Author Topic: Fix Chug's oil burner!  (Read 13507 times)

Offline Chug

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Re: Fix Chug's oil burner!
« Reply #15 on: July 22, 2015, 09:33:57 AM »
Thank you Jules, it looks the same unit,
in the last picture there is a squarish looking component (green I think) in the middle between relay and solenoid, this is the other bit that broke apart.

On the plus side I won a complete boiler for 99p
http://www.ebay.co.uk/itm/Used-Oil-Boiler-/231617897918?pt=LH_DefaultDomain_3&hash=item35ed80a5be

and bought another three burners for £25
http://www.ebay.co.uk/itm/pressure-jet-oil-burners-x-3-/221824604928?pt=LH_DefaultDomain_3&hash=item33a5c6db00

I managed to get the complete boiler firing up by removing and replacing the fuel pump solenoid with a bolt, but it goes to lockout after about 20 secs every time, but it does burn really well, with a stronger flame than the electro oil.

Jules would the solenoid unit not being connected cause this?

I also took a control box of one of the other units I got for £25 and I've now also got my burner running again, and today I'm gonna have another play with them now that I have a few spares.


Offline Chug

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Re: Fix Chug's oil burner!
« Reply #16 on: July 22, 2015, 12:40:45 PM »
Right I've been experimenting and using my original, now working burner, I sussed out three working solenoids (and one duff one) and managed to get the new complete boiler burner running.

But it seems to have a slight problem, after the initial light it will start up again fine if you switch it off then back on within a few seconds but if I leave it for a 30 seconds to a minute then it wont and needs several on/off cycles and it eventually lights up again (but then my original burner sometimes does the same, although usually that one starts up again just fine after the initial start)

I also cut the end of the non working solenoid to use as a bypass and in both burners it locks out after 20 secs or so, so I've answered my question to Jules in that the control box somehow senses there is no solenoid working and cuts the power to the pump, with a working solenoid it keeps running until I switch it off.

So I now have two working burners and I just need to sort out some plumbing connections for the boiler to a central heating pump.

Offline Tony

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Re: Fix Chug's oil burner!
« Reply #17 on: July 22, 2015, 02:21:04 PM »
Perhaps it is looking for a coil resistance on the solenoid - perhaps if you wired in a working dummy solenoid (not actually attached to anything) it would run longer?

Offline Chug

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Re: Fix Chug's oil burner!
« Reply #18 on: July 22, 2015, 08:41:07 PM »
Good idea Tony, I never thought to try that, and the coil was there still just hanging to the side, so I'll try putting a working solenoid inside the coil next, it would be handy for future troubleshooting if it keeps it running.

Offline Chug

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Re: Fix Chug's oil burner!
« Reply #19 on: July 25, 2015, 11:31:41 PM »
I tried a working solenoid in the coil but it still locks out after a short fire, so that answers that question.

Anyway, this afternoon I got all pipes and fittings and CH pump and the other odd bits and pieces I've been collecting together for heating the hot tub and did a dry run (well I suppose dry run is not a good phrase but you know what I mean)

I started with just filling the boiler with water then circulating from a large bucket through the boiler and back to the bucket, once this was working well with no leaks I plugged in the burner, in two minutes the water in the bucket was 60 degrees.

So I went and found a bigger drum of about 60 litres and with the boiler at its lowest setting (60C degrees) it soon heated the water to 45C and the burner switched off, I left the pump circulating through the boiler and the drum temp continued to climb up to 60C again.

I then added cold water to the drum to cool the circulating water to see at what temp the burner would fire up again and after several tests heating and cooling it seems to cut back in around 35-40C degrees drum temp and cut out around 45 - 50C drum temp with water output at 60C.

So bearing in mind this was only a smallish drum with a small surface area for evaporation in comparison to the 10ft diameter pool, I think a test on the pool is next (maybe tomorrow if it don't rain) but I'm hopeful that it will keep the water nicely hot, but if not I can always turn the boiler up, it has a maximum of 90C and I had it on its lowest of 60C.

And I'm glad I didn't test it on the pool straight off as the crap that came out of the boiler and the two long rubber pipes that I'm using (previously run diesel and veg in) made the water a rainbow streaked grey/brown! thankfully all clear now after several hours pumping and changing water.

Oh and on a bio/cherry mix its burning completely smokeless, the only way you can tell its burning is to put your hand over the flue pipe and feel for heat, well apart from the slight humming noise from the air fan and oil pump.

« Last Edit: July 25, 2015, 11:49:40 PM by Chug »

Offline julesandtash

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Re: Fix Chug's oil burner!
« Reply #20 on: July 26, 2015, 09:29:37 AM »
Dont run the pool water through the boiler chug. It is very oxygenated water and will continually corrode the steel heat heat exchanger in the boiler, slowly turning the water orange.
You really want a stainless heat exchanger to keep the pool water (which is full of chlorine and oxygen) separate from the boiler water (which you use corrosion inhibiter in if you want).
A flat plate heat exchanger would do it
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Offline therecklessengineer

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Re: Fix Chug's oil burner!
« Reply #21 on: July 26, 2015, 10:52:08 AM »
Dont run the pool water through the boiler chug. It is very oxygenated water and will continually corrode the steel heat heat exchanger in the boiler, slowly turning the water orange.
You really want a stainless heat exchanger to keep the pool water (which is full of chlorine and oxygen) separate from the boiler water (which you use corrosion inhibiter in if you want).
A flat plate heat exchanger would do it

This.

Offline Tony

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Re: Fix Chug's oil burner!
« Reply #22 on: July 26, 2015, 03:52:06 PM »
Oooh, that sounds very promising!  I'm just envious that I'm not at the field to enjoy watching this all come together :)

Offline Chug

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Re: Fix Chug's oil burner!
« Reply #23 on: July 27, 2015, 09:23:02 AM »
Just a quick post as I'm just off out the door but we spent several blissful hours in the 'hot tub' in the rain yesterday afternoon, the water was like a bath, had it cranked up to heat the water quicker and ended up turning it down to minimum as it was getting too hot for me and even Lynda who likes a hot bath said it was getting too hot for her.

More info later when I get the time.

Offline Chug

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Re: Fix Chug's oil burner!
« Reply #24 on: July 28, 2015, 09:42:40 AM »
I hear ya about the rusting problem, so I'm on the look out for a HX, my british gas neighbour uses one for his hot tub and is looking out for me.

We started filling pool about 11-30am and I started putting all the pipes and pump together, had a slight problem with pump positioning, it wouldn't suck from the boiler end so had to place it at the pool end but after an hour filling we started adding heat, after 20 -30 mins it looked promising as water was slowly warming even with the cold still being added along with cold rain water.

After another good hour or so of filling, it was about half way full, we stopped adding cold water then as we knew we wouldn't have time to fill it completely and heat it to temp, then it soon started warming and by about 2pm it was warm enough that we jumped in.

By 3pm it was warmer than the BBB temp and was lovely, so I turned the boiler down to halfway, by 4pm it was toasty warm, good enough for a bath, by 5pm I switched the boiler to minimum as it was getting too hot for me and we had steam coming from the pool. (will try and upload Lynda's video later)

It was still warming (so warm that I had to sit as upright and out of the water as possible to allow rain and wind to keep me cool) until we got out at about 6-30 -7pm, absolutely marvelous, these times are approximate, but near enough to get an idea of its performance, obviously with a full pool it will take longer to heat to temp but it got so hot that I think cycling on the minimum setting it will keep a full pool well toasty.

It was a good test with outside temps being quite cool and cold rain hitting the surface, so on a warm sunny day it should perform even better.

Lynda and I wouldn't dream of being in a bath for 4 hours but having cold rain on ya back (and big cold drops from the tree if you were that side of the pool) and then ducking into hot water was bliss, our thoughts turned to hot tubbing in winter with snow/frost to plunge into and dark starry skies to look at!

We are well chuffed!

Massive thanks to all you guys!

Offline Tony

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Re: Fix Chug's oil burner!
« Reply #25 on: July 28, 2015, 12:21:37 PM »
Hehe really nice to hear it's getting used!

The only problem I can see with using it in winter and with the snow falling is the inevitable having-to-get-out stage  8)

Offline dgs

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Re: Fix Chug's oil burner!
« Reply #26 on: July 29, 2015, 12:22:51 PM »
Only 11 months to go for next bbb, sounds great Chug, can't wait to get in!
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