It took about 16 hours of pondering and checking to "get it." The radator return pipe and feed from the cold part of the tank were swapped around, meaning the four port valve was always delivering hot water, even when it thought it wasnt. The controller was getting confused, and hot return water from the heating was being delivered to the wrong part of the tank.
The plumber came round on the evening of 3rd May, and it took a couple of minutes to explain the error to him. Then a couple of minutes more to convince the distributor's representative as well.
Paul's back on Friday 6th to partially drain down the system, re-fettle the pipework, and add the inhibitor and other odd tasks. Hopefully we should be good to go.

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