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I've tried everything from 1 to 6 makes no difference. I have a feeling that the way the installer reduced the pipe from 22 to 15mm then back to the 22mm return may cause it not to function correctly. Minimum flow, the pump should take care of that, the bypass really should only trip in when...

Open vented I was thinking about too much heat loss but then changed my mind as it goes into s53 within 1m of starting which would never be enough time to circulate water around the system

Open vented, Speed 3

Sorry forgot to say it's an open vented s-plan system.

I'm having the dreaded s53 problem and also s7. 418 ecotec plus (10yrs old) 15-50 pump External controls (pump boiler controlled) 2 zones (CH and HW) ABV After pump but before valves, back to return circuit Magnaflow 10 radiators (one is 2m long single, one is 1.9m high double 8kbtu, rest are...