firstly hot water expands, and have you checked the pressure in the expansion vessel? should be 1bar, 14 psi, it you press the valve on the vessel and water comes out, then the vessel is faulty and you need a new one, secondly air expands more than water and if the pressure vessel is faulty then this would only add to the pressure build up in the system. and is the fill loop valve leaking and over filling the system?
ppan
November 2007