Sounds riduclous but when you drained the system did you turn anyt isolating valves off under the boiler including the gas valve, and forgot to turn them back on?
There's something I have in the back of my mind about the function of the diff pressure switch during a call to Vaillant service. It does two things and I remember we had a Vaillant with a seemingly irrational fault which boiled down to the operation of this switch.
I have now read your post, Gasguru, (sorry I missed it) and I wish my memory was better about the operation of it from my discussion with Vaillant tech! Suggest the OP gives them a call.
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