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You've cleaned the water flow sensor pipes but have you checked the venturi on the pump? I had a few if these block.
 
Yes Sorry guys, did'nt mean to leave you all hanging, its just that i didn't want to tempt fait. Waiting for a call from client in the morning with an update. Mountainman was bang on. The venturi on the pump manifold was blocked with black crud, cleared with a fin piece of wire and blew through with some compressed air. Re-assembled all good so far. Will up date you in the morning.
 
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Thanks for everyones advice, the boiler seems to be working well, client happy thats the main thing. Cheers all.
 
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