Flame size looks good.
as to the clag in the chamber, excess air can do that, as can poor fuel quality.
the only way to set them up right is to do it the right way- pressure gauge and combustion analyser. That's probably worth the £75 a year as you can blow 10% efficiency up the flue as excess air...
But as to this one and it's lockouts? Being a Riello makes it really difficult as the pcb uses a tapping on the motor for it's power supply, but I'm looking at the lockout chart and there are no specifics for lockout w/ NO light so I'd be suspecting the box if there's a clean 50v from the motor. Open the box and look for dry joints.