THORLABS BBD301 User manual

BBD30x Series Brushless DC Motor Controllers
HA0427T
BBD301, BBD302, &
BBD303 Brushless
DC Motor Controllers
Kinesis User Guide
Original Instructions

BBD30x Series Brushless DC Motor Controllers
HA0427T
Table of Contents
Chapter 1 Introduction and Overview..............................................................................................1
1.1. Introduction..........................................................................................................1
1.2. Kinesis Software Overview ..................................................................................2
1.2.1. Introduction.................................................................................................................2
1.2.2. Kinesis Graphical User Interface .................................................................................2
1.3. Kinesis Programmable Interface..........................................................................2
1.4. Software Upgrades...............................................................................................3
1.5. Ethernet Connectivity...........................................................................................3
Chapter 2 Safety ..................................................................................................................................4
2.1. Safety Information................................................................................................4
2.2. General Warnings.................................................................................................4
Chapter 3 Installation..........................................................................................................................5
3.1. Installing the Software ...........................................................................................5
3.2. Mechanical Installation.........................................................................................5
3.2.1. Siting ..........................................................................................................................5
3.2.2. Environmental Conditions ...........................................................................................5
3.3.
Electrical Installation .............................................................................................6
3.3.1. Connecting the Supply................................................................................................6
3.3.2. Fuses .........................................................................................................................6
3.3.3. Rear Panel Connections BBD301 ...............................................................................7
3.3.4. Rear Panel Connections BBD302 and BBD303...........................................................8
3.3.5. Configuring the Rear Panel BNC I/O Connectors ........................................................8
3.4. Front Panel Controls and Indicators..................................................................10
3.5. Connecting the Hardware and Powering Up......................................................11
3.5.1. Extra steps needed for Ethernet Connectivity............................................................11
3.6. Updating the Firmware.......................................................................................12
3.7. Verifying Software Operation.............................................................................12
3.7.1. Initial Setup...............................................................................................................12
Chapter 4 Operation from the Front Panel ...................................................................................13
4.1. Introduction........................................................................................................13
4.2. Front Panel Menu Index .....................................................................................13
4.3. System Startup...................................................................................................14
4.4. Setting Motor Velocity and Acceleration............................................................15
4.5. Moving the Stage................................................................................................15

BBD30x Series Brushless DC Motor Controllers
4.6. The Teach Facility: Inputting Stage Set-Points..................................................15
4.7. The Knob Control: Setting Functionality ...........................................................16
4.8. Miscellaneous: Screen Brightness, Knob Sensitivity, Firmware Version, IP
Address, Serial Number .....................................................................................16
4.9. Comments on Rotary Stages .............................................................................16
Chapter 5 PC Operation - Quick Start Guide................................................................................17
5.1. Introduction........................................................................................................17
5.2. Homing Motors...................................................................................................17
5.3. Changing Motor Parameters and Moving to an Absolute Position....................18
5.4. Disabling, Enabling and Stopping the Stage ..................................................... 19
5.5. Jogging and Driving...........................................................................................19
5.6. Setting Move Sequences....................................................................................20
5.7. Changing and Saving Parameter Settings .........................................................20
5.8. Using A Joystick Console..................................................................................20
Chapter 6 Software Reference: Kinesis GUI Application...........................................................21
6.1. Introduction........................................................................................................21
6.2. GUI Panel............................................................................................................21
6.3. Synchronized Moves..........................................................................................23
6.3.1. Entering Positions for a Synchronized Vector Move ..................................................23
6.3.2. Path Designer Synchronized Moves..........................................................................24
6.3.3. Circle ........................................................................................................................25
6.3.4. Circular Arc...............................................................................................................26
6.3.5. Line Segment ...........................................................................................................27
6.3.6. Raster Scan..............................................................................................................28
6.3.7. Loading a Saved File ................................................................................................29
6.4. Settings Panel ....................................................................................................30
6.4.1. Base Unit - LCD Display Tab ....................................................................................30
6.4.2. Base Unit - I/O Tab ...................................................................................................31
6.4.3. Channel Settings ......................................................................................................32
6.4.4. Moves/Jogs tab ........................................................................................................33
6.4.5. Stage/Axis tab ..........................................................................................................36
6.4.6. Advanced Tab ..........................................................................................................38
6.4.7. Advanced - Misc. Tab ...............................................................................................42
6.4.8. Triggering Tab ..........................................................................................................45
6.4.9. Defaults Tab .............................................................................................................49

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6.4.10.Troubleshooting and Restoring Default Parameters ..................................................49
6.4.11.Rotation Stages Tab .................................................................................................50
Chapter 7 Kinesis API Reference ...................................................................................................51
7.1. Available References..........................................................................................51
7.2. API Commands and Related Kinesis GUI Functionality ....................................51
Chapter 8 Rear Panel Connector Pin-out Details........................................................................56
8.1. Rear Panel MOTOR DRIVE Connectors .............................................................56
8.2. Rear Panel FEEDBACK Connector ....................................................................56
8.3. Rear Panel AUX I/O Connector and BNC connectors ........................................56
8.3.1. Pin Identification .......................................................................................................56
8.3.2. Differential Outputs...................................................................................................58
8.3.3. Digital Outputs ..........................................................................................................58
8.3.4. +5 V Supply ..............................................................................................................59
8.4. Rear Panel HANDSET Connector.......................................................................60
8.4.1. Pin Identification .......................................................................................................60
Chapter 9 Using the RS232 or Virtual Comm Port ......................................................................61
Chapter 10 Preventive Maintenance ................................................................................................63
10.1. Safety Testing ....................................................................................................63
10.2. Fuses..................................................................................................................63
10.3. Cleaning .............................................................................................................63
Chapter 11 Specifications..................................................................................................................64
11.1. Specifications.....................................................................................................64
Chapter 12 An Introduction to Multi-Axis Synchronized Moves ................................................65
12.1. Introduction........................................................................................................65
12.2. Trapezoidal Move Profiles..................................................................................65
12.3. Complex Move Shapes.......................................................................................66
12.4. Repeated Patterns..............................................................................................67
12.5. Starting a Synchronized Trajectory ...................................................................67
Chapter 13 Regulatory........................................................................................................................68
13.1. Declarations of Conformity ................................................................................68
13.1.1.For Customers in Europe ..........................................................................................68
13.1.2.For Customers in the USA ........................................................................................68
Chapter 14 Thorlabs Worldwide Contacts......................................................................................69

BBD30x Series Brushless DC Motor Controllers Chapter 1: Introduction and Overview
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Chapter 1 Introduction and Overview
1.1. Introduction
The BBD30x is a family of three Brushless DC Motor Controllers that are ideal for motion control applications demanding
high speed (100s of mm/s) and high encoder resolution (<100 nm) operation:
BBD301 Single Channel Controller
BBD302 Two Channel Controller
BBD303 Three Channel Controller
These controllers offer high-precision motion control in a wide range of applications, and in particular when used along with
our DDS series fast translation stages, where speeds of up to 300 mm/sec can be achieved. Designed using the 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 2.5 Amp peak coil current.
It offers Thorlabs standard control and programming interface, allowing easy integration into the customer’s own automated
motion control applications. These units are capable 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.
A new feature of the controller is its Ethernet connectivity, allowing full system control at significantly greater distances than
available with USB and thus ideal for remote working environments.
Figure 1 BBD303 Three Channel Brushless DC Servo Motor Controller
Operation of the BBD30x Series Controllers 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.
For convenience and ease of use, movement of stages and adjustment of many key parameters is possible either through
direct interaction with the front panel controls (see Chapter 4), or via a PC and virtual graphical panel (see Chapter 5).
Furthermore, all such settings and parameters are also accessible through the Kinesis programmable interfaces for
automated alignment sequences.
Using the Kinesis® software, 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 Kinesis 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.
The reference section (Chapter 6) covers all operating modes and parameters in detail.

BBD30x Series Brushless DC Motor Controllers Chapter 1: Introduction and Overview
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1.2. Kinesis Software Overview
1.2.1. Introduction
As a member of the Thorlabs range of controllers, the BBD30x series 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. These
features are also available when using the new Ethernet connectivity that is available with the BBD30x controllers.
The Kinesis software suite provides a flexible and powerful PC based control system both for users of the equipment, and
software programmers aiming to automate its operation.
The User Interface allows ‘out-of-box’ operation without the need to develop any further custom software. It provides 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 troubleshooting. The Kinesis Application Programming Interface (API) is also used by
software developers to allow the creation of advanced automated positioning applications very rapidly and with great ease.
1.2.2. Kinesis Graphical User Interface
The Kinesis software suite includes a graphical user interface (GUI), Thorlabs.MotionControl.Kinesis.exe, which is an
application capable of simultaneously controlling the BBD30x and other devices. When this application is run, each
connected device can be controlled using a dedicated instrument panel. The instrument panel for the BBD30x, which is
shown in Figure 2, can both operate and adjust many of the BBD30x's settings, including position, velocity, and PID
parameters.
Consider the control supplied for the BBD30x Brushless DC Servo Controller unit:
Figure 2 Standard PC GUI with Kinesis
Updates to the instrument panel take place automatically and provide information about the current operating state of the
associated device. The operating state will update in the GUI regardless of whether the change was made by interacting
with this panel, pressing buttons on the front panel of the controller, or by a different program based on the Kinesis API. For
example, if a stage moves in response to pressing buttons on the BBD30x's front panel, the progress of the move is reflected
automatically by position readout changes on the graphical user interface, without the need for further programming
intervention.
See Chapters 5 and 6 for more information about the GUI. In addition, a help file that provides an overview of the GUI can
be accessed by pressing Ctrl + F1 while running the application.
1.3. Kinesis Programmable Interface
The individual compiled software controls used to create the GUI are also available for Windows application development.
Included are controls used to manipulate image files, connect to the Internet, or simply provide user interface components
such as buttons and list boxes. In some cases, the functionality offered by these controls exceeds that provided by the GUI
described in Section 1.2.2.
Within the Kinesis software suite, .Net controls are deployed to allow direct control over (and also reflect the status of) the
range of electronic controller units, including the BBD30x series controllers. Software applications that use .Net controls are
often referred to as 'client applications.' A .Net control is a language-independent software component. Consequently, the
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 Microsoft Office applications such as Excel and Word via VBA.

BBD30x Series Brushless DC Motor Controllers Chapter 1: Introduction and Overview
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Each of the controllers has an associated GUI control, which is described in the following chapters. The relationship between
the GUI, the underlying .Net messages, and custom applications created using the controls is illustrated in Figure 3.
Figure 3 System Architecture Diagram
For more information, see Chapter 6, as well as the on-line help file and example applications. The available commands
are also described in the programming reference available from the "Communications Protocol" tab in the Software
Download section of the website
(https://www.thorlabs.com/software_pages/ViewSoftwarePage.cfm?Code=Motion_Control)
1.4. Software Upgrades
Thorlabs operate a policy of continuous product development and may issue software upgrades as necessary. The latest
software can be downloaded from the ‘Services’ section of www.thorlabs.com.
1.5. Ethernet Connectivity
The Ethernet interface on the BBD30x controllers supports communication via TCP/IP. All commands have the same format
and the bytes exchanged between the controller and the control PC are the same regardless of whether the underlying
physical interface is USB or TCP/IP (Ethernet).
The current implementation only supports DHCP (Dynamic Host Configuration Protocol) and uses Port number 40303. The
local DHCP server assigns the controller IP address, and all IP addresses are IPv4 (rather than IPv6).
It may be useful to configure the DHCP server to reserve a particular IP address for the BBD30x unit; this will prevent
scenarios where the device appears offline due to the DHCP server assigning a different IP address to the unit when the
lease expires.

BBD30x Series Brushless DC Motor Controllers Chapter 2: Safety
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Chapter 2 Safety
2.1. 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.
2.2. General Warnings
Warning: Risk of Electrical Shock
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.
Warning
If this
equipment is used in a manner not specified in the handbook, 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
absorbent tissue. Do not allow spilled fluid to enter the internal mechanism.
The equipment is for indoor use only.
When running custom move sequences, or under fault conditions, the stage may move unexpectedly. Operators
should
take care when working inside the moving envelope of the stage.

BBD30x Series Brushless DC Motor Controllers Chapter 3: Installation
Rev D April 2022 Page 5
Chapter 3 Installation
3.1. Installing the Software
DO NOT CONNECT THE STAGE TO YOUR PC YET
1) Download the Kinesis software. Thorlabs.com/Products/Software Downloads or
https://www.thorlabs.com/software_pages/ViewSoftwarePage.cfm?Code=Motion_Control
2) Run the .exe file and follow the on-screen instructions.
3.2. Mechanical Installation
3.2.1. Siting
The unit is designed to be mounted free standing on a shelf, benchtop or similar surface.
3.2.2. Environmental Conditions
Location Indoor use only
Maximum altitude2000 m
Temperature range 5 oC to 40 oC
Maximum Humidity Less than 80% RH (non-condensing) at 31°C
To ensure reliable operation the unit should not be exposed to corrosive agents or excessive moisture, heat or dust.
If the unit has been stored at a low temperature or in an environment of high humidity, it must be allowed to reach
ambient conditions before being powered up.
The unit must not be used in an explosive environment.
Caution
Some PCs may have been configured to restrict the user’s ability to load software, and on these systems the software
may not install/run. If
you are in any doubt about your rights to install/run software, please consult your system
administrator before attempting to install.
If you experience any problems when installing software, contact Thorlabs on
[phone] and ask for Technical Support.
Caution
When siting the unit, it should be positioned so as not to impede the
operation of the rear panel power supply switch or
the control panel buttons.
Ensure that proper airflow is maintained to the rear of the unit.
Warning
Operation outside the following environmental limits may adversely affect operator safety.

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3.3. Electrical Installation
3.3.1. Connecting the Supply
3.3.2. Fuses
Two T 3.15A/250VAC anti-surge ceramic fuses are located in the fuse drawer on the mains inlet panel, one for the live feed
and one for the neutral as follows:
Fuse Rating Type Fused Line
F1
T 3.15 A
Ceramic; Antisurge
Live Feed
F2
T 3.15 A
Ceramic; Antisurge
Neutral Feed
When replacing fuses:
1) Switch off the power and disconnect the power cord before removing the fuse cover.
2) Always replace broken fuses with a fuse of the same rating and type. It is good practice to replace both fuses when a
fuse blows.
Warning
The safety of any system incorporating this equipment is the responsibility of the person performing the installation.
Warning: Risk of Electrical Shock
The unit must be connected only to an earthed fused supply of 100 to 240 V.
Use only power supply cables supplied by Thorlabs, other cables may not be rated to the same current. The unit is
shipped with appropriate power cables for use in the UK,
Europe and the USA. When shipped to other territories the
appropriate power plug must be fitted by the user. Cable identification is as follows:
Brown Live
Blue Neutral
Green/Yellow Earth/Ground

BBD30x Series Brushless DC Motor Controllers Chapter 3: Installation
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3.3.3. Rear Panel Connections BBD301
Figure 4 BBD301 Rear Panel Connections
MOTOR DRIVE - Provides all phase current drive connections to the DC motor actuators, via a female 8-pin DIN connector
– see Section 8.1.
FEEDBACK - 15-pin female D Connector. Provides connection for the position encoder feedback signals - see Section 8.2.
I/O 1 and I/O 2 – BNC connectors for use with external trigger input signals (5V TTL levels) – see Section 3.3.5.
ETHERNET - For use in Ethernet communications.
USB - USB port for system communications.
HANDSET IN - Provides connection, via a female Mini-DIN, for the MJC001 2-Axis Joystick - see Section 8.4.
AUX I/O - 37-pin female DIN Connector. The AUX I/O connector exposes a number of internal electrical signals. For
convenience, a number of logic inputs and outputs are included, thereby negating the need for extra PC based IO hardware.
Using the Kinesis support software, these user programmable logic lines can be deployed in applications requiring control
of external devices such as relays, light sources and other auxiliary equipment. - see Section 8.3. for further details.
Note
The USB cable length should be no more than 3 metres unless a powered USB hub is being used.

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3.3.4. Rear Panel Connections BBD302 and BBD303
Figure 5 BBD302 Rear Panel Connections
Figure 6 BBD303 Rear Panel Connections
3.3.5. Configuring the Rear Panel BNC I/O Connectors
The BBD30x brushless motor controllers offer additional triggering functions that expand the triggering capabilities of the
legacy BBD20X controllers. In the legacy controller family, triggering is
(a) implemented on a per-channel basis, i.e. each motor channel had its own dedicated trigger input and output.
(b) for the inputs, hardware triggering can be used to trigger an absolute, relative and home moves.
(c) the outputs can be asserted when the stage is in motion or reaches its maximum velocity.
The BBD30x controllers expand this functionality and add the following features:
(a) For ease of connectivity, the main trigger features are brought out on BNC connectors. This allows the use of off-the-
shelf BNC cables for connecting to external equipment rather than having to interface to D-type connectors.
(b) The trigger inputs and outputs are not hard wired to a particular I/O connector. In input mode, the same connector
can be used to trigger multiple motor channels. In output mode, any I/O connector can be used to output a trigger signal
from a motor channel.
(c) Low latency position triggering has been added. This operates at the speed of the hardware signals involved, offering
delays measured in tens of nanoseconds.
(d) An analogue monitor feature has been added, allowing various system variables to be monitored using an external
oscilloscope.
A block diagram of the BBD30x BNC trigger I/O is shown below:

BBD30x Series Brushless DC Motor Controllers Chapter 3: Installation
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Figure 7 BBD30x BNC trigger I/O Schematic
Main features:
•Each BNC port can be configured to be a digital input, a digital output or an analogue monitor output (only on BNC #1
and BNC #2).
•Each motor channel also has a trigger input and a trigger output signal.
•When a BNC I/O port is configured as an input, its signal can be routed to any one or more motor channels. This, for
example, as shown above, BNC #2 is routed to both Motor Channel #1 and Motor Channel #2.
•When configured as an output, the BNC I/O port can be driven by any of the motor channels (but only one, in order to
avoid the possibility of conflicts between different motor channels driving the same output).
•When configured as an analogue monitor, the BNC I/O port can be used to output an analogue voltage in the range of
0 to +5V. This can be assigned to a number of system variables and provides a very low latency way of monitoring the
state of the system as the signal follows any changes to the system variable at the speed of the hardware. For example,
absolute position can be monitored to aid PID tuning.
The BBD301 and BBD302 controllers provide two BNC trigger I/O ports whereas the BBD303 provides three.
The configuration of the BNC I/O connectors and the associated motor channels is detailed in Section 6.4.1

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3.4. Front Panel Controls and Indicators
Figure 8 Front Panel Controls and Indicators
Power - Rocker switch to turn power ON and OFF.
Jog Knob - Used to initiate moves in normal operation.
Main Display - In normal operation the display shows channel information, such as axis position and stage type
connected. In set-up mode the display allows various parameter settings to be changed - see Chapter 4.
Buttons – The buttons on the left are used to manually communicate with the BBD30x via information provided
in the corresponding position on the screen - see Chapter 4.
Channel – BBD302 and BBD303 only; located above the power switch. Used to toggle between the various
channels connected.

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3.5. Connecting the Hardware and Powering Up
Follow the set procedure for powering up, as described below. Specifically, a stage must only be connected to
and disconnected from a controller that is powered down.
1) Install the Software - see Section 3.1.
2) Connect the stage to the Controller unit using the Motor Drive and Feedback cables supplied.
3) Connect the Controller unit to your PC using the USB connection.
4) Connect the Controller unit to the power supply and switch ‘ON’.
WindowsTM should detect the new hardware. Wait while WindowsTM installs the drivers for the new hardware.
5) Wait for around 10 seconds for the initialization phase to complete.
If using USB connectivity, automatic recognition will allow the Kinesis GUI to be displayed – see steps 6 & 7. If
using Ethernet connectivity, some extra steps need to be taken – see section 3.5.1.
6) (USB only). Run the software and first click “Enable” followed by the ‘Home’ button on each GUI panel. When
homing is complete, the Channel Enable LEDs on the controller GUI front panel stop flashing.
7) The stage can now be moved using the GUI panel, or by sending commands to move each axis by relative
and absolute amounts – see the help-file supplied with the Kinesis API for more information.
3.5.1. Extra steps needed for Ethernet Connectivity
If using Ethernet connectivity, the controller is not currently auto detected by Kinesis and the IP address, assigned by the
local DHCP server, needs to be manually inserted before continuing.
Run Kinesis after connection and power up, then press the Connect button on the display that appears (top left, Figure 9a)
followed by Find Device (bottom left, Figure 9a). The IP address of the controller can now be inserted (in this case,
10.26.11.24). The address is available directly from the front LCD display ( Figure 9b) by pressing “Ch All” then “NEXT” on
the front panel controls; for further details see Chapter 4.
Once the IP address has been input, the device will appear in the drop-down list of devices: check and then press “Connect”.
The Kinesis GUI screen for the controller now appears – see next section.
Figure 9 Manually inputting the IP address when connection is via Ethernet
Note
The USB cable length should be no more than 3 metres unless a powered USB hub is being used.
Note
3-phase brushless DC motors are commutated electronically, i.e. the controller drives the coils with a precisely controlled
waveform that depends on the position of the rotor (or, with linear motors, the position of the coil housing). On power up,
the position of the rotor is not known. The controller establishes this by energizing the coils and measuring the resulting
movement. This is why on power up, the stage (motor) makes a slight buzzing noise and moves about slightly for a few
seconds. Phase initialization can only take place if the motor can move unobstructed during this time.

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3.6. Updating the Firmware
3.7. Verifying Software Operation
3.7.1. Initial Setup
The Software should be installed (Section 3.1) and the power up procedure performed (Section 3.5) before software
operation can be verified.
1. Run the software and check that the Graphical User Interface (GUI) panel appears and is active. If needed ‘Enable’
the motor(s) on the button just above ‘Identify’.
Figure 10 GUI Panel Showing Jog and Ident Buttons
2. Click the ‘Identify’ button. The display on the front panel of the associated controller flashes. This is useful in multi-
channel systems for identifying which driver unit is associated with which GUI.
3. Home the stage.
4. Click the jog buttons on the GUI panel and check that the motor or axis connected to the controller moves. The
position display for the associated GUI should increment and decrement accordingly. The default setting for the
Jog mode is "Continuous" i.e., clicking the jog buttons will move the stage a distance dependent on the time that
passes between clicking and releasing the mouse button. The Jog button behavior can be changed to "Single Step"
in the Settings panel, which provides discrete changes in position when a jog button is pressed.
Follow the tutorial steps described in Chapter 5 for further verification of operation.
Caution
Thorlabs often releases updated firmware for bug fixes and support for new features.
We recommend all users to download the latest version of Kinesis software and use the included firmware update
utility. Failure to do this could result in stages not being recognized by the latest controllers.

BBD30x Series Brushless DC Motor Controllers Chapter 3: Installation
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Chapter 4 Operation from the Front Panel
4.1. Introduction
The BBD30x can be used to drive attached stages directly via the front panel controls and display screen, without the specific
need of a computer connection and its peripheral software; only a mains power connection is needed, together with electrical
connections to each stage (15-pin D plug, and 8-pin DIN plug for each stage). However, the fullest functionality is available
if the front panel is used in conjunction with Kinesis software - described in more detail in Chapter 5 - and this will need a
USB connection to the computer.
This section describes the functionality and use of stage control via the front panel of the BBD30x controller. Throughout the
chapter, examples are given assuming linear stages are being addressed. For rotary stages, the same functionality is
available (so replace linear speed/acceleration/position with their angular counterparts). Any differences are specifically
addressed in section 4.9.
4.2. Front Panel Menu Index
The front panel main page, active on startup, allows intuitive access to an array of sub-pages that provide information on
the system status and parameters, the possibility to set and change parameters, and the ability to control the attached
stages. Figure 11 below provides an index of these pages (and where they can be accessed). More details can be found in
sections 4.3 to 4.8.
Figure 11 Front Panel Display Pages Map
Caution
There is maximum stage velocity at which the encoder can operate (which is motor-
dependent). Above this speed,
encoder pulse
s may be lost and, as a result, the position readout becomes incorrect. This renders normal operation
impossible because phase commutation of the motor is also based on the encoder reading.
When the stage is controlled by the BBD30x controller, the maximum velocity is limited to safe values. However, if the
Motor output is disabled (with the controller connected and monitoring the encoder position) and the stage is moved by
hand at high speeds, it is possible to exceed this limit. If the
controller is subsequently used again to move the stage,
the incorrect encoder reading will cause incorrect operation, often resulting in sudden uncontrolled moves. It is therefore
important not to move the stage excessively quickly when it is moved by hand.
The BBD controller has fault monitoring to detect the loss of encoder pulses. If this fault occurs, an error message will
be generated, and the controller must be powered down and re-
started so that correct phasing and commutation can be
re-established.

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4.3. System Startup
On powering up the controller for the first time, the BBD30x first initializes (Figure 12a) and retrieves information from the
stages connected, which is then displayed in the appropriate channel on the front panel home page. An example is shown
in Figure 12b for a Thorlabs DDS220 linear stage. Where more stages are attached (for example when using a BBD302 or
BBD303), information is also displayed in the Ch 2 and Ch 3 spaces. Note that the stage is disabled after initialization, and
it is necessary to enable and then home the stage before using it. To enable an individual connected stage, press the panel
button adjacent to the stage's Channel label to select the stage and open its control screen (Figure 12c). Then press the
button adjacent to the "Enable" label. The control screen of the enabled stage is shown in Figure 12d. The stage can be
disabled again by pressing the button next to the "Disable" label.
Figure 12 Startup Sequence for BBD301 under Front Panel Control
To home the stage, press the button next to the "Home" label (Figure 12d). During the homing process (Figure 13a), the
stage first travels to its encoder calibration position, which is typically an end switch. This is followed by a move to the preset
home position. At this point, the stage is ready for use (Figure 13b)."
Note that it is also possible to enable and then home all connected stages at the same time. To enable all at once, first press
the panel button next to the "Ch All" label (Figure 12b), and then press the button next to the "Enable All" label. Similar to
the case in which a single stage is enabled, all stages can be disabled by pressing the button next to the "Disable All" button.
Press "Home All" to start the homing procedure for all connected stages at once."
Figure 13 Homing in Operation
Additional information appears on the screen once a particular motor channel is selected, including: Maximum travel,
Velocity and Acceleration.
These are default values read from the firmware. The maximum travel is factory set according to the stage being driven, but
the velocity and acceleration can be changed via the controller front panel at any time: see Section 4.4.
Note
During the homing process when the stage is in motion, a red "STOP" sign is illuminated on the display (Fig. 4.3a) and
pressi
ng the corresponding panel button will immediately stop the stage's motion; for example, this might be needed in case
there is an observed obstruction to the stage's travel. The same applies whenever a motor is in motion. If there are 2 or mor
e
motors/axes, each axis must be selected and stopped separately.
Important: The stage stops traveling when the “STOP” button is released, not when it is depressed.

BBD30x Series Brushless DC Motor Controllers Chapter 3: Installation
Rev D April 2022 Page 15
4.4. Setting Motor Velocity and Acceleration
Individual motor speed and acceleration can be set by first selecting the appropriate channel (which produces a screen
similar to Figure 13b) then scrolling to the next page by pressing the lowest control panel button adjacent to "Next". This
brings up a screen similar to Figure 14a, where Step Size, Velocity and Acceleration can all be changed. Step Size relates
to stage movement when the knob control is operating in jog mode - see Section 4.5. for further details. However, in all
cases, the method of changing the parameters is the same: select what needs to be altered (e.g. Velocity in Figure 14b),
then use "+/-" buttons to increment/decrement the number indicated by the cursor. The cursor position is changed by the
Resolution button at the bottom. When finished, press Enter (top button).
Note: This page times out after 20 second of inactivity.
Note: The controller will prevent the inputting of parameters that are outside the permitted range of the device in question.
If required, these parameters can be viewed via the PC GUI described in Chapter 5.
Figure 14 Changing Motor Parameters
4.5. Moving the Stage
Moving motorized stages using the BBD30x front panel buttons is simple, and can be done via two methods:
1) By using pre-selected positions (up to 3) found under the "Teach" tab. In this mode, the stage travels directly to the
requested position at the speed/acceleration currently loaded into the firmware. Simply press the button
corresponding to Position 1/2/3 to send the stage to that point. See Section 4.6. on how to change these set-points.
2) By using the control knob on the front panel to increment/decrement the stage position. There are two options for
how this is done:
oJog Mode, whereby turning the control knob allows motion in either direction, one step at a time: keep
turning the knob for further steps. Allow the knob to return to its zero potion, and twist again for more
steps.
oContinuous Mode, whereby turning the control knob allows motion in either direction, one step at a time.
To initiate a jog, twist the knob in the desired direction. The stage will move as soon as torque is applied.
Release the knob to allow it to return to its zero position and twist it again to initiate another jog step.
See Section 4.7. for how the control knob functionality can be changed.
4.6. The Teach Facility: Inputting Stage Set-Points
On the title page of any chosen motor channel, the Teach facility is directly available (3rd button down - see Figure 13b).
Pressing this reveals a page similar to that shown in Figure 15a, where the current set-points are indicated. Pressing
Pos1/Pos2/ Pos3 will send the stage to those points. The positions are reset to factory defaults when the controller is
powered down.
However, if an alternative set-point position is required, move the stage into the desired position (the current position is
indicated on the screen on the right-hand side, even when the stage is moving). Note that the control knob can be used to
move the stage into position. Then hold down the button corresponding to the position that needs to be set. Wait for the
white progress bar in the bottom right-hand corner to complete (see Figure 15b), and the button can now be released. The
new set-point should then appear on the panel, and this will now have been loaded into the firmware for future use. When
finished, press 'Exit'.
Note that if precise calibration positions are required, this may be better achieved through the Kinesis software control option,
described in Chapters 5 and 6.

BBD30x Series Brushless DC Motor Controllers Chapter 3: Installation
Page 16 ETN056124-D03
Figure 15 Stage position Set-points and Changing them via Teach
4.7. The Knob Control: Setting Functionality
As noted in Section 4.5. the knob can control the motor stage position in either continuous-motion (default setting) or jog
mode; speed is set in the Set Stage parameters page (Figure 14a). The choice of continuous vs. jog action is set via toggle
action in the knob mode page (Figure 16a).
As seen from the page index overview (Figure 11), the knob function (continuous vs. jog mode) must be set for individual
motors and cannot be set for all stages simultaneously.
Note: this page times out after 20 second of inactivity.
Figure 16 Setting the Front Panel Knob Control Function
4.8. Miscellaneous: Screen Brightness, Knob Sensitivity, Firmware Version, IP Address, Serial
Number
The final Miscellaneous screen (Figure 16b) (accessed by pressing CH All/Next/Miscellaneous) allows setting of the knob
sensitivity (toggle between low, medium, and high); as this is applied to all stages, the page can only be accessed via the
All Channels route (see page index in Figure 11).
The screen brightness (1-100%) control is also found on this page and is useful for operating the controller in a variety of
lighting conditions. Selecting the button next to Brightness allows the change to be made in similar fashion to stage velocity
(Figure 14b).
The screen also provides information on Firmware version currently uploaded, Controller Serial Number and IP address of
the controller.
Note: this page times out after 20 second of inactivity.
4.9. Comments on Rotary Stages
For rotary sages, most of the functionality of the front panel resembles that of linear stages, except:
º replaces mm
º/s replaces mm/s
º/s2replaces mm/s2
The final difference is that, if the knob control is used to move the stage, there is no upper/lower hardware limit to motion;
the stages can freely rotate continuously. However, the recorded angle reverts to 0º once 360º is passed (i.e., 370º is read
as 10º) and any setting (e.g., in Teach) must be between 0º and 360º.