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Photograph of a modern oil-fired heating boilerOil Burner Operating Problems

Defects observed when the oil burner is running

  • 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.

Oil burner operating problem summary:

Here we summarize the common problems you can observe when the oil burner is actually running, or trying to run to heat a boiler, furnace, or water heater. These valuable clues can often diagnose an oil burner problem.

This article series describes 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 a description of common oil burner adjustment and operating problems and we illustrate some of 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 at the Oil Burner - During Operation: Odors, Noises, Soot, Goes Off on Reset

Oil burner schematic (C) Carson Dunlop Associates

Here we will describe a series of oil burner operating problems that you can observe when the burner is running - or trying to run.

For a very detailed explanation of how an oil burner and oil fired heating equipment works, see BOILER OPERATING STEPS, 39 steps in how a heating boiler works.

The oil burner parts sketch shown here is courtesy of Carson Dunlop Associates, a Toronto home inspection, report writing tool, & home inspection education company.

The following oil burner noise clues are excerpted from our more detailed article:

OIL BURNER NOISE SMOKE ODORS.

Oil Burner Smoke Test - Indicates Proper Combustion Air, Draft, Burner Adjustment

Oil burner smoke test equipment, Bachrach Kit (C) Daniel Friedman

The basic measurements made by any competent oil heat service technician include the stack temperature, draft, smoke level, and carbon dioxide level. These data tell us whether or not the equipment is properly adjusted and operating safely and economically.

One of these most basic tests performed by an oil heat service technician is the "smoke test" using a strip of filter paper and a pump to sample the oil burner exhaust, measuring the level of smoke in the exhaust.

Details of how to measure the oil burner smoke level, a key measure used in setting the combustion air level, and links to other oil burner measurement and asjustment procedures are now

at OIL BURNER SMOKE TEST

Our photo (above left) shows a traditional smoke testing pump (the black cylinder with a handle at its right end) used for decades. This equipment was produced by Bachrach, an oil burner test equipment manufacturer.

Oil Burner CO2 Test - Carbon Dioxide Level Indicates System Efficiency

The second common test performed by an oil heat technician evaluates the oil burner efficiency by measuring the carbon dioxide level or CO2 level in the oil burner exhaust. While there are electronic sensors used by some technicians for this purpose, many oil heat service tech's continue to use the time-tested Bachrach Fyrite™ oil burner tester.

Details of measuring the carbon dioxide level for oil burners, a second key measurement needed for proper setting of oil burner combustion air & operating temperature are now

at OIL BURNER CO2 TEST

This article series explains the inspection, diagnosis, & repair of oil burners used in heating appliances such as hot water boilers, steam boilers, & water heaters.

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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.
    • Audel's Oil Burner Guide by Frank D. Graham 1947
  • [1] 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, Or see

    AUDELS OIL BURNER GUIDE, INSTALLING, SERVICING, REPAIRING [Free online copy in series of web pages] Frank D. Graham, Theo. Audel & Co., New York 1946, 1947, 1955 (out of print, copies occasionally available from antique book dealers and on EBay). Use the link above to read our free online copy of this helpful classic textbook.
  • [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
  • 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 #200 for Residential Hydronic Heating Systems, 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.

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