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I suggest checking the manufacturer's website or contacting their customer support for assistance. They should be able to provide you with the appropriate owner's manual for your Big Boy Flame 200cc.
You did quite a bit of work. One other thing that controls the ignitor is called the flame detector. Its the black box looking thing mounted on the side of the big pipe the flame shoots into. Should be 2 wires going to it. A quick test to see if the ignitor comes on is to tie the 2 wires together. If you see the ignitor come on thats the bad part,
When a heater kicks on and a boom occurs, it is known as "delayed ignition". Sounds like the alignment of the pilot/ignitor and the main burner(s) is not correct, thus causing the boom at the end of a burning cycle.
Check your propane tank first; is it getting close to being empty? Check where the hose connects to the burner, there should be an air adjustment there; it looks like a rotating disc with two big holes on either side, this is turned when the burner is lit to adjust the amount of air mixing with the gas. If it's all the way open, you have a yellow flame, if it's closed all the way you have a blue (but weak) flame. Try adjusting that and if that doesn't work, try a different regulator...it is rare a regulator could cause this but it could cause it; just use that as your last resort.
This may be normal it's hard to tell from your description , The flame could possibly rollout for a second or 2...depending on the venting , how far the vent is from the chimney etc....you shouldn't hear a "Mini Explosion" you may hear the gas ignite with a bit of a woooosh...depending on the size of the boiler this could be quite normal...Boilers can be dangerous when they get plugged up or dirty....although Hydrotherm makes an EXCELLENT Cast Iron Boiler...I would still have it checked by an expert to be on the safe side....you should also have a "Slow Opening" valve which would eliminate that problem if the valve is working correctly , but it's possible it was replaced at some point with a regular opening valve and this could be the reason as well
You may need to resize the orifice, sounds to me like it is too big. If you have an adjustable orifice try tightening it down a quarter turn at a time till that flame turn pretty. Leave that shutter wide open till you start getting a blue flame. Make sure you have no cob webs blocking the orifice.Blow out and remove all rust from the burner.
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