Are you sure the pumps are 6100's and not 6000's? The 6000 was more prone to this, especially the 230V versions. Check that the driver potentiometer is not turned down (as Dan explained), it must be at full power. Basically the driver is not getting enough power to turn on the 100% LED, however it is still performing at 100% if the knob is turned all the way. This was an issue about 4 years ago and we reduced the resistance on the board for the top LED to come on. The 6000 put out less power especially at 50Hz and was more prone to this, usually even with the higher resistance a 6100 wouldn't do this. Interestingly, I also found that a dirty or worn pump could also cause this, but we don't have a technical answer for why this would happen except it may take power away from the controller.