Hi Guys,
Experienced the same thing a couple of months ago and it was the expansion vessel. I am reliably informed that this is a common fault on worcester-bosch. However, the good news is that it is not expensive to replace ( 170 bucks all in ) which is good value since it does take a couple of hours to replace and will last for 3 plus years. Bearing in mind, I purchased the boiler 5 years ago and this is the first issue I have had with it, this is not bad. By the way, my model is a 28 CDi. Also, you mention no leaks. If you take a look at the overflow from the boiler to the outside of the house, you will notice shortly after filling the boiler that wtaer starts to drip from the overflow pipe. This is where the water empties from your boiler hence you will not find any leaks in the house. Does the boiler fire up when you fill it or is it just not firing up?
Doc
November 2009