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Sounds as though it would be worth the replacing the motor again and see if the problem goes away. Thanks for your help.

Nickso, Are you thinking that that might make the valve inside keep bumping, or are you suggesting the noise is the gear slipping?

I installed my CH/HW system around 18yrs ago and it's been pretty trouble free. Recently, at the point the HW switches in, there is sometimes a regular knocking noise (around every half second), which continues until I turn the HW off at the controller. If I turn it straight back on the knocking...