Yay!
Don't want to tempt fate but the boiler finally seems to be working as it should be! It's now gone overnight supplying hot water and timed central heating with no trips or unusual pressure readings.
Just to help anyone else with similar problems I will quickly run through what happened. It is a Vokera Linea Plus AG 32kW, manufactured 2000.
1. Boiler pressure rising above 3bar, dropping down towards 0 when cool, boiler switching itself off for protection
This actually happened 18 months ago but I worked out a way of keeping the boiler running while we decided whether to repair or replace (basically, heating was either always on or off to stop pressure changes). In retrospect this long delay was a mistake and caused more problems.
2. Pressure vessel replaced
Had a pressure vessel that I had purchased myself fitted after I failed to get it in myself. Plumbers did not do any testing after fitting it and also managed to soak the boiler with water from the failed vessel. I suspect this may have contributed to later problems.
3. Pressure still rising when heating up, then slowly returning to a normal level. Overnight, the boiler trips the mains
Called out the same plumbers on an emergency call. Different member of staff who basically decided he did not want to work on the boiler at all due to dirty water in system, suggested power flush. Refused to remove or test any parts. Not particularly happy with this attitude, at least a token effort at finding a fix would have been appreciated.
4. Pump replaced
Having lost faith in this plumbing firm and being desperate to get some hot water in the house I gambled on fitting a new pump to see if that was what was causing the mains trip. At the same time I cleaned out the pipe union to the pressure vessel which was blocked solid with gunk (plumber had not looked at this at all). Pump was the wrong call. £65 down the drain but at the time I felt it was worth a punt as it would cost this much to get anyone out. Although I did learn that the Wilo brand pump sold in
Wickes does not fit into the pump housing on the Vokera boiler, it has to be a Grundfos 15-60.
5. Boiler still tripping mains, after a few restarts it starts showing error code 01 "failure to ignite" instead
At this stage I realised the problem was likely to be gas side and I wasn't going to touch it. Called out the Vokera engineer on their fixed fee service and was glad I did! Wish I had known about this on day one. Engineer seemed to really know his way around the boiler, fitted a new gas valve which got the boiler running, also replaced the heating and hot water control knobs as one was broken - the benefit of having a van full of spares!
6. Fixed!
All in all, big thumbs up to the Vokera service engineer, thumbs down to me for leaving the boiler unrepaired for so long, neutral thumbs for the original plumbers, on one hand I only asked them to fit a part, not diagnose a fault, on the other hand they could have gone the extra mile with the fault diagnosis when I called them out again.