53 | P a g e
144 Description: Pump feedback abnormal stop.
Cause: High power consumption on the pump leading to pump overheating. PWM > 82.5% and < 92.5% and the
pump led flashes red.
1. Where possible, use the customer information menu to check the pump PWM % and the pump flow rate.
2. Use the pump LEDs on page 66 to assist with diagnosis.
3. Check the pump for air and vent the system if required – use the boiler air purge to assist by turning off the
power at the fused spur for 5 seconds and the re-establish the power.
4. Check auto air vent is operating correctly and not contaminated with sludge.
5. Check pump/system for contamination/sludge.
6. The pump voltage may be too high or too low, check the following:
7. Check the operation and voltage of the pump with a demand.
You can force the pump 'on' via 2 methods:
• Preferred and safest method by using the manual settings in parameter menu 2. Set parameter
2.6.0 to 1 = Manual mode On, and 2.6.1 to 1 pump control 'On'. Please note change 2.6.0 to 0
manual mode 'off' after this test.
or
• By removing PWM cable at the pump to allow the 230v cable to power the pump at full speed. To
do this, ensure safe electrical isolation and then use a 4mm electrical screwdriver to push down the
clip below the PWM connector and gently pull the connector out. Re-establish power to the boiler
and the pump should run at full speed.
8. If the pump does not run, check 230v supplied from the PCB to the pump connector.
9. If voltage at pump connector, replace pump.
10. If no voltage at pump connector, check wiring harness and connectors for damage, corrosion, and loose
connections. Confirm continuity with a multimeter and replace harness if required.
11. Confirm 230v from the PCB via connector CN2, pins 5&6. If no voltage, replace PCB.
12. If 230v side ok, check the pump PWM via the 3-wire cable connection on the pump and pins 1 & 2 on the
PCB connector CN9:
• with the pump off the voltage is +/- 5VDC.
• 39% load the voltage is +/- 3VDC.
• 61% load the voltage is +/- 1.9VDC.
• 100% load the voltage is +/- 0.24VDC.
13. If the above DC voltages are correct are correct, replace the pump.
14. If the voltages are incorrect, replace the PCB.
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