Oil burner repair | Boiler servicing

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  • OVERALL DIFFICULTY INDEX: 3/10
  • IF YOU HAVE NO TOOLS, YOU PAY $20 TO GET THEM FOR THIS JOB
  • IF YOU HAVE NO EXPERIENCE YOU SPEND 2 HOURS TO CARRY OUT THIS JOB
  • RISK OF ELECTROCUTION AND ACCIDENTAL FIRE
BEFORE YOU START
​It is obvious that such works are to be carried out on a cold boiler.
Make sure to isolate the electrical circuit feeding the boiler. You should not proceed by simply shutting it off with the switch or thermostat but rather isolate its breaker.
DISCLAIMER:
Our pictorials are of informative nature and do illustrate works carried out by ourselves at our own premises for our own use and satisfaction.
Readers who envisage to carry out similar works inspired by the below method shall do this at their own risks and liability.

Oil burner removal from boiler

The removal of this burner requires only loosening a couple of nuts, tilting the burner and taking it out.
Proceed with steps 2 and 3 with care not to damage the gasket between the burner and its holder.

Oil burner dismantling before servicing

This burner needs a minimum of jet and electrodes replacement.
Such repair is the most common on any oil burner especially in areas where the sulfur level in gas-oil is high.
The jet replacement should occur at least once every two years and the electrodes depending on the visible wear.
In this case, the burner was still operational but the replacement is a preventive measure to avoid a failure during the cold weather when it is most needed.

The screws holding the cover are removed in order to access the electrodes wires which are pulled out of these as shown on the right.
Tilt the burner nozzle and take it out, then unscrew and remove the jet with the specific tool supplied with the burner or a spanner.
You might need to modify the positioning of the jet assembly to be able to access the screws that hold the electrodes (middle).
If so, note well the jet adjustment setting prior to proceeding with the modification.
Unscrew and remove the shield (right).
You can now easily take out the electrodes.

Oil burner service: refitting new oil burner parts

You should purchase:
  • A jet of the same size than the one fitted to your burner. This is expressed by the jet hole diameter (e.g. 0.50 mm) and the angle of flame spreading.
  • The electrodes could not be of that same exact match and would have to be adapted. See further below for details.
Before starting the reassembly, temporarily fit first the electrodes and jet as shown:
Bend and cut the electrodes with pliers to adapt them to the jet assembly.
Observe the following operational gaps:
  • between electrodes: 2 to 3 mm
  • electrodes to shield: 3.5 mm or more
  • electrodes to nozzle: 2.5mm or more
Re-assemble the electrodes, the shield and the jet, check the electrodes gaps, refit the nozzle.
Some electrics to complete the job:
The newly purchased electrodes might not have the same electrical connectors.
Crimp type adapters are available. Ask the vendor to provide these when you buy your new set.
Crimp them to the existing connectors - do not cut the high voltage wires - and then use them normally by pushing them into the electrodes.

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