Newport ESP300, ESP300-2, ESP300-1 User Manual

ESP300 Motion Controller/Driver

User's Manual

Warranty

Newport Corporation warrants that this product will be free from
defects in material and workmanship and will comply with Newport’s
published specifications at the time of sale for a period of one year from
date of shipment. If found to be defective during the warranty period,
the product will either be repaired or replaced at Newport's option.

To exercise this warranty, write or call your local Newport office or
representative, or contact Newport headquarters in Irvine, California.
You will be given prompt assistance and return instructions. Send the
product, freight prepaid, to the indicated service facility. Repairs will
be made and the instrument returned freight prepaid. Repaired
products are warranted for the remainder of the original warranty
period or 90 days, whichever first occurs.

Limitation of Warranty

The above warranties do not apply to products which have been
repaired or modified without Newport’s written approval, or products
subjected to unusual physical, thermal or electrical stress, improper
installation, misuse, abuse, accident or negligence in use, storage,
transportation or handling. This warranty also does not apply to fuses,
batteries, or damage from battery leakage.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES,
EXPRESSED OR IMPLIED, INCLUDING ANY IMPLIED
WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR USE. NEWPORT CORPORATION SHALL NOT
BE LIABLE FOR ANY INDIRECT, SPECIAL, OR
CONSEQUENTIAL DAMAGES RESULTING FROM THE
PURCHASE OR USE OF ITS PRODUCTS.

First printing 1999

Copyright 2002 by Newport Corporation, Irvine, CA. All rights
reserved. No part of this manual may be reproduced or copied without
the prior written approval of Newport Corporation.

This manual has been provided for information only and product
specifications are subject to change without notice. Any change will
be reflected in future printings.

 2002 Newport Corporation

1791 Deere Ave.
Irvine, CA 92606
[phone]

P/N 28187-02 Rev. F

ii Preface

Confidentiality & Proprietary Rights

Reservation of Title:

The Newport programs and all materials furnished or produced in
connection with them ("Related Materials") contain trade secrets of
Newport and are for use only in the manner expressly permitted.
Newport claims and reserves all rights and benefits afforded under
law in the Programs provided by Newport Corporation.

Newport shall retain full ownership of Intellectual Property Rights in
and to all development, process, align or assembly technologies
developed and other derivative work that may be developed by
Newport. Customer shall not challenge, or cause any third party to
challenge the rights of Newport.

Preservation of Secrecy and Confidentiality and Restrictions to
Access:

Customer shall protect the Newport Programs and Related Materials
as trade secrets of Newport, and shall devote its best efforts to ensure
that all its personnel protect the Newport Programs as trade secrets of
Newport Corporation. Customer shall not at any time disclose
Newport's trade secrets to any other person, firm, organization, or
employee that does not need (consistent with Customer's right of use
hereunder) to obtain access to the Newport Programs and Related
Materials. These restrictions shall not apply to information (1)
generally known to the public or obtainable from public sources; (2)
readily apparent from the keyboard operations, visual display, or
output reports of the Programs; 93) previously in the possession of
Customer or subsequently developed or acquired without reliance on
the Newport Programs; or (4) approved by Newport for release
without restriction.

Service Information

This section contains information regarding factory service for the
ESP300 System. The user should not attempt any maintenance or
service of the system or optional equipment beyond the procedures
outlined in this manual. Any problem that cannot be resolved should
be referred to Newport Corporation.

Preface iii

ESP300

1999

EU Declaration of Conformity

iv Preface

Table of Contents

Warranty ............................................................................ ii

Limitation of Warranty ....................................................... ii

Copyright ............................................................................ ii

EU Declaration of Conformity........................................... iv

Section 1 – Introduction ...........................................1-1

1.1 Scope............................................................... 1-1

1.2 Safety Considerations ..................................... 1-2

1.3 Conventions and Definitions........................... 1-3

1.3.1 Definitions and Symbols.................... 1-3

1.3.2 Terminology....................................... 1-5

1.4 System Overview ............................................ 1-6

1.4.1 Features .............................................. 1-6

1.4.2 Specifications ..................................... 1-7

1.4.3 Descriptions of Front Panel Versions 1-8

1.4.4 Rear Panel Description....................... 1-9

1.5 System Setup................................................. 1-11

1.5.1 Line Voltage..................................... 1-11

1.5.2 First Power ON ................................ 1-11

1.6 Quick Start .................................................... 1-12

1.6.1 Connecting Motion Devices............. 1-12

1.6.2 Motor On.......................................... 1-13

1.6.3 Homing............................................. 1-13

1.6.4 First Jog............................................ 1-14

Section 2 – Modes of Operation...............................2-1

2.1 Overview of Operating Modes........................ 2-1

2.1.1 LOCAL Mode .................................... 2-1

2.1.2 REMOTE Mode................................. 2-1

2.2 Operation in LOCAL Mode............................ 2-2

2.2.1 Accessing the Menu ........................... 2-2

2.2.2 Navigating the Menu.......................... 2-2

2.2.3 Changing Values ................................ 2-2

2.2.4 Motion from the Front Panel.............. 2-3

2.2.5 Detailed Description of Menu Items.. 2-5

Section 3 – Remote Mode.........................................3-1

3.1 Programming Modes....................................... 3-1

Preface v

3.2 Remote Interfaces............................................ 3-4

3.2.1 RS-232C Interface.............................. 3-4

3.2.2 IEEE488 Interface.............................. 3-5

3.3 Software Utilities ............................................ 3-6

3.4 Command Syntax............................................ 3-7

3.4.1 Summary of Command Syntax .......... 3-8

3.5 Command Summary ....................................... 3-9

3.5.1 Command List by Category ............. 3-10

3.5.2 Command List - Alphabetical .......... 3-14

3.6 Description of Commands ............................ 3-17

Section 4 – Advanced Capabilities ..........................4-1

4.1 Grouping ......................................................... 4-1

4.1.1 Introduction – Advanced Capabilities 4-1

4.1.2 Defining a Group & Group

Parameters.......................................... 4-1

4.1.2.1 Creating a Group................. 4-1

4.1.2.2 Defining Group Parameters 4-2

4.1.3 Making Linear and Circular Moves ... 4-2

4.1.3.1 Making Linear Move .......... 4-3

4.1.3.2 Making Circular Move........ 4-3

4.1.4 Making Contours................................ 4-4

4.1.5 Miscellaneous Commands ................. 4-7

4.2 Slaving a Stage to Trackball, Joystick, or a

Different Stage ................................................ 4-7

4.2.1 Introduction – Slaving a Stage ........... 4-7

4.2.2 Slave to a Different Stage .................. 4-8

4.2.3 Slave to a Trackball............................ 4-8

4.2.4 Slave to a Joystick.............................. 4-9

4.3 Closed Loop Stepper Motor Positioning......... 4-9

4.3.1 Introduction – Closed Loop Stepper .. 4-9

4.3.2 Feature Implementation ................... 4-10

4.4 Synchronize Motion to External and Internal

Events............................................................ 4-12

4.4.1 Introduction – Synchronize Motion . 4-12

4.4.2 Using DIO to Execute Stored

Programs .......................................... 4-12

4.4.3 Using DIO to Inhibit Motion ........... 4-14

4.4.4 Using DIO to Monitor Motion

Status................................................ 4-14

Section 5 – Motion Control Tutorial.........................5-1

5.1 Motion Systems............................................... 5-1

5.2 Specification Definitions................................. 5-2

5.2.1 Following Error.................................. 5-3

vi Preface

5.2.2 Error ................................................... 5-3

5.2.3 Accuracy ............................................ 5-3

5.2.4 Local Accuracy .................................. 5-4

5.2.5 Resolution .......................................... 5-6

5.2.6 Minimum Incremental Motion........... 5-6

5.2.7 Repeatability ...................................... 5-7

5.2.8 Backlash (Hysteresis)......................... 5-8

5.2.9 Pitch, Roll and Yaw ........................... 5-9

5.2.10 Wobble ............................................. 5-10

5.2.11 Load Capacity .................................. 5-10

5.2.12 Maximum Velocity .......................... 5-11

5.2.13 Minimum Velocity........................... 5-11

5.2.14 Velocity Regulation ......................... 5-12

5.2.15 Maximum Acceleration.................... 5-12

5.2.16 Combined Parameters ...................... 5-13

5.3 Control Loops ............................................... 5-13

5.3.1 PID Servo Loops.............................. 5-14

5.3.2 Feed-Forward Loops ........................ 5-16

5.4 Motion Profiles ............................................. 5-18

5.4.1 Move ................................................ 5-18

5.4.2 Jog .................................................... 5-19

5.4.3 Home Search .................................... 5-20

5.5 Encoders........................................................ 5-22

5.6 Motors ........................................................... 5-26

5.6.1 Stepper Motors................................. 5-26

5.6.1.1 Stepper Motor Types.......... 5-31

5.6.2 DC Motors........................................ 5-32

5.7 Drivers........................................................... 5-33

5.7.1 Stepper Motor Drivers ..................... 5-33

5.7.2 Unipolar-Bipolar Drivers ................. 5-35

5.7.3 DC Motor Drivers ............................ 5-36

5.7.3.1 PWM Drivers ..................... 5-38

Section 6 – Servo Tuning .........................................6-1

6.1 Tuning Principles ............................................ 6-1

6.2 Tuning Procedures .......................................... 6-1

6.2.1 Hardware and Software Requirements6-2

6.2.2 Correcting Axis Oscillation ............... 6-2

6.2.3 Correcting Following Error................ 6-2

6.2.4 Points To Remember.......................... 6-4

Section 7 – Optional Equipment ..............................7-1

7.1 Hand-held Keypad .......................................... 7-1

7.1.1 Description of Keys ........................... 7-2

7.1.2 Activating the Keyboard .................... 7-2

Preface vii

Appendix A – Error Messages................................. A-1

Appendix B – Trouble-Shooting/Maintenance ....... B-1

B.1 Trouble-Shooting Guide .................................B-2

B.2 Fuse Replacement ...........................................B-4

B.2.1 Replacing Fuses on the ESP300 Rear

Power Line Panel ...............................B-4

B.3 Cleaning ..........................................................B-5

Appendix C – Connector Pin Assignments............ C-1

C.1 ESP300 Rear Panel .........................................C-1

C.1.1 GPIO Connector (37-Pin D-Sub) ......C-1

C.1.2 Signal Descriptions (Digital I/O, 37-Pin

JP4 Connector)..................................C-1

C.1.3 Motor Driver Card (25-Pin) I/O

Connector ..........................................C-2

C.1.4 Signal Descriptions (Motor Driver Card,

25-Pin I/O Connector).......................C-3

C.1.5 Auxiliary Encoder Inputs ..................C-5

C.1.6 IEEE488 Interface Connector (24-

Pin) ....................................................C-6

C.1.7 RS-232C Interface Connector (9-Pin

D-Sub)...............................................C-6

C.1.8 RS-232C Interface Cable...................C-7

C.1.9 Motor Interlock Connector (BNC) ....C-7

Appendix D – Binary Conversion Table ................. D-1

Appendix E – System Upgrades ............................. E-1

E.1 Adding Axes ...................................................E-2

E.2 Adding IEEE488.............................................E-3

E.3 Changing the Front Panel Option....................E-4

Appendix F – ESP Configuration Logic...................F-1

Appendix G – Programming Non-ESP Compatible

Stages................................................ G-1

viii Preface

Appendix H – Factory Service................................. H-1

H.1 Service Form .................................................. H-2

List of Figures

Figure No. Page

Figure 1.1: ESP 300 Controller/Driver ..........................................1-6

Figure 1.2: ESP300 Front Panel with displays ..............................1-9

Figure 1.3: Rear Panel of the ESP300..........................................1-10

Figure 2.1: Menu Section................................................................2-2

Figure 2.2: Menu Item.....................................................................2-3

Figure 2.3: Motion from the Front Panel Displayed ......................2-3

Figure 3.1: Command Syntax Diagram ..........................................3-7

Figure 4.1: A Contour with Multiple Circular Moves ....................4-5

Figure 4.2: A Contour with Multiple Linear and Circular Moves 4-5
Figure 4.3: Block Diagram of Via Point Data Handling

By Command Processor.............................................4-6

Figure 4.4: Block Diagram of Via Point Data Handling

By Trajectory Generator...........................................4-7

Figure 4.5: Block Diagram of Closed Loop Stepper Motor

Positioning .......................................................... 4-11

Figure 5.1: Typical Motion Control Systems ..................................5-1

Figure 5.2: Position Error Test.......................................................5-4

Figure 5.3a: High Accuracy for Small Motions..............................5-5

Figure 5.3b: Low Accuracy for Small Motions...............................5-5

Figure 5.4: Effect of Stiction and Elasticity on Small Motion ........5-6

Figure 5.5: Error Plot .....................................................................5-6

Figure 5.6: Error vs. Motion Step Size ...........................................5-7

Figure 5.7: Hysteresis Plot .............................................................5-8

Figure 5.8: Real vs. Ideal Position..................................................5-9

Figure 5.9: Pitch, Roll and Yaw Motion Axes.................................5-9

Figure 5.10: Pitch, Yaw and Roll Motion Axes...............................5-9

Figure 5.11: Wobble Generates a Circle ......................................5-10

Figure 5.12: Position, Velocity and Average Velocity................. 5-11

Figure 5.13: Servo Loop ...............................................................5-14

Figure 5.14: P Loop ......................................................................5-15

Figure 5.15: PI Loop.....................................................................5-15

Figure 5.16: PID Loop..................................................................5-16

Figure 5.17: Trapezoidal Velocity Profile ....................................5-17

Figure 5.18: PID Loop with Feed Forward..................................5-17

Figure 5.19: Tachometer-Driven PIDF Loop...............................5-18

Figure 5.20: Trapezoidal Motion Profile......................................5-19

Figure5.21: Position and Acceleration Profiles ...........................5-19

Figure 5.22: Home (Origin) Switch and Encoder Index Pulse.....5-21

Preface ix

Figure 5.23: Slow Speed Home (Origin) Switch Search............5-21

Figure 5.24: High/Low-Speed Home (Origin) Switch Search ...5-21
Figure 5.25: Home (Origin) Search From Opposite

Direction ...............................................................5-22

Figure 5.26: Encoder Quadrature Output .................................5-23

Figure 5.27: Optical Encoder Scale...........................................5-23

Figure 5.28: Optical Encoder Read Head .................................5-24

Figure 5.29: Single-Channel Optical Encoder Scale and

Read Head Assembly.............................................5-24

Figure 5.30: Two-Channel Optical Encoder Scale and

Read Head Assembly.........................................5-25

Figure 5.31: Stepper Motor Operation ......................................5-26

Figure 5.32: Four-Phase Stepper Motor ...................................5-27

Figure 5.33: Phase-Timing Diagram.........................................5-27

Figure 5.34: Energizing Two Phases Simultaneously................5-28

Figure 5.35: Timing Diagram, Half-Stepping Motor.................5-28

Figure 5.36: Energizing Two Phases with Different

Intensities ..........................................................5-28

Figure 5.37: Timing Diagram, Continuous Motion (Ideal) .......5-29

Figure 5.38: Timing Diagram, Mini-Stepping ...........................5-29

Figure 5.39: Single Phase Energization ....................................5-30

Figure 5.40: External Force Applied .........................................5-30

Figure 5.41: Unstable Point.......................................................5-30

Figure 5.42: Torque and Tooth Alignment ................................5-30

Figure 5.43: DC Motor ..............................................................5-32

Figure 5.44: Simple Stepper Motor Driver................................5-34

Figure 5.45: Current Build-up in Phase ....................................5-34

Figure 5.46: Effect of a Short ON Time on Current ..................5-34

Figure 5.47: Motor Pulse with High Voltage Chopper..............5-35

Figure 5.48: Dual H-Bridge Driver ...........................................5-36

Figure 5.49: DC Motor Voltage Amplifier.................................5-36

Figure 5.50: DC Motor Current Driver.....................................5-37

Figure 5.51: DC Motor Velocity Feedback Driver....................5-37

Figure 5.52: DC Motor Tachometer Gain and

Compensation....................................................5-38

Figure 7.1: Alphanumeric Hand-held Keypad.............................7-1

Figure B.1: Rear Power Line Panel Fuse Replacement ............. B-4

Figure C.1: RS-232C Connector pin-out .................................... C-7

Figure C.2: Connector, Pin-to-Pin RS-232C Interface Cable....C-7

Figure C.3: Motor Interlock Connector (BNC) with dust cap .... C-8

Figure E.1: Removal of the Top Cover ....................................... E-2

Figure E.2: Interior of the unit explaining the connectors ......... E-3

Figure E.3: How to remove screws inside the unit for the

Front Panel .......................................................... E-4

Figure F.1: Configuration Logic................................................. F-2

x Preface

List of Tables

Table No. Page

Table 3.5.1: Command List by Category..................................... 3-10

Table 3.5.2: Command List - Alphabetical.................................. 3-14

Table 4.1: Slave to a Different Stage Steps ................................... 4-8

Table 4.2: Slave to a Trackball Steps ............................................ 4-9

Table 4.3: Slave to a Joystick Steps............................................... 4-9

Table 4.4: An Example of Closed Loop Stepper Motor

Positioning Setup .................................................. 4-11

Table 4.5: Closed Loop Stepper Positioning Commands............ 4-12

Table 4.6: Commands to Synchronize Motion to External

Events .................................................................... 4-15

Table 6.1: Servo Parameter Functions ......................................... 6-5

Table B.1: Trouble-Shooting Guide Descriptions.........................B-2

Table C.1: Digital Connector Pin-Outs ........................................C-1

Table C.2: Driver Card Connector Pin-Outs................................C-2

Table C.3: Auxiliary Encoder Connector Pin Outs ......................C-6

Table C.4: IEEE488 Interface Connector.....................................C-6

Table D.1: Binary Conversion Table, using decimal and

ASCII copies........................................................... D-1

Table H.1: Technical Customer Support Contacts ...................... H-1

Preface xi

Command Index (Section 3)

Command Description Page in section 3-

AB abort motion...............................................................................................20

AC set acceleration...........................................................................................21

AE set e-stop deceleration................................................................................23

AF set acceleration feed-forward gain.............................................................25

AG set deceleration...........................................................................................26

AP abort program.............................................................................................28

AU set maximum acceleration and deceleration ..............................................29

BA set backlash compensation.........................................................................30

BG assign DIO bits to execute stored programs ..............................................31

BK assign DIO bits to inhibit motion...............................................................32

BL enable DIO bits to inhibit motion ..............................................................33

BM assign DIO bits to notify motion status......................................................34

BN enable DIO bits to notify motion status .....................................................35

BO set DIO port A, B direction........................................................................36

BP assign DIO bits for jog mode .....................................................................38

BQ enable DIO bits for jog mode.....................................................................39

CL set closed loop update interval...................................................................40

CO set linear compensation..............................................................................41

DB set position deadband.................................................................................42

DC setup data acquisition .................................................................................43

DD get data acquisition done status..................................................................45

DE enable/disable data acquisition ..................................................................46

DF get data acquisition sample count ..............................................................47

DG get acquisition data ....................................................................................48

DH define home................................................................................................49

DL define label.................................................................................................50

DO set dac offset ..............................................................................................51

DP read desired position ..................................................................................52

DV read desired velocity..................................................................................53

EO automatic execution on power on ..............................................................54

EP enter program mode ...................................................................................55

ES define event action command string ..........................................................56

EX execute a program ......................................................................................58

FE set maximum following error threshold.....................................................59

FP set position display resolution....................................................................60

FR set encoder full-step resolution ..................................................................61

GR set master-slave reduction ratio .................................................................62

HA set group acceleration ................................................................................63

HB read list of groups assigned ........................................................................65

HC move group along an arc............................................................................66

xii Preface

HD set group deceleration ................................................................................68

HE set group e-stop deceleration .....................................................................70

HF group off.....................................................................................................71

HJ set group jerk..............................................................................................72

HL move group along a line.............................................................................73

HN create new group........................................................................................75

HO group on .....................................................................................................77

HP read group position ....................................................................................78

HQ wait for group command buffer level ........................................................79

HS stop group motion ......................................................................................80

HV set group velocity.......................................................................................81

HW wait for group motion stop.........................................................................82

HX delete group................................................................................................84

HZ read group size ...........................................................................................85

ID read stage model and serial number...........................................................86

JH set jog high speed.......................................................................................87

JK set jerk rate.................................................................................................88

JL jump to label ..............................................................................................89

JW set jog low speed ........................................................................................90

KD set derivative gain ......................................................................................91

KI set integral gain..........................................................................................92

KP set proportional gain ..................................................................................93

KS set saturation level of integral factor..........................................................94

LP list program ................................................................................................95

MD read motion done status .............................................................................96

MF motor off ....................................................................................................97

MO motor on.....................................................................................................98

MT move to hardware travel limit ....................................................................99

MV move indefinitely .....................................................................................100

MZ move to nearest index ..............................................................................102

OH set home search high speed......................................................................103

OL set home search low speed .......................................................................104

OM set home search mode ..............................................................................105

OR search for home........................................................................................106

PA move to absolute position ........................................................................108

PH get hardware status...................................................................................109

PR move to relative position..........................................................................112

QD update motor driver settings.....................................................................113

QG set gear constant.......................................................................................114

QI set maximum motor current .....................................................................115

QM set motor type...........................................................................................116

QP quit program mode...................................................................................117

QR reduce motor torque .................................................................................118

QS set microstep factor..................................................................................119

QT set tachometer gain ..................................................................................120

QV set average motor voltage ........................................................................121

Preface xiii

RS reset the controller....................................................................................123

SB set / get DIO port A, B bit status..............................................................126

SI set master-slave jog velocity update interval...........................................129

SK set master-slave jog velocity scaling coefficients....................................130

SL set left travel limit ....................................................................................131

SM save settings to non-volatile memory ......................................................132

SN set axis displacement units.......................................................................133

SR set right travel limit ..................................................................................134

SS define master-slave relationship ..............................................................135

ST stop motion...............................................................................................136

SU set encoder resolution ..............................................................................137

TB read error message ...................................................................................138

TE read error code .........................................................................................139

TJ set trajectory mode...................................................................................140

TP read actual position ..................................................................................141

TS read controller status ................................................................................142

TV read actual velocity ..................................................................................143

TX read controller activity .............................................................................144

UF update servo filter ....................................................................................145

UH wait for DIO bit high................................................................................146

UL wait for DIO bit low.................................................................................147

VA set velocity ...............................................................................................148

VB set base velocity for step motors..............................................................149

VE read controller firmware version..............................................................150

VF set velocity feed-forward gain .................................................................151

VU set maximum velocity..............................................................................152

WP wait for position .......................................................................................153

WS wait for motion stop.................................................................................154

WT wait .........................................................................................................155

XM read available memory .............................................................................156

XX erase program...........................................................................................157

ZA set amplifier I/O configuration.................................................................158

ZB set feedback configuration .......................................................................161

ZE set e-stop configuration............................................................................163

ZF set following error configuration .............................................................165

ZH set hardware limit configuration ..............................................................167

ZS set software limit configuration ...............................................................169

ZU get ESP system configuration ..................................................................171

ZZ set system configuration ..........................................................................173

xiv Preface

Section 1 - Introduction

1.1 Scope

This manual provides descriptions and operating procedures for the
integrated 3 axis ESP300 Controller/Driver (ESP = Enhanced System
Performance). There are two configurations available:

ESP300 - XXXXX1: 150W Power Supply Models
ESP300 – XXXXX2: 400W Power Supply Models
Safety considerations, conventions and definitions, and a system
overview are provided in Section 1, Introduction.

Procedures for unpacking the equipment, hardware and software
requirements, descriptions of controls and indicators, and setup
procedures are provided in Section 1, Introduction.

Instructions for configuring and powering up the ESP300 and stage
motors, for home and jog motions, and for system shut-down are
provided in Section 1, Introduction.

Overview of operating modes (LOCAL and REMOTE) and Menu
Options in LOCAL Mode are provided in Section 2, Modes of
Operation.

Motion commands, language-specific information, and error-handling
procedures are provided in Section 3, Remote Mode.

An overview of motion parameters and equipment is provided in
Section 4, Motion Control Tutorial.

Servo tuning principles and procedures are given in Section 5.

Procedures for ordering, installing, and using optional equipment are
provided in Section 6.

The following information is provided in the Appendices:

• Error messages

• Trouble-shooting and maintenance

• Connector pin assignments

• Decimal/ASCII/binary conversion table

• System upgrades for software and firmware

• Factory service

Section 1 – Introduction 1-1

1.2 Safety Considerations

The following general safety precautions must be observed during all
phases of operations of this equipment. Failure to comply with these
precautions or with specific warnings elsewhere in this manual
violates safety standards of design, manufacture, and intended use of
the equipment.

Disconnect or do not plug in the power cord in the following
circumstances:

• If the power cord or any other attached cables are frayed or

• If the power plug or receptacle is damaged.

• If the unit is exposed to rain or excessive moisture, or liquids are

• If the unit has been dropped or the case is damaged.

• If you suspect service or repair is required.

• When you clean the case.

damaged.

spilled on it.

To protect the equipment from damage and avoid hazardous
situations, follow these recommendations:

• Do not make modifications or parts substitutions.

• Return equipment to Newport Corporation for service and repair.

• Do not touch, directly or with other objects, live circuits inside

the unit.

• Keep air vents free of dirt and dust.

• Do not block air vents.

• Keep liquids away from unit.

• Do not expose equipment to excessive moisture (>90% humidity).

WARNING

All attachment plug receptacles in the vicinity of this unit are to

be of the grounding type and properly polarized. Contact an

electrician to check faulty or questionable receptacles.

1-2 Section 1 - Introduction

WARNING

This product is equipped with a 3-wire grounding type plug. Any

interruption of the grounding connection can create an electric

shock hazard. If you are unable to insert the plug into your wall

plug receptacle, contact an electrician to perform the necessary

alterations to assure that the green (green-yellow) wire is attached

to earth ground.

WARNING

This product operates with voltages that can be lethal. Pushing

objects of any kind into cabinet slots or holes, or spilling any

liquid on the product, may touch hazardous voltage points or

short out parts.

When opening or removing covers observe the following
precautions:

• Turn power OFF and unplug the unit from its power source

• Remove jewelry from hands and wrists

• Use insulated hand tools only

• Maintain grounding by wearing a wrist strap attached to

instrument chassis.

1.3 Conventions and Definitions

This section provides a list of symbols and their definitions, and
commonly used terms found in this manual.

1.3.1 Definitions and Symbols

The following are definitions of safety and general symbols used on
equipment or in this manual.

WARNING

Section 2 – Modes of Operation 1-3

p

p

p

WARNING

Calls attention to a procedure, practice or condition which, if not

correctly performed or adhered to, could result in injury or death.

CAUTION

Calls attention to a procedure, practice, or condition which, if not

correctly performed or adhered to, could result in damage to

property or equipment.

NOTE

Calls attention to a procedure, practice, or condition that is

considered important to remember in the context.

This symbol indicates the principle On/Off

ush-push switch is in the ON position when
ressed in, and in the OFF position when de­ressed.

Protective conductor terminal

Caution, risk of electric shock

Caution (refer to accompanying documents)

1-4 Section 1 - Introduction

Fuse

Stop (of action or operation)

1.3.2 Terminology

The following is a brief description of the terms specific to motion
control and the ESP300 Motion Controller/Driver.

Axis – a logical name for a stage/positioner/ motion device

Encoder – a displacement measuring device, term usually used for

both linear and rotary models.

ESP – Enhanced System Performance motion system is comprised
of compatible stage(s). ESP is synonymous with a plug-and-play
motion system.

ESP – compatible – refers to Newport Corporation stage with its
own firmware-based configuration parameters. Newport stages or
other stages without this feature are referred to as being not ESP­compatible and must be uniquely configured by the user.

Home (position) – the unique point in space that can be accurately
found by an axis, also called origin.

Jog – a motion of undetermined-length, initiated manually.

Motion device – electro-mechanical equipment. Used

interchangeably with stage and positioner.

Move – a motion to a destination

Origin – used interchangeably with home

PID – a closed loop algorithm using proportional, integral, and

derivative gain factors for position control

Positioner – used interchangeably with stage and motion device

Stage – used interchangeably with motion device and positioner

Section 2 – Modes of Operation 1-5

1.4 System Overview

The Enhanced System Performance (ESP) architecture consists of the
ESP300 Controller/Driver and ESP-compatible stages. The ESP300 is
an advanced stand-alone controller with integrated motor drivers. It
can control and drive up to 3 axes of motion in any stepper and DC
motor configuration.

The ESP plug-and-play concept significantly increases user
friendliness and improves overall motion performance.

The ESP300 is used as a stand-alone controller to drive an ESP
motion device. All components are designed for optimal performance.

1.4.1 Features

A number of advanced features make the ESP300 an excellent choice
for many applications:

• Integrated controller and driver design is cost effective and space

saving

• Compact, standard 2U height rack mountable or bench-top

enclosure

• Allows any combination of motor types (2 phase stepper and

brush DC) up to 3A, 48V per axis

• Digital Signal Processing architecture

• Real-time high speed command processing

• Powerful commands for most demanding applications

• Motion program storage (up to 99 programs) in 64kB non-volatile

memory

• Advanced motion programming capabilities and complex digital

I/O functions

• User selectable displacement units

• Optional full-featured front panel with position and status displays

for each axis, push-buttons for simple motion sequences and
access to an elaborate menu that allows setup of the system
without use of a computer

• Optional handheld keypad for full access to ESP300 command set

without computer.

Figure 1.1: ESP300 Controller/Driver

1-6 Section 1 - Introduction

1.4.2 Specifications Function:

• Integrated motion controller and driver.

Number of motion axes:

• 1 to 3, in any combination or order of 2 phase stepper and brush

DC motors, up to 48VDC, 3A per axis.

Trajectory type:

• Trapezoidal velocity profile

• S-curve velocity profile.

Motion device compatibility:

• Family of motorized Newport motion devices, using either stepper

or DC motors

• Custom motion devices (call for compatibility).

DC motor control:

• 18 bit DAC resolution

• 4 MHz maximum encoder input frequency

• Digital PIDFF servo loop, 0.4 ms update rate.

Stepper motor control:

• Up to 1000 microstep resolutions per full step.

Computer Interface:

• RS232-C, 19200 baud, 8 bits, 8, N, 1

• IEEE-488 – optional, Please contact Newport for information

Utility interfaces:

• 16 bit digital inputs/outputs, user definable, in blocks of 8.

• Remote motor off input (interlock).

User Memory:

• 64 KB non-volatile program memory

• 512 byte command buffer

Operating modes:

• Local mode – stand-alone operation, executing motion from the

front panel

• Remote mode – executing commands received over one of the

computer interfaces or the optional handheld keypad

• Program execution mode – execution of a stored program.

Section 2 – Modes of Operation 1-7

Optional display:

• 80 character alpha-numeric LCD display

• Displays position, status, utility menus and setup screens.

Dimensions:

• 3" (2U) H x 16.5" W x 12" D (75 x 412 x 300 mm) for ESP300-

XXXXX1 Models

• 3" (2U) H x 16.5" W x 13.5" D (75 x 412 x 342.9 mm) for

ESP300-XXXXX2 Models

Power requirements:

• 100-240VAC ±10%, 50/60 Hz

• 4A max for ESP300 - XXXXX1 Models

6.3A max for ESP300 - XXXXX2 Models

Fuses:

• T4A / 250VAC for XXXXX1 Models

• T6.3A/250VAC for XXXXX2 Models

Weight:

• 10.90Lbs. max (4.9kg) max for ESP300 - XXXXX1 Models

• 14.05Lbs. max (6.37kg) max for ESP300 - XXXXX2 Models

Operating conditions:

• Temperature: 0°C to 40°C

• Humidity: 20% to 90% RH, non-condensing

Other :

• Pollution degree :2

• Installation category: II

• Altitude: <2000m

• Instrument use: the model ESP300 is intended for indoor use only.

1.4.3 Descriptions of Front Panel Versions

The ESP300 is available with either a blank front panel or a front
panel with LCD display and manual control buttons. With the display
version, a menu allows the user to change velocities, accelerations
and more, without a computer interface.

1-8 Section 1 - Introduction

FRONT PANEL DISPLAY
A general view of the front panel is shown in (Figure 1.2). There are
two distinct areas: a display/menu section and a motion/home section
that allows simple manual motion sequence like JOG and HOMING.

X-Y buttons

Home Buttons

Stop All Axis

Power

Display

Window

Figure 1.2: ESP300 Front Panel with Displays

Menu

Button

BLANK FRONT PANEL

This version does not provide a display or local operation.

Power Section

The black push button type switch on the lower left corner is used to
turn power On or Off . The on state is indicated with a green LED
above the push-button.

1.4.4 Rear Panel Description

NOTE

See Appendix C for pin-outs.

AXIS CONNECTORS (AXIS 1 – AXIS 3)

J og Buttons

Keypad

Connector

There are up to three 25-pin D-Sub connectors on the rear panel, one
for each axis. Unused axes have blank panels.

Section 2 – Modes of Operation 1-9

+/GPIO CONNECTOR

This is a 37-pin D-Sub connector used for general purpose, digital
Input/Output signals. A variety of commands are available to control
these ports. See Section 3, Remote Mode and Appendix C for
Connector Pin Outs.

Serial No. Label

Motor

Interlock

AUX Encoder

RS232-C

GPIO

IEEE-488 (optional)

Axis 3 Axis 2 Axis 1

Axis Connectors

Power Entry

Module

Figure 1.3: Rear Panel of the ESP300 (400 Watt chasse shown)

AUXILIARY ENCODER

This 25 pin D-Sub connector provides input for 3 auxiliary encoder
channels (axis 4, 5, 6). For signal description, see Section C.1.4.
These channels can be used for master-slaving (see Section 4.2),
trackball and other applications. Additionally, 4 digital I/O pins are
provided (See Section C.1.2).

MOTOR INTERLOCK CONNECTOR

The coaxial connector provides remote motor power interlock
capability. One or more external switches can be wired to remotely
inhibit the motor power in a way similar to the Stop All button on the
front panel.

The controller is shipped with a mating connector that provides the
necessary wiring to enable proper operation without an external
switch.

RS232-C CONNECTOR

The RS232-C interface to a host computer or terminal is made
through this 9 pin D-Sub connector. The pin out enables the use of an
off-the-shelf, pin-to-pin cable.

IEEE-488 CONNECTOR

1-10 Section 1 - Introduction

1.5 System Setup

This is a standard 24 pin connector to interface with a standard
IEEE-488 device.
Note:
This is an optional feature.

POWER ENTRY MODULE

The power entry section on the right side of the rear panel provides a
standard IEC 320 inlet, a fuse holder, and a binding post to ground the
controller if the main power supply wiring does not provide earth
ground terminals.

This section guides the user through the proper set-up of the motion
control system.

Carefully unpack and visually inspect the controller and stages for
any damage.

Place all components on a flat and clean surface.

1.5.1 Line Voltage

The controller can operate from 100-240VAC, ±10%, at a

1.5.2 First Power ON

Plug the AC line cord supplied with the ESP300 into the power entry
module on the rear panel.

Do not block AC line cord entry area for disconnecting purpose.

Plug the AC line cord into the AC wall-outlet.

Push in the POWER switch on the lower left side of the front panel.

Shortly after the power is switched on, the ESP300 with front panel
display will perform a start-up sequence as described below.

NOTE

frequency of 50/60 Hz.

CAUTION

• Momentarily display: "Newport ESP300" and the Firmware

Version

Section 2 – Modes of Operation 1-11

1.6 Quick Start

• Momentarily show the stage type that is connected. Since there

should be no stages connected at this point, the "NO STAGE"
message is displayed for all axes.

NOTE

Any time you call for technical support, the firmware version is

essential to trouble-shoot a problem. It is displayed every time the

controller power is turned on. Users of the blank front panel can

query the version with the "VE" command

(see Section 3, Remote Mode).

This section serves as a quick start for ESP300 with front panel
display only.

The following paragraphs guide you through a very basic motion
sequence that verifies that the system is working properly.

1.6.1 Connecting Motion Devices

NOTE

Never connect/disconnect stages while the ESP300 is powered on.

Power the ESP300 off.

If an ESP motion control system was purchased, all necessary
hardware for set-up is included.

With ESP compatible stages, the configuration of each axis is
identified automatically by the ESP300 at power up. ESP compatible
stages are visually identified with a blue "ESP Compatible" sticker,
on the stage.

Carefully connect one end of the supplied cables to the stage and the
other end to the appropriate axis connector on the rear of the
controller. Secure both connectors with the locking thumb-screws.

1-12 Section 1 - Introduction

H

Users of the ESP300 with blank front panel can skip to Section 3,
Remote Mode.

1.6.2 Motor On

After the controller and the stages are connected as described, the
motors can be powered on.

Make sure that the motion devices are placed on a flat surface and
their full travel is not obstructed.

CAUTION

Be prepared to quickly turn the motor power off by pressing the

STOP ALL button or power switch if any abnormal operation is

observed.

After the power switch is pushed in, the controller performs the start­up sequence as described in Section 1.5.2.

The default state after start-up is motor power off.

To apply power to the motors, press the button on the right of the
display to enable power for the respective axis. The ON state of the
motor power is indicated on the display. Blank Front Panel must use
external interface to enable motor power.

1.6.3 Homing

HOME Search

The HOME Search routine is a sequence of motion segments through
which the controller determines the exact location of a home (origin)
switch. A detailed description of the algorithm can be found in the

Motion Control Tutorial (Section 5).

It is recommended that the user perform a home search routine

after each controller power-on. The controller must know the
exact initial position of the motion device not only to accurately
repeat a motion sequence (program) but also to prevent it from

NOTE

hitting the travel limits (limit switches).

To perform a home search routine, press the home function key for
the respective axis.

Section 2 – Modes of Operation 1-13

The display will indicate that a home routine is in progress with
to the left of the axis number.

NOTE

The position value is reset at the home position.

Only one axis can be homed at a time; i.e., even if multiple homing
commands are issued, the prior axis has to finish homing before the
second can start homing.

1.6.4 First Jog

If left jog key is pressed, the selected axis will move slowly in the
negative direction. To move a single step at a time, press this switch
once. See Section 2.2.4 for details.

If right jog key is pressed, the selected axis will move slowly in the
positive direction. To move a single step at a time, press this switch
once. See Section 2.2.4 for details.

If the HIGH SPEED key between the jog keys is pressed
simultaneously with one of the jog keys, the axis will jog fast in the
selected direction. See Section 2 for setting of high speed rate.

At this point, you may proceed to Section 2 of this manual, to get
familiar with the controller and the local motion modes.

NOTE

Remember that only motions inside the software travel limits are

allowed (see 'SL' command in Section 3, Remote Mode). Any

move outside these limits will be ignored.

1-14 Section 1 - Introduction

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Section 2 – Modes of Operation 1-15