THORLABS BBD102 User manual

BBD102 and BBD103
Brushless DC Servo Controllers
User Guide

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Contents
Chapter 1 For Your Safety .............................................................................4
1.1 Safety Information .................................................................................. 4
1.2 General Warnings .................................................................................. 4
Chapter 2 Overview and Setup ..................................................................... 5
2.1 Introduction ............................................................................................. 5
2.2 APT PC Software Overview ................................................................... 7
2.2.1 Introduction .........................................................................................................7
2.2.2 APTUser Utility ...................................................................................................8
2.2.3 APT Config Utility ...............................................................................................9
2.2.4 APT Server (ActiveX Controls) ...........................................................................9
2.2.5 Software Upgrades ...........................................................................................11
Chapter 3 Getting Started ............................................................................12
3.1 Installing APT Software ........................................................................ 12
3.2 Mechanical Installation ......................................................................... 13
3.2.1 Siting ................................................................................................................13
3.2.2 Environmental Conditions ................................................................................13
3.3 Electrical Installation ............................................................................. 14
3.3.1 Connecting To The Supply ...............................................................................14
3.4 Fuses .................................................................................................... 14
3.4.1 Rear Panel Connections ..................................................................................15
3.5 Front Panel Controls and Indicators .................................................... 16
3.6 Connecting The Hardware and Powering Up ....................................... 17
3.7 Verifying Software Operation ............................................................... 18
3.7.1 Initial Setup .......................................................................................................18
Continued...

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2- and 3--Channel Brushless DC Servo Controller
Chapter 4 Operation - Tutorial ................................................................... 19
4.1 Introduction 1...........................................................................................9
4.2 Using the APT User Utility ....................................................................20
4.3 Homing Motors .....................................................................................21
4.4 Moving to an Absolute Position ............................................................22
4.5 Changing Motor Parameters ................................................................23
4.6 Jogging .................................................................................................24
4.7 Graphical Control Of Motor Positions (Point and Move) .......................25
4.8 Setting Move Sequences ......................................................................27
4.9 Using A Joystick Console .....................................................................30
4.10 External Triggering ...............................................................................31
4.11 Creating a Simulated Configuration Using APT Config ........................31
Chapter 5 Software Reference .................................................................... 35
5.1 Introduction ...........................................................................................35
5.2 GUI Panel .............................................................................................35
5.3 Settings Panel ......................................................................................37
5.3.1 Moves/Jogs tab ................................................................................................ 37
5.3.2 Stage/Axis tab .................................................................................................. 41
5.3.3 Advanced - Control Loop SettingsTab ............................................................. 44
5.3.4 Advanced - Misc. Tab ...................................................................................... 48
5.4 Troubleshooting and Restoring Default Parameters ............................54
Appendices
Appendix A Rear Panel Connector Pinout Details .................................... 56
Appendix B Preventive Maintenance ......................................................... 65
Appendix C Specifications and Associated Parts .................................... 66
Appendix D Motor Control Method Summary ........................................... 67
Appendix E Regulatory ................................................................................ 73
Appendix F Thorlabs Worldwide Contacts ................................................ 75

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Chapter 1 For Your Safety
1.1 Safety Information
For the continuing safety of the operators of this equipment, and the protection of the
equipment itself, the operator should take note of the Warnings, Cautions and Notes
throughout this handbook and, where visible, on the product itself.
The following safety symbols may be used throughout the handbook and on the
equipment itself.
1.2 General Warnings
Shock Warning
Given when there is a risk of injury from electrical shock.
Warning
Given when there is a risk of injury to users.
Caution
Given when there is a risk of damage to the product.
Note
Clarification of an instruction or additional information.
Warnings
If this equipment is used in a manner not specified by the manufacturer, the
protection provided by the equipment may be impaired. In particular,
excessive moisture may impair operation.
Spillage of fluid, such as sample solutions, should be avoided. If spillage does
occur, clean up immediately using absorbant tissue. Do not allow spilled fluid
to enter the internal mechanism.

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2- and 3--Channel Brushless DC Servo Controller
Chapter 2 Overview and Setup
2.1 Introduction
The BBD series Brushless DC Motor Controllers are ideal for motion control
applications demanding high speed (100s of mm/s) and high encoder resolution
(<100 nm) operation. These new controllers offer up to three channels of high-
precision motion control in a wide range of applications, and in particular in
microscopy sample manipulation when used along with our MLS203 dual axis
scanning stage. Designed using latest digital and analog techniques and with high-
bandwidth high-power servo control circuitry, these new controllers are capable of
driving a range of rotary and linear brushless 3-phase DC motors of up to 5 Amp peak
coil current.
Integrated into the apt family of products, it offers Thorlabs standard control and
programming interface, allowing easy integration into the customer’s own automated
motion control applications. These units are cable of being reprogrammed in-field,
allowing the option of upgrading the units with future firmware releases as soon as
new programming interfaces (such as microscopy standard command sets) are
added..
Fig. 2.1 APT Three Channel Brushless DC Servo Motor Controller (BBD103)

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Chapter 2
Operation of the BBD series brushless DC motor unit is fully configurable
(parameterized) with key settings (e.g. PID settings, min and max position values, and
limit switch operation) exposed through the associated graphical interface panels.
PID control loop values can be adjusted for a particular application, minimum and
maximum position values can be entered to suit different stages as required, and limit
switch configuration is accommodated through a flexible set of limit switch logic
settings. Moreover, relative and absolute moves can be initiated with move profiles
set using velocity profile parameters. Similarly, home sequences have a full set of
associated parameters that can be adjusted for a particular stage or actuator. For
simplicity of operation, the apt™ software incorporates pre-configured settings for
each of the Thorlabs stages and actuators, while still exposing all parameters
individually for use with other DC motor driven systems.
For convenience and ease of use, adjustment of many key parameters is possible
through direct interaction with the graphical panel. For example a move to the next
position can be initiated by clicking directly on the position display and entering a new
value (see the tutorial in Chapter for further details). Furthermore, all such settings
and parameters are also accessible through the ActiveX® programmable interfaces
for automated alignment sequences.
In the remainder of this handbook, the Tutorial section (Chapter ) provides a good
initial understanding on using the unit, and the reference sections (Chapter 5) covers
all operating modes and parameters in detail.

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2- and 3--Channel Brushless DC Servo Controller
2.2 APT PC Software Overview
2.2.1 Introduction
As a member of the APT range of controllers, the BBD102 and BBD103 DC motor
controllers share many of the associated software benefits. This includes USB
connectivity (allowing multiple units to be used together on a single PC), fully featured
Graphical User Interface (GUI) panels, and extensive software function libraries for
custom application development.
The APT software suite supplied with all APT controllers, including the BBD102 and
BBD103 DC Servo controllers, provides a flexible and powerful PC based control
system both for users of the equipment, and software programmers aiming to
automate its operation.
For users, the APTUser (see Section 2.2.2.) and APTConfig (see Section 2.2.3.)
utilities allow full control of all settings and operating modes enabling complete ‘out-
of-box’ operation without the need to develop any further custom software. Both
utilities are built on top of a sophisticated, multi-threaded ActiveX ‘engine’ (called the
APT server) which provides all of the necessary APT system software services such
as generation of GUI panels, communications handling for multiple USB units, and
logging of all system activity to assist in hardware trouble shooting. It is this APT
server ‘engine’ that is used by software developers to allow the creation of advanced
automated positioning applications very rapidly and with great ease. The APT server
is described in more detail in Section 2.2.4.
Aside
ActiveX®, a Windows®-based, language-independent technology, allows a user
to quickly develop custom applications that automate the control of APT system
hardware units. Development environments supported by ActiveX® technology
include Visual Basic®, LabView™, Borland C++ Builder, Visual C++, Delphi™,
and many others. ActiveX® technology is also supported by .NET development
environments such as Visual Basic.NET and Visual C#.NET.
ActiveX controls are a specific form of ActiveX technology that provide both a user
interface and a programming interface. An ActiveX control is supplied for each
type of APT hardware unit to provide specific controller functionality to the
software developer. See Section 2.2.4. for further details.

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Chapter 2
2.2.2 APTUser Utility
The APTUser application allows the user to interact with a number of APT hardware
control units connected to the host PC. This program displays multiple graphical
instrument panels to allow multiple APT units to be controlled simultaneously.
All basic operating parameters can be altered and, similarly, all operations (such as
motor moves) can be initiated. Settings and parameter changes can be saved and
loaded to allow multiple operating configurations to be created and easily applied.
For many users, the APTUser application provides all of the functionality necessary
to operate the APT hardware without the need to develop any further custom
software. For those who do need to further customise and automate usage of the
controller (e.g. to implement a positioning algorithm), this application illustrates how
the rich functionality provided by the APT ActiveX server is exposed by a client
application.
Use of the APT User utility is covered in the PC tutorial (Chapter ) and in the APTUser
online help file, accessed via the F1 key when using the APTUser utility.

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2- and 3--Channel Brushless DC Servo Controller
2.2.3 APT Config Utility
There are many system parameters and configuration settings associated with the
operation of the APT Server. Most can be directly accessed using the various
graphical panels, however there are several system wide settings that can be made
'off-line' before running the APT software. These settings have global effect; such as
switching between simulator and real operating mode, and associating third party
mechanical stages to specific motor actuators.
If a BBD series controller is used with the MLS203 microscopy scanning stage, all
stage-associated settings are made automatically when the stage is connected to the
controller.
The APTConfig utility is provided as a convenient means for making these system
wide settings and adjustments for third party brushless DC motor driven stages. An
overview of APTConfig is provided in Section 2.2.3. Full details are contained in the
online help supplied with the utility.
2.2.4 APT Server (ActiveX Controls)
ActiveX Controls are re-usable compiled software components that supply both a
graphical user interface and a programmable interface. Many such Controls are
available for Windows applications development, providing a large range of re-usable
functionality. For example, there are Controls available that can be used to
manipulate image files, connect to the internet or simply provide user interface
components such as buttons and list boxes.
With the APT system, ActiveX Controls are deployed to allow direct control over (and
also reflect the status of) the range of electronic controller units, including the BBD102
and BBD103 DC motor controllers. Software applications that use ActiveX Controls
are often referred to as 'client applications'. Based on ActiveX interfacing technology,

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Chapter 2
an ActiveX Control is a language independent software component. Consequently
ActiveX Controls can be incorporated into a wide range of software development
environments for use by client application developers. Development environments
supported include Visual Basic, Labview, Visual C++, C++ Builder, HPVEE, Matlab,
VB.NET, C#.NET
and, via VBA, Microsoft Office applications such as Excel and Word.
Consider the ActiveX Control supplied for one channel of the BBD103 APT Brushless
DC Servo Controller unit.
This Control provides a complete user graphical instrument panel to allow the motor
unit to be manually operated, as well as a complete set of software functions (often
called methods) to allow all parameters to be set and motor operations to be
automated by a client application. The instrument panel reflects the current operating
state of the controller unit to which it is associated (e.g. such as motor position).
Updates to the panel take place automatically when a user (client) application is
making software calls into the same Control. For example, if a client application
instructs the associated DC motor Control to move a motor, the progress of that move
is reflected automatically by changing position readouts on the graphical interface,
without the need for further programming intervention.