which boiler? is it a duotec, platinum etc..? if all avenues have been explored this is something i've come accross before with condensing boilers. disconnect the condense pipe and direct it into a bucket. leave the boiler off over night and check in the morning, it should be dry. if not, system water is passing down the condense waste somehow. usually a faulty main or secondary heat exchanger. this depends on the boilers heat exchanger type so a boiler GC number woould be helpfull
andy gas man, March 2009