Newport MM4006 User manual

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8-Axis High-Performance
Motion Controller/Driver
Version 7.01 Firmware
00 Newport •Motion Controller •Medd eddled
USER'S MANUAL

MM4006 8-Axis Motion Controller/Driver
Warranty
Newport Corporation warrants this product to be free from defects in
material and workmanship for a period of 1 year from the date of shipment.
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 representative,
or contact Newport headquarters in Irvine, California. You will be given
prompt assistance and return instructions. Send the instrument, trans-
portation 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 mis-
use of any product or part. This warranty also does not apply to fuses, bat-
teries 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.
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.
C%,
EDH0181En1020 — 03/03 li (Newport.

MM4006 8-Axis Motion Controller/Driver
Warranty
Table of Contents
ii
iii
Section 1 - Introduction
Table of Contents
1.1 Safety Considerations
1.2 Conventions And Definitions
1.2.1 Symbols and Definitions
1.2.2 Terminology
1.3 General Description
1.1
1.3
1.5
1.5
1.6
1.7
1.3.1 Features 1.9
1.3.2 Specifications 1.9
1.3.3 Modes of Operation 1.11
1.3.4 Rear Panel Description 1.14
1.3.5 Blank Front Panel 1.16
1.3.6 Equipped Front Panel 1.17
1.3.7 Display Configuration 1.18
1.3.8 Display Structure 1.20
1.4 System Setup 1.25
1.4.1 Connecting Motion Devices 1.25
1.4.2 First Power On 1.26
1.4.3 Verifying Default Devices 1.27
Section 2 - Local Mode
Table of Contents 2.1
2.1 Quick Start 2.3
2.1.1 Motor On 2.3
2.1.2 Home Motion Devices 2.4
2.1.3 First Jog 2.4
2.1.4 First Move 2.5
2.2 Controller Configuration 2.7
2.2.1 General Setup 2.7
2.2.2 Axis Setup 2.17
2.3 Operating In Local Mode 2.32
2.3.1 HOME Search 2.33
2.3.2 Manual Jog 2.33
2.3.3 Zero Display 2.35
2.3.4 Relative Moves 2.35
2.3.5 Absolute Moves 2.37
2.3.6 Program Execution 2.38
2.3.7 Axis Infinite Movement 2.40
2.4 Programing in Local Mode 2.41
2.4.1 General Concepts 2.41
2.4.2 Creating a Program 2.42
2.4.3 Modifying a Program 2.47
2.5 Operating in Blind Front Panel 2.48
2.5.1 Dip Switches to Configure the Communication 2.48
2.5.2 RS-232-C Communication Setup 2.49
2.5.3 IEEE-488 Communication Setup 2.50
2.5.4 RS-485 Point-to-Point Communication Setup 2.51
2.5.5 RS-485 Network Communication Setup 2.52
Table of Contents
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%levvport. iii EDF10181EnI020- 03/03

MM4006 Table of Contents
Table of Contents
3.1 Remote Interfaces
3.1.1 RS-232-C Interface
3.1.2 IEEE-488 Interface
3.1.3 RS-232-C Interface
3.2 Softwares
3.2.1 MOTION Suite 32
3.2.2 MM4006 Terminal
3.2.3 MM4006 Servo
3.2.4 MM4006 XY Draw
3.1
3.3
33
3.4
34
3.5
3.5
36
36
36
3.3 MOTION Suite 32 Quick Start 3.7
3.3.1 Installation of the MOTION Suite 32 3.7
3.3.2 PC/Controller Communication 39
3.3.3 Axis Motion Control 3.12
3.3.4 Acquisition 3.13
3.4 Communication Principles 3.16
3.4.1 Command Syntax 3.17
3.5 Command Summary 3.18
3.5.1 Command List by Category 3.19
3.5.2 Command List by Name 3.21
Section 4 - Motion Control Tutorial
Table of Contents 4.1
4.1 Motion Systems 4.3
4.2 Specification Definitions 4.4
4.2.1 Following Error 4.4
4.2.2 Error 4.5
4.2.3 Accuracy 4.5
4.2.4 Local Accuracy 4.6
4.2.5 Resolution 4.6
4.2.6 Minimum Incremental Motion 4.7
4.2.7 Repeatability 4.8
4.2.8 Backlash (Hysteresis) 4.8
4.2.9 Pitch, Roll and Yaw 4.9
4.2.10 Wobble 4.10
4.2.11 Load Capacity 4.10
4.2.12 Maximum Velocity 4.11
4.2.13 Minimum Velocity 4.11
4.2.14 Velocity Regulation 4.12
4.2.15 Maximum Acceleration 4.12
4.2.16 Combined Parameters 4.12
4.3 Control Loops 4.13
4.3.1 PID Servo Loops 4.14
4.3.2 Feed-Forward Loops 4.16
4.4 Motion Profiles 4.18
4.4.1 Move 4.18
4.4.2 Default Mode: S-CURVE Profile 4.19
4.4.3 Jog 4.20
4.4.4 Home Search 4.20
Section 3 - Remote Mode
EDI10181En1020 - 03/03 iv
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(Newport.

MM4006 Table of Contents
5.7.1 Trajectory Setup Commands
5.7.2 Trajectory Elements Definition Commands
5.7.3 Reporting Commands
5.7.4 Trajectory Synchronization Commands
5.7.5 Execution of a Trajectory
5.10
5.10
5.10
5.10
5.10
Section 6 - Feature Descriptions Tutorial
Table of Contents 6.1
6.1 Synchronizing Events to Motion 6.3
6.1.1 Pulses Synchronized to One Axis 6.3
6.1.2 Pulses Synchronized to a Trajectory 6.5
6.1.3 Synchronizing Events to Trajectory Elements 6.6
6.1.4 Synchronizing Events to Trajectory Position 6.7
6.2 Synchronized Axes (Electronic Gearing) 6.8
6.3 Joystick 6.9
6.4 Executing Sub-routines in a Program: EX Command 6.11
Section 7 - Servo Tuning
Table of Contents 7.1
7.1 Servo Tuning Principles 7.3
7.1.1 Hardware Requirements 7.3
7.1.2 Software Requirements 7.3
7.2 Tuning Procedures 7.4
7.2.1 Axis Oscillation 7.4
7.2.2 Increasing Performance 7.5
7.2.3 Points to Remember 7.6
Section 8 - Appendices
Table of Contents 8.1
AError Messages 8.3
Error List 8.3
BIEEE-488 Link Characteristics 8.6
IEEE-488 Functions Supported by MM4006 Controller 8.6
IEEE-488 Function Subsets 8.7
SRQ Using 8.7
Section 5 - Trajectory Functions Tutorial
Table of Contents 5 1
5.1 Definition of Terms5.3
5.1.1 Trajectory 5 3
5.1.2 Trajectory Element5.3
5.1.3 Trajectory Vector 5 3
5.1.4 Vector Velocity5.3
5.1.5 Vector Acceleration5.3
5.2 Trajectory Description and Conventions5.4
5.3 Geometric Conventions5.4
5.4 Defining Trajectory Elements5.5
5.4.1 Defining Lines 5.6
5.4.2 Defining Arcs5.6
5.5 Programing a Trajectory5.8
5.6 Trajectory Element Parameters5.9
5.7 Trajectory-Specific Commands 5 10
%Jevvport. EDI10181En1020 - 03/03

MM4006 Table of Contents
CConnector Pinouts8.9
Labeling Conventions8.9
Power Inhibition Connector (9-Pin D-Sub)8.9
Remote Control Connector (15-pin D-Sub)8.10
Auxiliary Connector (25-Pin D-Sub)8.11
GPIO Connector (37-Pin D-Sub)8.12
RS-232C Interface Connector (9-Pin D-Sub)8.14
RS-232C Interface Cable8.14
IEEE488 Interface Connector (24-Pin)8.16
RS-485 Interface Connector (5-Pin)8.16
Motor Interface Connector (25-Pin D-Sub)8.19
Pass-Through Board Connector (25-Pin D-Sub)8.20
DMotion Program Examples8.21
ETroubleshooting Guide8.29
FDecimal/ASCII/Binary Conversion Table8.32
GStages Preset in the Controller8.35
Default Stages8.35
Translation Stages8.35
Rotation Stages8.37
Actuators8.38
Drives8.38
HFactory Service8.39
Service Form8.40
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We declare that the accompanying product, identified with the "CE" mark, meets
all relevant requirements of Directives:
•73/23/EEC, for Low Voltage Compatibility.
•89/336/EEC for Electromagnetic Compatibility.
Generic standard:
Emission: NF EN61326-1, for measurement, lab and control equipment.
Immunity: NF EN61326-1, for measurement, lab and control equipment.
Safety: EIC 1010-1, safety standards for measurement, lab and control
equipment.
Newport Corporation shall not be liable for damages when using the product:
•Modification of the product.
•Using modified connector, or modified or not supplied cables.
•Connecting this product to non-CE equipment.
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ED110181En1020 — 03/03 vi Newport.

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Motion Controller/Driver
CE Declaration of Conformity
We declare that the accompanying product, identified with the
"CE" mark, meets all relevant requirements of Directive:
•73/23/CEE, for Low Voltage Compatibility.
•89/336/EEC for Electromagnetic Compatibility.
Compliance was demonstrated to the following specifications:
EMISSION:
Radiated and Conducted Emission in accordance with
relative prescription to the EMC, NF EN61326-1: Standards
for measurement, lab and control equipment.
Class A device.
IMMUNITY:
Radiated and Conducted Emission in accordance with
relative prescription to the EMC, NF EN61326-1: Standards
for measurement, lab and control equipment.
SAFETY:
CEI 1010-1, safety standards for measurement, lab and
control equipment.
L=144_7)
Jean-Marc DELAHAYE
Quality Director
Zone Industrielle
45340 Beaune-la-Rolande, France
alt

()
F.D11 0 1 81E n 1 02 0 — 03/03 b%Jewport.

Section 1
Introduction
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MM4006 8-Axis Motion Controller/Driver
(%)
%evvport.

MM4006 8-Axis Motion Controller/Driver
1.1 Safety Considerations 1.3
1.2 Conventions And Definitions 1.5
1.2.1 Symbols and Definitions 1.5
1.2.2 Terminology 1.6
Axis 1.6
Controller 1.6
Encoder 1.6
End-of-run 1.6
Function key 1.6
Home search or origin 1.6
Index pulse 1.6
Jog 1.6
Mechanical zero 1.6
Motion device 1.6
Move 1.6
Origin 1.6
Origin switch 1.6
PID 1.6
Remote 1.6
Stage 1.6
1.3 General Description 1.7
1.3.1 Features 1.9
1.3.2 Specifications 1.9
Function 1.9
Number of motion axes 1.9
Trajectory type 1.9
Motion device compatibility 1.9
CPU type 1.9
DC motor control 1.9
Stepper motor control 1.10
Computer interfaces 1.10
Utility interface 1.10
Operating modes 1.10
Programing 1.10
Program memory 1.10
Display 1.10
Dimensions 1.10
Power requirements 1.10
Fuses 1.10
Operating conditions 1.11
Storage conditions 1.11
Weight 1.11
1.3.3 Modes of Operation 1.11
LOCAL Mode 1.11
Table of Contents
Section 1 Introduction
cv
Newport. 1.1 81E11 i 1)20 - 03/03

Table of Contents - Section 1
REMOTE Mode 1.12
Immediate Mode1.12
Remote Commands In LOCAL Mode1.12
1.3.4 Rear Panel Description1.14
Axis Modules1.14
GPIO Connector1.14
Power Inhibition Connector1.14
Auxiliary Connector1.15
Remote Control Connector1.15
RS-232-C Connector 1.15
IEEE-488 Connector1.15
RS-485 Connectors 1.15
Power Switch/Entry Module1.15
Ground Post1.15
1.3.5 Blank Front Panel 1.16
Power Stand-by1.16
Motor ON/OFF1.16
End-of-Run Status1.17
Access to Communication Dip Switches 1.17
1.3.6 Equipped Front Panel 1.17
Power Stand-by1.17
Motor ON/OFF1.18
Numeric Keypad1.18
Function Keys / Display 1.18
1.3.7 Display Configuration 1.18
Display Organization 1.18
Menu Structure1.19
Common Function Keys1.19
Status Display1.20
1.3.8 Display Structure1.20
MOTOR OFF Menu1.21
MOTOR OFF Menus Synoptic Table 1.22
MOTOR ON Menu1.23
MOTOR ON Menus Synoptic Table1.24
1.4 System Setup 1.25
1.4.1 Connecting Motion Devices1.25
1.4.2 First Power On1.26
1.4.3 Verifying Default Devices1.27
(%)
HM0181E111020- WOO 1(Newport.

MM4006 8-Axis Motion Controller/Driver
Section 1
Introduction
1.1 Safety Considerations
The following general safety precautions must be observed during all phas-
es of operation of this equipment. Failure to comply with these precautions
or with specific warnings elsewhere in this manual violates safety stan-
dards of design, manufacture and intended use of this equipment.
Disconnect or do not plug in the power cord in the following circum-
stances:
•If the power cord or any other attached cables are frayed or damaged in
any way.
•If the power plug or receptacle is damaged in any way.
•If the unit is exposed to rain, 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.
•Whenever you clean the case.
To protect the equipment from damage and avoid hazardous situations, fol-
low these recommendations:
•Do not open the equipment. There are no user serviceable or adjustable
parts inside.
•Do not make any modifications or parts substitutions to the equipment.
•Return the equipment to Newport for any service and repair needs.
•Do not touch, directly or with other objects, live circuits inside the unit.
•Do not operate the unit in an explosive atmosphere.
•Keep all air vents free of dirt and dust.
•Do not block air vents with paper or other objects.
•Keep all liquids away from unit.
•Do not expose equipment to excessive moisture (>85% humidity).
(%,
Nevvport. 1.3 M10181E01020 tWO3

MM4006 Introduction
WARNING
All attachment plug receptacles in the vicinity of this unit are to be of the
grounding type and properly polarized.
Contact your electrician to check your receptacles.
CAUTION
This product is equipped with a 3-wire grounding type plug. Any inter-
ruption of the grounding connection can create an electric shock hazard.
If you are unable to insert the plug into your wall plug receptacle, con-
tact your electrician to perform the necessary alterations to assure that
the green (green-yellow) wire is attached to earth ground.
CAUTION
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-circuit parts.
CAUTION
Opening or removing covers will expose you to hazardous voltages.
Refer all servicing internal to this instrument enclosure to qualified ser-
vice personnel who should observe the following precautions before pro-
ceeding:
•Turn power OFF and unplug the unit from its power source
•Disconnect all cables
•Remove any jewelry from hands and wrists
•Use only insulated hand tools
•Maintain grounding by wearing a wrist strap attached to the instru-
ment chassis.
EDI-10181 En 020 — 1)3 13 11 rNeVVpOrt.

MM4006 Introduction
1.2 Conventions And Definitions
1.2.1 Symbols and Definitions
The following are definitions of safety and general symbols used on equip-
ment or in this manual.
Chassis Ground. Indicates a connection to the equipment chassis which
includes all exposed metal structure.
WARNING Warning. Calls attention to a procedure, practice or condition which, if not
correctly performed or adhered to, could result in injury or death.
CAUTION Caution. Calls attention to a procedure, practice or condition which, if not
correctly performed or adhered to, could result in damage to equipment.
cv
NOTE
Motor OFF
Note. Calls attention to a procedure, practice or condition which is consid-
ered important to remember.
Menu Level (sample). Indicates the menu level from which to start a cer-
tain Quick front panel sequence.
STATUS Function Key (sample). Represents one of the four function keys identified
on the display's menu line with the indicated word.
UP Function Key (sample). Represents one of the four function keys identified
on the display's menu line with the indicated word that must be pressed
multiple times.
Fast Front Panel Sequence. Indicates a quick key sequence description to get
the described function. It is intended to be used by more experienced users
as a quick reminder.
Remote Command. Indicates a remote command equivalent to the local
function being described.
Numeric Keypad. Represents the numeric keypad on the front panel.
Shown in a fast sequence, indicates a numeric entry on the keypad.
Newport 1.5 El )11(1181E111 - 03/03

MM4006 Introduction
1.2.2 Terminology
The following is a brief description of terms specific to motion control and
this instrument that are used in this manual.
Axis
Alogical name for a motion device.
Controller
In this manual refers mostly to the MM4006 controller/driver.
Encoder
Incremental rotary or linear sensor fitted on the lead-screw or carriage
which reports the stage moves.
End-of-run
Sensor which reports that the travel limit is reached.
Function key
One of the four keys associated with the display; its function is determined
by the current menu.
Home search or origin
Sequence of move handled by the controller to find with repeatability the
reference point on the travel.
Index pulse
Pulse generated by the encoder and used in combination with the mechani-
cal zero during the home search.
Jog
Undetermined length motion initiated manually.
Mechanical zero
Sensor stage equipment which gives the controller a reference point.
Motion device
An electromechanical motion device.
Move
Motion to a destination initiated manually or remotely.
Origin
Used sometimes instead of home.
Origin switch
Aswitch that determines an approximate point in space. used in the home
search routine.
PID
Type of closed-loop control algorithm.
Remote
In this manual refers to the mode of operation where communication is
performed over a computer interface link.
Stage
The most common type of motion device for the MM4006. used inter-
changeably in this manual for rotary and linear positioners.
EI)111)1SIEn1021, — 03'03 1.6
(%)
Newport

MM4006 Introduction
1.3 General Description
The MM4006 is an advanced, stand-alone, integrated motion controller/dri-
ver. It can control and drive up to 8 axes of motion, in any stepper and DC
motor combination. The MM4006 controller/driver (also referred to in this
manual as "the controller") was specifically designed to operate with
Newport's broad line of motion devices. This way, it significantly increases
the user friendliness and raises the overall motion system performance.
Using other motion devices is possible but not recommended for optimal
system performance.
Fig. 1.1 shows a minimal system configuration. The MM4006 is used as a
stand-alone unit to control and drive a motion device. The only compo-
nents needed are a motion device. a connecting cable, the MM4006 and a
power cord.
Fig. 1.1 — Minimal system configuration.
In this configuration all commands are received from the front panel.
Programs can be generated and executed without using an additional com-
puter.
C*)
INewpOrt. 1.7 El +10181 En I 020 — 03 03

MM4006 Introduction
Amore common setup is shown in Fig. 1.2. The MM4006 drives multiple
stages and is controlled by a remote computer.
Fig. 1.2 —A common controller setup.
Amore complex configuration, shown in Fig. 1.3, could have up to 4 motion
devices, digital and analog I/O signaling for motion Synchronization,
remote safety "motor off' switches and be part of a larger multi-axis sys-
tem, controlled by a remote computer.
To other
Motion Controller
Remote Motor
OFF
Digital/Analog
I/O's
Fig. 1.3 — A more complex controller configuration.
To explore all capabilities of the MM4006 controller and identify the system
configuration that best fits your application, you will have to read most of
this manual or contact our applications support group for advice.
(%)
I0110181E111020 — 1.8 Nevvport.

MM4006 Introduction
1.3.1 Features
Many advanced features make the MM4006 the preferred choice for preci-
sion applications:
•Integrated controller and driver design is more cost effective and a
space saving solution.
•Compact, rack-mountable or bench-top enclosure.
•Allows any combination of motor types (stepper and DC) and sizes.
•Supports closed-loop operation of stepper motors.
•Feed-forward servo algorithm for smooth and precise motion.
•Velocity feedback motor drivers for best motion performance.
•Advanced multi-axis Synchronization (linear interpolation).
•Powerful command set for the most demanding applications.
•Motion program storage and management capability.
•Advanced motion Programing capabilities with up to 100 nested loops
and complex digital and analog I/O functions.
•User-selectable displacement units.
•User-settable compensation for accuracy and backlash errors.
•Full-featured front panel with bright fluorescent backlit display, numer-
ic/jog keypad, context-sensitive function keys, full motion selection and
control capability and motion program creation and editing capability.
•Multilingual display capability — English or French.
1.3.2 Specifications
Function
•Integrated motion controller and driver.
Number of motion axes
•1 to 8, can be used simultaneously or in any combination or order of
stepper and DC motors.
Trajectory type
•Non-Synchronized motion.
•Multi-axis Synchronized motion (linear interpolation).
•S-Curve or Trapezoidal velocity profile for non-synchronized and syn-
chronized motion. The default configuration is S-Curve velocity profile.
•2D complex trajectory (XY linear and circular interpolation).
Motion device compatibility
•Entire family of motorized motion devices, using ether stepper or DC
motors.
CPU type
•AMD5x86/133 Processor.
DC motor control
•16 bit DAC resolution.
•25 MHz maximum encoder input frequency.
•PID with velocity feed-forward servo loop.
•Digital servo cycle: 0.3 ins, up to 4 axes.
0.5 ms, from 5 to 8 axes.
C*J
NeWpOrt. 1.9 F1)110181En1020 —1 09