I really can't think of why you would experience popping and clicking. I have a Core i7 16GB RAM machine running S3 standalone with an RME Digiface at a 32 samples buffer with no clicks/pops. Strange that the clicks/pops are still there when you raise the buffer.
So, when you run in a DAW with the same buffer and S3 preset, there is no clicks? Only in standalone? Is any particular preset better or worse? The preset doesn't matter?