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Oil Burner Disassembly for Repair
- POST a QUESTION or COMMENT about oil burner inspection, diagnosis, & repair, troubleshooting procedure, how to get the oil burner running again, best order of diagnostic steps.
How to disassemble basic oil burner parts:
To diagnose and repair the most-common oil burner operating problems some disassembly is often required.
Watch out: oil burner service and repair, to be both safe and effective, requires training and special equipment. A homeowner can not properly adjust the oil burner combustion air, pressure, nor other features. However, understanding basic and commonly cleaned or replaced oil burner parts such as the nozzle, nozzle adapter, electrodes, turbulator, can help diagnose and fix oil burner trouble.
The page top sketch is courtesy of Carson Dunlop Associates, a Toronto home inspection, education, & report writing tool company.
This article series explains how to inspect, diagnose & repair oil burners used on oil-fired heating boilers or furnaces using a visual inspection approach as well as (optional) simple test equipment. We include descriptions of oil burner adjustment and operating problems and we illustrate the basic oil burner tests and measurements made in servicing and adjusting the equipment for safe, efficient operation.
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Signs of Trouble Inside the Oil Burner - Simple Disassembly, Inspection, Testing
We look for obvious trouble signs before making any changes or adjustments to the oil burner assembly by turning off power to the equipment, shutting off the oil supply line at the closest service valve, and opening the oil burner for inspection.
Our sketch (left) shows how an oil burner gun atomizes and sprays heating oil into the combustion chamber
- AUDEL OIL BURNER GUIDE [PDF online copy of this book]
The oil burner parts sketch shown at the top of this page was provided courtesy of Carson Dunlop Associates, a Toronto home inspection, report writing tool, & home inspection education company. [Click to enlarge any image]
Most oil burners are opened by loosening two screw clamps at the front of the transformer box mounted atop the oil burner tube and folding the hinged transformer back to expose the interior of the tube, the oil burner nozzle assembly, and other parts.
Some obvious trouble signs inside the oil burner include the following
- Cad cell sensor sooty or dirty (probably from backpressure in the combustion chamber combined with sooty operation - can force an oil burner to remain "off on reset" when the CAD CELL SENSOR that informs the safety control cannot sense that a flame is present.
See CAD CELL RELAY SWITCH for details and also
Alsoi review RESET SWITCH on PRIMARY CONTROL. - Cracked, damaged ceramic electrode insulators on the oil burner assembly - a short here will cause improper ignition
- Dirty turbulator assembly (if present) mounted on the end of the oil burner nozzle - can interfere with proper air flow around the nozzle and thus with proper heating oil combustion.
The turbulator is a fan-like collection of fins that is mounted, usually on the end of the oil burner nozzle by a bracket, and that provides increased air turbulence to improve heating oil atomization and spray pattern, thus improving combustion efficiency.
Debris and soot can block the air space between the turbulator blades, causing this device to stop working, and leading to dirty sooty oil burner operation. - Dirty oil burner nozzle, especially crud build-up that is blocking oil flow or shorting out the oil burner nozzle electrodes -
see OIL BURNER ELECTRODES
- Loose, damaged, misaligned oil burner electrodes (use a simple oil burner nozzle gauge or a small steel rule to see that the position of the oil burner electrodes in their gap apart, their distance above the oil burner nozzle orifice, and their distance forward or backwards relative to the face of the oil burner nozzle are according to the manufacturer's specification.
See OIL BURNER ELECTRODES for details.
- Damaged squirrel cage blower assembly - loose, wobbly bearings, bent fins, dirt and debris; this problem will reduce combustion air input to the oil burner and will result in poor, sooty operation.
- Damaged coupling joining the electric motor that drives the oil burner, the combustion air blower squirrel cage fan, and the shaft that turns the fuel pump unit itself.
In our photo, we see tarry goop around the fuel unit drive shaft - a fuel unit drive shaft oil leak discussed
at OIL BURNER FUEL UNIT.
Even a small leak in this location can lead to loss of combustion air and improper burner operation. - Oil and debris inside the oil burner tube - possible leaks, incomplete combustion, improperly mounted oil burner gun assembly
- Overheating inside the oil burner tube, tarry goop leaking out of the transformer assembly
Oil Burner Won't Run: Diagnostic Steps - what to check in what order
This topic has moved. Now
at OIL BURNER WONT RUN we have collected oil burner diagnostic procedures from several texts, [1] - [22] adapted, expanded, and generally re-ordered steps in order of most likely to be successful and easiest to perform.
Readers needing an approach to heating system inspections that assures thoroughness, should also
see
HEATING SYSTEM INSPECTION PROCEDURE where we explain an organized approach to inspecting the entire heating system, beginning outdoors, continuing indoors, and ultimately in most detail in the boiler or furnace room.
This article series explains the inspection, diagnosis, & repair of oil burners used in heating appliances such as hot water boilers, steam boilers, & water heaters.
To find what you need quickly, if you don't want to scroll through this index you are welcome to use the page top or bottom SEARCH BOX to search InspectApedia for specific articles and information.
An expert inspection of an oil burner begins either with having made note of building owner/occupant concerns (noises, odors, no heat, high fuel costs), or with having made some basic visual observations outside: a sooty chimney top, for example.
The oil burner inspection continues indoors, even before entering the utility room where the oil burner (or often more than one of them if oil fuel is used for both heating and a separate water heater) is located: look at the building interior as you enter: are there odors, soot deposits, noises associated with the heating system?
The oil burner inspection becomes detailed, and diagnostic, when you can actually see the equipment. It's obvious that you should notice oil leaks, soot in the boiler or furnace room, noises, odors, signs of repeated repairs, piles of junked parts, signs of unprofessional work (covers off of controls, sloppy wiring or plumbing). But just what each of these clues might mean bears some additional explanation that we offer below.
...
Reader Comments, Questions & Answers About The Article Above
Below you will find questions and answers previously posted on this page at its page bottom reader comment box.
Reader Q&A - also see RECOMMENDED ARTICLES & FAQs
On 2020-11-13 by (mod) - need ceramic electrode assembly for Ducane DRC-10A
Thanks for the follow-up; if you contact one of the suppliers I list It's quite possible that they'll have the part you need.
ICPT Tempstar Parts has many parts for the DRC10A Ducane oil burner. Tel: 888-828-8317 Website: icptempstarparts.com/model/icp-tempstar-heil-drc10a-parts/
See part no. ICP B0811114 ELECTRODE DUCANE (about $100. U.S.)
On 2020-11-12 by Marie
Thank you very much for this information. We will try looking for the right piece. It's challenging to find one that fits DRC-10A.
Unfortunately
Crown 21182-02 Set Of Replacement Electrodes For Ducane DMR-15A ---- We have DRC-10A
Crown 21182-02 Set Of Replacement Electrodes For Ducane DMR-15A With 7" Blast Tube Fits Ducane DMR15A, DMR-15A, DMR15A1, DMR-15A-1 Oil Burners ----We have DRC-10A
On 2020-11-12 by (mod) - where to find replacement electrodes for a Ducane oil burner
Marie:
Please find your question and my detailed reply now at OIL BURNER ELECTRODES - as that may help you and other readers
and where we will add more detail about finding a replacement for your Ducane oil burner.
You may need to clear or refresh your browser cache to see the updated page. We welcome your further photos, comments, questions.
On 2020-11-12 by Marie
Hello,
The electrode (ceramic) part is cracked on our 1993 Ducane oil burner. See images. The system works however twice last week there was a strong smell of burnt oil in our home when the furnace kicked. We don't know how long the crack has been there, it was not found in the last maintenance 10 months ago.
We are trying to get more information on how soon we should replace our system. We need a full furnace replacement as those parts are not available anymore.
What is the worst thing that can happen from this crack ?
thanks
On 2019-11-02 by Lou
Thanks I will look at it again.
On 2019-10-27 by (mod) - Small leaks along the oil burner nozzle line
Small leaks along the nozzle line can drip into and accumulate in the bottom of the blower compartment of the oil burner;
But if the drip is below the pump it's probably a leak at a connection to the pump or possibly a pump gasket;
Wipe everything totally clean, seams, fittings, etc. then watch all of those areas for an oil seep.
On 2019-10-27 by Lou
PS: I did open the unit to inspect the electrodes and nozzle area. I did not see any oil at this point. It DOES appear to be coming right from under the pump - could be a poor seal. Lou
I understand. I have watched the unit carefully running so far and all it does is leak from under the pump a small bit - it LOOKS like a big leak because oil tends to spread out.
However I will have the unit checked. As I stated before it only leaks when the unit stops working - maybe there is an internal valve in the pump that does not completely close when the unit turns off? Id love to see an internal schematic/diagram.( I am a curious engineer). Lou
On 2019-10-27 - by (mod) -
TEXACO OIl Burner Head.
Lou
By careful inspection (probably with help from your oil heat service tech) we need to identify the leak point: it could be a damaged nozzle adapter, a leak in the high pressure line between fuel unit and burner, a leak at the fuel unit, etc.
Watch out: the burner may be unsafe.
On 2019-10-26 by Lou
I have a TEXACO OIl Burner Head. Looks like a Beckett Unit Painted Red. The unit runs well and provides a good flame but when it stops running it leaks oil out onto the floor. How can this be repaired short of replacing the whole burner head?
On 2019-02-15 - by (mod) -
Roland I would step through the diagnostics at
OIL BURNER WONT RUN - Diagnostic Steps - what to check in what order
https://inspectapedia.com/heat/Oil_Burner_Wont_Run.php
On 2019-02-15 by roland
my oil burner runs for hours then stops running again
On 2018-10-18 - by (mod) -
Billy
Check the diagnostic procedure at
https://inspectapedia.com/heat/Oil_Burner_Wont_Run.php
On 2018-10-18 by Billy
My oil burner keeps cutting out
...
Continue reading at OIL BURNER WONT RUN - Diagnostic Steps - what to check in what order, or select a topic from the closely-related articles below, or see the complete ARTICLE INDEX.
Or see these
Recommended Articles
- BOILER / FURNACE ROOM TROUBLE SIGNS
- BUILDING EXTERIOR Oil Burner Trouble
- BUILDING INTERIOR Oil Burner Trouble
- OIL BURNER INSPECTION & REPAIR - topic home
- OIL BURNER CO2 TEST
- OIL BURNER ELECTRODES
- OIL BURNER INSIDE TROUBLE
- OIL BURNER OPERATING TROUBLE
- OIL BURNER SMOKE TEST
- OIL BURNER VISUAL INSPECTION
- OIL BURNER WONT RUN - Diagnostic Steps - what to check in what order
- OIL TANK EFFECTS on OIL BURNER
- HEAT WON'T TURN ON
Suggested citation for this web page
OIL BURNER INSIDE TROUBLE at InspectApedia.com - online encyclopedia of building & environmental inspection, testing, diagnosis, repair, & problem prevention advice.
Or see this
INDEX to RELATED ARTICLES: ARTICLE INDEX to HEATING OIL, OIL BURNERS, OIL FIRED HEATERS, OIL TANKS
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Citations & References
In addition to any citations in the article above, a full list is available on request.
- Anthony Alaggio can be contacted through Bottini Fuel (Hudson Valley, NY) or directly for HVAC service at 914-489-0632. Email: crackin95vtec@yahoo.com Special thanks to Mr. Alaggio, an HVAC service technician for technical suggestions regarding oil heat troubleshooting & more causes of oil burner short-cycling 4/12/2013.
- [2] Beckett Corporation, 38251 Center Ridge Rd., North Ridgeville, OH 44039 440-327-1060 Email: sales@beckettcorp.com supplies residential and commercial oil burners for boilers, furnaces, and water heaters - see www.beckettcorp.com/
- [3] Audels Oil Burner Guide, Installation, Servicing, Repairing, Frank D. Graham, 1947 edition (obsolete, out of print). See Brumbaugh, James E. Audel HVAC Fundamentals, Volume 2: Heating or see various versions of this guide available in editions from 1947, 1950, 1955, 1958, 1959, 1962, 1965, 1967, and at prices from around $3.00 to nearly $70.00 - useful for simple, clear, but not current, explanation of how heating equipment works. The original retail price was $1.00. Used copies are available
- [3a] Brumbaugh, James E., Audel HVAC Fundamentals, Volume 2: Heating, Audel [J Wiley]; All New 4th Edition edition (July 2, 2004) ISBN-10: 0764542079 ISBN-13: 978-0764542077
- [4] A Total Look at Oil Burner Nozzles, available from Delavan Fuel Metering Products, a reference guide for oil burner service technicians, Delavan Spray Technologies, Fuel Metering Products Division, PO Box 969, Bamberg SC 29003, Tel: 800-982-6943 or 803-245-4347, ( Delavan is a division of BF Goodrich); web search 12/30/2010, original source: http://www.delavaninc.com/pdf/total_look.pdf
Note & disclosure: when we (DF) were servicing oil burner equipment, Delavan nozzles gave us such excellent results, especially using hollow cone spray patterns in solving combustion problems, that this brand was our standard stock-item on our truck. Other brands of oil burner nozzles are of course also of excellent quality. It is the proper matching of nozzle size and type and spray pattern to the equipment that is critical. - [5] Fuel Nozzles for Oil Burners, Technical Aspects of Applications, E. O. Olson, Chief Engineer (deceased)
Delavan Fuel Metering Products Operation, Bamberg, South Carolina, Delavan Fuel Metering Products, a reference guide for oil burner service technicians, Delavan Spray Technologies, Fuel Metering Products Division, PO Box 969, Bamberg SC 29003, Tel: 800-982-6943 or 803-245-4347, ( Delavan is a division of BF Goodrich); web search 12/30/2010, original source: http://www.delavaninc.com/pdf/Fuel_Nozzles_for_Burners.PDF - [6] Domestic and Commercial Oil Burners, Charles H. Burkhardt, McGraw Hill Book Company, New York 3rd Ed 1969.
- National Fuel Gas Code (Z223.1) $16.00 and National Fuel Gas Code Handbook (Z223.2) $47.00 American Gas Association (A.G.A.), 1515 Wilson Boulevard, Arlington, VA 22209 also available from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. Fundamentals of Gas Appliance Venting and Ventilation, 1985, American Gas Association Laboratories, Engineering Services Department. American Gas Association, 1515 Wilson Boulevard, Arlington, VA 22209. Catalog #XHO585. Reprinted 1989.
- [7] The Steam Book, 1984, Training and Education Department, Fluid Handling Division, ITT [probably out of print, possibly available from several home inspection supply companies] Fuel Oil and Oil Heat Magazine, October 1990, offers an update,
- [12] "Residential Steam Heating Systems", Instructional Technologies Institute, Inc., 145 "D" Grassy Plain St., Bethel, CT 06801 800/227-1663 [home inspection training material] 1987
- [13] "Residential Hydronic (circulating hot water) Heating Systems", Instructional Technologies Institute, Inc., 145 "D" Grassy Plain St., Bethel, CT 06801 800/227-1663 [home inspection training material] 1987
- [14] "Warm Air Heating Systems". Instructional Technologies Institute, Inc., 145 "D" Grassy Plain St., Bethel, CT 06801 800/227-1663 [home inspection training material] 1987
- [15] Heating, Ventilating, and Air Conditioning Volume I, Heating Fundamentals,
- [16] Boilers, Boiler Conversions, James E. Brumbaugh, ISBN 0-672-23389-4 (v. 1) Volume II, Oil, Gas, and Coal Burners, Controls, Ducts, Piping, Valves, James E. Brumbaugh, ISBN 0-672-23390-7 (v. 2) Volume III, Radiant Heating, Water Heaters, Ventilation, Air Conditioning, Heat Pumps, Air Cleaners, James E. Brumbaugh, ISBN 0-672-23383-5 (v. 3) or ISBN 0-672-23380-0 (set) Special Sales Director, Macmillan Publishing Co., 866 Third Ave., New York, NY 10022. Macmillan Publishing Co., NY
- [17] Installation Guide for Residential Hydronic Heating Systems
- [18] Installation Guide #200, The Hydronics Institute, 35 Russo Place, Berkeley Heights, NJ 07922
- The ABC's of Retention Head Oil Burners, National Association of Oil Heat Service Managers, TM 115, National Old Timers' Association of the Energy Industry, PO Box 168, Mineola, NY 11501. (Excellent tips on spotting problems on oil-fired heating equipment. Booklet.)
- [19] Crown Serviceman's Handbook: Ignition Electrode Assemblies, Terminals and Cable, Tools and Accessories, Crown Engineering Corporation, Marlboro, NJ 07746 [1986]. This publication includes oil burner troubleshooting diagnostic suggestions reprinted with permission of Fuel Oil & Oil Heat Magazine.
- [21] The Wholesaler's & Installer's Guide to OEM Oil Specifications, R.W. Beckett Corporation, PO Box 1289, Elyria, OH 44036, 216-327-1060 [1988] This publication gives the model, burner type, air tube combination, head type, static plat dimensions, blower wheel dimensions, and oil burner nozzle type for just about ever manufacturer and model of oil fired heating equipment including Addison Products, Axeman-Anderson, Bard Manufacturing, BDP, Borg-Warner, Boyertown Furnace, Burnham, Carrier Corp., Clare Brothers, Columbia Boiler Co., Crown Industries, Dornback Furnace, Ducane, Dunkirk Radiator, Duo-Matic/Olsen, Electric Furnace-Man, Ener Royal Technology, Energy Kinetics, Everhot All-Corporation, F.P. Industry, Fraser-Johnston, Heat Controller, Hydrotherm Inc., Johnson Corp., Lochinvar, Logwood-Marathon Heater, Inc., Longwood Furnace Corp., Luxaire, Magic Chef, Melvin Manufacturing Corp., Metromatic Mfg. Co., Miller Heating & A/C, Modine Manufacturing, Newmac Manufacturing, New Yorker, Oneida Heater, Peerless Heater, Perfection Products, Pow-R-Matic, Inc., Reznor, Rheem Manufacturing, Ruud, Slant/Fin, H.B. Smith, State Industries, Tekton Corp., Teledyne Laars, Thermo Dynamics, Thermo Products, Trianco, Inc., Ultimate Eng., Utica Boiler, Vallant, Van Wert Manufacturing, Weil-Mclain, Williamson Co., Wise, Inc., XXth Century. But believe it or not this is not the whole list of manufacturers from the 1970's and 1980's. Reference [22] below includes a still longer list.
- [22] Steinen's [Oil Burner] Nozzle Guide, Oil burner nozzle specifications, draft regulators, nozzle filters, flame mirrors, oil burner nozzle kits, nozzle racks, nozzle extractors, nozzle adapters. Wm. Steinen Mfg. Co., 29 East Halsey Rd., Parsippany NJ 07054, Tel: 201-887-6400 [1970].
- [22] Burnham Heating Helper, [heating system design & layout in a mini booklet], Burnham Corporation, PO Box 3089, Lancaster PA 17603, Tel: 717-481-8400, 9th printing, 7/01
- Our recommended books about building & mechanical systems design, inspection, problem diagnosis, and repair, and about indoor environment and IAQ testing, diagnosis, and cleanup are at the InspectAPedia Bookstore. Also see our Book Reviews - InspectAPedia.
- Audels Oil Burner Guide, Installation, Servicing, Repairing, Frank D. Graham, 1940's edition (obsolete). Updated versions of this guide are available in various editions, 1947, 1950, 1955, 1958, 1959, 1962, 1965, 1967, and at prices from around $3.00 to nearly $70.00 - useful for simple, clear, but not current, explanation of how heating equipment works. The original retail price was $1.00. Used copies are available
- Domestic and Commercial Oil Burners, Charles H. Burkhardt, McGraw Hill Book Company, New York 3rd Ed 1969.
- National Fuel Gas Code (Z223.1) $16.00 and National Fuel Gas Code Handbook (Z223.2) $47.00 American Gas Association (A.G.A.), 1515 Wilson Boulevard, Arlington, VA 22209 also available from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. Fundamentals of Gas Appliance Venting and Ventilation, 1985, American Gas Association Laboratories, Engineering Services Department. American Gas Association, 1515 Wilson Boulevard, Arlington, VA 22209. Catalog #XHO585. Reprinted 1989.
- The Steam Book, 1984, Training and Education Department, Fluid Handling Division, ITT [probably out of print, possibly available from several home inspection supply companies] Fuel Oil and Oil Heat Magazine, October 1990, offers an update,
- Principles of Steam Heating, $13.25 includes postage. Fuel oil & Oil Heat Magazine, 389 Passaic Ave., Fairfield, NJ 07004.
- The Lost Art of Steam Heating, John Doe [Dan Holohan], 516-579-3046 FAX, at Amazon.com>
- Principles of Steam Heating, Dan Holohan, technical editor of Fuel Oil and Oil Heat magazine, 389 Passaic Ave., Fairfield, NJ 07004 ($12.+1.25 postage/handling).
- Principles of Home Inspection: Steam, Electric & Wall/Floor Heating, Carson Dunlop Associates, at Amazon.com>
- "Residential Steam Heating Systems", Instructional Technologies Institute, Inc., 145 "D" Grassy Plain St., Bethel, CT 06801 800/227-1663 [home inspection training material] 1987
- Boilers, Boiler Conversions, James E. Brumbaugh, ISBN 0-672-23389-4 (v. 1) Volume II, Oil, Gas, and Coal Burners, Controls, Ducts, Piping, Valves, James E. Brumbaugh, ISBN 0-672-23390-7 (v. 2) Volume III, Radiant Heating, Water Heaters, Ventilation, Air Conditioning, Heat Pumps, Air Cleaners, James E. Brumbaugh, ISBN 0-672-23383-5 (v. 3) or ISBN 0-672-23380-0 (set) Special Sales Director, Macmillan Publishing Co., 866 Third Ave., New York, NY 10022. Macmillan Publishing Co., NY
- Installation Guide for Residential Hydronic Heating Systems
- Installation Guide #200, The Hydronics Institute, 35 Russo Place, Berkeley Heights, NJ 07922
- The ABC's of Retention Head Oil Burners, National Association of Oil Heat Service Managers, TM 115, National Old Timers' Association of the Energy Industry, PO Box 168, Mineola, NY 11501. (Excellent tips on spotting problems on oil-fired heating equipment. Booklet.)
- In addition to citations & references found in this article, see the research citations given at the end of the related articles found at our suggested
CONTINUE READING or RECOMMENDED ARTICLES.
- Carson, Dunlop & Associates Ltd., 120 Carlton Street Suite 407, Toronto ON M5A 4K2. Tel: (416) 964-9415 1-800-268-7070 Email: info@carsondunlop.com. Alan Carson is a past president of ASHI, the American Society of Home Inspectors.
Thanks to Alan Carson and Bob Dunlop, for permission for InspectAPedia to use text excerpts from The HOME REFERENCE BOOK - the Encyclopedia of Homes and to use illustrations from The ILLUSTRATED HOME .
Carson Dunlop Associates provides extensive home inspection education and report writing material. In gratitude we provide links to tsome Carson Dunlop Associates products and services.
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