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Many thanks for your help guys. I'll give them a go.

Thanks for responding twgas. Because there was so much hot water and heat in the expansion tank, the first thing i did was drop it to low. Problem is still the same. Someone has suggested the circuit board on the boiler? what do you think?

I have TRV's downstairs and 2*2ports upstairs. It takes no longer than 45-1hr before the trouble starts. The boiler starts to sound like it has a large bubble inside it. The rads are very very hot also. Would Hi/Lo stats on the boiler play a part in this?

I have just installed a new O/H stat on the boiler, i had issues with the pilot light cutting out after 10 - 15mins, which seemed to do the trick. After a couple of days now the boiler is getting piping hot and now over heating, the expansion tank last night was like a sauna (red hot with...