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Is your boiler set at 'max'. If not it should be. Try it and see what happens. Also, the timer should always be set to 'on' not timed.

1 to 1.5 hours max to change a diaphragm on a cdi. Thats with any problems.

Which pin? There are 2. One points up and is the pump proving or main flow switch (operates on ch and hw) and the other is horizontal and operates the hw. If both are moving it could be the hw thermistor/sensor.

Yes, the air pressure switch is still available, probably different maker (honeywell not yamatake) but compatible.

Get your rgi to check the pump overrun stat (if fully pumped) and even if its wired correctly. Quite common for the pump live not to be run from these boilers (when fully pumped) As an after thought, do you have a Honeywell zone/mid position valve? (usually silver box in airing cupbourd)...

On your description you have 2 HW off?

since they were produced. Nice to see you didn't disagree with the other common faults :wink:

Common faults with these are gas valves, electrodes, combustion door seals, oh, and anything else.

1 Ohm or less I should think. Normally the problems with the electrode rather than the cable though.

Is it an irregular or regular banging? If its irregular, which I suspect, then you have sludge in your heat exchanger, often worse when the boilers cold or just heating up. Might need a good flush (not always successful) or system silencer added. Or just put up with it :wink:

http://wiki.answers.com/Q/What_is_flame_rectification

Sounds like its overheating. That boiler, although excellent, is now somewhat old and is probably due for replacement. Also not all parts are available now. It needs an engineer to look at it first though, could be something as simple as low system pressure.

The Ideal Response is a terrible boiler but the expansion vessel if I remember rightly is on the right hand side and easy to change, but if its 10 years old you've been very lucky with yours :o

Is it locking out? i.e does it need resetting. If not sounds temperature related so get the other thermistor changed.

Did he change both thermistors, if not he should have.

Fernox F4 internal leak sealer. Works a treat.

Make sure the earth lead from the burner to the pcb is connected properly as these can cause problems.

You'll have to get him back. Sounds like the leads are not connected properly or its over gassed.