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Sorry Thanks to you all I will let you know the outcome

Thanks for your advice Craig much appreciated.

Do I assume from this that the conclusions are that it is possible that the gas mixtures would change in a matter of an hour and also that incorrectly set mixtures could cause this level of noise in the burners?

Open the upper rads again and run boiler, post back with what happens I did this as I thought this may the problem with water circulation. It made no difference the noise was still there. I did wonder if I had forced more water around the lower radiators stirring up dirt and this has got into...

The boiler had a service and check about 2 years ago by the Bosch engineer. He adjusted the levels at that time. They were slightly out then I remember him telling me that. He also did a mod on the ignition to make the holes larger to stop any corrosion shorting against the burner case.

I have a Bosch Greenstar HE35 plus boiler (3 years old) and it’s a fantastic bit of kit. However I wanted to heat the lower floor radiators this weekend so shut off the top floor radiators and ran the heating. All was fine for a few hours but then the boiler started to make a loud roaring...