PI E-621.SR User manual

Physik Instrumente (PI) GmbH & Co. KG, Auf der Roemerstrasse 1, 76228 Karlsruhe, Germany
Phone [phone], Fax [phone], Email [e-mail], www.pi.ws
This document describes the
following
product:

E-621.SR
LVPZT Controller/Amplifier, Single Channel, for
Strain Gauge Sensors
W
ith servo controller submodule and computer
interface and command interpreter submodule
.
Capacitive
sensor E-621 versions are described in a
separate manual,
PZ160E.
PZ115E User Manual
E-621.SR LVPZT Controller/Amplifier Module
Release: 2.3.0 Date: 2021-09-21

Physik Instrumente (PI) GmbH & Co. KG is the owner of the following company names and
trademarks:
PI®, NanoCube®, PICMA®, PILine®, NEXLINE®, PiezoWalk®, NEXACT®, Picoactuator®,
PInano®, PIMag®, Q-Motion®
Notes on brand names and third-party trademarks:
Microsoft® and Windows® are registered trademarks or trademarks of Microsoft Corporation in
the USA and/or other countries.
LabVIEW, National Instruments and NI are trademarks of National Instruments. Neither the
driver software nor the software programs offered by PI or other goods and services are
connected to or sponsored by National Instruments.
Copyright 1999–2021 by Physik Instrumente (PI) GmbH & Co. KG, Karlsruhe, Germany.
The text, photographs and drawings in this manual enjoy copyright protection. With regard
thereto, Physik Instrumente (PI) GmbH & Co. KG reserves all rights. Use of said text,
photographs and drawings is permitted only in part and only upon citation of the source.
First printing 2021-09-21
Document Number PZ115E Eco, BRo, Release 2.3.0
E-621UserPZ115E230.doc
Subject to change without notice. This manual is superseded by any new release. The newest
release is available for download at www.pi.ws.

About This Document
Users of This Manual
This manual is designed to help the reader to install and operate the E-621.SR LVPZT
Controller/Amplifier Module. It assumes that the reader has a fundamental understanding of
basic servo systems, as well as motion control concepts and applicable safety procedures.
The manual describes the physical specifications and dimensions of the E-621.SR LVPZT
Controller/Amplifier Module as well as the hardware installation procedures which are required
to put the associated motion system into operation.
Updated releases are available for download from www.pi.ws or via email: contact your Physik
Instrumente Sales Engineer or our customer service department (mailto:[email protected]).
Conventions
The notes and symbols used in this manual have the following meanings:
WARNING
Calls attention to a procedure, practice or condition which, if not
correctly performed or adhered to, could result in injury or death.
DANGER
Indicates the presence of high voltage (> 50 V). 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
equipment.
NOTE
Provides additional information or application hints.
Related Documents
The hardware components and the software tools which might be delivered with E-621.SR
LVPZT Controller/Amplifier Module are described in their own manuals. All documents are
available as PDF files. Updated releases are available for download from www.pi.ws or via
email: contact your Physik Instrumente Sales Engineer or our customer service department
(mailto:[e-mail]).
!

Contents
1. Introduction 3
1.1 How to use the Documentation.................................................3
1.2 Intended Use ............................................................................5
1.3 Safety Precautions....................................................................6
1.4 Unpacking.................................................................................9
2. Quick Start 10
2.1 Line Power and Fuses ............................................................10
2.2 Installation...............................................................................11
2.3 First Steps...............................................................................13
3. Operation 16
3.1 Front Panel Elements..............................................................16
3.2 Modes of Operation ................................................................19
3.2.1 Control Modes.......................................................................... 19
3.2.2 Servo Modes (ON / OFF).........................................................21
3.3 Networking on I2C Bus............................................................23
3.4 User Electronics and Sensor Monitor Signal ...........................24
4. Calibration 25
4.1 Sensor Connection and Adjustment........................................25
4.1.1 Open-Loop Zero-Point Adjustment ..........................................26
4.1.2 Open-Loop Sensor Range Adjustment.................................... 28
4.1.3 Servo-Control Static Gain Calibration...................................... 30
4.2 Servo-Control Dynamic Characteristics...................................32
5. Electronics Details 33
5.1 E-621.SR Block Diagram........................................................33
5.2 Components and Adjustment Elements ..................................34
5.2.1 Jumpers.................................................................................... 35
5.2.2 Switches................................................................................... 36
5.2.3 Potentiometers......................................................................... 36
5.3 E801B1008 Sensor Processing Submodule............................36
5.4 E-802 Servo Controller Submodule.........................................37
6. Troubleshooting 38

Contents
7. Customer Service 42
8. Old Equipment Disposal 43
9. Technical Data 44
9.1 Specifications..........................................................................44
9.2 Frequency Response Diagram................................................46
9.3 Pin Assignments.....................................................................47
9.3.1 32-Pin Main Connector ............................................................47
9.3.2 Strain Gauge Sensor Wiring ....................................................48
10. Appendix 49
10.1 Lifetime of PICMA® Actuators.................................................49
10.2 European Declarations of Conformity......................................51

Introduction
www.pi.ws E-621.SR PZ115E Release 2.3.0 Page 3
1. Introduction
The E-621.SR amplifier/controller is designed as a EURO board
plug-in module which can be mounted in a 9.5” desktop chassis
(E-501.621) or a 19" rack chassis (E-500.621).
The E-621.SR amplifier/controller is designed to drive and
control the displacement of a low-voltage piezoelectric
positioner or actuator (LVPZT). The E-621.SR provides DC
sensor processing for usage with strain gauge sensors (SGS;
via E801B1008 sensor submodule).
The E-621.SR comes with an E-802 Servo Controller and an E-
816 Computer Interface and Command Interpreter installed as
standard.
Networking of E-621 modules allows controlling up to 12
devices over a single RS-232 or USB computer interface. The
modules to be networked must be installed in the same chassis.
E-621.CRs for use with capacitive sensors are described in
detail in their own manual, PZ160.
Fig. 1: E-621s installed in compatible PI chassis (E-500.621 in
this example) are automatically networked
1.1 How to use the Documentation
You can download all manuals listed below as well as manuals
for PC software from our website. For downloading, use the
links „E-816“ and „PI software“ from the file "A000T0081-
Downloading Manuals from PI.pdf", which can be found in the
\Manuals folder on the PI software CD that is included in the
scope of delivery.

Introduction
www.pi.ws E-621.SR PZ115E Release 2.3.0 Page 4
In general, the latest versions of our manuals are available for
download on our website (www.pi.ws).
E-621.SR User Manual (this document)
This User Manual enables you to put your positioner with the E-
621 into operation for the first time. Furthermore, it gives an
overview of the E-621 functions and specifications.
Always keep this user manual available by the E-621.
Add all information given by the manufacturer to the User
Manual, for example supplements or Technical Notes.
If you pass the E-621 on to other users, also turn over
this User Manual as well as all other relevant information
provided by the manufacturer.
Only use the device on the basis of the complete User
Manual. Missing information due to an incomplete User
Manual can lead to injury as well as property damage.
Only install and operate the E-621 after having read and
understood this User Manual.
E-816 User Manual (PZ116E)
Remote control via computer interface ("computer-controlled
mode", p. 20) makes use of the E-816 computer interface
module which is integrated in the E-621. During remote control
via computer interface, the E-621 is therefore identified as “E-
816”. For detailed instructions, descriptions and examples, refer
to the E-816 User Manual.
E-802 User Manual (PZ150E) and E801B1008 User
Manual (PZ117E)
In addition to the E-816 computer interface module, the
following submodules are integrated in the E-621.SR:
E-802.55 servo controller submodule
E801B1008 sensor processing submodule
The information given in the User Manuals of those submodules
is only relevant if you should ever need to re-calibrate your
system. For normal operation of the E-621, you do not need
those manuals because your system will be fully calibrated
before being shipped. Note that re-calibration should only be
done by appropriately trained personnel and after consultation
with PI.

Introduction
www.pi.ws E-621.SR PZ115E Release 2.3.0 Page 5
1.2 Intended Use
The E-621.SR LVPZT Controller/Amplifier Module is designed
for installation in a suitable chassis, e.g. the E-500.621 or E-
501.621 provided by PI.
Based on its design and realization, the E-621.SR LVPZT
Controller/Amplifier Module is intended to drive capacitive
loads, in the present case, piezoceramic actuators. The E-
621.SR must not be used for applications other than stated in
this manual, especially not for driving ohmic (resistive) or
inductive loads.
E-621.SRs can be used for both static and dynamic
applications.
The E-621.SR can be operated in closed-loop mode using
strain gauge sensors (SGS). Appropriate sensors are provided
by PI and integrated in the mechanics according to the
mechanics product specifications. Other sensors may be used
as position sensors only with permission of PI.
Observe the safety precautions given in this User Manual.
E-621.SR meets the following minimum specifications for
operation*:
Indoor use only
Altitude up to 2000 m
Ambient temperature from 5°C to 40°C
Relative humidity up to 80% for temperatures up to 31°C,
decreasing linearly to 50% relative humidity at 40°C
Line voltage fluctuations of up to ±10% of the line voltage
Transient overvoltages as typical for public power supply
Note: The nominal level of the transient overvoltage is the standing surge
voltage according to the overvoltage category II (IEC 60364-4-443).
Degree of pollution: 2
*Any more stringent specifications in the Technical Data table are, of course,
also met.

Introduction
www.pi.ws E-621.SR PZ115E Release 2.3.0 Page 6
1.3 Safety Precautions
DANGER
High Voltage: Read This Before Operation:
E-621.SR LVPZT Controller/Amplifier Modules generate
voltages up to 130 V for driving LVPZTs. The output power
may cause serious injury.
When working with these devices or using PZT products
from other manufacturers we strongly advise you to follow
general accident prevention regulations.
All work done with and on the equipment described here
requires adequate knowledge and training in handling High
Voltages. Any cabling or connectors used with the system
must meet the local safety requirements for the voltages
and currents carried.
Procedures which require removing the E-621 module from
the chassis should be carried out by authorized, qualified
personnel only.
Disconnect the chassis from power when removing
modules, and when resetting internal switches or jumpers.
When a module removed from the chassis must be
operated, use a 32-pin extension connector (P-895.00, not
included). Voltages of up to 130 V can be exposed. Do not
touch internal conductors.
Be sure to connect pin 14a and 14c to a Protective
Ground!
WARNING
Connect the AC power cord of the E-500.621 or E-501.621
chassis in which the E-621 is installed to the wall socket
(100 to 240 VAC).
Only use the supplied power cord or a sufficiently
dimensioned power cord to connect the chassis to the
power source.
To disconnect the system from the supply voltage
completely, remove the power plug from the wall socket, or
remove the power cord from the chassis.
Install the system near the AC outlet and such that the AC
power plug can be reached easily.

Introduction
www.pi.ws E-621.SR PZ115E Release 2.3.0 Page 7
CAUTION
Place the chassis with the E-621(s) in a location with
adequate ventilation to prevent internal heat build-up. Allow
at least 10 cm (4 inches) clearance from the top and the
rear of the unit and 5 cm (2 inches) from each side.
Never cover the ventilation slots of the chassis as this will
impede ventilation.
CAUTION
E-621 modules are ESD-sensitive (electrostatic discharge
sensitive) devices. Observe all precautions against static
charge buildup before handling these devices. Avoid
touching circuit components, pins and PCB traces.
Discharge any static electricity you may have on your body
by briefly touching a conductive, grounded object before
you touch any electronic assembly. Pose PCBs only on
conductive surfaces, such as ESD-safe transport
containers (envelopes, foam). Electronic subassemblies
must always be kept and transported/shipped in conductive
packaging.
Make sure that no conductive particles of any kind (metallic
dust or shavings, broken pencil leads, loose screws)
contact the device circuitry.
CAUTION
The E-621 main connector pinout is not compatible with
the PI EURO board modules of the E-500 series (e.g. E-
509 servo controller or E-50x amplifier).
CAUTION
For successful operation of two or more E-621.CRs—
which are described in a separate manual—, their E-
500.621 or E-501.621 chassis must have been
manufactured after August 2006. Contact PI if you are not
sure about the manufacturing date of your chassis.
!
!
!
!

Introduction
www.pi.ws E-621.SR PZ115E Release 2.3.0 Page 8
CAUTION
Calibration should only be done after consultation with PI,
otherwise the internal configuration data may be destroyed
by erroneous operation.
CAUTION
Thermally stable systems have the best performance. For
a thermally stable system, switch on the E-621 at least one
hour before you start working with it.
CAUTION
If the piezo positioner starts oscillating (humming noise):
In closed-loop operation, switch off the servo immediately.
The load and / or the dynamics of operation probably differ
too much from the setup for which the system was
calibrated.
In open-loop operation, stop the motion immediately. Do
not operate the piezo positioner at its resonant frequency
even though the notch filter by default is also active in
open-loop operation.
Otherwise the piezo positioner could be irreparable
damaged.
!
!
!

Introduction
www.pi.ws E-621.SR PZ115E Release 2.3.0 Page 9
1.4 Unpacking
According to your order, the E-621.SR LVPZT
Controller/Amplifier Module comes separately or installed in an
E-500.621 or E-501.621 chassis. Unpack the system with care.
Compare the contents against the items covered by the
contract and against the packing list. The following items should
be included with an E-621 unit:
RS-232 null-modem cable for PC connection (C-815.34)
USB cable (USB-A (m)/USB Mini-B (m)) for PC
connection (000036360)
SMB/BNC adapter cables (E-692.SMB) 1.5 m, two units
32-pin multipoint socket connector (DIN 416123) for
installing the E-621 module in custom electronics (588)
User Manual for E-621.SR (PZ115E), this document
PI software CD for E-816-interface devices (C-990.CD1)
Inspect the contents for signs of damage. If parts are missing or
you notice signs of damage contact PI immediately.
Save all packing materials in the event the product needs to be
shipped elsewhere.

Quick Start
www.pi.ws E-621.SR PZ115E Release 2.3.0 Page 10
2. Quick Start
2.1 Line Power and Fuses
This section is only relevant if the E-621 comes installed in an
E-500.621 or E-501.621 chassis provided by PI.
The power connection and the line fuses are located on the rear
panel of the E-500.621 or E-501.621 chassis. The chassis is
equipped with a wide-range power supply and with fuses that
are admissible for both 115 V and 230 V operation. No settings
need be changed when connecting the system to a different
supply voltage. The orientation of the fuse carrier is irrelevant.
WARNING
Connect the AC power cord of the E-500.621 or E-501.621
chassis in which the E-621 is installed to the wall socket
(100 to 240 VAC).
Only use the supplied power cord or a sufficiently
dimensioned power cord to connect the chassis to the
power source.
To disconnect the system from the supply voltage
completely, remove the power plug from the wall socket, or
remove the power cord from the chassis.
Install the system near the AC outlet and such that the AC
power plug can be reached easily.
WARNING
Before you open the door of the fuse carrier, remove the
power plug from the wall socket to disconnect the system
from the power supply completely.
CAUTION
Both fuses are active and have to be replaced if there is a
fault.
!

Quick Start
www.pi.ws E-621.SR PZ115E Release 2.3.0 Page 11
To access the line power fuses, proceed as follows:
1 Switch the system off and remove the power cord.
2 Wait one minute to be sure that all electric circuits are
discharged completely.
3 Pry open the door that covers the fuse carrier (see Fig.
2) and pry out the fuse carrier.
4 Be sure to replace both fuses with:
IEC 4 AT (slow blow)
Note that IEC-standard fuses are designed to carry the
nominal current indefinitely. Other fuse rating standards
differ.
5 Reinstall the carrier and close the door.
Fig. 2: Fuse location on the rear panel and in the carrier (1 of 2
fuses visible)
2.2 Installation
This section is only relevant if the E-621 modules come without
chassis.
CAUTION
E-621 modules are ESD-sensitive (electrostatic discharge
sensitive) devices. Observe all precautions against static
charge buildup before handling these devices. Avoid
touching circuit components, pins and PCB traces.
Discharge any static electricity you may have on your body
by briefly touching a conductive, grounded object before
you touch any electronic assembly. Pose PCBs only on
conductive surfaces, such as ESD-safe transport
containers (envelopes, foam). Electronic subassemblies
must always be kept and transported/shipped in conductive
packaging.
Make sure that no conductive particles of any kind (metallic
dust or shavings, broken pencil leads, loose screws)
contact the device circuitry.
!

Quick Start
www.pi.ws E-621.SR PZ115E Release 2.3.0 Page 12
Before operation is possible, the E-621 must be installed in a
suitable chassis. Required input and output lines must be
connected via the 32-pin main connector. To do this, you can
use the included multipoint socket connector (588). For pinout
see “32-Pin Main Connector” on p. 47.
CAUTION
E-621 is only compatible with E-50x.621 chassis but
incompatible with other chassis of PI’s E-500-series.
NOTE
All front-panel connections except of the USB lines are
duplicated on the 32-pin main connector.
For a custom or OEM installation, consider the following:
Networked units must have the I2C networking lines
connected to each E-621 in parallel (pins 32a and 32c).
The network bus lines are limited to a maximum length of
1 m and a maximum capacitance of 400 pF. See
“Networking on I2C Bus” on p. 23 for details
Each unit requires sufficient power. A DC-DC converter is
installed on the main board of the E-621 module with an
input voltage range of 12 to 30 VDC (recommended
supply 15 V). This converter generates -25 and +125 V
for the power amplifier and +/-15 V for the sensor and
servo controller. When powering up the module, the DC-
DC converter needs a peak current of about 1.5 A to start
oscillating. The power supply should have a buffer
capacitor or should be able to supply the 1.5 A per E-621
for at least 1 second. The inputs and outputs of the DC-
DC converter are not connected internally. Using a
unipolar power supply, we recommend connecting the
negative supply at pin 18a and 18c with the Test GND at
pin 14a and 14c. This provides a defined GND level and
helps to minimize noise. Be sure to connect pin 14a and
14c to a protective ground!
If a DC-offset potentiometer is to be used, connect the
wiper to pin 12c, the zero-offset contact (presumably
CCW) to pin 22c, 14a or 14c (GND) and the other contact
(CW) to pin 12a. Make sure the external pot is activated
with J3 in position 1-2
By connecting pin 28a on the main connector to pin 14a
or 14c (GND), the E-621 is set to closed-loop operation
!

Quick Start
www.pi.ws E-621.SR PZ115E Release 2.3.0 Page 13
(servo ON). In this case, switching to open-loop operation
(servo OFF) is neither possible with DIP switch 3 on the
front panel nor with the SVO command via the E-816
computer interface submodule
2.3 First Steps
CAUTION
Thermally stable systems have the best performance. For
a thermally stable system, switch on the E-621 at least one
hour before you start working with it.
CAUTION
If the piezo positioner starts oscillating (humming noise):
In closed-loop operation, switch off the servo immediately.
The load and / or the dynamics of operation probably differ
too much from the setup for which the system was
calibrated.
In open-loop operation, stop the motion immediately. Do
not operate the piezo positioner at its resonant frequency
even though the notch filter by default is also active in
open-loop operation.
Otherwise the piezo positioner could be irreparable
damaged.
1 Connect the E-621 to the supply power. Depending on
your system configuration, consider the information in
“Line Power and Fuses” on p. 10 or “ Installation” on
p. 11
2 Make sure the E-621 is switched off
3 Make the DIP switch settings required for the control
mode (analog or computer-controlled) and the servo
mode (ON or OFF) you wish to use. See “Front Panel
Elements” on p. 16 and "Modes of Operation” on p. 19
for details.
Notes:
The servo must be ON in analog mode, when you want
to work with a computer-generated signal (e.g. from a
DAQ board) and PI’s drivers for NI LabVIEW (see
step 5 below).
!
!

Quick Start
www.pi.ws E-621.SR PZ115E Release 2.3.0 Page 14
To give the E-816 computer interface submodule
complete control over the servo mode selection, DIP
switch 3 on the E-621 front panel must be set to open-
loop operation (= right). When installing the E-621 in a
custom chassis, for servo mode selection via the E-816
furthermore make sure that pin 28a on the main
connector is not grounded (i.e. not connected to pin
14a or 14c)
4 Connect the piezo positioners/actuators to the proper
E-621.SR units. If your system was calibrated by PI,
the controllers and positioners are not interchangeable.
Respect the assignment given by the serial numbers
marked on the calibration label of the controller
5 Connect a suitable signal source to the “ANALOG
INPUT” SMB socket. Depending on the control-mode
selection, this input signal is either used as control
input (in analog mode), or as trigger signal for wave
table output and triggered motion (in computer-
controlled mode). See “Front Panel Elements” on p. 16
for signal details.
In analog mode, the control input voltage can also be a
computer-generated analog signal (e.g. from a DAQ
board). You can use PI’s drivers for NI LabVIEW from
the PI software CD to generate that analog signal.
Note: After installing the drivers, it is necessary to
activate the analog functionality, see the
Analog_Readme.txt file in the installation directory
(C:\ProgramData\PI\LabVIEW).
6 Optional: Connect a suitable measurement device to
the “SENSOR MONITOR” SMB socket. This socket
carries the filtered and processed sensor output value,
with 0 to 10 V representing nominal travel range. See
“User Electronics and Sensor Monitor Signal” on p. 24
for further specifications
7 Switch on the E-621
8 Command motion of the connected piezo
positioner/actuator:
Analog mode: Change the control input signal on
“ANALOG INPUT” in the range of 0 to 10 V
Computer-controlled mode: Follow the instructions in
“First Steps” in the E-816 Computer Interface
Submodule User Manual

Quick Start
www.pi.ws E-621.SR PZ115E Release 2.3.0 Page 15
If at the yellow “Overflow” LED glows in closed-loop operation
(servo ON), then a zero-point adjustment is necessary. Follow
the instructions for zero-point adjustment given in Section 4.1.1
on p. 26. To avoid an overflow of the amplifier in open-loop
operation, do not exceed the allowable control input range.

Operation
www.pi.ws E-621.SR PZ115E Release 2.3.0 Page 16
3. Operation
3.1 Front Panel Elements
NOTE
All front-panel connections except of the USB lines are
duplicated on the 32-pin main connector.
Fig. 3: E-621.SR Front Panel

Operation
www.pi.ws E-621.SR PZ115E Release 2.3.0 Page 17
Power LED, green
Permanent glow indicates that the E-621 is powered on.
Overflow LED, yellow
Overflow signal, indicates power amplifier is so near the end of
its range that it is no longer able to follow input changes
properly (piezo voltage output outside of -30 V to 130 V range).
If this LED glows in closed-loop operation (servo ON), a zero-
point adjustment is necessary. Follow the instructions for zero-
point adjustment given in Section 4.1.1 on p. 26. To avoid an
overflow of the amplifier in open-loop operation, do not exceed
the allowable control input range (see “ANALOG INPUT”).
On Target LED, green
On target signal from E-802 servo controller submodule,
indicates distance from target less than ±0.19% of range
ANALOG INPUT
SMB coaxial, GND on outer line. Usage of this input line
depends on the mode settings made with the “Settings” DIP
switches (see below):
Analog mode: ANALOG INPUT is used as control input
voltage which gives the target (either as voltage or
position, depending on the servo mode; see below). The
input signal should always be in the range of -2 to 12 V.
Note that excursions to -3 or +13 V are possible but may
cause overflow, especially with servo on, and reduce
actuator lifetime, see “Lifetime of PICMA® Actuators” on
p. 49 for details.
The control input voltage can also be a computer-
generated analog signal (e.g. from a DAQ board). You
can use PI’s drivers for NI LabVIEW from the PI
software CD to generate that analog signal. See
“Control Modes” on p. 19 for details
Computer-controlled mode: ANALOG INPUT is used as
trigger input signal for wave table operation and
triggered motion (Active HIGH; LOW: 0 to 0.5 V, HIGH:
3.0 to 5.0 V, maximum 10 V; max. freq. 400 Hz; min.
width: 200 μs). See the User Manual for E-816
Computer Interface and Command Interpreter
Submodule (PZ116E) for more information
SENSOR MONITOR
SMB coaxial, GND on outer line, 0 to 10 V on inner line
Filtered and processed sensor output value, 0 to 10 V
representing nominal travel range.