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Can't bind HR92s

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Hello everyone (first post),

I have attempted to bind several HR92s without (recent) success. I managed it before and read the manual several times so feel I know what I doing. I even called Honeywell who made a good job of reading the manual to me - so I learned nothing new there.
The problem: During binding, either as a new zone or a fresh 'guided config' the evohome controller tells me binding is successful, however I do not get a success message on the HR92 itself. The Evohome relays and schedule is operating well but I have no control over the HR92's since they are not bound.
I have gone through guided config 5 times now and beforehand always clear the memory of the relays and the HR92's by holding the 'Binding' button for 15 seconds or so.
I think the Hot Water, Evohome Control and Relays are working but the HR92's are not.
Background info: I have 3 heating circuits controlled by relays wired to motorised valves for upstairs, downstairs and hot water. There is only 1 downstairs zone using the Evohome control temp sensor. Upstairs I have 6 HR92's split into 4 zones. Hot water circuit is working well.
- During the guided config, I have said I have no boiler relay. Anyone know if that is correct?
- The upstairs zones are set to Application = Zone Valves / Sensor = Remote devices sensor
- I know there is some comms between the HR92's and the control because it's successfully reading the temp. I think it also call on the boiler when a zone gets cold but the HR92's are not opening and closing with the schedule.
More clues:
- After installation (when the HR92's behaved) I was never able to turn the dial to start the boiler so I have little confidence there is 2 way comms.
- The problem started when the upstairs circuit fired during the night even though there was no call for heat from any sensor (controller, HR92 or hot water).

Any ideas?

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