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15B-K
Cast Iron Gas Fired Boilers
For Forced Hot Water
With Resideo Control
INSTALLATION, OPERATION
& MAINTENANCE MANUAL
Models
15B-060K
15B-095K
15B-120K
15B-150K
15B-175K
15B-205K
15B-235K
Manufactured by:
ECR International Inc.
2201 Dwyer Avenue, Utica, NY 13501
Tel. 800 325 5479
www.ecrinternational.com
PN 240012786 REV. D [08/15/2021]
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Table of Contents
Related Manuals for ECR International 15B-K
Summary of Contents for ECR International 15B-K
- Page 1 For Forced Hot Water With Resideo Control INSTALLATION, OPERATION & MAINTENANCE MANUAL Models 15B-060K 15B-095K 15B-120K 15B-150K 15B-175K 15B-205K 15B-235K Manufactured by: ECR International Inc. 2201 Dwyer Avenue, Utica, NY 13501 Tel. 800 325 5479 www.ecrinternational.com PN 240012786 REV. D [08/15/2021]...
- Page 2 Check our website frequently for updates: www.ecrinternational.com Information and specifications outlined in this manual in effect at the time of printing of this manual. ECR International reserves the right to discontinue, change specifications or system design at any time without notice and without incurring any obligation, whatsoever.
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Page 3: Table Of Contents
TABLE OF CONTENTS 1 - Physical Data ........................... 4 2 - Safety Symbols And Warnings ......................5 2.1. Safety Information ........................5 3 - Locating The Boiler .......................... 7 3.1 Installation Requirements ......................7 3.2 Minimum Clearances To Combustible Construction................7 3.3 Recommended Clearances For Service ..................... -
Page 4: Physical Data
1 - PHYSICAL DATA Model 15B-060K 15B-095K 15B-120K 15B-150K 15B-175K 15B-205K 15B-235K # Sections 13-³/8" 13-³/8" 16-1/4" 19" 21-7/8" 27-¹/2" 27-¹/2" A Width (Jacket) 340 mm 340 mm 411 mm 483 mm 555 mm 700 mm 700 mm 22" 17-⁵/8" 19-¹/4"... -
Page 5: Safety Symbols And Warnings
2 - SAFETY SYMBOLS AND WARNINGS FOR YOUR SAFETY READ BEFORE OPERATING Become familiar with symbols identifying potential hazards. DANGER This is the safety alert symbol. Symbol alerts you to potential personal injury hazards. Obey all safety messages following this symbol to avoid possible injury or death. - Page 6 2 - SAFETY SYMBOLS AND WARNINGS WARNING WARNING Combustion chamber insulation in this product This product contains Fibrous glass. Fibrous glass contains ceramic fiber material. Ceramic fibers is a synthetic fiber made from tiny particles of can be converted to cristobalite in very high glass.
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Page 7: Locating The Boiler
3 - LOCATING THE BOILER 3.2 Minimum Clearances to Combustible WARNING Construction Fire hazard! Do not install boiler on carpeting. Minimum clearances to combustible construction are: Failure to follow these instructions could result in death or serious injury. 10 inches (254 mm) Front Alcove* CAUTION... -
Page 8: Boiler Location Considerations
3 - LOCATING THE BOILER 3.4 Boiler Location Considerations • System piping exposed to freezing conditions: Use • Ambient room temperature always above 32°F (0°C) to inhibited propylene glycol solutions certified by fluid prevent the potential of freezing. manufacturer for use with closed water heating system. Do not use automotive or ethylene glycol. -
Page 9: Connecting Supply & Return Piping
4 - CONNECTING SUPPLY & RETURN PIPING • Supply and return may be piped to either side of boiler, WARNING as desired. Both supply and return shall be on same Burn and scald hazard. Boiler supplied with dust caps side of boiler. Do not "cross pipe" as boiler may not on supply and return tappings (4). -
Page 10: Safety Relief Valve Installation
4 - CONNECTING SUPPLY & RETURN PIPING WARNING WARNING Burn and scald hazard. Safety relief valve could Burn and scald hazard. Safety relief valve shall be discharge steam or hot water during operation. installed with spindle in upright position only, Install discharge piping per these instructions. -
Page 11: Flush And Rinse System
4 - CONNECTING SUPPLY & RETURN PIPING connected to the high point of the heating system. WARNING 4.4 Water Treatment • Poison hazard. Ethylene glycol is toxic. Do not Manufacturer recommends a water analysis be done on use ethylene glycol. water used to fill the system. -
Page 12: Supply And Return Requirements
4 - CONNECTING SUPPLY & RETURN PIPING 4.5 Supply and Return Requirements Installation using circulators and zone valves are shown in Figures 4-4 through 4-9. For further piping Boiler used in connection with refrigeration system, information refer to AHRI Installation and Piping install so chilled medium is piped in parallel with boiler Guide. - Page 13 4 - CONNECTING SUPPLY & RETURN PIPING • Boiler used in connection with refrigeration system. Do not expose boiler and piping to freezing Note Install piping in parallel with boiler, with appropriate temperatures. valves to prevent chilled medium from entering boiler. •...
- Page 14 4 - CONNECTING SUPPLY & RETURN PIPING Piping legend: BACK FLOW VALVE Figure 4-5 - Bypass Piping With Automatic Mixing Valve PURGE VALVE Back Flow Valve ASME Relief Valve DRAIN VALVE PN 240012786, Rev. D [08/15/2021]...
- Page 15 4 - CONNECTING SUPPLY & RETURN PIPING Piping legend: BACK FLOW VALVE Figure 4-6 - Bypass Piping - Fixed Low Temp Only With Zone Valve ASME Relief Valve Drain Valve Drain Valve Manually adjust until proper system temperature is reached. PN 240012786, Rev.
- Page 16 4 - CONNECTING SUPPLY AND RETURN PIPING Piping legend: BACK FLOW VALVE Figure 4-7 - Bypass Piping (4-Way Valve Option With Circulator On Supply side) Back Flow Valve ASME Relief Valve Drain Valve PN 240012786, Rev. D [08/15/2021]...
- Page 17 4 - CONNECTING SUPPLY AND RETURN PIPING Piping legend: BACK FLOW VALVE Figure 4-8 - Single Zone System With DHW Priority Back Flow Valve ASME Relief Valve Purge Drain Valve Valve PN 240012786, Rev. D [08/15/2021]...
- Page 18 4 - CONNECTING SUPPLY AND RETURN PIPING Piping legend: BACK FLOW VALVE Figure 4-9 - Multi Zone System With Zone Valves And DHW Priority (With Zone Valve) * Hot Water Supply Tempered Tank Sensor Optional Indirect DHW Tank T & P Relief Cold Valve to Water...
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Page 19: Ventilation & Combustion Air
5 - VENTILATION & COMBUSTION AIR 5.1 Requirements B. Known Air Infiltration Rate. See Table 5-1 for space with boiler only. Use equation for multiple WARNING appliances. Do not use an air infiltration rate (ACH) Asphyxiation Hazard! Provide enough air openings greater than 0.60. -
Page 20: Vent System Modification
6 - VENT SYSTEM MODIFICATION 6.1 Removal Of Existing Boiler From Venting System Typical Masonry Chimney Requirements Figure 6-1 - When an existing boiler is removed from a common venting system, the system is likely too large for proper venting of appliances still connected to it. -
Page 21: Vent Installation
7 - VENT INSTALLATION Boiler series is classified as a Category I. Vent WARNING installation shall be in accordance with "Venting of Equipment," of the National Fuel Gas Code, ANSI Boiler and venting installations shall be performed Z223.1/NFPA 54, or "Venting Systems and Air Supply by a qualified expert and in accordance with the for Appliances,"... -
Page 22: Vent Damper Installation & Instructions
8 - VENT DAMPER INSTALLATION & INSTRUCTIONS 8.1 Vent Damper Fasten sections of vent pipe with sheet metal screws to make piping rigid. Support horizontal potions of vent Connecting The Vent Damper And Vent Connector system to prevent sagging. Use stovepipe wires every 5’ to Refer to page 4 for size and location of vent (flue opening). - Page 23 8 - VENT DAMPER INSTALLATION & INSTRUCTIONS Figure 8-2 - Vent Damper Placement Figure 8-3 - Vent Damper Position Indicator PN 240012786, Rev. D [08/15/2021]...
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Page 24: Connecting Gas Service
9 - CONNECTING GAS SERVICE DANGER Table 9-1 Natural Gas Propane Fire Hazard. Do not use matches, candles, open Min. Supply Pressure 5" w.c. 11" w.c. flames, or other methods providing ignition source. Max. Supply Pressure 13.5" w.c. 13.5" w.c. Failure to comply will result in death or serious 10"... -
Page 25: Electrical
10 - ELECTRICAL WARNING Electrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury. 10.1 Electrical Wiring See wiring diagrams on the following pages for details. -
Page 26: Wiring Diagram
11 - WIRING DIAGRAM WARNING Modification, substitution or elimination of factory equipped, supplied or specified components may result in personal injury or loss of life. Figure 11-1 - Integrated High Limit & Electronic Ignition Control PN 240012786, Rev. D [08/15/2021]... - Page 27 11 - WIRING DIAGRAM Figure 11-2 - Integrated High Limit & Electronic Ignition Control PN 240012786, Rev. D [08/15/2021]...
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Page 28: Lighting Instructions
12 - LIGHTING INSTRUCTIONS WARNING 12.2 Operating Instructions For Intermittent Pilot System If you do not follow these instructions exactly, a fire or explosion may result STOP! Read the safety information to the left. causing property damage, personal injury Set the thermostat to lowest setting. or loss of life. -
Page 29: Normal Sequence Of Operation
13 - NORMAL SEQUENCE OF OPERATION A. Power remains off until boiler water temperature WARNING drops below high limit setting. Burn Hazard. View port on burner door may be hot. B. Circulator continues to operate under this condition Wear personal protection when servicing this boiler. until thermostat is satisfied. -
Page 30: General Maintenance And Care Instructions
14 - GENERAL MAINTENANCE AND CARE INSTRUCTIONS 14.2 Clean Flue Gas Passageways WARNING Label all wires prior to disconnection when servicing Follow this procedure to clean flue gas passageways: controls. Wiring errors could cause improper and Remove burner tray from heat exchanger by dangerous operation. -
Page 31: General Maintenance
14 - GENERAL MAINTENANCE AND CARE INSTRUCTIONS 14.3 General Maintenance Figure 14-1 - Burner Tray BURNERS • Visually inspect main burner and pilot flames at start of heating season and again in mid-season. ◊ Main burner flame should have well defined inner blue mantel with lighter blue outer mantel. -
Page 32: Adjusting Gas Input
14 - GENERAL MAINTENANCE AND CARE INSTRUCTIONS 14.4 Adjusting Gas Input Adjust gas input to boiler by removing protective cap on pressure regulator and turning screw clockwise increase input and counterclockwise to decrease input. See Figure 12-1 page 28. Manifold pressures are taken at outlet side of gas valve. See page 24 for proper pressure recommendations. -
Page 33: Ratings & Data - Natural Gas & Propane Gas
15 - RATINGS & DATA - NATURAL GAS & PROPANE GAS Table 15-1 - Ratings and Capacities Recommended Flue High Number of Heating Net AHRI Air Cushion Input AFUE Diameter Altitude Model No. Sections Capacity Rating Water Tank BTU/HR Inches Input BTU/ BTU/HR BTU/HR... -
Page 34: Appendix A - Control Module
APPENDIX A - CONTROL MODULE A.3 Adjusting Settings WARNING To discourage unauthorized changing of settings, procedure If you do not follow these instructions to enter adjustment mode is required. exactly, a fire or explosion may result To enter adjustment mode, press UP, DOWN, and I buttons causing property damage, personal injury simultaneously for three seconds. - Page 35 APPENDIX A - CONTROL MODULE Figure A-1 Segment LED Display - Installer Mode Options 2nd Screen Default Range Description Screen Screen Adjust High Limit setting HL=SP Unless <High Limit> ° 130 to 220 °F an envirocom module is in use °C <High Limit Differential>...
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Page 36: Operation
APPENDIX A - CONTROL MODULE A.5 Operation Control determines burner operation is required, module proceeds to start burner (see state codes list) Module continuously monitors boiler water temperature and and heats water in boiler until setpoint temperature is fires or shuts off burner based on this temperature data. achieved or thermostat is satisfied. - Page 37 APPENDIX A - CONTROL MODULE Table A1 conti. - Vent Damper Models Operation State Codes State Order Code Definition Explanation Number 2. Other possible state codes System is purging before ignition trial; includes Pilot Valve circuit diagnostics. On vent Pre-purge damper models, this is so quick it will typically be over before the display can flash this code, and therefore will rarely be visible.
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Page 38: Boiler High Limit Temperature Controller
APPENDIX A - CONTROL MODULE A.7 Troubleshooting A.6 Boiler High Limit Temperature Controller • Following service procedures are provided as general • When water temperature reaches setpoint, controller guide. ends heating cycle. • On lockout and retry models, meter readings between •... - Page 39 APPENDIX A - CONTROL MODULE Table A2 - Troubleshooting Error Codes Error Display clearing ( once error condition has disappeared) Error Clears itself Up/down Code Definition Cycle Push when root key when Number Power Explanation Things to look for problem is status is solved displayed...
- Page 40 APPENDIX A - CONTROL MODULE Table A2 - Troubleshooting Error Codes - conti. Error Display clearing ( once error condition has disappeared) Error Clears itself Up/down Code Definition Cycle Push when root key when Number Power Explanation Things to look for problem is status is solved...
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Page 41: Intermittent Pilot
APPENDIX A - CONTROL MODULE A.9 Intermittent Pilot Ignition System Checks STEP 1: Check ignition cable. • Verify ignition cable does not make contact with metal surfaces. • Verify only factory supplied Ignition cable (or approved replacement) is used. • Verify connections to ignition module and igniter or igniter-sensor are clean and tight. - Page 42 APPENDIX A - CONTROL MODULE WARNING Electrical shock hazard. Ignition circuit generates over 10,000 volts. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury. Figure A4 - Troubleshooting Pilot Flame Energize module and listen for audible sparking noise.
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Page 43: Appendix B - Vent Damper Installation
APPENDIX B - VENT DAMPER INSTALLATION WARNING Figure 1a - Horizontal Installations Flow Asphyxiation, burn hazard. Improper operation of vent damper may result in serious injury or death due to fire or to asphyxiation from poisonous gases Vent Damper To Boiler o Chimney such as carbon monoxide which is odorless and Install vent damper with actuator to sides of... -
Page 44: Vent Damper Harness - Molex Plugs
APPENDIX B - VENT DAMPER INSTALLATION B.3 Vent Damper Harness - Molex Plugs Figure 4 WARNING Follow all instructions regarding safety operational controls in this manual. Failure to follow these instructions could result in death or serious injury. When servicing controls, all wires must be Note labeled prior to disconnection. -
Page 45: Vent Damper Troubleshooting Guide
APPENDIX B - VENT DAMPER TROUBLESHOOTING B.4 Vent Damper Troubleshooting Guide Normal Sequence of Operation WARNING 24 VAC Power ON Damper Position Power Follow all instructions regarding safety operational 4 & 1 All times Open or Closed controls in this manual. Failure to follow these instructions could result in death or serious injury. - Page 46 NOTES PN 240012786, Rev. D [08/15/2021]...
- Page 47 INSTALLATION AND CHECK-OUT CERTIFICATE Boiler Model Serial # Date Installed___________ Measured BTU/HR input____________ Installation instructions have been followed Checkout procedure and adjustments performed Maintenance and Service issues reviewed with owner/ maintenance person Installation booklet affixed on or adjacent to boiler Installer (Company) Address Phone...
- Page 48 • This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater. • This boiler is equipped with a tankless coil. 2201 Dwyer Avenue, Utica, NY 13501 All specifications subject to change without notice. Tel. 800 325 5479 ©2021 ECR International, Inc. www.ecrinternational.com...
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Questions and answers
Boiler lights all flashing with a 250
When all lights are flashing on an ECR International 15B-K boiler with a 250 error code, it indicates a vent damper failure. This means the damper is not operating correctly, and the boiler will not ignite as a safety precaution. You should follow the vent damper troubleshooting steps, including checking for 24V at the Molex plug, verifying damper and control connections, and using a jumper wire to bypass the damper to confirm the issue.
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