Why a run-out is a problem
When the tank reaches zero, air enters the gas lines as appliances continue drawing on what's left. Air mixed with the residual propane in the lines creates a combustible mixture that can ignite at appliance pilot lights or burners — exactly why NFPA 58 requires a leak test before service resumes.
The leak-test procedure
After a complete run-out, your dealer's technician must:
- Refill the tank to operating level
- Pressure-test the system above operating pressure
- Watch for pressure decay over a specified period (any drop indicates a leak)
- Purge air from lines by bleeding individual appliances
- Relight pilot lights and verify appliance operation
What it costs
Typical leak-test / restart fee: $50–$150. Some dealers waive the fee for active auto-fill customers when the run-out is the dealer's fault. Confirm your dealer's policy when signing up — this is a common point of dispute.
How to avoid running out
- Enroll in auto-fill — the most effective protection. Dealer schedules from your usage pattern.
- Monitor your gauge monthly in winter — even on auto-fill, occasional manual check catches forecast errors.
- Refill at 25%, not at 10%. The standard auto-fill trigger gives you a buffer.
- Tell your dealer about changes — new generator, addition, occupant change — anything affecting usage.
FAQ
Can I refill my own propane tank after a runout?
No. NFPA 58 requires a licensed technician to perform the leak test before service resumes. DIY restart is illegal and uninsurable.
How long does the leak test take?
Typically 30–60 minutes for a residential system. Longer for complex installations or multiple appliances.
Will the dealer pay for the leak test if it was their fault?
Most reputable dealers waive the fee when run-out occurred under an active auto-fill agreement and the dealer failed to deliver as scheduled. This should be specified in your contract.