I have a 14 year old Rudd hot air gas furnace in a basement with a standing pilot/thermocouple. It uses a Honeywell gas valve. It has a funnel over the pilot, connected to a pilot blower fan (is this a combustion blower) via a tube which is connected to a metal flue that is vented through the chimney. The chimneys were last cleaned about 5 years ago. There is an identical furnace sidewise mounted in the attic which has never exhibited this problem.
The pilot started to go on the basement furnace out a couple of years ago, more and more frequently, but intermittently. Lately, it occurs about 5 out of every 7 or 8 days when the heat is on, even if there is no significant wind.
I replaced a pitted and eroded thermocouple, but no apparent effect on problem. . I had an HVAC technician in who after 2 hours of diagnosis still isn=E2=80= =99t sure what the problem is, but here=E2=80=99s what we observed and did.
- Adjusted the thermocouple so that it was farther into the pilot flame. No effect.
- Replaced the thermocouple =E2=80=93 twice. No effect.
- Tightened the gas line from the valve to the pilot. No effect.
- Observed that the pilot flame goes down by about 1/3 to =C2=BD when the blower motor comes on, but only if the funnel over the pilot is installed. o No observable effect if the funnel is removed.
- Observed that the pilot going out can be replicated but not consistently, as follows: o Pilot Blower fan shuts off (due to thermostat going off or manually switching off furnace). Happens frequently but intermittently, e.g.
5/10 times. =EF=82=A7 Like a backdraft is occurring or something else is interrupting g= as flow to the pilot. o Banging on cover of main fan motor. Happened once. o Doing nothing. There were no fans running, and pilot just went out.- Replaced the thermocouple (twice). Pilot keeps going out.
- According to the tech, there are no lights or other diagnostics indicating any problems, specifically with the pilot blower.
- Removing the funnel over the pilot seems to fix the problem. However, the funnel and tube are clean, unblocked and don=E2=80=99t show any soot or other deposits.
- He tested removing the external vent from the blower motor but only once, the pilot stayed on when the pilot blower fan was shut off.
His conclusion after talking to a senior technician is that there is probably a problem with the pilot blower motor, which =E2=80=9Csounds funny= =E2=80=9D to him. I don=E2=80=99t know what it is supposed to sound like, but it=E2=80=99s no= t grinding, clinking, etc. He says this is a $400 part (plus labor), including the housing.
He left the pilot funnel off, said I should have the flue cleaned just to eliminate that as an issue, which I will. He says if that=E2=80=99s not the problem the next thing they will have to = do is replace the blower motor.
Do you agree with this diagnosis? Is it safe to leave the pilot funnel removed with the furnace operating?
Thanks much