Yeah, my hovel is a bit run down. It's old. Something always needs to be fixed. Come heating season, I usually end up working on the furnace a few times to keep it running reliably... which basically means it's not so reliable. This year it turned into a bigger project.
Winter (ok, technically late Fall) has been pretty mild this year. When I first fired up the furnace, I measured the oil in the tank and estimated the run-out date. For me, that involves application of trigonometry to determine volume and forecasting based on prior rate data. At least I don't factor in degree-days! Why wait to buy fuel oil? I factor in the historic cost of fuel oil over past years to predict the optimal purchase time within the window of need. Usually this means buying in mid-summer, or mid-December. Usually I procrastinate. For other folks it might be too much effort to save $0.50 per gallon, but in some sad way I find it entertaining. Scary. Of course this year it didn't work out so well with oil prices nearly doubling during hurricane season and never coming down much. If you look at the price graph, I caught that dip early in December. Keep in mind in my area, oil distributors charge over $1 more than the price on the graph.
Now to the fun part. Recently I got my fuel tank filled after nearly running out. The next time I turned on the furnace, it worked. The time after that, it wouldn't light. I pulled the gun, changed the filter and changed the nozzle, even though both checked out fine. I figured that when the tank was filled some sediment was stirred up and got in the line. The furnace worked when I put it back together. Once. I pulled it apart again and checked the nozzle. It seemed ok. I put it all back together, and no-go. I could hear the spark, so fuel was the problem. It was late, so I put it to bed. An electric space heater would have to do, even though the night's low was 3F (-16C) and it was the season's first major snowstorm that delivered 8" of powder.
The next step was a bit more drastic. I pulled the gun and set it up on my front porch for testing. I was getting tired of working with the stink of fuel oil inside my home. Short the thermostat contacts and put a little electrical tape over the photocell and you're good to go. Or not. Again, spark but no fuel spray. Obviously it's a clogged nozzle. By the way, did I mention that it's really cold and there's snow everywhere? I pulled the nozzle and ran without one. Again, no fuel. Now it's time for more extreme measures. I disconnected the nozzle feed line from the pump. Nothing came out of the port when it running. Next I pulled the entire pump and tested it with a drill. Low and behold, it blew bubbles out the inlet port when running clockwise. How cute. I thought the it was marked for CW operation, but put the drill in reverse, and the pump works from the inlet to the return ports, but no fuel ever comes out of the nozzle port. The pump is a dud.
Try to find a CCW 1725 rpm fuel mini-pump with a right-hand outlet. I dare you. I spent quite a bit of time trying to track one down at a few local stores. In fact they do exist; they just aren't kept in stock because no one uses them. I know my furnace is old, but I didn't expect its pump to be so unusual. I drove back home and double-checked everything before special-ordering a new unit and getting stuck with something I didn't need. I verified that the pump did function when turned CCW. But amazingly the motor does turn it CW. So either 1) the pump is labeled correctly and broken, or 2) the motor is running backwards (possible), the pump is mislabeled, and the pump is also broken. Being the optimist, I opted for the lesser of two failure scenarios.
I picked up a "standard" CW pump with a right-side outlet. Of course, the other ports didn't match up perfectly so the tubing had to be adjusted considerably. First I tested the pump. No suction at all. Oops, I forgot to read the directions, which indicated a 2-line configuration requires the installation of a 1/4" internal plug. Once that was done, everything worked fine, and a nice flame was produced. There's nothing like running a furnace gun on your front porch to make your neighbors wonder.
It's just a matter of reinstalling the burner and hooking up to the new port locations. I did all that... and then nothing happened. Rather, I was in the same boat as when I started this journey. Was there also a problem with the lines? Was one plugged or crushed or iced up? I blew out both the feed and return line; everything seemed ok. Then I found an inlet fitting was loose. Tightened it up and away we go! It's working as good as a 40-year old furnace can.
It is kind of like camping. At least that's what I told myself. In the time I spent working on the furnace off-and-on, it was a cool 55-60F in my home. The poor little electric heater could only do so much. Once I reminded myself that I enjoy camping, it wasn't a big deal. You just put on a sweatshirt and use an extra comforter at night.
In all, I replaced the pump, filter, electrodes, insulators, nozzle, and bought oil for the winter. The pump was $75, the other parts were about $20, and the oil was $360. With the oil prices so high, I didn't order enough for a toasty winter. I'll try to stretch it, but might have to buy more. We'll see. Maybe I should take up knitting... blankets.
Total costs:
keeping a decrepit furnace running one more winter, $455;
another misadventure in home repair, priceless.