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Hi Slug, I've tried that with no success. I now have the bypass open about half way and it's slightly noisier when the noise happens, and slightly higher in pitch. As it is not cold yet it may be there is not enough of a circulation path through the heating system, as it's ok when heating...

I had to replace a radiator so I took the opportunity to change my pump (grundfoss 15/60) like for like, 2 zone valves (tower to honeywell 22mm), and chemically flushed the 11 year old pipework, and removed and cleaned the radiators. Anyway got all that done and got things up and running again...