Pureflow Ag4 Boiler temperature limit control tapping

Plumberman860

Hello everyone, I am a master plumber and carry my s2 license. My experience in the heating field is fitting pipe for a welder and not much on the residential side. I was given a Pureflow Ag4 boiler ( https://www.fwwebb.com/product/Burnham/PurePro-Advantage-Water-Boiler/AG4-HN/496454 ) and I do not see where the tapping for the Hydrostat's electro well installs into the boiler. Can someone direct me where to install it? Thanks!

MikeGordon

Hello Plumberman860;

For current production, looks like the well installs in the block 3/4 tapping behind the jacket vestibule panel. Remove the jacket door and you will see the painted vestibule panel.

Page 28 of the installation manual shows this jacket panel (Item 5D) with the hole for the well. Manual can be found with this link

https://fwwebbimage.fwwebb.com/ProductInfo/AGSeriesOIManual(Advantage).pdf

The Hydrolevel control then mounts to the well.

Seems I recall the design changing in about 2021 for the latest round of boiler minimum efficiency changes. That's when the ratings went to the current 84%. The design was quite different prior to that. I'm thinking you have the older design.

If you do have an older boiler, looks like the well mounts in a tapping below the vertical water supply pipe.

This is not the manual for Pureflow boiler, but I believe the design was exactly the same, both manufactured by Burnham/US Boiler. Please see this old manual

http://contentz.mkt3954.com/lp/17286/554771/FORCEwithHydroStatIOandS.pdf

Well location is shown on Page 4 (top drawing), page 7 (figure 2), page 11 (figure 7), and page 26 (block drawing)

The Hydrolevel control mounts on the side jacket panel towards the front, and the well/sensor wire is run remotely from the well location to the control. However, that's not shown clearly anywhere I could find. On a factory package everything would already be mounted.

For either design, the control and well installation and wiring instruction are at the Hydrolevel website

Hope this helps.

Plumberman860

Hi Mikegordon, thanks for responding. Your post was very helpful.

My boiler has this Burnham-103966-01-Control-Board installed. Is it safe to say that this was installed and prewired when the boiler was purchased? I will utilize this instead of a Hydrostat correct? I should be able to wire everything into this control to run the boiler, correct?

MikeGordon

The control shown in your photo is a Honeywell integrated control. It combines the functions of the temperature/circulator control (Hydrolevel 3200), and the ignition module (Honeywell S8610M). I don't know if at some point this control was offered from the factory on your boiler or not.

This type of control was provided on similar Burnham/US Boiler produced products (New Yorker/Crown/X-2, etc). A similar control appears to be current production on the New Yorker CG-F. Please see this manual fo details on the wiring and control layout

https://s3-us-west-2.amazonaws.com/catsy.782/CG-F+IO.PDF

Extreme caution is advised. The integrated control incorporates every safety function of the boiler system. Get it wrong, and things get very unsafe, very fast.

The safest and recommended approaching my opinion is to exactly match what was supplied by the factory. If at all possible, it would make sense to get a copy of the manual supplied with the boiler, see what was provided from the factory, and follow what is in there.

Plumberman860

Mike, Thanks again for all of your help.

I will be hiring an electrician to wire up the controls seeing as I do not have any experience with this control. At least now I know what boiler controls I have installed on the boiler. This control did come preinstalled on the unit. I cannot find the manual that was with the boiler, however, there is a wiring diagram that was stuck to the front cover from the factory. I hope you have a good day and thanks again!