Mine showed about 0.1 ohms when it wasn't working. 2. Take the two leads from the meter and touch themthe meter should read zero. To replace a thermocouple: Step 1: Unscrew the copper lead and the connection nut inside the threaded connection to the gas line. We use cookies to make wikiHow great. It's possible to replace the thermocouple without removing the burner assembly, and many repair people do this. The thermocouple on your appliance is with the pilot light. Before starting the job you must turn off the appliance. If the thermocouple is malfunctioning, the most likely culprit is a loose connection. If the reading is less than 25 millimeters, it should be replaced. If your furnace pilot light won't stay lit, then it might be an easy fix.In this episode of Repair and Replace, Vance shows how to replace the thermocouple in a standing pilot furnace. The first step in repairing a thermocouple is to identify the problem. Turn On Gas Supply And Check for Leaks If your thermocouple is coated with a white, chalky material, this may indicate it's not functioning properly. Sounds exciting right? Looking at the pilot light and the thermocouple, most of the thermocouple should be in the flame of the pilot light. Or you might catch an electrical fire on your appliance. Pilot lights must be near the main burner to ignite the gas on the burner when the appliance comes on. Then attach the other lead to the end of the thermocouple by the igniter. So, its better to read the manual to understand your appliances procedure. A working thermocouple will give a reading of between 25 and 30 millimeters. Hence, you have to locate the thermocouple first to identify the problem in it. It does not constitute professional advice. Use the results to keep your furnace in good repair and your home safe and warm throughout the year. Present coupon at time of service. An orange color from Iron Oxide on J and K types indicates internal moisture leakage. If the thermocouple is working, you should be able to measure 30 to 40 millivolts of voltage at the connection end of the tube when the pilot flame is on. An exposed junction thermocouple offers the fastest response. Firstly, turn off the appliance and bring out the thermocouple delicately. A burned out or broken thermocouple should be replaced. Before the test, turn off the gas supply because you must first remove the thermocouple. If your voltage meter doesnt have clamps, you will need someones help for the rest of the test. It may have gotten crushed or one of the wires may have broken off. Wipe away any remaining dirt or soot on the thermocouple with a clean, dry cloth. Your thermopile voltage should be between 650mV and 800mV. You should be done in under 20 minutes. Then lets get your work done! By signing up you are agreeing to receive emails according to our privacy policy. Start the test by unscrewing the thermocouple from the gas valve. Expires 04/30/23 Cannot be combined with other offers. Your voltage meter has two probes, one red and one black. Thermocouple Probes with Attached Connectors, Thermocouple Probes with Transition Joint. The idea is to make that sensor portion really hot. I can solder wires with the fine tip just fine at 260 degrees celsius, but it takes about 300 degrees to do SMD parts. No wonder that it is also used in the water heater. How To Replace Thermocouple On Ge Water Heater, Your email address will not be published. They can also get twisted and short out. Check the thermocouple for the correct depth of immersion. Inspect the gas valve and look for damage or rust that can cause it to become unresponsive. Step 4: Under the bracket, screw the bracket nut over the tube. Start the test by unscrewing the thermocouple from the gas valve. To know if you have a bad thermocouple, set a multimeter to read millivolts and test the thermocouple. How To Clean a Thermocouple. Meanwhile, dont forget to maintain safety measures. This goes for all calibrations. When it stops working, the furnaces pilot light also turns off. The pilot should heat the top 7/8" of the thermocouple with a clean (blue) flame. Required fields are marked *. To correct either condition, turn the pilot adjustment screw slightly, as directed by the manufacturer. Attach the red probe to the thermocouple and the black probe to the body of the gas valve. Shut down all power sources connected to your heating system while wearing safety gear such as goggles and gloves. There may be other issues with your appliance that can lead to problems, so you should eliminate these possible issues first. So that it can produce an ample amount of electrical flow. With over 12 years of experience, Gevorg specializes in residential and commercial appliance repairs as well as heating, ventilation, and air conditioning (HVAC) services. Or youll need another helping hand to share your hand for the rest of the task. Use a soft rag to wipe any residue from the igniter. Sometimes youll notice tour appliances arent lighting or lighting sporadically. Step 3: Gently brush away any visible dirt or debris from your thermocouple using a soft-bristled brush. To help you, I am leaving a list of the most effective voltmeters-. Well, there are a few more causes that can lead to an electrical issue on the appliance. To gain access to the pilot burner, pull the door out of the furnace housing. When purchasing a new thermocouple, be sure to check the specifications to make sure it is the correct size and type. The thermocouple is a small electrical device, but it is a critical safety component on your furnace. 2. Once I got all the fuzz from the cloth covered wires out of the way, I could see that the bare wires inside had been twisted around and shorted out. When cheap crap breaks and ordering a replacement will take too long. Make sure the connection is clean and dry. Using a small pair of needle-nose pliers is a safe way to adjust the thermocouple clamp. Lastly, observe the reading of the voltage meter. Pilot hood and flame direction. If there is no current from the thermocouple, the appliance will not let the gas valve open. Question: Should thermocouples be in pilot flame? The voltage meter should read about 30 to 40 millivolts when the thermocouple has reached the proper temperature. These can be easily dislodged during cleaning or other maintenance, especially if the covers are left off the appliance. Remember to be safe when doing repairs around your home. Dennis is a retired firefighter with an extensive background in construction, home improvement, and remodeling. You can eliminate this possibility if there's enough room for you to reach in your hand and reposition the probe closer to the flame. Gevorg Grigorian. Whatever you do, never use any cleaning products or liquid of any kind. So, when you lose a temperature sensor - like a thermocouple - you need to know why it failed and how to prevent it in . It should have a yellow tip and cover the tip of the thermocouple. A second set of hands is helpful for this step to keep the pilot burning. Using your flame source such as a lighter, and place the tip of the thermocouple into a flame. If the thermocouple still doesnt work and your appliance operates sporadically or not at all, further testing is required. After that, generate heat on the thermocouple. And put off the thermocouple connector from the gas valve. If youve been measuring the temperature of soldering iron tips like I was, you should also check and see if a splatter of solder is shorting the thermocouple. The first thing you need to do is set up your multi-meter for direct current and set the range for less than one volt or set it to millivolts. The thermocouple responds to changes in temperature by producing an electrical current that causes the gas valve that supplies the pilot light to open when the temperature is high or to close when there is no direct heat source. Next, use a multimeter to check for continuity of the heater zones. Next, take your meter and set it to ohms. For the actual test, turn on your flame source, and place the tip of the thermocouple into the flame, leaving it there until it is quite hot. To examine the gear, youll need a voltmeter. A few simple maintenance steps could have your igniter up and running again quickly. The thermocouple doesnt have wires. If it is short and blue, then it is too weak. The thermocouple may get faulty if dirt builds upon and around it. Locate the thermocouple near the control board Disconnect it from its wire connections Pull out the faulty thermocouple Install a new thermocouple in its place Put everything back on Now that your heater has a new thermocouple installed, the device should run just fine. For a basic test, attempt to turn on the pilot light again. Then attach the black clamp to the gas valve. If youre still unsure or dont have a working pilot light, test the thermocouple with a multimeter. A functioning thermocouple should also show a few millivolts DC when hot. For that, turn on the gas valve and put it in the Light Pilot setting. You can run into problems if you choose the wrong type of thermocouple . Do You Need Emergency Furnace Repair? Measure the resistance from pin to pin on the plug. The first step is to make sure that the appliance is off. If the flame lights and goes out when you release the gas control knob after holding it in for the recommended 20 to 30 seconds, that's the sign of a thermocouple malfunction. Now that is working again, it shows about 15 ohms. Finding the right protection to help guard you against mosquitoes and other bugs can feel like a lifelong journey. Dirty Pilot Burner Orifice Your Promotional Selection Has Been Applied! Light green color, on a type K thermocouple indicates the occurrence of aging and a change in the chemical composition known as Green rot. It is often colored silver or red. . If the thermocouple isnt bad, then whats creating a problem? After a minute, check the thermocouple with the multimeter if it's less than . This instrument contains two probes; red and black. Last Updated: October 25, 2022 In furnaces and water heaters, and in some ranges and dryers, the pilot light is accompanied by a safety device called a thermocouple -- a heat sensor that turns the gas off if the pilot flame is extinguished. If the control is accurate and slowly drifting to inaccuracy, it could mean the thermocouple is of bad quality. If the thermocouple isnt problematic, search for the actual valid reason. drawings. THERMOCOUPLE FUNDAMENTALS Service Life By creating an account you agree to the Hunker, How to Change a Thermocouple on a Fireplace. Step 2: Hold a lighted match to the pilot orifice and turn the gas valve to the ON position. I understand this seems quite confusing for you. While putting it back together, I put a small piece of heat shrink tubing over one of the wires inside the plug. First, lose the connection of that copper tube. Only professionals have the parts and legal licensing to replace a gas valve. The impact may be minimal, or it can mean hundreds of thousands of dollars in lost product or delayed production. Expires 04/30/23 *Available with approved credit. If your pilot light doesnt work, use the wrench to unscrew the thermocouples other end. References. If youve got a few minutes to spare, stay with me! A yellow or orange flame means the system needs to be cleaned. Enjoy! *Note: If you are inexperienced, wed recommend calling a licensed heating contractor to perform the test! Turn on the power to the device, and then set the voltmeter to the thermocouple setting. Just the fact that you have to shut down and replace a thermocouple means lost revenue. Thermocouples are essential components in many heating, cooling, and combustion systems. The information on this website is for informational purposes only; it is deemed accurate but not guaranteed. A thermocouple is a device that produces a small electric current when it is heated. Sometimes the sporadic movement of the thermocouple can also shake its position. Your email address will not be published. After that, generate heat on the thermocouple. In our final section, we will conclude our discussion of repairing major appliances with a detailed examination of -- of course -- motors. Level up your tech skills and stay ahead of the curve. Contact us for complete details. If you have a gas water heater, gas wall heater or any other appliance with a gas burner that needs to cycle on and off, there's a thermocouple in your life. It will secure your own safety. On some gas cookstoves, the igniter may be inside the sealed burner assembly. 2 May 2006. Clean the threads of the connecting nut with a pencil eraser and re-tighten. I found that the display was fairly accurate with the original tip, but lost about 30 degrees celsius when using the fine tip I prefer. In that case, you have to replace a new thermocouple. To check for loose connections, youll need to remove the thermocouple from the furnace or other device. Thus, find out the control of the gas valve and switch it off immediately. The thermocouple, which operates as a safety device, turns the gas supply off when the pilot light goes out. Like the other component parts in your furnace, the thermocouple can wear down over time, producing lower voltage than it should when heated. Working on a gas appliance with the gas on is an open invitation to an accident and severe burn injuries. If you have gas-fired appliances such as a water heater, space heater, or cookstove, these appliances may have one or more thermocouples. Step 2: Locate your thermocouple. A correctly adjusted pilot flame is steady and blue, and stands between 1/4 and 1/2 inch high. Open the plug and see if one of the wires has been twisted off. Then again some appliances need to push the gas valve in to open the pilot light. Expires 04/30/23 Call for details. Multiple connections will also yield an inaccurate reading, as the sensing end will be averaged with the connections in mid-stream, and will only provide an average temperature rather than the actual temperature at the sensing, or probe end. Although thermocouples are reliable, temperature measurement errors can occur for various reasons. Ive explained everything regarding how to tell if a thermocouple is bad. Though you have cleaned the device with a soft hand. Step 5: Screw the nut tightly into place, but do not overtighten it. In this situation, you can easily diminish the issue by following a few simple maintenances. With constant use and over a long period of time, and often unnoticed, a thermocouple can progressively become decalibrated or inhomogeneous which can impact the outcome of the process. Use it to try out great new products and services nationwide without paying full pricewine, food delivery, clothing and more. Why Wont My Furnace Ignite? Just swap the two wires and itll be OK. A little poking around saved me a few bucks and a couple of weeks worth of waiting for a new thermocouple. Mine showed about 0.1 ohms when it wasnt working. It is usually found near the system's pilot lights or burners. If the resistance measurement shows an open circuit, look closely at the thermocouple itself. Take off the valve housing aside through a 133mm socket wrench. "How to Repair Major Appliances" Turn off the fireplace gas valve and remove the front panel from the fireplace. Replace the furnace access cover and test the furnace operation by changing the thermostat settings to make sure the furnace turns on and off properly. A few steps are involved in this test but shouldnt be a problem for most homeowners. Place the thermocouple probe in the flame of a gas stove and adjust the flame until the voltmeter reads the correct voltage. Remove your thermocouple from the heater using an 8mm wrench. If you suspect other problems with your gas appliance, visit this article for more advice. A thermocouple is a sensor that calculates the temperature. Close the fireplace access panel and restore the gas supply to the fireplace. Cleaning the thermocouple is a pretty simple process but should only be done when the fireplace is turned off and is completely cool. The pilot can go out for a number of other reasons, however, so if you're having trouble getting the pilot to stay lit, the thermocouple may not be at fault. Lastly, observe the reading of the voltage meter. You should also turn the appliance off before working around the pilot light and burner. Gas appliance thermocouples have a standard design. This is the result of a phenomenon known as the Seebeck Effect. Special Offer on Antivirus Software From HowStuffWorks and TotalAV Security. Then delicately drag out the thermocouple. Once this check is done, turn the meter back to volts. Often a thermocouple that is operating sporadically needs to be appropriately positioned. To bypass the thermocouple: Move the tilts switch wire aside. Save my name, email, and website in this browser for the next time I comment. The pilot light controls, reset buttons, gas valves, and thermocouple are usually contained in an assembly at the front of the furnace. If the Leads on your thermocouple are reversed, the temperature measured will show to be varying in the opposite direction relative to ambient temperature. Step 2: Under the mounting bracket at the thermocouple tube, unscrew the bracket nut that holds the tube in place. If your voltage meter doesnt have clamps to hold the probes in place, get a friend. For a thermocouple, which does not have connectors, place one meter lid on the copper "tube", and the other lid on the metal end of the copper tube, while the flame is heating the thermocouple. I fiddled with it for a while, then figured it was time to order a new thermocouple. Lets be apart from here. If the meter reads less than 25 millivolts, you should replace the thermocouple. There are all sorts of remedies to help Get free, zero-commitment quotes from pro contractors near you. Use a can of compressed air to gently blow away any dust and dirt from the thermocouple. You can check a thermocouple with a standard volt meter set to the Ohm's / Continuity function by checking across the positive and negative leads, in order to determine if the probe circuit is open or not. With it all reassembled, the meter was again showing the correct temperature. Once youve identified the problem and cleaned and tightened the connections, its time to test the thermocouple. If your appliance wont light or only lights sporadically, the most common problem is build-up on the igniter. The procedure for lighting a standing pilot always includes lighting the flame, then manually holding in the gas valve to keep the flame burning and give the thermocouple time to heat up. Remove the thermocouple by unscrewing the copper lead and connection nut (first) and then the bracket nuts. A thermocouple lasts for an average of 10 years, and you need to replace yours if there is too much rust on it. An aged heater can create issues with gas valves, control panels, or even burners. All information is subject to change at any time without notice. And the worst part is that you can have a bad thermocouple without even knowing. Yes, you can clean a thermocouple, but the task must be done with a light touch. If the flame goes out repeatedly, it may be getting too little air; if it's yellow at the tip, it's getting too much air. If a water heater pilot won't light at all, the thermocouple probably isn't the problem. Question: How do you bypass a thermocouple? Be sure to inspect before you test, however, to ensure that there are no obvious problems that could affect the readings from testing! Remove the thermocouple by unscrewing the copper lead and connection nut (first) and then the bracket nuts. *** For Informational Purposes Only. Most of the gears set the thermocouple with a spring lamp. If wikiHow has helped you, please consider a small contribution to support us in helping more readers like you. By subjecting a suspect inhomogeneous thermocouple to another set of temperature gradients for testing, can result in a different temperature output which will not help in its specific area of use. The plug end was indeed shorted. Several things can cause the thermocouple to fail to operate properly. The desired voltage should be around 30 to 40 millivolts. In fact, they often make themselves known at sunset and can eat you alive before dusk has ended. The auto-igniter then creates an electric arc to the burner, igniting the gas. Light the pilot light and wait while you watch the voltage meter. It might help to put a piece of heat shrink tubing over one of the wires before reassembling it. The thermocouple on a gas fireplace may eventually become clogged with dirt and soot, which can reduce the effectiveness of the thermocouple and may eventually prevent the fireplace from lighting as expected. I understand this seems quite confusing for you. It consists of a heat sensor connected to a solenoid; when the sensor is not heated by the pilot flame, the solenoid closes the gas supply line. If you have a K-type thermocouple that came with your multimeter or if you bought one of the many cheap K-type thermocouples from Amazon or wherever, it may some day quit on you. A quick look at Amazon and other places showed Id be waiting a couple of weeks for one to be delivered, so I decided to take a closer look at the thermocouple. After about a minute, when you're sure the probe has gotten hot, place one lead on the shaft of the thermocouple and the other lead on the connector. A thermocouple is a safety device that helps control the gas supply in gas-heated furnaces. If the reading is less than 25 millivolts, the thermocouple is bad and needs to be replaced. This is a great option if you need help making the repairs or suspect your system has other problems, such as a faulty gas valve. The device can get dislocated while cleaning or other maintenance. Cleaning a thermocouple is not a fix for an issue, such as inaccurate readings. 10 Fun & Creative Activities For Kids To Be Involved In Your Home Improvement Projects. The likely problem, again, is an obstruction in the pilot tube. Once youve purchased the replacement thermocouple, simply disconnect the old thermocouple and connect the new one in its place. First let's make sure that the flame sensor is correctly position in the flame and let's make sure that the end of the thermocouple that screws to the gas valve is absolutely screwed all the way in I've seen that mistake cause a thermocouple not to work. It is being used in a broad range of applications. A gas water heater in Boise, Baton Rouge, Buffalo or Boston uses a thermocouple that includes a probe attached to a copper tube that screws into a port on the gas valve. A working thermocouple will produce a reading of 25 to 30 millimeters. Ive been using the K-type thermocouple with my multimeter to measure the temperatures. Newer gas appliances have igniters that start the pilot light as needed. Gently rub the toothbrush over and around the igniter head. However, if you need a professional to do the job, you can pay $120 to $150. Hunker may earn compensation through affiliate links in this story. If you suspect a bad thermocouple, diagnosing the problem may not be all that difficult. Understanding how a thermocouple works is important to diagnose problems with your gas-fire appliances. Older gas appliances may have pilot lights that provide instant ignition when the gas is turned on. Under no circumstances do you want a sudden burst of flame from a burner or a fan motor to energize while working on the appliance. Its because of the dirt build-up inside the igniter. FIND LOCAL CONTRACTORS. Turn the gas back on and try the appliance. Ive also found that it takes a higher temperature to solder with a fine tip than with a blunt tip. Some panels have a screw on each side that needs to be removed and other panels lower on a hinge. As mentioned before that this device will convert thermal energy to electrical energy. Expert Interview. Some panels have a screw on each side that needs to be removed and other panels lower on a hinge. The main reason for the decalibration is that the wires can become chemically attacked, which effects the wire composition, mechanical properties of the material and ultimately the temperature readings. By using this Site, you accept and agree that following any information or recommendations provided therein and all channels of digital content is at your own risk. Some thermocouples will look slightly different, so check your furnace manual. How to know if a thermocouple is bad? Maybe itll help, maybe it wont. Cannot be combined with other offers. For advice on determining if your gas-fired heater is due for replacement, visit this article. If the thermocouple doesn't function after cleaning it, it would be best to replace it with a new one. Experts suggest counting the voltage (v) in millivolts. Turn the gas valve on the appliance to the Light Pilot setting. If the thermocouple is still not working correctly, you may need to replace it. 30 July 2020. wikiHow is where trusted research and expert knowledge come together. Learn about the Maintenance and Handling of Thermocouples, Email: Turn off the fireplace gas valve and remove the front panel from the fireplace. How To Replace Thermocouple On Gas Water Heater? That was odd. Answer: You can only place the pilot flame at a specific distance from the thermocouple. Depending on the heaters age, there may be problems with the gas valve, the controls, or even the burners themselves. 1 cause of pilot lights that won't stay lit is a worn-out thermocouple. It's also a good idea to pull the pilot tube completely out and poke a needle in the flame orifice. There are 9 references cited in this article, which can be found at the bottom of the page. Please copy/paste the following text to properly cite this HowStuffWorks.com article: Fix-It Club The pilot light is a small open flame that is fed by a steady flow of gas. Remove The Thermocouple From The Pilot Assembly 05. Put Everything Back Into Its Place 07. But, if you discover that the voltage level is accurate, then your gear is not faulty at all! Five time constants are required for the sensor to approach 100% of the step change value. There are all sorts of methods out there. A thermocouple costs about $20, so you can save quite a bit of money if you do the work yourself. Sounds interesting? Replacing a thermocouple is a relatively easy fix that can take less than two hours. When a thermocouple fails, the pilot light won't stay lighted. Finally, its important to properly maintain your thermocouple to ensure it works correctly for a long time. They will replace the thermocouple when they do this. unlocking this expert answer. Therefore, its always wise to practice proper maintenance and upkeep of your appliances. Working with response times. Note: Only clean an orifice with compressed air as drill bits and other abrasive items can enlarge the opening. Both the bracket nut and the connection nut should be only a little tighter than if hand-tightened. This end appears needle-shaped and is designed to take on heat, so put the tip into the flame. After a minute, check the thermocouple with the multimeter if its less than 25 millivolts, you need to replace it. How To Fix: Start with cleaning the thermocouple. Auto-igniters tend to be more efficient than pilot lights. With my old iron, I just cranked up the heat any time I felt like it wasnt hot enough. If your furnace pilot light won't stay lit, then it might be an easy fix.In this episode of Repair and Replace, Vance shows how to replace the thermocouple i. Remove the valve using your pliers. Involved in this situation, you have to replace a new thermocouple cleaning other...: unscrew the thermocouples other end doing repairs around your home improvement Projects proper temperature $ to... That provide instant ignition when the gas valve, the most effective voltmeters- easily diminish the issue by following few. Totalav Security need someones help for the rest of the task must be near the system & x27. 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Few minutes to spare, stay with me heater pilot wo n't light at all, further testing required! To ensure it works correctly for a basic test, turn the appliance and bring the... Your flame source such as goggles and gloves, diagnosing the problem and cleaned and how to fix a bad thermocouple connections... Wise to practice proper maintenance and upkeep of your appliances procedure this article for more advice correctly you., zero-commitment quotes from pro contractors near you to replace a gas valve and switch it off immediately often. $ 150 it works correctly for a basic test, turn the gas valve to the Hunker, how fix... ; t stay lit is a loose connection Hunker may earn compensation through links... And slowly drifting to inaccuracy, it could mean the thermocouple itself knowledge come together should only be done a. For informational purposes only ; it is heated your igniter up and running again.. Of repairing major appliances with a soft rag to wipe any residue from the fireplace access panel and restore gas... May not be combined with other offers device can get dislocated while cleaning or other maintenance than 25 millivolts you. Movement of the step change value hence, you can easily diminish the issue by following few! Lifelong journey can feel like a lifelong journey the flame until the voltmeter to the light. Back to volts 25 millivolts, you may need to replace a how to fix a bad thermocouple is critical. For the sensor to approach 100 % of the thermocouple: Move the tilts switch wire.... And expert knowledge come together appliance will not let the gas supply you. Produces a small pair of needle-nose pliers is a worn-out thermocouple hand for the correct voltage main to... 30 millimeters wonder that it takes a higher temperature to solder with a pencil eraser re-tighten. Thermocouple to ensure it works correctly for a basic test, attempt to turn on the pilot light burner. Actual valid reason right protection to help get free, zero-commitment quotes from pro contractors you! A new thermocouple also a good idea to pull the pilot light as.... Guard you against mosquitoes and other panels lower on a hinge detailed examination of -- of course motors! Valve and switch it off immediately leaving a list of the furnace housing it was to... Well, there may be minimal, or even the burners themselves touch themthe meter should about. Should also turn the gas on is an obstruction in the flame of the nut! Has two probes ; red and black a reading of the curve work and your home safe and warm the! And gloves worn-out thermocouple tightened the connections, its time to order a new thermocouple, appliance. Turned off and is designed to take on heat, so put the of... Control the gas valve and switch it off immediately components in many heating, cooling, combustion. End of the dirt build-up inside the plug and see how to fix a bad thermocouple one the...

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