Emerson BW1 Manuel D’Utilisation

IntelliGear Plus™ Variable Speed MD Gearmotors

Drive not powered

Check for drive input power

Display unplugged or failed

Check display plug connection

Numeric display shows Pump RPM, indicates motor running

Drive Ready (Enabled & Not Running)

In AUTO mode, make sure AUTO-RUN contact is closed 

between pins 5 & 6 of 6-pin connector if pump should be 

running

Drive Inhibited (Not Enabled)

Install jumper between IntelliGear terminals 11-12

Motor thermostat trip - Overtemp

Check motor thermostat connections between IntelliGear 

terminals 5 & 9  

(Install jumper if motor has no thermostat wires -P1/P2)
Check motor fan & clean debris or obstruction to air flow
Check for motor overload

Internal brake resistor trip - Overtemp

Contact factory

Pump RUN DRY or HIGH PRESSURE fault trip

Check for proper flow and pressure in pump

DC Bus Undervoltage

Check incoming power for voltage level too low

DC Bus Overvoltage

Check incoming power for voltage level too high
Check for over-running load (pressure over-driving pump)
Adjust drive parameter 04 (deceleration time) to a higher 

setting using drive keypad/display

Loss of a motor phase

Check motor connections at IntelliGear grey terminal strip

Overcurrent at Drive Output

Check motor connections at IntelliGear grey terminal strip
Check for ground fault or line-line fault in motor wiring
Check for moisture or insulation damage in motor windings

Motor Overload (I X t)

Check for excessive torque load at pump

Overheating in Output Transistors

Check heatsink fins for debris or obstruction to air flow
Provide supply of cool air if ambient exceeds 40°C
Reduce torque load from pump

Overheating in Brake Transistor

Adjust drive parameter 04 (deceleration time) to a higher 

setting using drive keypad/display
Reduce start/stop frequency

Stator Resistance Measurement Fault

Check motor connections at IntelliGear grey terminal strip

Serial connection between keypad and drive broken

Check display plug connection

EEPROM fault in drive

Contact factory

Overcurrent at Brake Transistor

Contact factory

Not Running, No Fault 

Indication on Display

Drive not in HAND or AUTO mode

Press HAND or AUTO button on Keypad

Drive in AUTO mode, but AUTO-RUN contact not 

closed

Close AUTO-RUN contact or 

Jumper pins 5-6 on 6-pin connector cable

Unit Runs Only at Low 

Speed in AUTO mode

4-20 mA signal is not present

Connect 4-20 mA signal  and Verify that the signal 

current is present  (pins 1 & 2 of 6-pin connector)

4-20 mA signal polarity is reversed

Verify current enters pin 1 of 6-pin connector  Reverse 

the connections if necessary

In AUTO, Unit Does 

Not Achieve Maximum 

Output RPM at 20 mA 

Signal Input

4-20 mA signal not achieving full 20 mA at maximum 

speed reference

Signal source may not be capable of producing 20 

mA with the drive input impedence of 500 ohms - 

must be able to produce at least 10 VDC at pin #1 of 

6-pin connector cable

Maximum speed setting of operator keypad setting is 

not set to 100%

Press UP ARROW on keypad until maximum speed 

is attained

IntelliGear MAXIMUM SPEED setting has been turned 

down

Adjust drive parameter 02 to 2700 RPM using drive 

keypad/display