You really need to take readings as close together as possible, otherwise you are just averaging. Temperatures are easy, d.40 and d.41 provide the info. Unfortunately there is no equivalent for boiler output, so you have to take gas meter readings. 2 minutes apart should be sufficient, but wait until the boiler has stabilized, i.e temperatures are constant. (d.34 gives the fan speed, which controls the output, but Vaillant don't publish a conversion chart.)
I believe later versions of the 4XX boilers have a revised PCB which doesn't restart at max output. My boiler (not a Vaillant) always restarts at min output, then ramps up if necessary.
Yes, I have the revised PCB. However, it definitely still starts up on "full" output. Someone previously mentioned it works on a %age of d0.
I'll have a look into d.34, see if I can correlate it to gas consumption. Would certainly make it easier to take readings.