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the pipe between the house and garage is 22mm and probably undulates a bit. I did try without the pump running but it didn't really get hot (perhaps i wasn't patient enough)

Any suggestions?

Very similar layout, Both underfloor manifolds have been pumped to clear any air, I can only think its air in the pipe between the house and garage. [/img]http://www.diynot.com/network/rainman/albums/22944/85704]

Please can someone help on this one? Did you resolve your issue? I have the exact same issue with a Gledhill open vented thermal store. My setup is almost identical apart from my heating circuit is underfloor and I don't have a wood burner When the pump starts water is drawn in from the...