The strange thing is that it apparently doesn't trip either of two pressure switches that (hopefully) monitor airflow by measuring differential pressures the purpose of which is to indicate a blocked intake, exhaust,or malfunctioning/waterlogged/whatever fan.
Yet, the flame sometmes "rolls out"/doesn't get sucked into the heat exchanger or lights at the back of the burner(s), eventually tripping the "rollout switch".
To the O.P., were the burners ever removed, examined, and cleaned during this?
Also, it would sure be interesting to "catch it in the act".
I have a high efficiency gas furnace in my shop, and several months ago, it was just lighting when the power flickered a couple of times.
I was working not far from the furnace, and noticed it was making an odd noise after the power settled down.
I lifted the cover off, and one of the burners was burning at the back end.
I shut it off and then recycled it, and AFAIK, it's been fine ever since.
I DID make it a point before the worst of winter set in to remove, check, and clean the burners.
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