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Unless he's stripped the brass thread :cry:

possibly motor bearings on the way out...

Could be oil pump or motor bearings causing it to stick (the humming) possibly capacitor. You could try to remove the oil pump, if this something you're confident to do, and check whether the shaft is tight when turning by hand (or leaking which could also cause motor bearings to fail).

Did you clean heat exchanger on return visit? it must have been sooty with a smoking boiler - even after cleaning I'd expect some black on smoke paper until soot has burned off, I'd run it for at least 20mins before attempting to put the analyser anywhere near it. You could cut some...

Is it a Riello burner? or something else? a .60 60 ES nozzle (personally I'd use a Delavan W nozzle on a Riello) should be set @110psi (as suggested by DCawkwell) and air setting is suggested @ 2.4 according to MI's - but you really need to set up with an analyser to ensure it's running...

I'll add my vote to the solenoid coil :)

If it's smoking badly it's going to need cleaning out before any attempt is made to alter anything! If the pump pressure was set correctly then it's likely to be an air problem as suggested already - what CO2 setting did the service guy leave it at?? Who has been doing the air adjustment? 3...

Are you sure it's not the NRV that's failed? There is usually an air bubble in the flexi on these boilers - what are the symptoms? If it's been working fine without a TL I'd save the customer the expense, the oil pump should be sufficient to pull once primed.

I've not worked at Virgin for a couple of years, but when I was there if the cable was nicked in more than one place from the customers property edge to the house it would have to be replaced back to the green box. Customer would be billed and then customer would have to take up issue with...

Close it Pressure will go up as boiler gets warm but shouldn't reach 3bar if all is ok, when it's cold you can let a bit out to set at 1bar for peace of mind.

http://www.jmwlimited.co.uk/Tester_301C_Cable_Fault_Locator.html Is it anything like this one? PDF instructions may be of use...

http://www.oftec.org/easy_guides.asp http://www.jseed.co.uk/regulations.htm both of the above are good sources of info on oil tanks

Take the measurements of the existing ones and find a local blacksmith/sheet metal firm to make them for you?

Does it struggle more on the colder days ?

Sounds like it's over aired, what CO2 reading did your guy get on it? and why did he replace the control box?

Changing motor and pump will still require recommissioning.

Wondered whether it could be combustion settings (air) - Is it an indoor or outside boiler? have you tried cleaning the electrodes? Could be a weak capacitor, could be a stiff oil pump shaft... Ideally you need to be there when it locks out to see how far it gets (or doesn't) when it tries to...

Photocell is a good place to start. Has it run OK it warmer weather and played up in colder? Could be slightly over aired but you'd ideally need CO2 test equipment to set this up properly.

Was it serviced in the summer?

I thought 28sec kero used to be called paraffin in the UK?