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Thanks Mogget. I will have another look at the setup tomorrow and see if your suggestions work.

No! Oil fired. I took the damn thing out to my workshop to do the welding. It was either that or fork out for a new boiler.

I had to take the boiler out altogether in order to weld a new inlet (the old one had completely rusted!). This was done successfully and the boiler reinstated. All was working fine apart from the above problem.

I Realise this topic has been discussed many times but I couldn't find a solution to my particular issue! Basically the hot water in the c/h system is overflowing into the expansion tank and then circulating back through the system. Tho I've just discovered that this doesn't happen if I turn...