Benjamin Heating products CC500 User manual

A DIVISION OF
W.R. BENJAMIN
PRODUCTS LIMITED
HEATING PRODUCTS
OWNERS MANUAL
MODEL
CC500
IS CERTIFIED TO:
UL391
UL726
1
CSA B140.7.1
CAN/CSAB366.1
Unit Serial #
Burner Serial #
PurchasedFrom
Company Address
Name of Installer
Installer Telephone #
Date Installed
IMPORTANT
Thismanualmust be given tothe homeowner.Pleaseread the warranty
and return the warrantycard to initiatecoverage.
We StronglyRecommend TheUseOfA CarbonMonoxideDetectorWhen
Using Any ProductThatConsumesFossilFuels.
It isthe responsibility ofthe person or companyinstallingthisboiler to verify before the
installation that the boilercertificationsshown on thispage,meet or exceed all local,state and
regulatoryrequirements for installation anduseof thisboiler.Failure todoso voids all claims
and warranties.
June 2006 Aussidisponible en Francais.

KEEP THIS MANUAL FOR FUTURE REFERENCE. Follow all instructions
carefully for installation, maintenance & operation of the CC500boiler.
TABLE OF CONTENTS
1. TakingDelivery & Unpacking
Assembly
Chimney and SmokePipes
2. Placement ofthe Unit
Installation Clearances
Fuel TankSupply
Combustion Air
VeryImportanthomeownerinformation
3. Aquastat Settings
Oil BurnerInstallation
Installation of BlockedFlueSensor
How MuchWater toRunin System
4. Electrical
Piping
Adjustments of DamperMotor and Chain(Diagram)
5. OperatingInstructions(WoodSection)
Normal Operation
OperatingInstructions(OilSection)
To Start the Burner
To Stop the Burner
To Stop the Burner foran ExtendedPeriod of Time
6.To Start the Burner after an ExtendedShutdown
If the Burner Fails to Operate
When the Burner isin Operation
Special Procedures
ExtremeWoodFire
Flue Fire
7. ElectricalPowerFailure
To ResetCombustionControls
General MaintenancePointers
BurnerMaintenance
8. Care ofthe BoilerWhen NotinUse
Replacing Hot WaterCoils
Cleaning and ServicingWoodSection
Cleaning and Servicing Oil Section
9. Cleaning and Servicing Oil SectionContinued(Diagram)
To Clean the Oil Burner
To Clean theOil Filter
To Clean the Strainer
10. ChimneyConnections(Diagram)
11. Piping and WiringLayout(Diagram)
12. Electrical(Diagram)
13. Domestic Hot Water & MixingCirculator(Diagram)

TAKING DELIVERY AND UNPACKING
Note: The consignee is responsible for ensuringthat the packages havearrived in goodcondition.Examine the
packages for damages, if found,note the same on carriers' bill of lading and make a claim tothe carrier.
Each unit is carefully inspectedbeforeleaving our factory.
Package (1)The cratedboiler(assembled)
Package (2)Theoil burnerpack:
1 - Choice of Burner 1- DamperMotor & Chain
1- Vz" DrainValve 1- PressureReducingValve
1- N.O. Zone Valve 2-24 VA Transformers
1 - PressureReliefValve
1 - SingleAquastat
1- Wiring Harness
1 - TripleAquastatRelay
1 - Nozzle
3 - Wells
1 - Tridicator
1 - TripleAquastat 1- BlockedFlueSensor
2- CirculatorPumps c/w Flanges
Please note: Thetwo circulatorpumps are required for properoperation of thisboiler.
Installation of thisunitshould bein accordancewith the regulations ofthe authoritieshaving jurisdiction. Reference
should be made to: hi Canada, CSA B139, "InstallationCode forOil BurningEquipment" for recommended
installation practices; Inthe United States, UL 391 "Solid-Fuel and Combination-Fuel Central and Supplementary
Furnaces " andUL726 "OilFiredBoilerAssemblies".
ASSEMBLY
Benjamin "CC500" boilers are factoryassembled. The burner and controls are field mountedusing the wiring
harnesssupplied.Otherwiring forthe thermostats and zonevalves arenot supplied.(seewiringdiagram on page
12)
CHIMNEY AND SMOKE PIPES
(For proper set up, see the diagram on page 10)
The specification ofthe chimney tobe usedmustcomply with the requirementthatotherthan solid-fuel/oil
combinations and add-ons, woodburning appliances shall notbe connected toa ventingsystemserving an appliance
vented by anothertype of fuel. Connect the boiler toan approvedsolid fuel factory-builtchimney: In CANADA-
CAN/ULC S629standard for 650° F chimney; Inthe UNITED STATES-UL103 Chimneys for ResidentialType
and BuildingHeatingAppliances,FactoryBuilt ora safe,clean, soundcondition,masonrychimneyequippedwith
an approvedliner: In CANADA-CAN/ULC-S635-M90 Standard for LiningSystems for existingmasonry or
FactoryBuiltChimneys and Vents; hi the UNITED STATES-UL1777 ChimneyLiners(e.g.,stainlesssteel,clay,
etc.). The chimneymust be equivalent toa minimum of 7" roundinsidediameter, or8" roundmaximum. The
chimneymust be capable of maintaining a negative updraft atall times andinall conditions.Carefullyinspect the
chimney for safety and dirtbeforemakingconnections.Place the boiler as close tothe chimney as possible.
The smokepipeshould be blue or blacksteel, 24 ga. or heavier. Useasfew turns as possiblebetween the boiler and
the chimney, as each 90° elbowadds 10' of restriction anda 45° elbowadds 5' of restriction. The draft regulator
should be7 " diameter andsetat -.04 W.C. to open.Install the regulator a minimum of 18 " anda maximum of 24 "
fromthe boilerbreech.Avoidlonghorizontalruns of smokepipe.Maintain a minimum of Vz" rise per foot of pipe
from the boiler tothe chimney.
DO NOT run the pipedownhill fromthe boiler tothe chimney.Confirmthat the installationclearances aremet
or exceeded.Secure all smokepipejointswiththreesheetmetalscrews in eachjoint.
DO NOT pass the smokepipesthrough a wall,floor or ceiling to reach the chimney.
-1-

PLACEMENT OFTHE UNIT
The CC500should beas close tothe chimney as possible. The CC500 canbe installed ona COMBUSTIBLE floor
using a non-combustible pad extending 20" front and rear and6"on eachside. The boilermust be properly
LEVELED. A 1" (2.5cm)minimum air spacemust be maintainedunder the appliance.This canbe achieved by
using four non-combustibleblocks, a minimum of 1" (2.5cm)thick x 4" (10cm)wide x 8" (20cm)long, onetobe
placed undereachcorner.
INSTALLATIONCLEARANCES (very important)
Front: 48"One Side: 6"
Rear: 24" OtherSide: 24"
SmokePipe: 18"
FUEL TANKSUPPLY
The fuel supplytank and fuel linesshould be installed a minimum of 6' from the boiler andin accordancewith
codes and standardshavingjurisdiction in yourarea. Useflared fittingsonly.
DO NOT use furl fittings.Protect theoil line from the wood fire door.
COMBUSTION AIR
To achievesatisfactorycombustion, an adequatesupply of fresh airis required. In confinedareas, a grilledopening
shall be provided. The minimumtotalarea ofa grilledopening is2 square feet. Where fans are used inthe fuel
storagearea,theyshould be installed soasnotto createnegativepressures inthe roomwhere the furnace is installed.
VERY IMPORTANT (READ CAREFULLY)
1. The furnace must be installed bya qualifiedtechniciancurrentlyactive inthe heatingtrade & meet
or exceed all local or nationalcodes.
2. DONOT TAMPER WITH THE UNIT OR CONTROLS - CALL A QUALIFIED SERVICE
TECHNICIAN.
3.Use No.2 furnace oil only. DONOTUSE GASOLINE,CRANKCASEDRAININGS, ORANYOIL
CONTAININGGASOLINE. Useof other fuels coulddamage the unit or present a serious safety
hazard.
4.DONOTuse furnace oilinthe solid fuel section.
5.DONOT BURNGARBAGE OR PAPER INTHE UNIT OR LEAVECOMBUSTIBLE
MATERIALSAROUND THE UNIT.
6. Know the location ofthe emergencydisconnectswitch forthe unit.
7. Contact a qualified servicetechnicianbeforeremodeling, for annualservice/maintenance,before
extendedperiods of shutdown and beforestart-up.
8. DONOT stackitems onor around the boiler - check requiredclearances on thispage.
9.DONOT store flammable materials inthe vicinity ofthe furnace.
10.DONOT startthisunit all components are securely in place.
11. DONOT start the wood oroil sectionuntil the boiler is properly filled withwater(damagewill
resultvoiding the warranty).
*Ensure that the water pressurereducingvalve is workingproperly(set at12 p.s.i.). Too high a pressurewill
damage the boiler(voiding the warranty).
*Care must be taken to ensurethat the boiler will notbe exposed to thermalshockwhich canbe causedwhen
the systemreturnwatertemperature is morethan 40°F below the systemsupplywatertemperature.
-2-

AQUASTAT SETTINGS
As shown onthe wiringdiagram on page 12.
Recommendation If Using The Domestic Hot WaterCoils InThe Boiler
When the woodsection of yourboiler isnotinuseforan extended period of time,change theoil aquastat setting
to a low limit of1 SOT anda highlimit, notto exceed200°F.This isto betterassist inthe heating ofthe domestic
hot water.
CAUTION: Be sure to return the settings tothe normal(low 150°F & high 170°F) beforestartingyour
woodsectionagain.
OIL BURNER INSTALLATION
Proper noz/les and settings for (Use No.2 Furnace OiH:
Burner
Aero HF-US
AeroHF-US
Beckett AFG
Beckett AFG
Riello F5
Hiello F5
Nozzle
Delevan0.85 x 80°B
Delevanl.OOx80°B
Delevan0.75 x 80°B
Delevan0.85 x 80°B
Delevan0.75 x 80°B
Delevan 0.85 x 80°B
Input
0.85 gph
l.OOgph
0.89 gph
1.01 gph
0.90 gph
1 .02 gph
Pump
Pressure
100 psi
100 psi
140 psi
140 psi
145 psi
145 psi
Turbulator
1.5
3.25
Initial
Air
38625
38626
3.5
3.75
BTU/Hour
101200
118300
106600
118700
107000
120700
Insertion
4.00"
4.00"
4.00"
4.00"
4-1/8"
4-1/8"
Theoil burner is mounted onthe3 studsprovided onthe lower front combustionchamberaccesspanel.Extreme
care should be takenwhenmounting the burner, notto damage the moldedcombustionchamber.
Theair opening on the oil burnershould be adjusted to obtain a#0 Bacharachsmokespot. At thispoint,maximum
fuel efficiency is obtained.Havingobtained the propersmokespot, the followingshould be observed: TheCOin
the flue should be between 10 and 13.5%. Draft setting -notto exceed -.04" W.C..(the draft is adjustable by means
of adjusting the screw/wheellocated onthe front ofthe barometric draft regulator).
INSTALLATION OF BLOCKED FLUESENSOR
Install the Field Controls WMO-1 intheoil fluepipe as given inthe sensor installation instructions.
HOW MUCH WATER TORUNINTHE SYSTEM
Forhot waterheating,beginningwith the lowestradiator,open the vent and allow airto escape,closing the vent
when the waterbegins to flow from it. Repeatthis onall otherradiators,continuing tothe second and thenhigher
floors. (Radiatorsequippedwithautomatic air ventvalves donot requireventing by handexcept to speed up initial
filling of system).Check the waterlevelregularly for loss dueto leaks or evaporation. All systems must be provided
with an expansiontank and reliefvalve.Watershould befedtothe system by means ofan automatic fill valve
available for thatpurpose and backflow preventionmust be used.
The reliefvalveshould be opened occasionally to makesure itis operative. The reliefvalveshouldopenwhen the
pressureindicated onthe combinationgaugeexceedsthirtypounds. If thispressure is exceededbefore the relief
valve opens,shut offthe fill valve and drain the water from the system until the pressure is reducedbelowthirty
pounds and have the valverepaired or replacedimmediately. A waterlogged air cushiontank is indicated by rapid
increase in pressurewithonlyslightincrease in temperature, or frequent escape of water from the reliefvalve.
CHECK THE SAFETY RELIEF VALVE ONTHE BOILER MONTHLY. Test the safety reliefvalve by
momentarily pulling the lever to observe free escape ofhot water.
NOTE: Drain pipes from the safety relief andthe boiler drainvalvesshall be piped toa safedrain.
-3-

ELECTRICAL
Electrical installationsmustconform toall local and nationalcodes and standards as theirjurisdiction may apply.
See page 12.
DAMPER MOTOR
PIPING
Pining mustconform toall local and nationalcodes and standards as theirjurisdiction may apply. See pages 11&
13. The dumpzoneshould be your existinglargestzone (that hasall piping above the boiler.-e.g. Livingroom or
master bedroom). With a homebuilt on slab or heatingwith an underfloor radiantsystem, a separatezoneshould
be added above the boiler.Thiszonewould beof adequatesize to dissipate at least 15,000 btu/hr. The pipingmust
be a minimum of3//' (18 mm) diameter and able to withstand a minimumtemperature of 225°F (107°C). Thisloop
shall be suchthat itcan only be madeinoperative bya deliberatemanualaction.
Please ensure that the pressure relief valve andthe boiler drain valve are piped toa safe drain (water discharging
from either could be extremely hot and dangerous).
All piping will be suchthatexcessivepressurewill notbe developed inany portion ofthe boiler or system.
NOTE: Itis important to install a throttle flow valve in order to control theflowof waterthrough the domestic
watersystem. Setthe valve to regulate theflowatthe requiredtemperature.
ADJUSTMENTS OF DAMPER MOTOR AND CHAIN
The damper chain should be adjusted when the damperdoor isin
the downposition. In thisposition the chainshould be adjusted
so there isa small amount of slack.
The amount of lift or opening ofthe damper door is adjusted by
moving thetwo pinchnuts onthe stoveboltthreadcloser or
further away from the lift strap. The dampershould besetat
3A"
to1" opening. After properadjustment ofthe draft chain and
damper door the thermostat and aquastatwillkeep thefire within
safe limits.
CAUTION: Thissettingshould notbe altered for
increased firing,forany reason.
NOTE:
- DO NOT use automaticstoking or sawdust fueling on
thisboiler.
-DO keep the boilerareaclean and clear ofall debris at
all times.
- DO NOTbum gasoline,naphtha,kerosene,engineoil, (fuel oil
in the woodsection) or othervolatile,creosotesoakedwood or
drift wood. (Damage to your boiler will result and void the
warranty.)
- Thisboiler will burnmostwood fuels. However, itis
recommended thatdry,untreated,naturalhardwood be used as
much as possible. It affords cleanermore efficient burningwith
PINCH
NUTS
MAGNIFIED
BOILER
FRONT
FIREDOOR
less soot, creosote andash build-up, as well as less frequentfiringintervals.
- Storewood in neat, well supportedpiles at least 4 feet from the chargingdoor.
- To prevent injury, DONOT allowanyone whois unfamiliar with the operation ofthe boiler to attend it.
-4-

OPERATING INSTRUCTIONS (WOOD SECTION)
Proper draft inthe wood section will notbe achieveduntil 2"to3"ofashis built upinthe firebox.This canbe
readily accomplishedusingsoftwoods,whichcreates ash quickly oruse cleansand(with "no salt" in it).
Caution: DONOTfire thisboiler until all requirements are complete andthe operatinginstructions
are fully understood.
NOTE: Your oil burner may startevenwhen the wood fire ison. This is caused by largeamounts of heatbeing
taken from the unit.This is normal, astheoil burnerwillboost the watertemperaturearound the coilsensuring
ample domestic hot water.
NORMAL OPERATION
1. Theoil burner will start ifthe systemtemperature is below the setting ontheoil controlaquastat.
2. The dampermotoropens the damperdoor ifthe temperature ofthe boiler falls below 170F.
3. The thermostatscontrol the opening of zonevalves. The primary(House)circulatorrunswhen the
zone thermostatscall for heat.
4. Should an extreme fire cause the high limit switch to close, the dampermotorwillclose the damper
door, the normallyopen (N.O.) zonevalvewillopen andthe circulatorwillstart. Theoil burner will notbe
able to start
Note: Establish a routine for the storage of fuel, care of the appliance, and firing techniques.Checkdaily for
creosotebuild up, until experience shows how often cleaning is necessary. Be aware that the hotter thefire,the less
creosote is deposited and weeklycleaning maybe necessary in mildweathereventhoughmonthlycleaning maybe
enough inthe coldestmonths.Have a clearlyunderstoodplan to handle a fluefire.
OPERATING INSTRUCTIONS (OIL SECTION)
TO START THE BURNER
See that all valves intheoil lines are open.
1. With the maincutoutswitch fortheoil burnerelectricalcircuit inthe "OFF"position, setthe thermostat ata
pointaboveroomtemperature.
2. Setthe electricswitch tothe"ON " position. Ifthe burner fails to startinstantly, setthe masterswitch tothe
"OFF"position and call a qualifiedservicetechnician.
3. Ifthe burnerstarts to operatenormallyleave the switch"ON" and reset the thermostat tothe desired
temperature.
Never start the burnerunder the followingconditions:
1. WHENEXCESS OILHAS ACCUMULATED.
2. WHEN OIL VAPORS ARE PRESENT.
3. WHEN THE COMBUSTIONAREA IS VERYHOT.
4. WHEN THE CLEAN OUT COVERS ARENOT SECURE.
5. When the smokepipe is removed or blocked.
6. Any situationthatwouldlead toan unsafe condition.
Never push the reset on the burner more than once; contact a heating technician.
TO STOP THE BURNER
1. Setthe maincutout tothe "OFF"position.
2.Setthe thermostat asfar belowroomtemperature as possible.
TO STOP THE BURNER FOR
AN EXTENDED PERIOD OF TIME
1. The maincutoutswitchshould besettothe "OFF"position.
2.ALLOIL VALVESSHOULD BE CLOSED.
3. The burnershould be covered to protect it from dust and dampness.
-5-

TO START THE BURNERAFTER
AN EXTENDED SHUTDOWN
1. The strainer inthe pumpshould be cleaned, andifa filter is installed intheoil line, it should be cleaned and
the filter cartridgereplaced.
2.Thefanandthe blowerhousingshould be cleaned andtheairfilter replaced.
3.The ignitionpointsshould be checked andthe nozzlecleaned and replaced.
4.Oilthe motor.
5. Start the burner by following the instructionsunder the paragraph, "TO START THE BURNER".
7.Itis recommendedthat a qualifiedservicetechnician be called to clean the unit and burner and makesure
that the burner is operatingproperly. The installershould identify the emergencyshut off switch and valves.
IFTHE BURNER FAILS TO OPERATE
Call a qualified servicetechnician. The trouble maybedueto:
1. Blown fuses inthe electricalcircuit.
2.The thermostat maybeset belowroom temperature.
3. Combustioncontrol may require"resetting" (DONOT press the resetmorethan two times).
4.Theoil valve maybe closed.
5. Theoil supply maybetoo low.
6.The blocked flue sensor maybe tripped.
WHEN THE BURNER ISIN OPERATION
1. Check theflame periodically, ifit becomes outof shape or smoky,callyourserviceman.
2. Whencleaning the boilerroom or utilityroom,alwaysstop the burner to reduce the amount of dust and lint
drawn into the burner.
3.The electricignitionsystem andall controlsshould be checkedperiodically for reliability of operation and
adjusted if necessary.
SPECIALPROCEDURES
EXTREME WOODFIRE (Due t9 improperoperation)
1. Disconnect the damperchain to prevent the damperdoor from opening.
2. Block the over-fire draft slot inthe door.
3. Increase all thermostats to maximum.
4. Excessiveheat may causesafetyreliefvalve to open.(Ensure itis piped toa safe drain.)
5. DONOT shutpoweroff.
FLUE FIRE
1. Call the FireDepartment.
2. Prepare to evacuate the house.
3. Shut offthe mainpowerswitch tothe boiler.
4. Diminish thefireinthe boiler by closing all combustion air openings.
5. DONOT remove theflue pipes until thefireis completely out.
6. Have the chimneyinspected and repair theflue beforeusing it again.
i
-6-

ELECTRICALPOWERFAILURE
NOTE: DONOT operateyourappliance,unlessyourtotalheatingsystem has beendesigned and installed to
operate properlywithout electricity.
1. Maintain
1A
the normal fire load.
2. Theair dampermust be manuallyoperated. (DO NOT prop ortie open.)
3. Fire the boiler carefully. Remember youarenowon gravity circulationonly. Itis necessary to
manually open the zonevalve (if used).Eachsystem is different, extremecaremust be useduntil a safe rate
.of firing is known for yoursystem, ina no powersituation.
TO RESETCOMBUSTIONCONTROLS
The reset control consists ofan electrical relay operating in conjunction with a flame detector mounted ontheoil
pipe ofthe drawerassembly ofthe burner.When forany reason the burner fails to ignitepromptly the control will
stop the burner. After being shut offin thismanner, the burnercannotagain be started until the control is "RESET".
The burnermountedrelay is attached tothe burnerhousing andis reset by pushing the "RESET"button and then
releasing. DONOT press the resetbuttonmorethantwice. Call a qualified servicetechnician.
The blockedflue sensor is designed to shut off the burner inthe event that the flue has becomeblocked.Whenthis
has happened, the burnercannot be startedagainuntil the sensor has beenreset.Pushing inthered button,which
is accessedthrough the hole inthe front ofthe sensor,resets the sensor.Only try this once and then call a
qualified servicetechnician.
GENERAL MAINTENANCE POINTERS
1. Keep thefluesinthe boilerclean.Becausesoot isa nonconductor of heat, a dirtyboilerrequiresmore fuel to
heat a house than a cleanone.
2. The smokepipeshould be taken offat leastonce a year and thoroughlycleaned ofall soot.
3. Ifyou wish to leave the boilershut off duringfreezingweather, first drain allthe water from the entire
heatingsystem;thisincludes allthe piping andthe radiatorsthemselves.
BURNER MAINTENANCE
Use the followingchecklistwhenperformingannualburnerservice. Tobe performed bya qualified service
technician.
D Replace theoil supply line filter.The filter bodyshould be thoroughlycleanedbeforeinstalling a new
cartridge.
D Remove and clean the pumpstrainer (if applicable).
D Replace the nozzlewith an equivalentnozzle.
D Clean and inspect the electrodes for damage, replacing any that are cracked or chipped.
D Checkelectrode tip settings.
D Inspect the transformercontacts.
D Clean thecad cell.
D Oilthe motor (if applicable) a goodgrade of mediumdetergent-freeautomobileengine oil should be used.
Twice each year one table spoon ofoil should be poured slowlyinto theoilcup
D Clean the blowerwheel, air inlet,retentionhead and throttleplate ofany lint orany foreign material.
D Check all wiring for secureconnections or insulationbreaks.
D Check the pumppressure.
D Adjust the burner to propersettings on page 3 "usingproperinstruments".
-7-

CARE OFTHE BOILERWHEN NOTINUSE
When the boiler isoutof service foran extendedperiod of time, carefully and thoroughlyclean the smokepipe,
chimney, firebox andany partwhich has been in contactwith hot gases.This is extremelyimportant as rusting and
corrosionoccurwhen the boiler is idle.
REPLACING THEHOT WATERCOILS
The rearcasingpanel of yourboilermust be removed to gainaccess tothehot watercoilsmountingplates. Itis
necessary to remove the smokepipes before removing the rearpanel.(ENSURETHAT NO FIRE IS PRESENT
AND POWERDISCONNECTS AREOFF BEFOREREMOVINGSMOKEPIPES). The watermust be drained
from the boilerbeforeremovingcoilmountingplates,ensure the watersupply tothe coils isoff beforeremoving.
Two openings are provided in your boiler forhot water coils.
CLEANING AND SERVICING(WOODSECTION)
It is necessary to remove ashand occasionallybrush the innersurfaceswith a wirebrush and check the smokepipe
for ashor creosote as necessary.Leave 2"ofashinthe woodfireboxwhencleaning, toaidin combustion.
IMPORTANT: Fire canbe caused by improperstorage of ashescontainingdormant hot coals.Store
ashes ina tightlycoveredmetalcontainer. DONOT placeotherwaste in thiscontainer.
VERY IMPORTANT: Replace all damaged or worngasketsbeforereassembling.Firedoorgaskets and seals
must be maintained in goodcondition for safe operation.
CLEANING AND SERVICING(OILSECTION)
IT IS HIGHLY RECOMMENDED THAT A QUALIFIED SERVICE TECHNICIAN (REGULARLY ENGAGED IN
THE HEATING TRADE) BE EMPLOYED TO DO THE CLEANING AND SERVICING.
YourBenjamin "CC500" boiler is equipped with oneof the most modernmolded combustion chambersavailable.
However, itis easilydamaged and caremust be takenhandling it.To remove the chamber,(see diagram right} first
remove theoil burner (8) from the threemountingstuds,thenremove the combustionchamberaccesspanel (6)by
means oftwo nuts and bolts. Use extremecarewhenremoving the panel, asthe combustionchamber is mounted
on the rear ofthe panel. The combustionchamber is removed by loosening the bolt onthe metalclampingring (13),
releasing the combustionchamber. Thenew combustionchamber is installed by reversing the order of removal.
(INSPECT ALL INNER SURFACES AND BAFFLES, CLEAN BEFORE REPLACING.)
At leastonce a year (preferably at theend of the heating season), thoroughlyclean the innersurfaces ofthe boiler,
the flue passages, flue pipe and chimneys. Itis recommendedthat a properlyequippedservicetechnician do thisjob.
Onceyearly oras necessary,remove theoil burner by means of threenuts.Inspect and service the burner.Remove
the oil chamberaccesspanel by means of four nuts. Itmaybe necessary to remove the combustion baffles 10 and
14 by means of2 screws(12).Clean the inner surfaces with a wirebrush. (DONOT USE A WIRE BRUSH ON
THE COMBUSTION CHAMBER, DAMAGE WILL RESULT.) Also inspect the smoke pipe and flue forashor
creosotebuildup and clean if necessary.
-8-

CLEANING AND SERVICING(OIL SECTION)continued
OIL BURNER
The oil burnershould be removed at leastonceeachheatingseason,cleaned and serviced.Alsoinspect and
clean any accumulatedsoot and debris fromthe combustionchamber and transferduct.Inspect and replace the
burner gasket if necessary. Tobe performed bya Qualified ServiceTechnician.
OIL FILTER
The cartridgeshould be replaced at leastonce a year. The filter bodyshould be thoroughlycleaned before installing
anew cartridge.
TO CLEAN THE STRAINER
1. Oil valvesbetween the tank andthe burnershould be closed.
2.The strainercovershould be removed.
3.The strainerbasketshould be taken outand washedwithkerosene.
4. The strainerbasket and coversshould be reassembledwithgasketsthat are clean andin goodcondition.
1. LOADINGDOOR FOR WOOD
2. INNERDOORSHIELD
3. WOODFLUEBAFFLE
(ORDER # CC524)
4. SMOKE PIPE - WOOD-7" I.D.
5. DOMESTIC HOT WATER COIL X 2
(ORDER # CC552) /<
6.OIL CHAMBER ACCESS PANEL
V
(ORDER # CC539)
GASKET
(ORDER # CC603)
7. SIGHTPORT DOOR
(ORDER # CC592)
GASKET
(ORDER # CC593)
8.OIL BURNER
9. OIL COMBUSTIONCHAMBER
(ORDER # CC598)
10. STEELCOMBUSTIONBAFFLE
(ORDER # CC597)
11. SMOKEPIPE - OIL-7" I.D.
12. OIL BAFFLESPACER
(ORDER # CC604)
13. COMBUSTIONCHAMBER
SUPPORTASSEMBLY
(ORDER # CC636)
14. STAINLESSCOMBUSTION
BAFFLE
(ORDER # CC533)
15. OIL FLUEBAFFLE
(ORDER # CC535)
16. COILGASKET
(ORDER # CC586)
2) WOOD r3
SECTION
-9-

CHIMNEYCONNECTIONS FORTHE CC500BOILER
A LINEDMASONRY
CHIMNEYAPPROVED
FOR BURNING SOLID
FUELSAFELY.
SMOKEPIPEMUST
HAVE A MIN. W PER
FOOT RISE FROM THE
BOILER TOTHE FLUE.
AN APPROVED 7"
C.S.A. BAROMETRIC
DRAFT REGULATOR
MAX.FLUEDRAFT
SETTING0.04
INCHW.C.
4" MIN.—^
CCSOO BOILER
o
FACTORY BUILT
CHIMNEYAPPROVED
FOR SOLID FUELS
SMOKE PIPE MUST
HAVE A MIN.
1/2"
PER
FOOT RISE FROM THE
BOILER TOTHE FLUE.
WHMK
J 4"MIN.
CLEANOUT
TEE
AN APPROVED 7'C.S.A.
BAROMETRIC DRAFT
REGULATOR
MAX.FLUEDRAFT
SETTING 0.04INCH W.C

CC500 PIPING & WIRINGLAYOUT
P2
;;£"*-3/8 Flexible Metal Conduit
PI - Return From System
P2- ColdWater Supply
P3- Supply To System Zones
P4- Mixing Loop
1 - Normally Closed Zone Valve
2- Air CushionTank
3- Stop Valve
4- BackFlow Preventer
5- Pressure Reducing Valve
(SetAtl2PSI)
6- DrainValve
7- Pressure ReliefValve
(Pipe To A SafeDrain)
8- Normally Open Zone Valve
9- SingleAquastat
10 - Line In (120v Power Supply)
11 - Temperature & Pressure Gauge
(Indicator)
12 -Triple Aquastat
13 -Damper Motor
14-Wood Smoke PipeC 7 "I. D
15 - 24V Transformer
16- AquastatRelay(Oil)
17 - Domestic Hot Water Coil
18- PrimaryCirculator Pump
19-Oil Smoke Pipe( 7"1.D.)
20 Throttle Valve
W!
"
3 Wire
<Black-
whlte & Red> I2° Volt
21 - MixingCirculator Pump'
W2
-
24 Volt To
Thermostats & Zone Valves
•»•> - Blocked Flue Sensor
W3
"
24 Volt Io DamPer Motor
22
W4 - 2 Wire (Black & White) 120 Volt
W5 - 2 Wire(Black & White) 120 Volt
W6 - 2 Wire (Black & White) 120 Volt
NOTE:
W7
'2
wire
^Red
& Black> I2° Volt
All 120 Volt, 60 HZ Wire Must Be 16(1 TEW 90' C, Encased In CSA or
UL Certified
3/&"
Flexible Metal Conduit, using anti-shorts in cable ends
-11-

LINE IN
115 VI 1 760 Hz
White ("Neutral)
WOOD
Triple Aquastat
Single Aquastat
Damper Motor
Low Limn High Limit
set20(ff
24 Volt
IVansformcr
Normally Open
ZoneValve
MAXIMUM LOAD 30VA (LOAD 24V)
Black
OILAqii
NOTE: Ifyouare using the
domestic coils from the boiler
adjust theoil aquastat to
LOW-18CHF and HIGH-200"F
for the summer months.
Burner Control
W.R. BenjaminProductsLimited
Wiring schematic for
CC500 COMBINATION
WOOD/OIL BOILER
MAY 2006
N C Z.V. -- Normally Closed Zone Valve
N O Z.V. — Normally Open Zone Valve
MO Motor
120 Volts 60HZ
24 Volts
AERO OR
BECKETT
BURNER

DOMESTIC HOT WATER
SUGGESTED PLUMBING FOR COILS
1, Cold Water Inlet
2, Shut Off Valve
3, Check Valve
4, Tempering Valve (8" below the coil Outlet)
5, Hot Water To Appliances
6, 120°F Max, Tempered Water to Fixtures
7, ThrottleFlowValve
MIXING CIRCULATOR PLUMBING
PRIMARY
CIRCULATOR
1 ViFEED-
TO HOUSE
BALANCE
VALVE
MIXING
CIRCULATOR
RETURN FROM —
HOUSE