THORLABS DDS300 User manual

HA0324T
DDS300(/M)
Direct Drive Translation
Stage
User Guide
Original Instructions

Page 0 ETN013636-D02
DDS300 Direct Drive Translation Stage
Contents
Chapter 1 Introduction ................................................................................................ 1
Chapter 2 Safety .......................................................................................................... 2
2.1 Safety Information ............................................................................. 2
2.2 General Warnings .............................................................................. 2
Chapter 3 Installation .................................................................................................. 3
3.1 Unpacking ........................................................................................... 3
3.2 Environmental Conditions ................................................................ 3
3.3 Mounting ............................................................................................. 4
3.3.1 Vertical Mounting .................................................................................... 4
3.3.2 General ................................................................................................... 4
3.3.3 Cable Routing and Cable Extension ....................................................... 4
3.3.4 Mounting the Stage to the Work Surface ................................................ 5
3.4 Electrical Connections ...................................................................... 7
Chapter 4 Operation .................................................................................................... 9
4.1 Getting Started ................................................................................... 9
4.2 General Operation ............................................................................ 10
4.3 Stopping the Stage .......................................................................... 13
4.4 Position Error Messages ................................................................. 14
4.5 Maintenance ..................................................................................... 14
4.6 Transportation.................................................................................. 15
4.7 Troubleshooting............................................................................... 15
Chapter 5 Specification and Accessories ............................................................... 16
5.1 Specification ..................................................................................... 16
5.2 Accessories List .............................................................................. 17
Chapter 6 Using the Legacy APT Software ............................................................. 18
Chapter 7 Regulatory ................................................................................................ 23
Chapter 8 Thorlabs Worldwide Contacts ..................................................................... 25

Rev F JAN 2023 Page 1
Chapter 1 Introduction
Chapter 1 Introduction
The Thorlabs’ DDS300 low-profile, direct-drive stage provides 300 mm of travel with 100 nm
minimum step size and a maximum speed of 400 mm/s. The stage is ideal for applications
that require high speeds and high positioning accuracy, including automated alignment,
surface inspection, mapping, and probing.
The innovative low-profile design with integrated brushless linear motors eliminates the
external housings that create mechanical clash points and impede access to the moving
platform. The direct-drive technology removes the need for a lead screw, eliminating
backlash. Twin, precision-grooved linear bearings provide superior rigidity and linearity with
excellent on-axis accuracy. This backlash-free operation coupled with high-resolution,
closed-loop optical feedback ensures a minimal bidirectional repeatability of better than
±0.25 µm.Furthermore, the stage features an integrated cable management system, thereby
eliminating the need for any user side cabling.
Characterized by high-speed translation and high-positional accuracy, the DDS300 stage is
well-suited for surface mapping and characterization applications where there is a need to
move a camera or probe at constant velocity while simultaneously capturing data. Very
precise, fine, positioning and control is easily achieved through the combination of the stable
closed-loop control system and associated MJC001 joystick option.
Fig. 1.1 DDS300 Long Travel Stage

Page 2 ETN013636-D02
DDS300 Direct Drive Translation Stage
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 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.
When bolting the stage to the work surface and when fixing a load to the top
platform, high tightening torque of the attachment bolts can result in an increased
resistive force on the moving platform. This in turn can lead to degraded
performance and may require the PID parameters to be adjusted. As a general guide,
70 N·cm is a recommended nominal torque when tightening the attachment bolts.

Rev F JAN 2023 Page 3
Chapter 3 Installation
Chapter 3 Installation
3.1 Unpacking
3.2 Environmental Conditions
Location Indoor use only
Maximum altitude 2000 m
Temperature range 5 to 40°C (41 to 104°F)
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.
Note
During handling or shipping, the moving platform must be constrained to avoid damage to
the bearings.
Retain the packing in which the unit was shipped, for use in future transportation.
Two handles are shipped with the unit to assist in handling. These handles should be fitted
to the center hole at either end of the stage. The handles require a minimum of three turns
to ensure safe load bearing of the product.
Caution
Once removed from its packaging, the stage can be easily damaged by mishandling.
The unit should only be handled by its base, not by any attachments to the moving
platform.
Warning
Operation outside the following environmental limits may adversely affect operator
safety.

Page 4 ETN013636-D02
DDS300 Direct Drive Translation Stage
3.3 Mounting
3.3.1 Vertical Mounting
3.3.2 General
3.3.3 Cable Routing and Cable Extension
Warning
The safety of any system incorporating this equipment is the responsibility of the
person performing the installation.
Warning
The stage is not suitable for mounting in a vertical (Z-axis) configuration.
Caution
The performance of the stage could be affected if the mounting surface is not flat to
within 200 µm. Care should be taken when bolting the stage to the work surface, to
ensure that the base does not warp, which could cause stiffness to be experienced in
the bearing rails. Shims should be fitted as necessary.
When mounting the stage close to other equipment, ensure that the travel of the
moving platform is not obstructed. If equipment mounted on the moving platform is
driven against a solid object, damage to the internal mechanism could occur. The
range of travel is 300 mm (11.81”).
When considering the stage movement in the proximity of other objects or
equipment, ensure that movement of cables connected to the moving carriage is not
impeded.
When bolting the stage to the work surface and when fixing a load to the top
platform, high tightening torque of the attachment bolts can result in an increased
resistive force on the moving platform. This in turn can lead to degraded
performance and may require the PID parameters to be adjusted.
As a general guide, 70 Ncm is a recommended nominal torque when tightening the
attachment bolts.
High drag forces can adversely affect phase initialization, homing, positioning
accuracy and general reliability. Take care to minimize drag caused by attachments
to the moving platform (cables, tubing, electrical wiring), especially when the stage
is changing direction.
Caution
The D-Type shell of the motor connector houses an ID chip which could be damaged
if the plug is opened. The encoder connector houses circuitry which could be easily
damaged by static discharge. Under no circumstances should these plugs be opened
or removed (e.g. to facilitate cable routing).

Rev F JAN 2023 Page 5
Chapter 3 Installation
3.3.4 Mounting the Stage to the Work Surface
The DDS300 stage is mounted to the work surface by four M6 x 25 mm (1/4”-20 x 1”) screws.
The mounting holes are accessed from the top of the stage as shown below.
Using a diagonal pattern, tighten the mounting bolts.
Fig. 3.1 Mounting

Page 6 ETN013636-D02
DDS300 Direct Drive Translation Stage
Below is an example of XY configuration when the top stage is bolted on a top plate of the bottom
stage.
Fig. 3.2 XY Configuration
Caution
When mounting the stage to the worksurface, use only the holes in the end of
the stage as shown above. The performance of the stage could be affected if the
mounting surface is not flat. Pads at the end and in the middle are not on the same
plane.The middle mounting holes should be used exclusively in cases when the ends have no
support.
Care should be taken when bolting the stage to the work surface, to ensure that the base plate
does not warp, which could cause stiffness to be experienced in the bearing rails.
After mounting the stage to the work surface, if any increased resistance is experienced when
moving the top platform, the likely cause is over tightening/torquing of the mounting bolts. As
a general guide, 70 N·cm is a recommended nominal torque when tightening the attachment
bolts.
Please contact tech support for more information.

Rev F JAN 2023 Page 7
Chapter 3 Installation
The stage can also be mounted on its side, using two AP90RL(/M) brackets - see Fig. 3.3.
Using a diagonal pattern, tighten the mounting bolts.
Fig. 3.3 Side Mounting
3.4 Electrical Connections
The stage must be driven by a Thorlabs BBD series and RBD201 controllers. Connect the
motor leads to the MOTOR DRIVE connectors, and the encoder feedback leads to the
FEEDBACK connectors. Ensure that the motor drive and feedback leads for each motor are
connected to the correct channel.
Caution
Ensure that any devices and components attached to the moving platform are
securely fastened. Incorrectly attached components could come loose when the stage
is operated.

Page 8 ETN013636-D02
DDS300 Direct Drive Translation Stage
Fig. 3.4 Electrical connections
Pin out information for the motor drive and encoder feedback connectors on the motor
flying leads is detailed below.
Fig. 3.5 DDS300 Motor Drive and Feedback Flying Lead Pin Out Details
1 Motor Phase V
2 GND
3 Thermistor (not used)
4 Motor Phase U
5 Stage ID
6 GND
7 Motor Phase W
8 Enable
1 Not Used
2 GND
3 Not Used
4 Enc Index -
5 QB -
6 QA -
7 5 V
8 5 V
9 GND
10 Limit Switch +
11 Limit Switch -
12 Enc Index +
13 QB +
14 QA +
15 Not Used
3
5
8
2
6
4
1
7
MOTOR DRIVE
ENCODER FEEDBACK
87654321
1514131211109

Rev F JAN 2023 Page 9
Chapter 4 Operation
Chapter 4 Operation
4.1 Getting Started
The stages are connected to the controller via 2 flying leads, one terminated in D-type
connector (FEEDBACK) and one terminated in a round 8-Pin DIN Connector (MOTOR DRIVE).
For a complete tutorial on using the stage, see the manual supplied with the controller. Basic
steps in controlling the stage are as follows:
1) Make electrical connections as detailed in Section 3.4.
2) Move the moving platform a few times over its full range of travel to overcome any
storage resistance, then position the moving platform to be around its central position.
3) Power up the controller and wait for 10 secs until the Channel Enable LEDs start flashing.
4) If a joystick control is being used, press and hold the ‘High/Low’ button for 2 seconds,
then release to home the stage. When homing is complete, the green LED stops flashing.
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.
The DDS300 stage is designed to be driven by the Thorlabs BBD30x or RBD201
Brushless DC Motor Controllers.
Warning
The motor controller must be switched OFF before the stages are plugged in or
unplugged. Failure to switch the controller off may result in damage to either the
controller, the stage, or both.
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.
Warning
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
motor coil housing. On power up, the position of the coil housing 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) may make a slight buzzing
noise and move slightly. Phase initialization can only take place if the motor can move
unobstructed during this time. Before powering up the BBD controller at item (2),
ensure that the stage movement is unobstructed.

Page 10 ETN013636-D02
DDS300 Direct Drive Translation Stage
5) If no joystick is being used, run the software utility and click the ‘Home’ button on each GUI
panel. When homing is complete, the Channel Enable LEDs stop flashing .
6) The stage can now be moved using the joystick, GUI panel, or by setting commands to
move each axis by relative and absolute amounts – see the handbook supplied with the
BBD controller, and the helpfile supplied with the APT or Kinesis software for more
information.
4.2 General Operation
The following sections contain a brief overview the stage using of the Kinesis software. For
more detailed information see the manual for the associated controller (BBD30x or RBD201).
For details using the legacy APT software please see Appendix A.
The stage is shipped already loaded with default parameter settings, which should give
satisfactory performance in most cases. However, depending on the application, it may be
necessary to adjust the PID loop parameter settings to fine tune the response. In the event
that these settings need to be changed, the user can create a custom settings group - see the
Kinesis Helpfile for more information.
1) If it is not already running, start the Kinesis software - Start/Programs/Thorlabs/Kinesis/
Kinesis.The server reads in the stage and controller information on boot up and the GUI
panel shown below is displayed.
Fig. 4.1 Kinesis GUI screen
Note
The stage design incorporates several reference markers on the encoder scale, which are
used to calibrate the position counter.
The need for homing comes from the fact that on power up the motor (stage) is at a random
position, so the value of the position counter is meaningless. Homing involves moving the
motor to allow the encoder readhead to scan through encoder scale's reference markers in
search of the reference marker designated for homing. The position counter is then reset,
and the software will show an absolute value once the homing move sequence is
completed.

Rev F JAN 2023 Page 11
Chapter 4 Operation
2) Click the Settings button on the GUI to display the Settings panel, then select the
‘Advanced’ tab.
Fig. 4.2 Advanced Control Loop Settings
Note
The MOTOR DRIVE connectors for each channel/axis contain an EEPROM, which stores the
factory default settings for the set up parameters. When the stage is connected, these settings
are loaded into the controller on start up, and are tuned for loads up to the 2.0 kg (4.4 lb)
maximum, at speeds up to 100 mm/s.
However, depending on the load being driven and the speed/duty cycle of the particular
application, it may be necessary to further optimize the Position PID loop settings.
If problems are encountered (e.g. stability of the closed loop position control, lost motion or
incomplete moves) the position loop PID parameters should be adjusted to tune the stage for
the given application. Normally, only minor adjustment of the Proportional, Integral and
Derivative parameters should be necessary, and some trial and error will be required before the
ideal settings for a specific application are achieved. In cases where further adjustment of the
control loop parameters is required, the following guidelines are provided in order to assist in
the tuning process.

Page 12 ETN013636-D02
DDS300 Direct Drive Translation Stage
3) Create a Custom Settings Group (see the Kinesis helpfile for more information) and then
adjust the PID settings to fine tune the control loop for your application. Refer to the
handbook supplied with the BBD301 control unit for more details on PID settings.
4) After the parameter changes have been performed, click the ‘Persist Settings to
Hardware’ box, then click ‘OK’. This will ensure that the same parameter settings will be
loaded next time the unit is powered up - even in the absence of a PC.
Caution
Default PID values for 2 kg load placed at the centre of the top plate have already been
optimized and stored within the stage, and these are loaded into the controller on
power up.
If problems are encountered (e.g. stability of the closed loop position control, lost motion or
incomplete moves) the position PID parameters can be adjusted to tune the stage for the given
application. Normally, only minor adjustment of the Proportional, Integral and Derivative
parameters should be necessary, and some trial and error will be required before the ideal
settings for a specific application are achieved.
Table 4.1 Suggested PID parameters
Load Proportional Integral Derivative Integral
Limit
Output
Gain
Derivative
Recalibration
Time
0-2 kg 800 1000 720 17000 2050 5
4 kg 1000 1000 800 17000 2300 6
6 kg 1000 1150 855 17000 2300 6
8 kg 1150 1150 1000 18000 2400 7
10 kg 1150 1500 1000 18000 2400 7
Caution
If settings are persisted, then a stage is changed, further parameter adjustment may
be required to achieve optimum performance with the new stage.

Rev F JAN 2023 Page 13
Chapter 4 Operation
See the manual supplied with the controller unit for more information.
4.3 Stopping the Stage
The drive channel is enabled and disabled by clicking the ‘Enable’ button on the GUI panel or
the front panel of the unit. The green indicator is lit when the drive channel is enabled.
Disabling the channel removes the drive power and allows the stage/actuator to be
positioned manually.
During operation, the stage can be stopped at any time by clicking the ‘Stop’ button on the
GUI panel. Using this button does not remove power to the drive channel.
Fig. 4.3 Kinesis GUI screen
Note
For a given load, a deviation of typically ±10% from the values quoted may be necessary. To
optimize parameters proceed as follows:
Stage overshoots the intended position- reduce the Integral term and increase the
Derivative and Proportional terms.
Stage fails to attain final position - increase the Integral and Proportional terms.
Motion is unstable - reduce the Proportional and Integral terms, increase the Derivative
term.
Stage sounds noisy - reduce the Derivative term.
Excessive sensitivity to noise - reduce Derivative time.
Please see the handbook supplied with the controller, for more information on changing
these settings.

Page 14 ETN013636-D02
DDS300 Direct Drive Translation Stage
4.4 Position Error Messages
4.5 Maintenance
Repetitive movement over long periods can result in build up of lubricant which can cause
uneven motion. Periodically, the stage should be powered down and the top platform moved
from one end of travel to the other several times to redistribute the bearing lubricant.
The product is maintenance free up to 5 million cycles. If any problems occur, the user should
contact the local Thorlabs tech support for more information. After 5 million cycles, a
replacement of the internal flexible cable, and a relubrication of the bearing carriers is
recommended. Contact your local Thorlabs tech support for more information.
Caution
The maximum velocity at which the encoder can operate is 400 mm/sec. Above this
speed, encoder pulses 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 BBD controller, the maximum velocity is limited
to safe values. However, if the output is disabled (with the controller connected and
monitoring the position) and the stage is moved manually at high speeds (i.e. above
400 mm/sec), it is possible to exceed this limit. If the BBD 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 manually.
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 established.
If this fault occurs when the stage is being controlled via the MJC001 joystick, in the
absence of a PC, the red LED on the joystick console is lit, and all operation is
suspended until the controller is shut down and rebooted.
Warning
Prolong and repeated contact of the lubricant used on the linear rail bearing may
cause skin irritation. Gloves should be worn when such contact is likely.
Caution
The coating on the bearing rails is easily damaged/removed by solvents ( e.g. paint
thinners) or similar aggressive substances. Do not allow such substances to contact
the bearing rail.

Rev F JAN 2023 Page 15
Chapter 4 Operation
4.6 Transportation
4.7 Troubleshooting
If an unexpected obstruction to the stage motion is encountered, the control system
interface software disables the current to the associated drive channel, which may or may
not result in the channel being disabled. After the obstruction to be removed, the associated
channel of the controller should first be disabled to clear any fault codes, then re-enabled.
In the event of a breakdown, or malfunction of the product please contact Thorlabs Tech
Support. Contact details are contained in Chapter C.
Caution
When packing the unit for shipping, use the original packing. If this is not available, use
a strong box and surround the unit with at least 100 mm of shock absorbent material.
In particular, the moving platform must be constrained to avoid damage during
shipping.

Page 16 ETN013636-D02
DDS300 Direct Drive Translation Stage
Chapter 5 Specification and Accessories
5.1 Specification
Parameter Value
Travel Range 300 mm (11.81")
Max Speed 400 mm/s
Max Acceleration110,000 mm/s2
Bidirectional Repeatability ±0.25 µm
Backlash2N/A
Encoder Resolution 50 nm
Min Incremental Movement 100 nm
Horizontal Load Capacity310.0 kg (22.0 lb)
Absolute On-Axis Accuracy ±7.5 µm
Straightness/Flatness ±4.0µm
Pitch ±100 µRad
Yaw ±150 µRad
Continuous Motor Force 10.0 N
Peak Motor Force (2 sec) 20.0 N
Bearing Type High Rigidity Recirculating Precision Linear Bearing
Limit Switches Magnetic Sensor at Each End of Stage
Operating Temperature Range45 to 40°C (41 to 104°F)
Motor Type Brushless DC Linear Motor
Cable Length 2.5 m (8.2‘)
Dimensions (Mid Travel) 500 mm x 130 mm x 50 mm
(19.69” x 5.12” x 1.97”)
Weight (Excluding Cables) 5.9 kg (12.98 lb)

Rev F JAN 2023 Page 17
Chapter 5 Specification and Accessories
5.2 Accessories List
Thorlabs’ MJC001 joystick console is designed for remote operation and enables intuitive,
tactile, manual positioning of a stage. This highly reliable, Hall effect joystick features XY
control, a speed adjustment for fast or high precision movement, and a high-quality,
anodized aluminum casing.
An adapter plate, DDSA04(/M) is available to raise the moving platform height to 62.5 mm
for compatibility with our series of 3-axis positioning stages.
Notes
All measurements were undertaken at 300 mm/s and 5,000 mm/s2 for the maximum travel
of 300 mm, at lab temperature 20 °C.
The default tuning parameters can be changed to optimize settling times for a specific
loads.
1 The acceleration should be set according to the load, and is limited by the continuous
motor force.
2 The stage does not suffer from backlash because there is no lead screw.
3 The controller default PID parameters are set for load up to 2.0 kg and may require
adjustment for higher loads. At higher loads the acceleration should be decreased. The
acceleration is limited by the motor force.
4 For operation at temperatures outside normal room temperature, the PID parameters
may require optimization.
Caution
In applications requiring high speed/acceleration or high loads, some heating of the
stage may occur and dimensional stability of the stage may be affected. This could
result in less than optimal repeatability and accuracy. For cases were repeatability and
accuracy are critical it is recommended that the stage temperature is allowed to reach
a steady state before measurements are taken.
Alternatively the load, acceleration and duty cycle should be reduced from the
maximum values. Some trial and error in setting these values may be necessary before
the ideal settings are attained. Please contact your local Thorlabs tech support office
for more details.
Product Name Part Number
MJC001 2-Axis Joystick Console
DDSA04(/M) Adapter Plate for 62.5 mm Deck Height

Page 18 ETN013636-D02
DDS300 Direct Drive Translation Stage
Appendix A Using the Legacy APT Software
A.1 General Operation
1) The stage is shipped already loaded with default parameter settings, which should give
satisfactory performance in most cases. However, depending on the application, it may
be necessary to adjust the PID loop parameter settings to fine tune the response - see
the following pages for more information.
2) If it is not already running, start the APT User utility - Start/Programs/Thorlabs/APT User/
APT User
The APT server reads in the stage and controller information on boot up and the GUI
panel shown below is displayed.
Fig. A.1 APT User GUI screen