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Thanks guys. I can confirm that the impeller can break loose on a Grundfoss pump. I suddenly lost heating downstairs yesterday and was still getting reduced heating upstairs. I can only assume that the upstairs was thermo-syphoning enough to circulate to some degree. On removing the pump...

I too once hated it but now I love it. If it's cold stand the tin in warm water for 20 mins before use, then stir gently (don't whisk it!) so as not to induce air bubbles. Apply a thinnish first coat so as not to have enough paint to run. A fairly stiff brush helps as Hammerite is thick. Wait...

FWIW I just had a problem with a Suprima 60 which looked like it was going to be the PCB although the Potterton fault finding chart was pointing to the air pressure switch. I tested the switch which seemed OK and with a bit of suck on the pipe to the pressure switch the boiler fired up reliably...