EM-243-PLI is a high-current full-bridge driver for brushed DC motors. It is designed for applications requiring bidirectional operation, adjustable motion profiles, current limiting and pulse-count-based end-limit functions.
Separate FW and BW inputs command forward and reverse operation, while the STOP input shuts down the motor. Two configurable speed settings are available for applications requiring separate normal and approach speeds.
The integrated pulse counter can be used for position-dependent end limits. Its counter value is stored in non-volatile memory and retained when the controller supply is switched off.
The FW and BW inputs start the motor in the forward or reverse direction. The STOP input shuts down motor operation.
Adjustable acceleration and deceleration ramps provide controlled starts, stops and direction changes while reducing mechanical shock and sudden current peaks.
Two configurable speed settings are available. The second speed is activated through the Speed 2 input and can be used as an approach speed, positioning speed or alternative operating speed.
The Speed 2 input can alternatively be configured as a 0–5 V analog speed-control input.
The PLI firmware includes a pulse counter that can be used for position-dependent end-limit functions. Pulses from an external sensor are counted to monitor motor or actuator movement.
The counter value is retained in non-volatile memory when power is removed. This allows the stored movement count to remain available when the controller is powered up again.
In continuous mode, the motor runs for as long as the corresponding direction input remains active.
In impulse mode, a short control pulse starts the motor. The operating state remains active until another impulse changes it.
The adjustable current limit protects the motor, power stage and mechanical system against excessive current and torque during start-up, overload and jam conditions.
The current limit can be adjusted from 1 A to 100 A. During the start ramp, the selected current limit is increased by 50% to provide additional breakaway torque.
The STOP input can alternatively be configured as an analog current-limit input. A 0–4 V command corresponds to a current-limit range of 0–100 A.
This allows motor torque to be adjusted dynamically using a PLC analog output or another compatible control source.
The configurable start-kick function provides additional starting effort for mechanisms requiring high breakaway torque.
The automatic-reverse function can change direction automatically when its configured trigger conditions are met.
The digital inputs are divided into control inputs and limit inputs. The logic type of each group can be configured independently for NPN or PNP operation.
This allows the driver to be used with different sensors, switches, PLC outputs and control-system architectures.
The NPN open-collector fault output indicates controller fault conditions, including overtemperature and configured current-trip events.
The active-low disable input prevents motor operation for as long as it is pulled below 1 V. The fault and disable connections of several controllers can be linked to provide synchronized stopping.
The brake output can be used to release an external electromagnetic brake. It can also control a suitably rated braking resistor during regenerative braking and overvoltage conditions.
The brake-load output is rated for loads up to 60 V and 5 A.
PCB version C v2 and later includes an NPN fan-control output. The output switches on when the driver temperature reaches 55 °C and switches off after the temperature falls to 50 °C.
The fan output is rated for loads up to 40 V and 2 A.
The 2 kHz PWM setting provides the highest continuous and peak-current capacity.
The 16 kHz setting moves the switching frequency above the normal audible range and provides quieter motor operation with reduced continuous and peak-current capacity.
Parameters are configured using the EM-236 Interface Unit. The same interface can be used to monitor controller operation and selected operating values during commissioning and diagnostics.
The controller can be installed directly using screw mounting. An optional DIN-rail mounting base is available for control-cabinet installations.
The EM-243-PLI is suitable for heavy linear actuators, industrial valves, hatches, doors, lifting mechanisms, material-handling equipment and other high-current brushed DC motor applications requiring pulse-count-based movement limits.
| Firmware version | v2.2 |
| PCB version | C |
| Nominal supply voltage | 12–48 VDC |
| Operating supply-voltage range | 10–58 VDC |
| Start-up voltage | 9 V |
| Shutdown voltage | 8 V |
| Idle current | typ. 15 mA |
| Motor current at 2 kHz and 100% duty cycle | 50 A |
| Motor current at 2 kHz and 20–99% duty cycle | 35 A |
| Peak motor current at 2 kHz | 100 A for max. 5 s |
| Motor current at 16 kHz and 100% duty cycle | 40 A |
| Motor current at 16 kHz and 20–99% duty cycle | 20 A |
| Peak motor current at 16 kHz | 60 A for max. 5 s |
| Adjustable current limit | 1–100 A |
| Start-ramp current-limit boost | 50% |
| Overtemperature limit | 100 °C |
| Adjustable start and stop ramps | 0–5 s |
| PWM frequency | 2 kHz or 16 kHz |
| Analog current-limit input | 0–4 V corresponds to 0–100 A |
| Digital input levels | High = 4–30 V / Low = 0–1 V |
| Pulse-input impedance | typ. 10 kΩ |
| Maximum pulse-input frequency | 1 kHz |
| Control-input impedance | typ. 10 kΩ |
| Control-input response time | typ. 5 ms |
| Fault output | NPN open collector, max. 40 V / 1 A |
| Disable input activation | Active when Uin < 1 V (NPN) |
| Fan activation | ON at 55 °C / OFF at 50 °C, PCB C v2 and later |
| Fan output | NPN, max. 40 V / 2 A |
| Brake-load output | Max. 60 V / 5 A |
| Vout limit output | Max. 25 V / 15 mA |
| Motor and supply connectors | Max. 2.5 mm² cable |
| Control connectors | Max. 1 mm² cable |
| Module dimensions | 107 × 73 × 40 mm |
| Dimensions with DIN-rail base | 110 × 80 × 55 mm |
| EMC | Tested for industrial environments |
| Operating temperature (Ta) | −40…+60 °C |
| Weight | 190 g |
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