THORLABS BBD301 User manual

Original Instructions
BBD301, BBD302, &
BBD303 Brushless
DC Motor Controllers
APT User Guide

HA0409T Rev B Aug 2021
Page 2
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
3.4 Connecting To The Supply...........................................................................14
3.5 Fuses.....................................................................................................14
3.5.1 Rear Panel Connections BBD301................................................................... 15
3.5.2 Rear Panel Connections BBD302 and BBD303..…………………………………16
3.6 Front Panel Controls and Indicators..................................................... 17
3.7 Connecting The Hardware and Powering Up ....................................... 18
3.8 Verifying Software Operation.................................................................19
3.8.1 Initial Setup..................................................................................................... 19
Chapter 4 Operation From the Front Panel................................................. 20
4.1 Introduction............................................................................................20
4.2 Front Panel Menu Index........................................................................21
4.3 System Start-up.....................................................................................22
4.4 Setting Motor Velocity and Acceleration............................................... 23
4.5 Moving the Stage.................................................................................. 24
4.6 The Teach Facility: Inputting Stage Set-points......................................24
4.7 The Knob Control: Setting Functionality................................................25
4.8 Miscellaneous: Screen Brightness, Knob Sensitivity, System Info........25
4.9 Comments on Rotary Stages ................................................................26
Continued...

BBD30x Series Brushless DC Servo Controllers
Page 3
Chapter 5 PC Operation - Tutorial .............................................................27
5.1 Introduction ........................................................................................ 27
5.2 Using the APT User Utility .................................................................. 28
5.3 Homing Motors ................................................................................... 29
5.4 Moving to an Absolute Position........................................................... 30
5.5 Stopping the Stage............................................................................. 30
5.6 Changing Motor Parameters............................................................... 31
5.7 Jogging............................................................................................... 32
5.8 Graphical Control Of Motor Positions (Point and Move)...................... 33
5.9 Setting Move Sequences.................................................................... 35
5.10 Using A Joystick Console ................................................................... 38
5.11 External Triggering.............................................................................. 39
5.12 Creating a Simulated Configuration Using APT Config....................... 39
Chapter 6 Software Reference ....................................................................43
6.1 Introduction......................................................................................... 43
6.2 GUI Panel........................................................................................... 43
6.3 Settings Panel..................................................................................... 45
6.3.1 Moves/Jogs tab .............................................................................................45
6.3.2 Stage/Axis tab ...............................................................................................49
6.3.3 Advanced - Control Loop SettingsTab ...........................................................52
6.3.4 Advanced - Misc. Tab....................................................................................56
6.4 Troubleshooting and Restoring Default Parameters........................... 62
Appendices
Appendix A Rear Panel Connector Pinout Details....................................64
A1. Rear Panel MOTOR DRIVE Connectors........................................... 64
A2. Rear Panel FEEDBACK Connector................................................... 64
A3. Rear Panel AUX I/O Connector......................................................... 65
A4. Rear Panel HANDSET/RS232 Connector......................................... 69
Appendix B Using the RS232 or Virtual Comm Port.................................70
Appendix C Preventive Maintenance .........................................................73
Appendix D Specifications and Associated Parts ....................................74
Appendix E Motor Control Method Summary............................................75
Appendix F Regulatory................................................................................79
Appendix G Thorlabs Worldwide Contacts ...............................................81

HA0409T Rev B Aug 2021
Page 4
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
Given when there is a risk of injury from electrical shock.
Shock Warning
Given when there is a risk of injury to users.
Warning
Given when there is a risk of damage to the product.
Caution
Clarification of an instruction or additional information.
Note
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 absorbent tissue. Do not allow spilled fluid
to enter the internal mechanism.
Warnings

BBD30x Series Brushless DC Servo Controllers
HA0409T Rev B Aug 2021
Page 5
Chapter 2 Overview and Setup
2.1 Introduction
The BBD30xisa familyofthreeBrushlessDCMotorControllersthatare ideal formotion
controlapplicationsdemandinghigh speed(100s of mm/s)andhigh encoderresolution
(<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 controlcircuitry, these
new controllers are capable of driving a range of rotary and linear brushless 3-phase
DC motors at 2.5 Amps continuous current (4 Amps peak), and up to 5.2 Amps
maximum in total.
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.
Fig. 2.1 APT Three Channel Brushless DC Servo Motor Controller (BBD303)

Chapter 2
HA0409T Rev B Aug 2021
Page 6
Operation of the BBD30x Series Controllers is fully configurable (parameterized) with
keysettings (e.g.PIDsettings,min and max position values,and limitswitch 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. The units are also fully
supported by Thorlabs Kinesis® software – see separate manual.
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 APT and Kinesis
programmable interfaces for automated alignment sequences.
The reference section (Chapter 6) covers all operating modes and parameters in
detail.
Finally, an Ethernet port is included in the rear panel for connection of the controller
to a computer, but at present is not supported by APT. For use of this port, please
refer to the Kinesis version of the BBD3* controller.

BBD30x Series Brushless DC Servo Controllers
Page 7
2.2 APT PC Software Overview
2.2.1 Introduction
As a member of the APT range of controllers, the BBD30x 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 BBD30x
series, 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.

Chapter 2
HA0409T Rev B Aug 2021
Page 8
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 from the same screen.
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 utilityis coveredin the PCtutorial(Chapter5)and in theAPTUser
online help file, accessed via the F1 key when using the APTUser utility.

BBD30x Series Brushless DC Servo Controllers
Page 9
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 BBD302
and BBD303 DC motor controllers. Software applications that use ActiveX Controls
are often referred to as 'client applications'. Based on ActiveXinterfacing technology,

Chapter 2
HA0409T Rev B Aug 2021
Page 10
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 BBD303 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 ofthat move
is reflected automatically by changing position readouts on the graphical interface,
without the need for further programming intervention.

BBD30x Series Brushless DC Servo Controllers
Page 11
The APT ActiveX Controls collection provides a rich set of graphical user panels and
programmable interfaces allowing users and client application developers to interact
seamlessly with the APT hardware. Each of the APT controllers has an associated
ActiveX Control and these are described fully in system online help or the handbooks
associated with the controllers. Note that the APTUser and APTConfig utilities take
advantage of and are built on top of the powerful functionality provided by the APT
ActiveX Server (as shown in Fig. 2.2).
Fig. 2.2 System Architecture Diagram
Refer to the main APT Software online help file, APTServer.hlp, for a complete
programmers guide and reference material on using the APT ActiveX Controls
collection. Additional software developer support is provided by the APT Support CD
supplied with every APT controller. This CD contains a complete range of tutorial
samples and coding hints and tips, together with handbooks for all the APT
controllers.
2.2.5 Software Upgrades
Thorlabs operate a policy of continuous product development and may issue software
upgrades as necessary.
Detailed instructions on installing upgrades are included on the APT Software
CD ROM.

HA0409T Rev B Aug 2021
Page 12
Chapter 3 Getting Started
3.1 Installing APT Software
DO NOT CONNECT THE STAGE TO YOUR PC YET
1) Go to Services/Downloads at www.thorlabs.com and download the APT software.
2) Run the .exe file and follow the on-screen instructions.
When operating via a PC, direct user interaction with the unit is
accomplished through intuitive graphical user interface panels (GUIs),
which expose all key operating parameters and modes. The user can
select multiple panel views displaying different information about a
particular hardware unit. The multitasking architecture ensures that the
graphical control panels always remain live, showing all current
hardware activity.
Note
system administrator before attempting to install.
Caution

Chapter 3
Page 13
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 altitude 2000 m
Temperature range 5oC to 40oC
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 beenstored ata low temperature orin an environment of high humidity,
it must be allowed to reach ambient conditions before being powered up.
When siting the unit, it should be positioned so as not to impede the
operation of the rear panel power supply switch.
Ensure that proper airflow is maintained to the rear of the unit.
Caution
Operation outside the following environmental limits may adversely affect
operator safety.
Warning

HA0409T Rev B Aug 2021
BBD30x Series Brushless DC Servo Controllers
Page 14
3.3 Electrical Installation
3.4 Connecting To The Supply
3.5 Fuses
Two T 3.15A/250V A.C. 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; anti-surge
Live feed
F2
T 3.15 A
ceramic; anti-surge
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.
The safety of any system incorporating this equipment is the
responsibility of the person performing the installation.
Warning
The unit must be connected only to an earthed fused supply of 110 to
230 V.
Use only powersupply cables suppliedby Thorlabs,othercablesmay 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
Shock Warning

Chapter 3
Page 15
3.5.1 Rear Panel Connections BBD301
Fig. 3.1 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 A.1.
FEEDBACK - 15-pin female D Connector. Provides connection for the positionencoder
feedback signals - see Section A.2.
I/O 1 and I/O 2 – BNC connectors for use with external trigger input and output signals
(5V TTL levels) or as monitor outputs. The function is set to trigger IN, trigger OUT or
Monitor via the settings panel - see Section 6.4.4.
ETHERNET - For use in Ethernet communications.
USB - USB port for system communications.
HANDSETIN- Provides connection, via a female Mini-DIN, for the MJC001 2-Axis Joystick
- see Section A.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
APT support software, these user programmable logic lines can be deployed in
applications requiring control ofexternal devices such a relays, lightsources and other
auxiliary equipment. - see Section A.3. for further details.
The USB cable length should be no more than 3 metres unless a powered
USB hub is being used.
Note

HA0409T Rev B Aug 2021
BBD30x Series Brushless DC Servo Controllers
Page 16
3.5.2 Rear Panel Connections for BBD302 and BBD303
Fig. 3.2a BBD302 Rear Panel Connections
Fig. 3.2b BBD303 Rear Panel Connections

Chapter 3
Page 17
3.6 Front Panel Controls and Indicators
Fig. 3.3a BBD301 Front panel controls and indicators
Fig. 3.3b BBD303 Front Panel Controls and Indicators
Power - Rocker switch to turn power ON and OFF.
Jog Knob - Used to initiate moves in normal operation. In set-up mode the knob is
used to make changes to parameter settings.
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.

HA0409T Rev B Aug 2021
BBD30x Series Brushless DC Servo Controllers
Page 18
3.7 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 APT Software - see Section 3.1.
2) Connect the stage to the Controller unit.
3) Connect the Controller unit to your PC.
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 - see the Getting Started guide for more information
5) Wait for 10 seconds for the initialization phase to complete.
6) Run the APTUser utility and click the ‘Home’ button on each GUI panel. The front
panel of the controller indicates when homing is complete.
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 helpfile supplied with
the APT server for more information.
8) See Chapters 4 & 5 of this manual, for a brief tutorial on the operation of the unit
via the controller front panel and software, respectively.
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 energising the coils andmeasuring 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
initialisation can only take place if the motor can move unobstructed
during this time.
Note

Chapter 3
Page 19
3.8 Verifying Software Operation
3.8.1 Initial Setup
The APT Software should be installed (Section 3.1.) and the power up procedure
performed (Section 3.7.) before software operation can be verified.
1) Run the APTUser utility and check that the Graphical User Interface (GUI) panels
appear and are active (one panel for each channel of operation).
Fig. 3.4 GUI panel showing jog and ident buttons
2) Click the ‘Ident’ button. The screen on the front panel of the controller flashes.
This is useful in multi-channel systems for identifying which driver unit is
associated with which GUI.
3) 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.
Follow the tutorial steps described in Chapter 5 for further verification of operation.
simulated setup, enable Simulator Mode and set up a ‘Simulated
instructions.
Note