newport’s option.
To exercise this warranty, write or call your local Newport office or repre-
sentative, or contact Newport headquarters in Irvine, California. You will
be given prompt assistance and return instructions. Send the instrument,
transportation prepaid, to the indicated service facility. Repairs will be
made and the instrument returned, transportation prepaid. Repaired
products are warranted for the balance of the original warranty period, or
at least 90 days.
Limitation of Warranty
This warranty does not apply to defects resulting from modification or
misuse of any product or part. This warranty also does not apply to fuses,
batteries, or damage from battery leakage.
This warranty is in lieu of all other warranties, expressed or implied,
including any implied warranty of merchantability or fitness for a particular
use. Newport Corporation shall not be liable for any indirect, special, or
consequential damages.
First Printing October, 1997
Copyright 1997 by Newport Corporation, Irvine, CA. All rights reserved.
No part of this manual may be reproduced or copied without the prior
written approval of Newport Corporation.
This manual has been provided for information only and product specifica-
tions are subject to change without notice. Any changes will be reflected in
future printings.
© 1997 Newport Corporation
1791 Deere Ave
Irvine, CA 92714
[phone]
P/N 22945-01, Rev. C
IN-04971 (1-98)
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iii
EC DECLARATION OF CONFORMITY
We declare that the accompanying product, identified with the
"" mark, meets the intent of the Electromagnetic Compatibility
Directive, 89/336/EEC and Low Voltage Directive 73/23/EEC.
Compliance was demonstrated to the following specifications:
EN50081-1 EMISSIONS:
Radiated and conducted emissions per EN55011, Group 1,
Class A
EN50082-1 IMMUNITY:
Electrostatic Discharge per IEC 1000-4-2, severity level 3
Radiated Emission Immunity per IEC 1000-4-3, severity level 2
Fast Burst Transients per IEC 1000-4-4, severity level 3
Surge Immunity per IEC 1000 4-5, severity level 3
IEC SAFETY:
Safety requirements for electrical equipment specified in
IEC 1010-1.
Alain Danielo Jeff Cannon
VP European Operations General Manager-Precision Systems
Zone Industrielle 1791 Deere Avenue
45340 Beaune-la-Rolande, France Irvine, CA USA
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iv
Table of Contents
Warranty ................................................................................................................ ii
EC DECLARATION OF CONFORMITY ................................................................ iii
List of Figures ....................................................................................................... ix
List of Tables ....................................................................................................... xii
Section 1 — Introduction␣ ...................................................................... 1-1
1.1 Scope .................................................................................................... 1-1
1.2 Safety Considerations ........................................................................ 1-2
1.3 Conventions And Definitions ............................................................ 1-3
1.3.1 Definitions and Symbols ........................................................ 1-3
1.3.2 Terminology............................................................................. 1-5
1.4 System Overview ................................................................................ 1-6
1.4.1 Features .................................................................................... 1-7
1.4.2 Specifications .......................................................................... 1-8
1.4.2.1 ESP6000 Controller Card........................................... 1-8
1.4.2.2 UniDrive6000 Universal Motor Driver..................... 1-9
1.4.2.3 Environmental Limits ................................................ 1-9
Section 2 — System Setup␣ ..................................................................... 2-1
2.1 Unpacking ............................................................................................ 2-1
2.2 PC Hardware and Software Requirements...................................... 2-2
2.3 Equipment Controls and Indicators ................................................ 2-2
2.4 Installation and Connection .............................................................. 2-5
2.4.1 Installing the ESP6000 Controller Card and
Software Driver ....................................................................... 2-5
2.4.2 Installing Windows Software ................................................. 2-9
2.4.3 Verifying Communication Between the ESP6000 Card
and the PC .............................................................................. 2-15
2.4.4 Selecting The UniDrive6000 Line Voltage .......................... 2-16
2.4.5 Connecting Stages ................................................................. 2-18
2.4.6 Connecting the UniDrive6000 to the
ESP6000 Controller Card ...................................................... 2-19
Section 3 — Quick Start␣ ......................................................................... 3-1
3.1 General Description ........................................................................... 3-1
3.2 Motor On.............................................................................................. 3-1
3.3 Homing a Stage ................................................................................... 3-3
3.4 Jog ......................................................................................................... 3-4
3.5 System Shut-Down .............................................................................. 3-6
Section 4 — Windows Utilities␣ ........................................................... 4-1
4.1 Motion Utility ...................................................................................... 4-1
4.1.1 General Description ................................................................ 4-1
4.1.2 Features .................................................................................... 4-1
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Table of Contents v
4.1.3 Operation ................................................................................. 4-1
4.1.3.1 File Menu .................................................................... 4-3
4.1.3.1.1 Reset System ......................................... 4-3
4.1.3.1.2 Save ........................................................ 4-3
4.1.3.1.3 Advanced ............................................... 4-3
4.1.3.1.4 Demo Mode ........................................... 4-3
4.1.3.1.5 Exit .......................................................... 4-4
4.1.3.2 Setup Menu ................................................................ 4-4
4.1.3.2.1 Motion .................................................... 4-5
4.1.3.2.2 Faults ...................................................... 4-7
4.1.3.2.3 Hardware ............................................... 4-8
4.1.3.2.4 Firmware .............................................. 4-11
4.1.3.2.5 UniDrive ............................................... 4-11
4.1.3.3 Motion Menu ............................................................ 4-12
4.1.3.3.1 Stop ...................................................... 4-12
4.1.3.3.2 Home .................................................... 4-12
4.1.3.3.3 Jog......................................................... 4-12
4.1.3.3.4 Cycle ..................................................... 4-12
4.1.3.3.5 Enable................................................... 4-13
4.1.3.4 Status Menu.............................................................. 4-13
4.1.3.4.1 Position ................................................ 4-14
4.1.3.5 Help Menu ................................................................ 4-14
4.1.3.5.1 About ESP 6000 ................................... 4-15
4.2 Servo Tuning Utility ......................................................................... 4-15
4.2.1 General Description .............................................................. 4-15
4.2.2 Features .................................................................................. 4-15
4.2.3 Operation ............................................................................... 4-15
Section 5 — Programming␣ .................................................................... 5-1
5.1 General Description ........................................................................... 5-1
5.1.1 Windows Programming .......................................................... 5-1
5.1.2 How To Use The Dynamic Link Library ............................... 5-1
5.2 Description of Commands ................................................................. 5-1
5.3 Commands ........................................................................................... 5-2
5.3.1 Command Summary ............................................................... 5-2
5.3.2 Command List ......................................................................... 5-6
Initialization␣ ............................................................................ 5-7
Configuration␣ ........................................................................ 5-11
Motion␣ ................................................................................... 5-31
Trajectory .............................................................................. 5-43
Motion-Related ...................................................................... 5-57
Servo ....................................................................................... 5-77
Data Acquisition .................................................................... 5-85
Digital I/O ............................................................................... 5-99
System .................................................................................. 5-105
5.4 User Programming ......................................................................... 5-109
5.4.1 Visual C ................................................................................. 5-109
5.4.1.1 Overview ................................................................ 5-109
5.4.1.2 Examples ................................................................ 5-109
5.4.2 Visual Basic .......................................................................... 5-109
5.4.2.1 Overview ................................................................ 5-109
5.4.2.2 Examples ................................................................ 5-109
5.4.3 LabVIEW ............................................................................... 5-109
5.4.3.1 Overview ................................................................ 5-109
5.4.3.2 Example(s) ............................................................. 5-110
5.4.4 Error Handling ..................................................................... 5-111
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Section 6 — Motion Control Tutorial␣ .............................................. 6-1
6.1 Motion Systems .................................................................................. 6-1
6.2 Specification Definitions .................................................................... 6-2
6.2.1 Following Error ........................................................................ 6-2
6.2.2 Error .......................................................................................... 6-3
6.2.3 Accuracy .................................................................................. 6-3
6.2.4 Local Accuracy ........................................................................ 6-4
6.2.5 Resolution ................................................................................ 6-4
6.2.6 Minimum␣ Incremental Motion............................................... 6-5
6.2.7 Repeatability ............................................................................ 6-6
6.2.8 Backlash (Hysteresis) ............................................................ 6-6
6.2.9 Pitch, Roll, and Yaw ................................................................ 6-7
6.2.10 Wobble ..................................................................................... 6-8
6.2.11 Load Capacity .......................................................................... 6-9
6.2.12 Maximum Velocity .................................................................. 6-9
6.2.13 Minimum Velocity ................................................................... 6-9
6.2.14 Velocity Regulation ............................................................... 6-10
6.2.15 Maximum Acceleration ........................................................ 6-10
6.2.16 Combined Parameters .......................................................... 6-11
6.3 Control Loops ................................................................................... 6-11
6.3.1 PID Servo Loops .................................................................... 6-12
6.3.2 Feed-Forward Loops ............................................................. 6-14
6.4 Motion Profiles.................................................................................. 6-15
6.4.1 Move ....................................................................................... 6-15
6.4.2 Jog ........................................................................................... 6-16
6.4.3 Home Search .......................................................................... 6-17
6.5 Encoders ............................................................................................ 6-19
6.6 Motors ................................................................................................ 6-22
6.6.1 Stepper Motors...................................................................... 6-22
6.6.2 DC Motors .............................................................................. 6-27
6.7 Drivers ................................................................................................ 6-28
6.7.1 Stepper Motor Drivers ......................................................... 6-28
6.7.2 DC Motor Drivers .................................................................. 6-30
Section 7 — Servo Tuning␣ ..................................................................... 7-1
7.1 Tuning Principles ............................................................................... 7-1
7.2 Tuning Procedures ............................................................................. 7-1
7.2.1 Hardware And Software Requirements ............................... 7-2
7.2.2 Correcting Axis Oscillation .................................................... 7-2
7.2.3 Correcting Following Error .................................................... 7-2
7.2.4 Points To Remember .............................................................. 7-4
Section 8 — Optional Equipment␣ ...................................................... 8-1
8.1 ESP6000 Controller Card ................................................................... 8-1
8.1.1 Terminal Block Board ............................................................ 8-1
8.1.2 Analog I/O Cable...................................................................... 8-3
8.1.3 Digital I/O Cable ...................................................................... 8-4
8.1.4 Auxiliary I/O Cable .................................................................. 8-5
8.1.5 Driver Interface (100-100 pin) Cable .................................... 8-6
8.1.6 Motor/Driver (100-68 pin) Cable ........................................... 8-6
8.2 UniDrive6000 ....................................................................................... 8-7
8.2.1 Motor Driver Card................................................................... 8-7
8.2.2 Rack-Mount Ears ..................................................................... 8-9
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Table of Contents vii
Section 9 — Advanced Capabilities␣ ................................................. 9-1
9.1 Motion Control Software Overview ................................................. 9-1
9.1.1 Introduction ............................................................................. 9-1
9.1.2 Control API ............................................................................... 9-1
9.1.2.1 System Initialization .................................................. 9-1
9.1.2.2 Configuration ............................................................. 9-1
9.1.2.3 Axis Control ................................................................ 9-2
9.1.3 Trajectory Control Process ................................................... 9-2
9.2 Data Acquisition Overview ............................................................... 9-2
9.3 PCI Bus Overview ............................................................................... 9-4
Appendix A — Error Messages␣ ........................................................... A-1
Appendix B — Trouble-Shooting and Maintenance␣ ................ B-1
B.1 Trouble-Shooting Guide..................................................................... B-1
B.2 Fuse Replacement .............................................................................. B-3
B.2.1 Replacing Fuses On The UniDrive Rear
Power Line Panel..................................................................... B-3
B.2.2 Replacing Fuses On The UniDrive Motor
Power Supply Board ............................................................... B-4
B.3 Cleaning ............................................................................................... B-7
Appendix C — Connector Pin Assignments␣ ................................ C-1
C.1 ESP6000 Controller Card ................................................................... C-1
C.1.1 Main I/O (100-Pin) Connector ............................................... C-2
C.1.2 Motor/Driver Interface (100-to-68 Pin) Cable ..................... C-6
C.1.3 Digital I/O (50-Pin) JP4 Connector ........................................ C-9
C.1.4 Auxiliary I/O (40-Pin) JP5 Connector ................................. C-11
C.1.5 Analog I/O (26-Pin) JP2 Connector ..................................... C-15
C.2 UniDrive6000 Universal Motor Driver ........................................... C-17
C.2.1 Controller Input Connector ................................................. C-17
C.2.2 Motor Driver Card 25-Pin I/O Connector ........................... C-17
C.3 Terminal Block Board ...................................................................... C-21
C.3.1 MD4 15-Pin Connector .......................................................... C-22
C.3.2 Eighteen-Lead Connector..................................................... C-24
C.3.3 Optional Power Supply Connector ..................................... C-26
C.3.4 Nine-Lead Connector ............................................................ C-27
C.3.5 Jumpers .................................................................................. C-28
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viii
Appendix D — Binary Conversion Table␣ ...................................... D-1
Appendix E — System Upgrades␣ ....................................................... E-1
E.1 ESP6000 Controller Card ................................................................... E-1
E.1.1 Installing New Software .......................................................... E-1
E.1.2 Installing New Firmware ........................................................ E-4
Appendix F — ESP Configuration Logic␣ ........................................ F-1
Appendix G — Factory Service␣ .......................................................... G-1
Service Form ...................................................................................................... G-3
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Table of Contents ix
List of Figures
Figure 1.4-1 — ESP6000 Controller Card ...........................................................................................................................1-6
Figure 1.4-2 — ESP Configuration ......................................................................................................................................1-7
Figure 2.3-1 — ESP6000 Controller Card ...........................................................................................................................2-2
Figure 2.3-2 — UniDrive6000 Front and Rear View ..........................................................................................................2-4
Figure 2.4-1 — Enclosure Removal ....................................................................................................................................2-6
Figure 2.4-2 — ESP6000 Controller Card Insertion Orientation .......................................................................................2-7
Figure 2.4-3 — Controller Card Device Driver Prompt (Representative Screen Only) .................................................2-7
Figure 2.4-4 — Install From Disk Message (Representative Screen Only)......................................................................2-8
Figure 2.4-5 — System Settings Change Message (Representative Screen Only) ...........................................................2-8
Figure 2.4-6 — Windows 95 Start-Up Screen .....................................................................................................................2-9
Figure 2.4-7 — Control Panel Menu ...................................................................................................................................2-9
Figure 2.4-8 — Add/Remove Programs Properties Menu ...............................................................................................2-10
Figure 2.4-9 — Install Program From Floppy Disk Or CD-ROM Screen ......................................................................... 2-11
Figure 2.4-10 — Run Installation Program .......................................................................................................................2-11
Figure 2.4-11 — ESP Welcome Screen .............................................................................................................................2-12
Figure 2.4-12 — ESP Select Destination Directory Screen .............................................................................................. 2-12
Figure 2.4-13 — ESP Ready To Install Screen ..................................................................................................................2-13
Figure 2.4-14 — Installing Message Screen......................................................................................................................2-14
Figure 2.4-15 — Insert New Disk Message Screen ..........................................................................................................2-14
Figure 2.4-16 — ESP Installation Completed Screen .......................................................................................................2-15
Figure 2.4-17 — ESP Initialization Screen .......................................................................................................................2-15
Figure 2.4-18 — ESP6000 Error Message Screen .............................................................................................................2-16
Figure 2.4-19 — Line Voltage Select Switch .....................................................................................................................2-17
Figure 2.4-20 — Stage To UniDrive Connection ..............................................................................................................2-18
Figure 2.4-21 — UniDrive To Controller Card Connection ............................................................................................. 2-19
Figure 3.2-1 — Motion Drop-Down Menu ..........................................................................................................................3-2
Figure 3.2-2 — Motor Power Menu .....................................................................................................................................3-2
Figure 3.3-1 — Home Stages Menu.....................................................................................................................................3-3
Figure 3.4-1 — Jog Menu .....................................................................................................................................................3-4
Figure 3.4-2 — Speed Menu ................................................................................................................................................3-5
Figure 3.4-3 — Set X(Y) Speed Menu .................................................................................................................................3-5
Figure 4.1-1 — Main Menu ..................................................................................................................................................4-2
Figure 4.1-2 — File Menu ....................................................................................................................................................4-3
Figure 4.1-3 — Setup Menu .................................................................................................................................................4-4
Figure 4.1-4 — Setup Resolution Sub-Menu .......................................................................................................................4-5
Figure 4.1-5 — Motion Setup PID Tab ................................................................................................................................4-6
Figure 4.1-6 — Motion Setup Trajectory Tab .....................................................................................................................4-6
Figure 4.1-7 — Setup Faults Sub-Menu ...............................................................................................................................4-7
Figure 4.1-8 — Setup Hardware Amplifier I/O Tab ...........................................................................................................4-8
Figure 4.1-9 — Setup Hardware Analog I/O Tab .............................................................................................................. 4-9
Figure 4.1-10 — Setup Hardware Digital I/O Tab .............................................................................................................4-9
Figure 4.1-11 — Setup Hardware Servo DAC Offset Tab ................................................................................................4-10
Figure 4.1-12 — Setup Hardware Travel Limit Tab .........................................................................................................4-10
Figure 4.1-13 — Setup UniDrive Sub-Menu ......................................................................................................................4-11
Figure 4.1-14 — Motion Menu...........................................................................................................................................4-12
Figure 4.1-15 — Stop Button .............................................................................................................................................4-12
Figure 4.1-16 — Cycle Motors Sub-Menu ..........................................................................................................................4-13
Figure 4.1-17 — Status Menu ............................................................................................................................................4-13
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x
Figure 4.1-18 — Position Status Menu ..............................................................................................................................4-14
Figure 4.1-19 — Help Menu ..............................................................................................................................................4-14
Figure 4.1-20 — About Screen ..........................................................................................................................................4-15
Figure 4.2-1 — Servo Tuning Main Screen ......................................................................................................................4-16
Figure 5.4-1 — VI Front Panel .........................................................................................................................................5-105
Figure 6.1-1 —Typical Motion Control System ..................................................................................................................6-1
Figure 6.2-1 — Position Error Test .....................................................................................................................................6-3
Figure 6.2-2 — High Accuracy for Small Motions ..............................................................................................................6-4
Figure 6.2-3 — Low Accuracy for Small Motions...............................................................................................................6-4
Figure 6.2-4 — Effect of Stiction and Elasticity on Small Motions ...................................................................................6-5
Figure 6.2-5 — Error Plot ....................................................................................................................................................6-5
Figure 6.2-6 — Error vs. Motion Step Size .........................................................................................................................6-6
Figure 6.2-7 — Hysteresis Plot ............................................................................................................................................6-7
Figure 6.2-8 — Real vs. Ideal Position ...............................................................................................................................6-7
Figure 6.2-9 — Pitch, Yaw, and Roll Motion Axes .............................................................................................................6-8
Figure 6.2-10 — Pitch, Yaw and Roll ..................................................................................................................................6-8
Figure 6.2-11 — Wobble ......................................................................................................................................................6-8
Figure 6.2-12 — Position, Velocity, and Average Velocity ................................................................................................6-9
Figure 6.3-1 — Servo Loop ................................................................................................................................................6-11
Figure 6.3-2 — P Loop .......................................................................................................................................................6-12
Figure 6.3-3 — PI Loop ......................................................................................................................................................6-13
Figure 6.3-4— PID Loop ....................................................................................................................................................6-13
Figure 6.3-5 — Trapezoidal Velocity Profile ....................................................................................................................6-14
Figure 6.3-6 — PID Loop with Feed-Forward ...................................................................................................................6-14
Figure 6.3-7 — Tachometer-Driven PIDF Loop ................................................................................................................6-15
Figure 6.4-1— Trapezoidal Motion Profile ......................................................................................................................6-16
Figure 6.4-2 — Position and Acceleration Profiles ..........................................................................................................6-16
Figure 6.4-3 — Origin Switch and Encoder Index Pulse .................................................................................................6-17
Figure 6.4-4 — Slow-Speed Origin Switch Search ........................................................................................................... 6-18
Figure 6.4-5 — High/Low-Speed Origin Switch Search ...................................................................................................6-18
Figure 6.4-6 — Origin Search From Opposite Direction .................................................................................................6-18
Figure 6.5-1 — Encoder Quadrature Output ....................................................................................................................6-19
Figure 6.5-2 — Optical Encoder Scale..............................................................................................................................6-20
Figure 6.5-3 — Optical Encoder Read Head ....................................................................................................................6-20
Figure 6.5-4 — Single-Channel Optical Encoder Scale and Read Head Assembly ....................................................... 6-20
Figure 6.5-5 — Two-Channel Optical Encoder Scale and Read Head Assembly ..........................................................6-21
Figure 6.6-1 — Stepper Motor Operation .........................................................................................................................6-22
Figure 6.6-2 — Four-Phase Stepper Motor .......................................................................................................................6-22
Figure 6.6-3 — Phase Timing Diagram ............................................................................................................................6-23
Figure 6.6-4 — Energizing Two Phases Simultaneously .................................................................................................6-23
Figure 6.6-5 — Timing Diagram, Half-Stepping Motor ....................................................................................................6-24
Figure 6.6-6 — Energizing Two Phases with Different Intensities .................................................................................6-24
Figure 6.6-7 — Timing Diagram, Continuous Motion (Ideal) ........................................................................................6-24
Figure 6.6-8 — Timing Diagram, Mini-Stepping ..............................................................................................................6-24
Figure 6.6-9 — Single Phase Energization .......................................................................................................................6-25
Figure 6.6-10 — External Force Applied ..........................................................................................................................6-25
Figure 6.6-11 — Unstable Point ........................................................................................................................................6-25
Figure 6.6-12 — Torque and Tooth Alignment.................................................................................................................6-26
Figure 6.6-13 — DC Motor .................................................................................................................................................6-27
Figure 6.7-1 — Simple Stepper Motor Driver ...................................................................................................................6-29
Figure 6.7-2 — Current Build-up in Phase ........................................................................................................................6-29
Figure 6.7-3 — Effect of a Short ON Time on Current .....................................................................................................6-29
Figure 6.7-4 — Motor Pulse with High Voltage Chopper .................................................................................................6-30
Figure 6.7-5 — DC Motor Voltage Amplifier ....................................................................................................................6-30
Figure 6.7-6 — DC Motor Current Driver .........................................................................................................................6-31
Figure 6.7-7 — DC Motor Velocity Feedback Driver........................................................................................................6-31
Figure 6.7-8 — DC Motor Tachometer Gain and Compensation ....................................................................................6-32
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Table of Contents xi
Figure 8.1-1 — Terminal Block Board ...............................................................................................................................8-2
Figure 8.1-2 — Analog I/O Cable .......................................................................................................................................8-3
Figure 8.1-3 — Digital I/O Cable ........................................................................................................................................8-4
Figure 8.1-4 — Auxiliary I/O Cable Connections ..............................................................................................................8-5
Figure 8.1-5 — Driver Interface (100-100 pin) Cable ........................................................................................................8-6
Figure 8.1-6 — Motor/Driver (100-68 pin) Cable ..............................................................................................................8-6
Figure 8.2-1 — Driver Card .................................................................................................................................................8-7
Figure 8.2-2 — Driver Card Installation .............................................................................................................................8-8
Figure 8.2-3— Rack-Mount Ear Installation .......................................................................................................................8-9
Figure 9.2-1 — Analog-To-Digital Flow Diagram ...............................................................................................................9-2
Figure B.2-1 — Rear Power Line Panel Fuse Replacement ............................................................................................. B-3
Figure B.2-2 — Rear Power Line Board Removal ............................................................................................................ B-5
Figure B.2-3 — Power Supply Board Removal ................................................................................................................. B-6
Figure B.2-4 — Power Supply Board Fuse Replacement ................................................................................................. B-7
Figure C.1-1 — Main I/O (100-Pin) Connector Orientation............................................................................................. C-1
Figure C.1-2 — One-Hundred to Sixty-Eight Pin Cable Connector Orientation............................................................... C-2
Figure C.1-3 — JP2/JP4/JP5 Connector Orientation ........................................................................................................ C-2
Figure C.2-1 — UniDrive Controller Input Connector Orientation ................................................................................ C-17
Figure C.2-2 — Driver Card Connector Orientation ....................................................................................................... C-17
Figure C.3-1 — Terminal Block Board Connector Orientation ...................................................................................... C-21
Figure E.1-1 — Add/Remove Programs Properties Screen ............................................................................................. E-2
Figure E.1-2 — Select Uninstall Method Screen ............................................................................................................... E-3
Figure E.1-3 -— Perform Uninstall Screen ......................................................................................................................... E-3
Figure E.1-4 — ESP6000 Setup Menu ............................................................................................................................... E-4
Figure E.1-5 — Update Firmware Message Screen .......................................................................................................... E-4
Figure E.1-6 — Open Screen .............................................................................................................................................. E-5
Figure E.1-7 — Firmware Update Screen .......................................................................................................................... E-5
Figure E.1-8 — ESP6000 Initialization Screen .................................................................................................................. E-6
Figure F-1 — Configuration Logic .......................................................................................................................................F-1
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xii
List of Tables
Table 2.3-1 — ESP6000 Controls And Indicators ...............................................................................................................2-3
Table 2.3-2 — UniDrive6000 Controls And Indicators ......................................................................................................2-4
Table 4.1-1 — Stage (Motor) Type Settings .......................................................................................................................4-2
Table 4.1-2 — Stage (Motor) Trajectory Settings ..............................................................................................................4-2
Table 5.2-1 — Software Version Requirements .................................................................................................................5-1
Table 5.2-2 — API Function Categories ..............................................................................................................................5-2
Table 5.3-1 — Commands ...................................................................................................................................................5-2
Table 7.2-1 — Servo Parameter Functions ........................................................................................................................7-5
Table 8-1 — Optional Equipment .......................................................................................................................................8-1
Table 8.1-1 — Terminal Block Board Functions ...............................................................................................................8-2
Table 8.1-2 — Analog I/O Cable Connections...................................................................................................................8-3
Table 8.1-3 — Digital I/O Cable Connections ...................................................................................................................8-4
Table 8.1-4 — Auxiliary I/O Connections .........................................................................................................................8-5
Table 9.2-1 — Acquisition Array ........................................................................................................................................9-3
Table 9.2-2 — Data Acquisition Commands ...................................................................................................................... 9-4
Table 9.3-1 — PCI Design Goals .........................................................................................................................................9-5
Table A-1 — Error Messages ............................................................................................................................................. A-2
Table B.1-1 — Trouble-Shooting Guide ............................................................................................................................. B-2
Table C.1-1 — Main I/O Connector Pin-Outs .................................................................................................................... C-3
Table C.1-2. — Motor/Driver Interface (100-to-68 pin) Cable Connector Pin-Outs ....................................................... C-7
Table C.1-3 — Digital Connector Pin-Outs ...................................................................................................................... C-10
Table C.1-4 — Auxiliary Connector Pin-Outs .................................................................................................................. C-12
Table C.1-5 — Analog Connector Pin-Outs ..................................................................................................................... C-15
Table C.2-1 — Driver Card Connector Pin-Outs .............................................................................................................. C-18
Table C.3-1 — MD4 Connector Pin-Outs ......................................................................................................................... C-22
Table C.3-2 — Eighteen-Lead Upper Connector Pin-Outs .............................................................................................. C-24
Table C.3-3 — Eighteen-Lead Lower Connector Pin-Outs .............................................................................................. C-25
Table C.3-4 — Optional Power Supply Connector Pin-Outs .......................................................................................... C-26
Table C.3-5 — Nine-Pin Connector Pin-Outs ................................................................................................................... C-27
Table C.3-6 — Jumpers .................................................................................................................................................... C-28
Table G-1 — Technical Customer Support Contacts ........................................................................................................ G-1
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Section 1 — Introduction 1-1
Section 1
Introduction
1.1 Scope
This manual provides descriptions and operating procedures for the
Enhanced System Performance (ESP) motion system, consisting of the
ESP6000 controller card, UniDrive6000 universal motor driver, and
various stages.
Safety considerations, conventions and definitions, and a system overview
are provided in Section 1, Introduction.
Procedures for unpacking the equipment, hardware and software require-
ments, descriptions of controls and indicators, and setup procedures are
provided in Section 2, System Setup.
Instructions for configuring and powering up the UniDrive and stage motors,
for home and jog motions, and for system shut-down are provided in
Section 3, Quick Start.
Features and operation of the Windows motion and tuning utilities are
described in Section 4.
Newport-provided commands, language-specific information, and error-
handling procedures are provided in Section 5, Programming.
An overview of motion parameters and equipment is provided in Section 6,
Motion Control Tutorial.
Servo tuning principles and procedures are given in Section 7.
Procedures for ordering, installing, and using optional equipment are
provided in Section 8.
The motion control software, data acquisition, and Peripheral Component
Interconnect (PCI) bus structure, are described in Section 9, Advanced
Capabilities.
The following information is provided in the Appendices:
– Error messages
– Trouble-shooting and maintenance
– Connector pin assignments
– Decimal/ASCII/binary conversion table
– System upgrades for software and firmware
– ESP configuration logic
– Factory service
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1-2
1.2 Safety Considerations
The following general safety precautions must be observed during all phases
of operation of this equipment. Failure to comply with these precautions
or with specific warnings elsewhere in this manual violates safety standards
of design, manufacture, and intended use of the equipment.
Disconnect or do not plug in the power cord in the following circumstances:
– If the power cord or any other attached cables are frayed or damaged.
– If the power plug or receptacle is damaged.
– If the unit is exposed to rain or excessive moisture, or liquids are
spilled on it.
– If the unit has been dropped or the case is damaged.
– If you suspect service or repair is required.
– When you clean the case.
To protect the equipment from damage and avoid hazardous situations,
follow these recommendations:
– Do not open the UniDrive6000 except to replace the rear power line
panel fuses and power supply board fuse (see Appendix B, Trouble
Shooting). There are no user-serviceable parts inside the UniDrive.
– Do not make modifications or parts substitutions.
– Return equipment to Newport Corporation for service and repair.
– Do not touch, directly or with other objects, live circuits inside the unit.
– Do not operate the unit in an explosive atmosphere.
– Keep air vents free of dirt and dust.
– Do not block air vents.
– Keep liquids away from unit.
– Do not expose equipment to excessive moisture (>90% humidity).
WARNING
All attachment plug receptacles in the vicinity of this unit are to be of
the grounding type and properly polarized. Contact an electrician to
check faulty or questionable receptacles.
WARNING
This product is equipped with a 3-wire grounding type plug. Any
interruption of the grounding connection can create an electric shock
hazard. If you are unable to insert the plug into your wall plug
receptacle, contact an electrician to perform the necessary alterations to
assure that the green (green-yellow) wire is attached to earth ground.
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Section 1 — Introduction 1-3
WARNING
This product operates with voltages that can be lethal. Pushing objects
of any kind into cabinet slots or holes, or spilling any liquid on the
product, may touch hazardous voltage points or short out parts.
WARNING
Opening or removing covers will expose you to hazardous voltages.
observe the following precautions:
• Turn power OFF and unplug the unit from its power source;
• Disconnect all cables;
• Remove jewelry from hands and wrists;
• Use insulated hand tools only;
• Maintain grounding by wearing a wrist strap attached to instru-
ment chassis.
1.3 Conventions And Definitions
This section provides a list of symbols and their definitions, and com-
monly-used terms found in this manual.
1.3.1 Definitions and Symbols
The following are definitions of safety and general symbols used on
equipment or in this manual.
Warning. Calls attention to a procedure, practice or condition which, if
not correctly performed or adhered to, could result in injury or death.
WARNING
Caution. Calls attention to a procedure, practice, or condition which, if not
correctly performed or adhered to, could result in damage to equipment.
CAUTION
Note. Calls attention to a procedure, practice, or condition which is
considered important to remember in the context.
NOTE
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1-4
This symbol indicates the principal on/off switch is in the on position.
This symbol indicates the principal on/off switch is in the off position.
A terminal which is used to connect instrument to earth ground.
This symbol informs operator to read instructions in the operator manual
before proceeding.
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Section 1 — Introduction 1-5
1.3.2 Terminology
The following is a brief description of the terms specific to motion control
and the ESP6000 controller card and UniDrive6000 universal motor driver
equipment.
API— Application Programmer Interface
Axis — a logical name for a stage/positioner/motion device
DLL — Dynamic Link Library
Encoder — a displacement measuring device, term usually used for both
linear and rotary models
ESP — Enhanced System Performance motion system comprised of
ESP6000 controller card, UniDrive universal motor driver, and compatible
stage(s). ESP is synonymous with a plug-and-play motion system.
ESP6000 — the ESP6000 controller card
ESP-compatible — refers to Newport Corporation stage with its own
firmware-based configuration parameters. Newport stages or other stages
without this feature are referred to as being not ESP-compatible and must
be uniquely configured by the user.
Home (position) — the unique point in space that can be accurately found
by an axis, also called origin
Home search — a specific motion routine used to determine the home
position
Jog — a motion of undetermined-length, initiated manually
Motion device — electro-mechanical equipment. Used interchangeably
with stage and positioner
Move — a motion to a destination, initiated manually
Origin — used interchangeably with home
PCI — Peripheral Component Interconnect (type of personal computer bus)
PID — a closed loop algorithm using proportional, integral, and derivative
gain factors.
Positioner — used interchangeably with stage and motion device
Stage — used interchangeably with motion device and positioner
UniDrive6000 — the universal motor driver used with the ESP6000 con-
troller card
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1-6
1.4 System Overview
The Enhanced System Performance (ESP) architecture consists of the
ESP6000 controller card, UniDrive6000 universal motor driver, and ESP-
compatible stages. The ESP6000 controller card (see Figure 1.4-1) is
designed for convenient installation in the user’s own PC.
The ESP 6000’s Windows-based setup utility provides a full range of
functions for configuring and operating from one to six axes.
The system is designed to operate with Newport Corporation’s ESP-
compatible stages, but can be configured to function with other stages. A
typical PC-based ESP 6000 system configuration with the UniDrive6000 and
one stage is shown in Figure 1.4-2.
N97005A
Figure 1.4-1 — ESP6000 Controller Card
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