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now you've edited your post i suggest you call in someone qualified as you shouldn't be in the combustion chamber & that is where the fault may emanate. even if it doesn't some things should be checked that you are unable to do.

from what i understand the expansion vessel accommodates the heated primary water used as dhw preheat. i don't quite understand the problem you had repressurising the vessel, explain please. with the boiler empty of primary water & boiler drain open it should be no problem to charge it to...

rectification ?

that attitude is not going to help you. you are receiving advice. anyone who responds is doing so in order to help you. it is a forum after all. no one is being paid to give you technical advice. perhaps you would be happier ringing the baxipot technical helpline 08706060780.

get it capped off.

can i have £60 too. i've been just as much help, & this is my 1st post on this thread. :)

as the installation is not very old sludge should not be a problem. have you not considered that it is piped up incorrectly. both feeds coming from the flow or return, rather than one from each.

i'm carrying out a similar job tomorrow & i will use some 54mm tube & 2 54*22 reducers which just happen to have had hanging about for years.

personally i don't like combined cf & ov. in problem circumstances like yours i would advocate 22mm cf & ov close coupled before the pump as yours was. with a surge arrestor fitted on the ov. basically this is a short (18" roughly) section of as large a diameter pipe as you can find set...

what model boiler is it ? i rarely come across a combi feeding a cylinder, but it is possible. do you have large house with a number of bathrooms ? which taps are fed from the combi as opposed to the hot water cylinder ?

don't quite understand that. but you are right, silly response, sorry about that. but you will need to get qualified guy in. :oops:

how does that work then. as i was told when i obtained my 'energy conservation' ticket. if the customer does not want to pay the extra that may be involved for the boiler or the extra involved in condensate disposal then just get it in writing & then everything is hunky dory.

you have received the appropriate response on this forum. & its no good being a 'Moderator don't call him a Knob'. ok i wont.

+ any left are calling for the skip.

shut the appropriate boiler flow & return valve/valves as necessary.

22mm cold feed &/or surge arrestor will fix it.

sorry this does not help. but my service was 3/4" black plastic. i used a 22mm valve with 3/4" olive & 15mm hep insert. worked a treat.

i believe so. :(