Opentherm gateway/thermostat with full integration for Home Assistant

If your boiler is running at 60°C, ideally, the return wants to be 60*0.7=42°C - If the return temperature is higher, then I’d suggest looking at the balance of all radiators and possibly reducing the pump speed if you can (I have my pump on the lowest setting).
Condensing only really kicks in at 54°C, so the lower the return temperature, the better. At 55°C, you’re probably only getting 86%, so plenty of scope to improve on that.

I have a heat meter (an L&G T230) plumbed in to the heating system. This gives a pretty good idea of how much heat is being put out by the radiators. If you know the flow & return temperatures along with the flow rate, it is a trivial calculation to work out how much energy has been consumed. From my notes:

 The specific heat of water is 4190 J/(kg⋅°C).
   It means that it takes 4190 Joules to heat 1kg of water by 1°C.
     Heat required to raise the temperature, Qt:
     Qt = cm*ΔT
 where:
     Qt is the specific heat capacity;
     cm is the mass;
     ΔT is the temperature differential
 Or:
     kWh = cm*ΔT*c
 
     c is specific heat of water divided by time: 4190/3600 = 1.163889

Looking at tables for my radiators, I know what each one is rated at based on a flow temperature of 70°C (often quoted as ΔT50). Using correction tables (e.g. https://www.clyderadiators.co.uk/delta-t-conversion ), one can work out how much heat will be radiated at a particular flow temperature. I have a total of 12.5kW of radiators, so at 40°C (ΔT20), my limit is 3.75kW - These figures are based on a room temperature of 20°C.
When a TRV (old skool 0-5 numbers) kicks in, it stops water flowing through the radiator. Effectively, taking that radiator out of the equation. As a result, the system is not able to dissipate as much heat.

Below, a plot showing flow/return temperatures and power dissipated by the radiators.

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@paul_c5x4 wow, thanks for the info. I have more research to do!
lol all my rads TRVs are set to the highest number to get as much heat out in to the rooms as quick as possible and room target temp is 23° for WAF, but see I should do some calcs

TRVs do not regulate the amount of heat being put out by a radiator. All it can do is turn the radiator off as the room gets up to temperature.
Same for the thermostat - Turning that up does not make the house heat up any quicker.

To heat a house up faster, you either need to fit larger radiators (impractical if you just need the occasional boost), or crank up the boiler temperature. However, that reduces efficiency and also increases the rate of corrosion inside your radiators. Go too high, and there is also the risk of burns if you touch the radiators - A very real danger for the elderly and small children.
Heat Geek is a good place to start if you want to know more about heating. Although primarily pushing heat pumps, much of what they have to say can be applied to gas boilers - I took on board quite a bit of their advice when replumbing my heating system with an eye on fitting a heat pump in the future. Bigger radiators, 22mm pipes for the bulk of the plumbing, and so on. Running the boiler at 40°C, I can heat the place reasonably well. Heat pumps will run at a similar temperature, so I’m set should the boiler pack up.

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