PiezoDrive PDUS210 User manual

PDUS210 V4
1
Modified 6/02/2021
PDUS210
210 Watt Ultrasonic Driver

PDUS210 V4
2
Modified 6/02/2021
Contents
Safety Warnings...............................................................................................................................3
Revision History...............................................................................................................................3
Quick Start Recommendations ........................................................................................................3
Delivery Contents (Standard)...........................................................................................................3
Overview..........................................................................................................................................4
Electrical Specifications ...................................................................................................................5
Standard Output Voltage Ranges ....................................................................................................5
Mechanical Specifications................................................................................................................7
PDUS210-FLEX Specifications........................................................................................................8
Introduction to Ultrasonic Transducers ............................................................................................8
PDUS210 Operation ......................................................................................................................10
Choosing the Voltage Range.........................................................................................................14
Front Panel ....................................................................................................................................16
Rear Panel.....................................................................................................................................17
Overload Protection.......................................................................................................................18
Desktop Software...........................................................................................................................19
PDUS210-FLEX Operation............................................................................................................29
Handheld Controller.......................................................................................................................31
RS485 Interface.............................................................................................................................33
Warranty and Service ....................................................................................................................34

PDUS210 V4
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Modified 6/02/2021
Safety Warnings
High Voltage
This product produces potentially lethal voltages up to 282 Vrms.
Observe Low-Voltage (as per ANSI C84.1-1989) safety precautions, e.g.
●Use an observer trained in low-voltage rescue
●Do not operate with exposed conductors
●Use appropriate signage, etc.
Revision History
Date
Manual
Changes
6/02/2020
R8
Added recommended impedance range
31/10/2020
R7
Added support for external transformers
Minimum frequency changed to 6 kHz
Added frequency range specifications
Added 175V version
15/01/2020
R6
Added notes to “Standard Output Voltage Ranges”
Quick Start Recommendations
Most users will need to read the following sections in detail to gain an understanding of transducer
characteristics and the various operating modes. That is, read the following sections in order.
If you already have expert knowledge of ultrasonic transducers and their different operating
modes, go straight to the section on Desktop Software.
Delivery Contents (Standard)
PDUS210 Amplifier (in chosen configuration)
Handheld controller
Handheld controller cable (DSUB9 3ft)
280W Desktop power supply
IEC Power cable suited to the destination shipping address
USB Cable (Type A)
3 Way plug-in screw terminals for output (Amphenol TJ0331530000G)
4 Way plug-in screw terminal for RS-485 connector (Amphenol TJ0431530000G)

PDUS210 V4
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Modified 6/02/2021
Overview
The PDUS210 is a complete solution for driving precision and high-power ultrasonic actuators.
Functions include high-speed resonance tracking of both series or parallel resonance modes,
vibration amplitude control, and analysis functions such as impedance and frequency response
measurement. The PDUS210 is well suited to both OEM product integration and laboratory use for
research and development. Applications include ultrasonic drilling and cutting, medical devices,
dental devices, ultrasonic testing, liquid cavitation, and vaporization.
The PDUS210 is controlled via USB and the included software package. An RS485 interface also
provides a straight-forward method to control and monitor the amplifier for automatic test and OEM
applications.
The PDUS210 generates a pure sine-wave output which avoids the excitation of secondary
resonance modes by the drive harmonics. This makes it ideal for operating at the electrical parallel
resonance, or ‘anti-resonance’. This operating point is close to the mechanical resonance
frequency but is less sensitive to changes in load dissipation, which is useful in precision
machining applications where constant vibration amplitude is desired.
The PDUS210 is available with standard output voltage ranges from 17 Vrms to 282 Vrms, and
current ranges from 0.7 Arms to 11 Arms. These ranges are optimized for load impedances
ranging from 1.5 Ohms to 400 Ohms at resonance. For research and development applications, a
reconfigurable version is available (PDUS210-FLEX), this version uses external output matching
transformers to allow operation at any of the available output voltage ranges.

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Electrical Specifications
Specification
Value
Notes
Output Voltage
0 –800 Vp-p
See standard voltage ranges
Output Current Max
0 –32 Ap-p
See standard voltage ranges
Load Impedance
1–5 
See standard voltage ranges
Output Waveform
Sine wave
DC Output Voltage
Zero
DC offset possible
Output Isolation
Isolated or grounded
Max Output Power
210 W
With optimal load impedance
Internal Power Dissipation
130 W
Maximum
Frequency Range
See table below
6kHz to 500kHz with modifications
Power Supply
48 V, 280 Watt
Controller
Phase tracking and
power control
2ms frequency update rate
Resonance or anti-resonance
Interface
USB, RS485
Digital IO
4 DIO
For manual control
Standard Output Voltage Ranges
The following table lists the specifications of each model variant, including: the maximum output
voltage, the maximum output current, optimal load impedance and the recommended frequency
range.
Order Code
Voltage
pk-pk
Voltage
RMS
Amps
pk-pk
Amps
RMS
Optimal
Load Ohms
Load Range
Ohms*
Frequency
kHz
PDUS210-800
800
282
2
0.71
400
260 –840
20 –200
PDUS210-600
600
212
2.6
0.92
225
146 –472
20 –200
PDUS210-400
400
141
4
1.4
100
65 –210
20 –200
PDUS210-200
200
70
8
2.8
25
16 –52
20 –200
PDUS210-175
175
62
9.1
3.2
19.1
12 –40
10 - 100
PDUS210-100
100
35
16
5.7
6.25
4 –13
20 –200
PDUS210-50
50
17
32
11.3
1.56
1 - 3
20 –200
Note: The output voltage resolution and tolerance is 8 bits, or 256 levels. Therefore, the smallest
possible change in voltage is full-scale range / 256. The minimum output voltage is also limited by
resolution. When the amplifier is enabled and the output voltage is set to zero volts, the actual
output voltage may be up to 2% of the full-scale range.
* The load impedance range is the range of impedances which guarantee more than 100W of
power supplied to the load. Higher or lower impedances can be driven but with reduced power.

PDUS210 V4
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The relationship between maximum achievable power and the load impedance is plotted in the
following figure. In this plot, the impedance is normalized by the optimal impedance; that is,
 

For example, the optimal impedance of the PDUS210-400 is 100 Ohms, so with a 50 Ohm load,
the normalized impedance is 0.5, From the plot, it can observed that greater than 100 W can be
achieved with a normalized impedance from 0.65 to 2.1, which for the PDUS210-400, is 65 Ohms
to 210 Ohms.
Figure 1. Maximum output power versus normalized impedance
The impedance ranges for other common power levels are listed in the following table. For
example, all amplifiers will supply more than 150W with a normalized load impedance between
0.71 and 1.4. For the PDUS210-400, this is equivalent to 71 Ohms and 140 Ohms.
Minimum Power
 Lower Bound
 Upper Bound
150W
  
  
100W
  
  
50W
  
  
Table 1. Minimum achievable power versus load impedance.

PDUS210 V4
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Modified 6/02/2021
Mechanical Specifications
Specification
Value
Notes
Enclosure Dimensions
227 x 168 x 54 mm
L x W x H
Mass
1.4 kg
Temperature Range
0C - 50C
Humidity
Non-condensing

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Modified 6/02/2021
PDUS210-FLEX Specifications
The PDUS210-FLEX is identical to the standard PDUS210 except that it requires an external
transformer connected between the amplifier and transducer using the supplied cable. This allows
the user to switch between different output voltage ranges by changing the external transformer.
Please refer to the section PDUS210-FLEX Operation for instructions.
The PDUS210-FLEX must be purchased with at least one external transformer. The available part
numbers and specifications are:
Order Code
Turns
Ratio
Voltage
pk-pk
Voltage
RMS
Amps
pk-pk
Amps
RMS
Optimal
Load Ohms
Load Range
Ohms*
Frequency
kHz
TX210-800
18.18
800
282
2
0.71
400
260 –840
20 –200
TX210-600
13.64
600
212
2.6
0.92
225
146 –472
20 –200
TX210-400
9.09
400
141
4
1.4
100
65 –210
20 –200
TX210-200
4.55
200
70
8
2.8
25
16 –52
20 –200
TX210-175
3.98
175
62
9.1
3.2
19.1
12 –40
10 - 100
TX210-100
2.27
100
35
16
5.7
6.25
4 –13
20 –200
TX210-50
1.14
50
17
32
11.3
1.56
1 - 3
20 –200
Table 2. External transformer specifications (only for the PDUS210-Flex)
A kit containing six transformers ranging from 17Vrms to 282Vrms is also available (TX210-Kit1).
This includes the following output voltage ranges: 17, 35, 70, 141, 212, and 282 Vrms.
Figure 2. Output transformer (e.g. TX210-800)
Specification
Value
Notes
Input Connector
Plug-in screw terminal
Connecting cable supplied
Output Connectors
Identical to PDUS210
See “Front Panel” section
Transformer Dimensions
104 x 57 x 51 mm
L x W x H
Mass
0.2 kg
Table 3. External transformer mechanical specifications

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Introduction to Ultrasonic Transducers
An introduction to the behaviour and operation of ultrasonic transducers can be viewed at the
following link. Please familiarize yourself with these concepts before operating the PDUS210.
https://www.piezodrive.com/ultrasonic-drivers/intro-ultrasonic/
The most important concept to understand is the relationship between the electrical and
mechanical impedance response of a transducer. Figure 3 plots the mechanical and electrical
frequency response of an ultrasonic transducer.
The impedance minima at 
is known as the series resonance, which is approximately equal to
the mechanical resonance frequency. At this frequency, the impedance phase response has a
high positive slope and a value of approximately zero degrees. In this mode, the current is
approximately proportional to the vibration amplitude, so current control is used to maintain
constant vibration amplitude. If the mechanical load does not vary significantly, constant voltage
amplitude is also appropriate.
The impedance maxima at 
is known as the parallel resonance, which also has an electrical
phase of approximately zero degrees but a high negative slope. In this mode, the voltage is
approximately proportional to the vibration amplitude, so constant voltage results in approximately
constant vibration amplitude regardless of mechanical load variations.
Figure 3. Electrical and mechanical frequency response of an ultrasonic transducer

PDUS210 V4
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Modified 6/02/2021
PDUS210 Operation
Overview
The operating principle of the PDUS210 is summarized in Figure 4. The transducer is connected
on the right hand side to the output transformer. The transformer converts the internal +/-24V drive
voltage to the desired output voltage range, for example +/-200V. By default, the output
connection to the transducer is electrically isolated from ground but the negative output can also
be internally grounded using the jumper shown.
During operation, the voltage and current in the transducer is used to estimate the phase . The
measured phase is then used to control the frequency of the signal generator by comparing it to
the phase set point . The frequency controller stabilizes the feedback loop and controls the
settling time of the closed loop system. The feedback gain is normally determined experimentally
by slowly increasing the gain until the desired performance is reached or the response begins to
become unstable.
The signal generator has a variable amplitude and the frequency is normally controlled by the
phase control loop. It is connected to the power amplifier, which drives the output transformer and
transducer.
Figure 4. Internal PDUS210 operation (in constant voltage, resonance tracking mode).
Resonance Tracking
The resonance tracking system of the PDUS210 is illustrated Figure 3. The phase detector (M)
measures the impedance phase angle between the primary voltage and current. The phase
controller 󰇛󰇜 varies the drive frequency to maintain a constant phase set point , which is
usually equal to zero.
To operate at a series resonance (impedance minima), the phase controller gain must be positive
to create a stable operating point.
To operate at a parallel resonance (impedance maxima), the phase controller gain must be
negative to create a stable operating point.
Transducer
Ground
Connection
Transformer
Transformer
Transformer
Power
Amplifier
Transformer
Phase
Setpoint
Signal
Generator
Frequency
Controller
Phase Detector