Mercedes Mullins
Oil burners require a sufficient quantity of good, clean fuel to function properly. However, a clogged oil filter or oil line can cause buzzing or vibration noises, oil leaks, and even the failure of the oil burner to ignite. To prevent this, it is important to regularly clean the oil line and filter. When doing so, it is recommended to attach a pressure gauge to one end of the line and use a hand pump to pressurize the line to about 10 psi. If your oil burner is not functioning properly, it may be due to a clogged or blocked fuel line, which can be repaired using a CO2 blowout gun, a hand pump, or a small canister of compressed air. Additionally, when hooking up a fuel line to an oil burner, it is important to ensure that the line nut is tightened properly to prevent leaks.
Characteristics and Values Table for Hooking Up a Fuel Line in an Oil Burner
| Characteristics | Values |
|---|---|
| Oil line clogging | Can be caused by sludge build-up, dirty oil filters, or both |
| Oil burner shut off | Due to a hole in the oil line or a clogged oil filter |
| Oil line cleaning | Use a pressure gauge, hand pump, or Karcher to clean the line; disconnect the line from the system to protect the fuel pump seal |
| Oil burner not igniting | May be due to a clogged oil line, buzzing or vibration noise, oil line leaks, or system going "off on reset" |
| Oil line clog repair | Use a CO2 blowout gun, hand pump, or compressed air to clear the blockage |
| Fuel line hook-up | Connect the flared end of the return line to the "Out" port fitting on the oil pump; tighten the line nut with an adjustable wrench without over-tightening |
| Fuel line bleeding | Locate the bleed fitting on the oil pump, loosen the hex, hit reset on the burner control, and tighten the hex once a steady stream of oil is achieved |
| Fuel line tubing | Use 3/8" copper tubing or 1/2" tubing to increase flow; protect the tubing with a sleeve if necessary |
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What You'll Learn
Clearing sludge from fuel lines
To clear sludge from fuel lines, you must first identify the source of the sludge. Sludge usually forms when petroleum is left in storage for extended periods, especially in a mostly empty tank. Holding off on a refill increases the chances that the sludge will enter your fuel line. Therefore, it is important to refill your oil tank before it reaches low fuel levels.
If you suspect that the sludge is coming from your oil tank, you can try using a sludge treatment additive. However, be cautious as these treatments can sometimes cause the sludge to break down into microscopic particles that pass through your filters and end up in your fuel lines. If you decide to use an additive, it is recommended to have a sample of your fuel tested first to determine the best treatment method.
If your fuel lines are clogged with sludge, there are a few methods you can try to clear them:
- Use a CO2 blowout gun: Attach a CO2 blowout gun to the oil line at the fuel unit and send a blast of carbon dioxide backwards through the oil supply line to dislodge the sludge.
- Use a hand pump: Attach a hand pump to one end of the oil line and pressurize the line to about 10 psi. This will help to dislodge any sludge or debris in the line.
- Use compressed air: Attach a small canister of compressed air with appropriate fittings to the oil line and gently blow out the sludge. This method is best for minimal clogging.
- Warm the fuel line: If the sludge is due to old, sludgy fuel, you can try warming the fuel line and pump with a small heater propped directly in front of the burner.
It is important to note that you should never clean your oil lines unless you plan to complete the job. Leaving the job unfinished can lead to further issues and even lawsuits. Additionally, always ensure that your oil lines are properly protected to prevent corrosion and mechanical damage.
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Bleeding an oil burner
Firstly, ensure your oil tank has oil in it. Locate the bleed fitting on the oil pump, which is usually on the left side of the oil burner where the oil line connects. It will have a hex with a small hose barb protruding. Place a small container directly below the fitting to catch any oil.
Loosen the hex with an open-end wrench; you may see some oil and bubbles. Now, hit the reset button on the burner control. Allow the burner to run until it achieves a steady stream of oil with no bubbles. Tighten the hex back up, and the burner should start once you close the bleeder.
You may need to reset the burner more than once. Be cautious, as pushing the reset button more than twice with failed ignition while pumping oil into the chamber can be dangerous. If your ignition control is a Honeywell R7184, the control will go into a hard lockout if you push the reset more than twice.
If the burner still doesn't fire, repeat the bleeding process. It can take up to ten attempts. If it still doesn't work, you may need to replace the inline filter. You'll know the burner has started as you'll hear a thump and a dull roar, and you'll be able to see through the pilot window.
Regarding the fuel line, it is important to consider the tubing size and any potential blockages. The standard size is 3/8", but some suggest using 1/2" tubing to increase flow and prevent tripping issues due to inadequate fuel supply. However, others argue that a 3/8" line is sufficient for any burner, and the larger size is unnecessary.
Additionally, ensure your fuel line is free of sludge or clogs, as this can cause issues with the oil burner ignition. Running the fuel line along the floor, rather than vertically, can help reduce the risk of sludge build-up.
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Using a CO2 blowout gun
A CO2 blowout gun is a tool used to clear blockages in fuel lines. It is a service tool, primarily for emergency use when a fuel line is clogged.
To use a CO2 blowout gun, the oil supply should be turned off ahead of the oil filter. The gun is then attached to the oil line at the fuel unit, with a screw-on fitting attaching to a threaded pipe. The high-pressure CO2 is released, and the force of the gas pushes the oil muck out of the fuel line and back into the oil tank.
There are a few things to be cautious of when using a CO2 blowout gun. Firstly, it is important to ensure that the line is completely disconnected from the system to protect the fuel pump seal from the pressure. Secondly, there is a risk of blowing open a line or fitting, which can cause a leak. This risk can be mitigated by using a pop relief on the gun to release pressure over 100 psi.
A CO2 blowout gun is an effective way to clear blockages in fuel lines, but it is important to use it safely and in accordance with the manufacturer's instructions.
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Using a hand pump
The first step is to clean the oil supply line. This can be done by attaching a pressure gauge to one end of the line and using a hand pump, also called a push/pull pump, on the other end to pressurize the line to approximately 10 psi. It is important to ensure that the line is completely disconnected from the system to protect the fuel pump seal from the pressure. If there is any leak in the line, it will be evident at this stage.
Once the line is confirmed to be leak-free, the next step is to connect the flared end of the supply line to the inlet port fitting on the furnace's oil pump. The inlet port is typically identified with an "In" marking cast into the body of the pump. Use an adjustable wrench to tighten the nut on the flared end in a clockwise direction.
The following step is to insert the open end of the return line into the remaining opening in the duplex fitting. Gently push the line in, using a measuring tape to ensure it reaches a depth of approximately 3 inches. Then, tighten the duplex bushing clockwise with the adjustable wrench. This step also helps seal the two lines within the bushing.
Finally, connect the flared end of the return line to the "Out" port fitting on the oil pump and tighten the line nut with the wrench. Be careful not to overtighten the line nuts, as this can distort the flaring and create leaks at the pump fittings.
It is important to note that oil burners and their components can vary, so it is always advisable to refer to the manufacturer's instructions or seek professional assistance if needed.
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Preventing leaks
Use Appropriate Materials and Fittings:
Use materials that are compatible with the oil burner system. Copper tubing is commonly used for fuel lines, but it requires careful handling to prevent leaks. Ensure all fittings, valves, and connections are secure and tight. Overtightening can distort the flaring, leading to leaks, so be careful when tightening line nuts and flare fittings.
Maintain Clean Fuel Lines and Filters:
Keep the fuel lines and filters clean and free from sludge or debris build-up. Regularly inspect and clean the lines to prevent clogs, which can lead to fluctuations in fuel pressure and potential leaks. Ensure the screen on the pump is clean as well.
Pressure and Vacuum Testing:
Perform pressure and vacuum tests to identify any leaks in the fuel line. Use a pressure gauge to pressurize the line, and observe for any drops in pressure or visible leaks. A vacuum test can also help identify the source of the problem. If there is a leak, repair or replace the affected section of the fuel line.
Protect the Fuel Line:
Protect the fuel line from potential damage. In the past, fuel lines were often run in a notch in the floor or along the wall, but codes may require the use of protective conduits. If the line runs vertically, consider the possibility of additional leak locations, especially when replacing filter cartridges.
Consider a Tiger Loop System:
A Tiger Loop system can help prevent air leaks and maintain proper fuel flow. It is a valuable solution, especially when dealing with frequent burner shutoffs or ignition issues.
Avoid Inadequate Flares:
When making flare connections, ensure the flared end of the tubing is of proper size. Inadequate flares can lead to leaks and potentially dangerous situations, including puffback explosions.
Add a Safety Valve:
Install an oil safety valve as an additional layer of protection. This device can prevent the loss of oil in case of a leak and provide valuable time to address the issue before a disaster occurs.
Remember, it is crucial to take your time and follow instructions carefully when hooking a fuel line to an oil burner. Do not rush the process, as preventing leaks is essential for the safe and efficient operation of the oil burner system.
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Frequently asked questions
To hook up a fuel line to an oil burner, you will need to locate the bleed fitting on the oil pump. It will be on the left side of the oil burner where the oil line connects and has a hex with a small hose barb protruding. Position a small container directly below it to catch the oil. Loosen the hex until you get a steady stream of oil with no bubbles. Tighten the hex back up and the burner should fire up.
If your oil burner won't ignite, it could be due to a clogged oil filter or oil line. You can attempt to clear the oil line by attaching a small canister of compressed air with appropriate fittings to the oil line at the fuel unit and blasting the debris and crud backward from the connection at the oil burner and back into the oil tank.
If your oil burner is tripping, it could be due to a lack of adequate fuel supply. Try eliminating the vertical rise of the fuel line to see if this improves the flow.
To prevent leaks, do not overtighten the line nuts as this can distort the flaring and create leaks at the pump fittings.
If your oil burner shuts off, it could be because the oil line has developed a hole or a leak. First, locate the source of the failure and then clean the oil line by blowing the line back to the tank, capturing the oil before it enters the tank.
