FERROLI OPTIMAX HE 31C flow sensor and water coming out the bottom!?

Hi All,

New to the forum but really hoping someone can advise,

We have a 5 year old OPTIMAX HE 31C boiler due to come out of warranty in May 2012, we are still covered under this.

I booked our annual check and visit as the boiler keeps flashing up A41 - Flow sensor disconnect according to the manual, pressing the reset key for 10 seconds kicks it back into life. Chap came out and services the boiler (hovered and checked CO2 levels - is that a full service ?!) - he also replaced the flow sensor on the top left of the boiler, same error is popping up, boiler works fine for a day or two then we get no hot water and the error appearing, having to hit reset.

Second problem is EVERY morning we find there is approx. 2 x table spoons of water on the worktop below the boiler, approx. left hand side below, this has been going on for over a year, I feel I've been fobbed off before and was told to insulate the overflow pipe outside as it must be freezing, this has been done and we ARE STILL getting the problem.

I've spoken to the engineer today and now he's saying the filters are clogged up but it’s not covered under warranty, I'm confused and could use some help !!

I want to get everything sorted BEFORE the warranty lapses in May, could some please advise what they think could be going on ?

Boiler is pressured to 1.5mb,

Many thanks
Andrew