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BBD102 and BBD103
Brushless DC Servo Controllers

User Guide

Summary of Contents for BBD102

Page 1: ...BBD102 and BBD103 Brushless DC Servo Controllers User Guide ...

Page 2: ... 4 APT Server ActiveX Controls 9 2 2 5 Software Upgrades 11 Chapter 3 Getting Started 12 3 1 Installing APT Software 12 3 2 Mechanical Installation 13 3 2 1 Siting 13 3 2 2 Environmental Conditions 13 3 3 Electrical Installation 14 3 3 1 Connecting To The Supply 14 3 4 Fuses 14 3 4 1 Rear Panel Connections 15 3 5 Front Panel Controls and Indicators 16 3 6 Connecting The Hardware and Powering Up 17...

Page 3: ...g 31 4 11 Creating a Simulated Configuration Using APT Config 31 Chapter 5 Software Reference 35 5 1 Introduction 35 5 2 GUI Panel 35 5 3 Settings Panel 37 5 3 1 Moves Jogs tab 37 5 3 2 Stage Axis tab 41 5 3 3 Advanced Control Loop SettingsTab 44 5 3 4 Advanced Misc Tab 48 5 4 Troubleshooting and Restoring Default Parameters 54 Appendices Appendix A Rear Panel Connector Pinout Details 56 Appendix ...

Page 4: ...Given when there is a risk of injury from electrical shock Warning Given when there is a risk of injury to users Caution Given when there is a risk of damage to the product Note Clarification of an instruction or additional information Warnings If this equipment is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired In particular excessive mo...

Page 5: ...est digital and analog techniques and with high bandwidth high power servo control circuitry these new controllers are capable of driving a range of rotary and linear brushless 3 phase DC motors of up to 5 Amp peak coil current Integrated into the apt family of products it offers Thorlabs standard control and programming interface allowing easy integration into the customer s own automated motion ...

Page 6: ... adjusted for a particular stage or actuator For simplicity of operation the apt software incorporates pre configured settings for each of the Thorlabs stages and actuators while still exposing all parameters individually for use with other DC motor driven systems For convenience and ease of use adjustment of many key parameters is possible through direct interaction with the graphical panel For e...

Page 7: ...ded 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 r...

Page 8: ...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 illustra...

Page 9: ...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 a...

Page 10: ...e 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...

Page 11: ...unctionality 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 complet...

Page 12: ...tion Note 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...

Page 13: ...ure 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 Caution When siting the unit it should be positioned so as not to impede the operation of the rear panel power supply switch Ensure t...

Page 14: ...e of the same rating and type Shock Warning The unit must be connected only to an earthed fused supply of 110 to 230V Use only power supply cables supplied by Thorlabs other cables may not be rated to the same current The unit is shipped with appropriate power cables for use in the UK Europe and the USA When shipped to other territories the appropriate power plug must be fitted by the user Cable i...

Page 15: ... be connected to the HANDSET IN connector on the next unit in the chain TRIG IN For Future Use TRIG OUT For Future Use AUX I O 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 deploy...

Page 16: ...ble channel functionality The associated LED is lit when the channel is enabled Disabling the channel allows the motor actuator to be operated manually Note On BBD102 units the Channel 3 LED is not used It becomes active if a third channel is added later by fitting an additional DC driver card Contact your Thorlabs representative for more information CHANNEL ENABLE 1 2 3 Power apt Brushless Servo ...

Page 17: ...el 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 the Getting Started Guide supplied with the controller or Chapter of this manual for a brief tutorial on operation of the unit Note The USB cable length should be no more than 3 metres unless a powered USB hub is being used Note 3 phase brushless DC ...

Page 18: ...es The position display for the associated GUI should increment and decrement accordingly Follow the tutorial steps described in Chapter for further verification of operation Note The APT Config utility can be used to set up simulated hardware configurations and place the APT Server into simulator mode In this way it is possible to create any number and type of simulated virtual hardware units in ...

Page 19: ...ate is approximately 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 BBD101 controller the maximum velocity is limited to safe values However if the output is disabled with the controll...

Page 20: ...s multiple graphical instrument panels to be displayed so that multiple APT units can be controlled All basic operating parameters can be set through this program and all basic operations such as motor moves can be initiated Hardware configurations and parameter settings can be saved to a file which simplifies system set up whenever APT User is run up Fig 4 1 Typical APT User Screen 1 Run the APT ...

Page 21: ...e of the limit switches or can be provided by some other signal The MLS series stages use an electronic reference marker and therefore the limit switches are not used for reference Fig 4 2 Motor Controller Software GUI 1 Click the Home button Notice that the led in the button lights to indicate that homing is in progress 2 When homing is complete the Homed LED is lit as shown above Note If a move ...

Page 22: ... measured in real world units e g millimetres relative to the Home position 1 Click the position display Fig 4 3 Absolute Position Popup Window 2 Enter 3 0 into the pop up window 3 Click OK Notice that the position display counts up to 3 000 to indicate a move to the absolute position 3 00mm ...

Page 23: ...e the parameters as follows Max Vel 100 Accn Dec 200 4 Click OK to save the settings and close the window 5 Any further moves initiated on channel 1 will now be performed at a maximum velocity of 100 mm per second with an acceleration of 200 mm sec sec Note Moves are performed using a Trapezoidal or S Curve velocity profile see Section 5 3 4 The velocity settings relate to the maximum velocity at ...

Page 24: ...e jog velocity while the button is held down 1 On the GUI panel click the Settings button to display the Settings panel Fig 4 5 Settings Panel Move Jogs Tab 2 Select the Move Jogs tab as shown in Fig 4 5 3 In the Jogs field enter parameters as follows see Section 5 3 1 for details of these parameters Max Vel 50 Accn Dec 50 Operating Modes Jogging Single Step Stopping Profiled Step Distance 0 5 4 C...

Page 25: ...on units per grid division and cursor position All units are displayed in real world units either millimetres or degrees The left hand display shows a circle which represents the current position of the motor associated with the specified controller absolute position data is displayed in the Chan Pos field The vertical divisions relate to the travel of the stage actuator being driven by the contro...

Page 26: ...ck the left hand mouse button to initiate the move Jog Mode When Jogging mode is selected the motors are jogged each time the left mouse button is clicked The Jog direction corresponds to the position of the cursor relative to the circle current motor position e g if the cursor is to the left of the circle the motor will jog left The Jog Step size is that selected in the Settings panel see Section...

Page 27: ...ns to be visited without user intervention For details on moving to absolute positions initiated by a mouse click see Section 4 11 1 From the Motor GUI Panel select Move Sequencer tab to display the Move Sequencer window Fig 4 7 Move Sequencer Window 2 Right click in the move data field to display the pop up menu Fig 4 8 Move Sequencer Pop Up Menu ...

Page 28: ...ell time is the time to wait in milliseconds Return if checked the system will move to the position specified in the Dist Pos field wait for the specified Dwell time and then return to the original position Min Vel Acc and Max Vel the velocity profile parameters for the move velocity parameters are entered in mm sec acceleration in mm sec sec The motor accelerates at the rate set in the Acc field ...

Page 29: ... clicking the data line s and selecting the appropriate option in the pop up menu shown below Fig 4 11 Pop Up Options 6 To run a single line of data right click the appropriate data and select Run from the pop up menu shown above 7 To run the entire sequence click the Run button shown below A Home move can also be performed from this panel by clicking the Home button Fig 4 12 Home and Run Buttons ...

Page 30: ...te the green LED stops flashing In order to establish control over a particular axis the joystick axes must be associated with the corresponding channels of the related controller This is achieved by setting the joystick ID switch located on the underside of the joystick console and the channel ident switches on the rear panel of the BBD controller The joystick ID switch assigns the selected numbe...

Page 31: ...utility can be used to set up simulated hardware configurations and place the APT Server into simulator mode In this way it is possible to create any number and type of simulated virtual hardware units in order to emulate a set of real hardware This is a particularly useful feature designed as an aid learning how to use the APT software and as an aid to developing custom software applications offl...

Page 32: ...g 4 13 APT Configuration Utility Simulator Configuration Tab 3 Enter a name e g LAB1 in the Configuration Names field 4 In the Simulator field check the Enable Simulator Mode box The name of the most recently used configuration file is displayed in the Current Configuration window ...

Page 33: ...allows an 8 digit serial number to be associated with each simulated unit It is good practice when creating simulated configurations for software development purposes to use the same serial numbers as any real hardware units that will be used Although serial numbers are 8 digits as displayed in the Load Configuration Details window the first two digits are added automatically and identify the type...

Page 34: ... Chapter 4 clicking the Remove button or by right clicking it and selecting the Remove option from the pop up window 9 Enter a name into the Configuration Names field 10 Click Save 11 Click Set As Current to use the configuration ...

Page 35: ...er Software GUI Note The serial number of the single channel driver cards is derived from the base unit serial number with the 73 prefix being replaced with 94 and the subsequent 6 digit number incremented by 1 for each card in the system e g a 2 channel unit with a base serial number 73123456 will have card serial numbers 94123457 and 94123458 The serial number of the driver card associated with ...

Page 36: ... LEDs are lit when the associated limit switch has been activated Settings display shows the following user specified settings Driver the type of control unit associated with the specified channel Stage the stage type and axis associated with the specified channel Calib File the calibration file associated with the specified channel Min Max V the minimum velocity at which a move is initiated and t...

Page 37: ...rough the ActiveX methods and properties on this Control refer to the Programming Guide in the APTServer helpfile for further details and to Section 2 2 4 for an overview of the APT ActiveX controls The various parameters are described below 5 3 1 Moves Jogs tab Fig 5 2 Move Jog Settings Moves Velocity Profile Moves can be initiated via the GUI panel by entering a position value after clicking on ...

Page 38: ...ed There are two jogging modes available Single Step and Continuous In Single Step mode the motor moves by the step size specified in the Step Distance parameter each time the jog key is pressed see Fig 5 3 In Continuous mode the Note Under certain velocity parameter and move distance conditions the maximum velocity may never be reached i e the move comprises an acceleration and deceleration phase...

Page 39: ... Step the motor moves by the step size specified in the Step Distance parameter Continuous the motor continues to move until the jog signal is removed i e jog button is released distance velocity distance velocity button pressed button pressed button pressed button released jog step size jog velocity jog velocity Single Step mode Continuous mode jog acceleration ...

Page 40: ...n reverse This ensures that during absolute or relative moves the target position is always approached in a forward direction The Backlash Correction Distance is specified in real world units millimeters To remove backlash correction this value should be set to zero Note Setting a negative value for backlash correction also results in zero correction Persist Settings to Hardware Many of the parame...

Page 41: ... properly by the system For Thorlabs stages the APT server will automatically apply suitable defaults for the parameters on this tab during boot up of the software Most of these parameters cannot subsequently be altered as it may adversely affect the performance of the stage and they are greyed out Description of these parameters is included for information only Caution Extreme care must be taken ...

Page 42: ...age to a particular area of interest Note For DDS220 and MLS203 users The Homing Limit Switch and Motor parameters described on the next two pages are not applicable for the DDS220 and MLS203 stages because the stage does not use a limit switch as a reference point for homing Instead it uses a special reference marker pulse from the encoder Homing on these stages involves a search for this referen...

Page 43: ...tio of X 1 i e every 1 turn at the output of the gearbox requires X turns of the motor shaft then the Gearbox Ratio value is set to X minimum 1 maximum 1000 For linear driven stages with no gearbox e g MLS203 this parameter is set to 1 and cannot be adjusted Persist Settings to Hardware Many of the parameters that can be set for the BBD10x series drivers can be stored persisted within the unit its...

Page 44: ...he amount of position error when an impulse event affects current target Caution The PID and other closed loop parameters must be set according to the stage or actuator type associated with the driver the load being positioned and the speed duty cycle of operation Default values have already been optimized and stored within the stage and these are loaded into the controller on power up If problems...

Page 45: ...ive is calculated Under normal circumstances the derivative term of the PID loop is recalculated at every servo cycle However it may be desirable to increase the sampling rate to a higher value in order to increase stability The Derivative Time parameter is used to set the sampling rate For example if set to 10 the derivative term is calculated every 10 servo cycles The value is set in cycles in t...

Page 46: ...ntegral This term provides the restoring force that grows with time ensuring that the current error is zero under a constant torque loading It accepts values in the range 0 to 32767 Integral Limit This term is used to cap the value of the lntegrator to prevent an excessive build up over time of the restoring force thereby causing runaway of the integral sum at the output It accepts values in the r...

Page 47: ...ored Integral Dead Band This parameter allows an integral dead band to be set such that when the error is within this dead band the integral action stops and the move is completed using the proportional term only It accept values in the range 0 to 32767 Feed Forward This parameter is a feed forward term that is added to the output of the PI filter It accept values in the range 0 to 32767 Persist S...

Page 48: ...er a current foldback condition is said to exist and the commanded current is limited to the value specified in the Current Limit parameter When this occurs the Current Foldback status bit bit 25 is set in the Status Register and the Current Limit LED on the GUI panel is lit When the accumulated energy above the Current Limit value falls to 0 the limit is removed and the status bit is cleared Moto...

Page 49: ...ve two conditions have been met for a specified number of cycles 1 cycle 102 4 µs set in the Settle Time field range 0 to 32767 The above settings are particularly important when performing a sequence of moves If the PID parameters see Section 5 3 3 are set such that the settle window cannot be reached the first move in the sequence will never complete and the sequence will stall The settle window...

Page 50: ...ed and other conditions such as whether a motion stop has been requested Profile Mode This field is used to set the profile mode to either Trapezoidal or S curve In either case the velocity and acceleration of the profile are specified using the Velocity Profile parameters on the Moves Jogs tab The Trapezoidal profile is a standard symmetrical acceleration deceleration motion curve in which the st...

Page 51: ... V at which it continues through segment 4 The profile then decelerates in a similar manner to the acceleration phase using the jerk value to reach the maximum deceleration D and then bring the axis to a stop at the destination Joystick If the optional Thorlabs joystick console is being used MJC001 the following parameters are used to set the velocity and acceleration limits and the direction sens...

Page 52: ...from and to external devices It is possible to configure a particular controller to respond to trigger inputs generate trigger outputs or both simultaneously For those units configured for both input and output triggering a move can be initiated via a trigger input while at the same time a trigger output can be generated to initiate a move on another unit The trigger settings can be used to config...

Page 53: ...ceived on the TRIG IN connector Home Move Trig Fall as above but the home move is initiated on receipt of a falling edge signal Trigger Out The Trigger Out output can be configured to be asserted to either logic HIGH or LOW as a function of certain motion related conditions such as when a move is in progress In Motion complete Move Complete or reaches the constant velocity phase on its trajectory ...

Page 54: ...tain 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 See Section 5 3 3 for further information Caution The PID and other closed loop parameters must be set according to the stage or actuator type associated with the driver the load being positioned an...

Page 55: ...ncontrollable If these settings are persisted the unit may not be able to phase initialise the axis correctly the next time it powers up and as a result APT will not display some or any of the panels If this occurs the unit can be set to a special mode where the persisted settings are ignored and the default safe operating parameters are loaded after power up To enter this mode power down the unit...

Page 56: ...n D Type and supplies connection for the motor encoder feedback lines Pins 7 and 8 are short circuit internally Fig A 2 FEEDBACK connector pin identification Pin Description Pin Description 1 Motor Phase V 5 Stage ID 2 GND 6 GND 3 Temp Sensor Not Used 7 Motor Phase W 4 Motor Phase U 8 Enable Pin Description Pin Description 1 Not Connected 9 GND 2 GND 10 Limit Switch 3 Not Connected 11 Limit Switch...

Page 57: ...ollector see Section A 3 1 iii Buffered versions of Encoder Quadrature signal for monitoring purposes iv Encoder index or reference signal for monitoring purposes Fig A 3 CONTROL I O connector pin identification Pin Description Return Pin Description Return 1 5V 9 9 iii QA 2 i Trigger In 9 10 iii QA 9 3 ii Trigger Out 9 11 iii QB 9 4 Ground 12 iii QB 4 5 Ground 13 iv Index Ref 9 6 For Future Use 1...

Page 58: ... V Fig A 4 Digital Output Schematic Please see the APTServer helpfile for details on software calls used to control these logic IO A 3 2 Trigger In Digital Input The digital input AxisIn circuit accepts signals in the range 0 to 24 V and has TTL compatible Schmidt trigger thresholds It has a pull up to 5V to allow direct interfacing to open collector souces without the need for an external pull up...

Page 59: ... joystick in the absence of a PC these outputs could be connected to an oscilloscope or custome circuit to facilitate monitoring of the position output Fig A 6 Differential Output Schematic A 3 4 5 Volt Supply A 5 V 250 mA supply is provided for interfacing to external circuits that require a power source Caution Do not exceed the 250 mA maximum output current For applications requiring higher cur...

Page 60: ...Pin Description Return Pin Description Return 1 Digital O P 1 5 9 10 9 Digital Ground 2 Digital O P 2 5 9 10 10 Digital Ground 3 Digital O P 3 5 9 10 11 For Future Use 5 9 10 4 Digital O P 4 5 9 10 12 For Future Use 5 9 10 5 Digital Ground 13 Digital I P 4 5 9 10 6 Digital I P 1 5 9 10 14 5V Supply Output 5 9 10 7 Digital I P 2 5 9 10 15 5V Supply Output 5 9 10 8 Digital I P 3 5 9 10 Warning Do no...

Page 61: ...igital outputs used here can be used to directly drive most optocouplers and the 5V supply available on pins 14 and 15 can be used to provide power for the optocouplers Fig A 9 Application Example Connection to Optocoupler Inputs The digital outputs can also be used to interface to external logic circuitry a pull up resistor may be needed if the external logic does not contain it or control other ...

Page 62: ...it and HIGH if the switch is closed When connected to a logic output or any other voltage source the input is guaranteed to read LOW if the voltage is above 2 4V and HIGH when the output is below 0 8 V Please see the APTServer helpfile for details on software calls used to control these logic IO A 4 4 5 Volt Supply A 5 V 250 mA supply is provided for interfacing to external circuits that require a...

Page 63: ...et MJC001 or RS232 Communications The pin functions are detailed in in Fig A 11 Fig A 11 HANDSET Connector Pin Identification Pin Description 1 Not Connected 2 TX controller output RS232 3 RX controller input RS232 4 Not Connected 5 Ground 6 Not Connected 7 Not Connected 8 Not Connected 9 Supply Voltage for Handset 5V Note Pin 9 is for use only with Thorlabs joystick MJC001 It should not be used t...

Page 64: ...s together The INTERCONNECT terminal should be connected to the HANDSET IN connector on the next unit in the chain The pin functions are detailed in in Fig A 12 Fig A 12 RS232 HANDSET Connector Pin Identification Pin Description 1 Not Connected 2 RX controller input 3 TX controller output 4 Not Connected 5 Ground 6 Not Connected 7 Not Connected 8 Not Connected 9 Not Connected 1 2 3 4 5 6 7 8 9 ...

Page 65: ... There is a risk of severe electrical shock if the equipment is operated with the covers removed Only personnel authorized by Thorlabs Ltd and trained in the maintenance of this equipment should remove its covers or attempt any repairs or adjustments Maintenance is limited to safety testing and cleaning as described in the following sections Caution The instrument contains a power supply filter In...

Page 66: ...ty Profile Trapezoidal S Curve Position Count 32 Bit Position Feedback Incremental Encoder Encoder Bandwidth 2 5 MHz 10 M Counts sec Encoder Supply 5V AUX Control Connector 15 Pin D Type Female User Digital IO 5 V O P Input Power Requirements Volts 85 to 264V AC Power 250 VA Frequency 47 to 63 Hz Fuse 3 15A General Dimensions 240 x 337 9 x 124 8 mm 9 5 x 13 3 x 4 9 in Weight 6 1kg 13 42 lbs Compat...

Page 67: ...t 6 digit number incremented by 1 for each card in the system e g a 2 channel unit with a base serial number 73123456 will have card serial numbers 94123457 and 94123458 The Methods and Properties of the Motor ActiveX Control can be used to perform activities such as homing stages absolute and relative moves and changing velocity profile settings A brief summary of each method and property is give...

Page 68: ...r position GetPosition_Position Gets the current motor position returned by value GetPositionEx Gets the current motor position GetPositionEx_UncalibPosition Gets the current uncalibrated motor position returned by value GetPositionOffset Gets the motor position offset GetRelMoveDist Gets the relative move distance GetRelMoveDist_RelDist Gets the relative move distance returned by reference GetSta...

Page 69: ...og Initiates a jog move MoveRelative Initiates a relative move MoveRelativeEnc Initiates a relative move with specified distances for encoder equipped stages MoveRelativeEx Initiates a relative move with specified distances MoveVelocity Initiates a move at constant velocity with no end point SaveParamSet Saves settings for a specific controller SetAbsMovePos Sets the absolute move position SetBLas...

Page 70: ...lied when the unit is settled SetDCCurrentLoopParams Sets the Current servo loop PID parameter values applied when the unit is moving SetDCPositionLoopParams Sets the Position servo loop PID parameter values SetDCMotorOutputParams Sets the limits that are applied to the motor drive signal SetDCTrackSettleParams Sets the parameters for the Track and Settle windows SetDCProfileModeParams Sets the pa...

Page 71: ...nd found to comply with the limits for a Class A digital device persuant to part 15 of the FCC rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause h...

Page 72: ...e bin logo see Fig 1 sold to a company or institute within the EC currently owned by a company or institute within the EC still complete not disassembled and not contaminated Fig 5 1 Crossed out wheelie bin symbol As the WEEE directive applies to self contained operational electrical and electronic products this end of life take back service does not refer to other products such as pure OEM produc...

Page 73: ...n or at a public waste disposal site E 2 3 Ecological background It is well known that WEEE pollutes the environment by releasing toxic products during decomposition The aim of the European RoHS directive is to reduce the content of toxic substances in electronic products in the future The intent of the WEEE directive is to enforce the recycling of WEEE A controlled recycling of end of life produc...

Page 74: ...Appendix E 74 HA0216T Rev D March 2012 ...

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