I think my problem is electrical, as the boiler trips around same time each night it must be an outside influence. Got good gas pressure now so checked the voltage and it starts to drop around 7pm, I can get down from 242V to 228V and this is when the problem starts. So I did a test this morning by switching every large load appliance on and watched the volts drop at the consumer unit, when we got below 230V the boiler tripped and went in to EA fault, got the volts back up and the boiler starting working once reset.
I then spoke to Worchester technical and whilst my boiler should work with voltage as low as 220V they suggested that parts should now be replaced and hence a new PCB and transformer are now on order.
I hope this works, parts will be fitted Thursday !
mark, April 2010