how to fix a bad thermocouplehow to fix a bad thermocouple

This guide reviews how to replace a thermocouple to ensure gas appliances stay in good working order, as well as how to relight a pilot light. If the connections appear loose or corroded, then you will need to clean them and tighten them. Richmond Water Heater Thermocouple Replacement: The How-To Steps 01. Question: How do you bypass a thermocouple? The thermocouple needs the full heat of the pilot light to create enough electrical current. Pull the valve housing aside using your 13mm socket wrench. Most problems with this type of valve are due to thermocouple problems. To do this, youll need a voltmeter with a thermocouple probe. It might help to put a piece of heat shrink tubing over one of the wires before reassembling it. Most of the gears set the thermocouple with a spring lamp. How To Replace Thermocouple On Ge Water Heater, Your email address will not be published. For that, turn on the gas valve and put it in the Light Pilot setting. Gas valves cannot be repaired. Use a soft rag to wipe any residue from the igniter. Lastly, observe the reading of the voltage meter. The first step is to make sure that the appliance is off. Remove the thermocouple from the process assembly, using a steel wool or emery cloth, lightly clean the tip removing any build up. Expert Interview. Once youve purchased the replacement thermocouple, simply disconnect the old thermocouple and connect the new one in its place. Ive been using the K-type thermocouple with my multimeter to measure the temperatures. If finding that the thermocouple does not read, the problem is most likely a bad connection, broken wiring, or open internally within the thermocouple probe circuit. Expires 04/30/23 Call for details. If the resistance measurement shows a dead short from pin to pin, check the thermocouple itself first. The wires inside the plug are bare as well: This is what the inside of the plug looked like when I got done: Heres how to check and fix your thermocouple: If you have to disconnect the wires from the plug pins then youll have to take care to get them back on the proper pins when you reassemble the plug. To replace the thermocouple, youll need to purchase a new one that is compatible with your device. If the resistance measurement shows an open circuit, look closely at the thermocouple itself. Locate the thermocouple on the gas control thermostat. In most cases, the thermocouple attaches to the gas valve with a thin copper tube. 1 cause of pilot lights that won't stay lit is a worn-out thermocouple. Next, attach the leads from the multi-meter to the thermocouple: put one on the side of the thermocouple, and attach the other lead at the end of the thermocouple that sits in the pilot light. Do You Need to Hire an Electrician? A thermocouple is a safety device that helps control the gas supply in gas-heated furnaces. It's possible to replace the thermocouple without removing the burner assembly, and many repair people do this. Its because of the dirt build-up inside the igniter. A few simple maintenance steps could have your igniter up and running again quickly. It does this by sending a tiny electric current to a sensor on the gas valve signaling the valve to stay open. 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. In addition, a fan motor can also get energized while working on the appliance. You may have to wiggle it a bit before it comes loose. Carefully remove the thermocouple from the gas valve by loosening the copper connector. 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. Look around the igniter as well and make sure there is no build-up on the burner or near the igniter. Youll know you did it wrong if you measure the temperature of some hot thing and the displayed temperature drops instead of rising. Water Heater Maintenance: Extend Water Heater Life Step 2 Burner assembly Remove the burner assembly and detach the thermocouple. Connection from the thermocouple to the valve. That was odd. You can test this yourself using a multimeter, but you may need a helper to keep the pilot flame burning while you do it. Remove the valve using your pliers. References. Clean the threads of the connecting nut with a pencil eraser and re-tighten. Here Ive shown a 5-step method to find out if your thermocouple is bad or not. If the resistance measurement shows an open circuit, look closely at the thermocouple itself. Remove the thermocouple by unscrewing the copper lead and connection nut (first) and then the bracket nuts. "How to Repair Major Appliances" 2. Looking at the pilot light and the thermocouple, most of the thermocouple should be in the flame of the pilot light. Find the thermocouple, which is located next to the pilot light and looks like a small straight pipe. What does a thermocouple look like and how do you find it? Turn On Gas Supply And Check for Leaks Step 2: Under the mounting bracket at the thermocouple tube, unscrew the bracket nut that holds the tube in place. Caution: Some older appliances may not have a safety device to turn the gas off when the pilot is extinguished. Then attach the other lead to the end of the thermocouple by the igniter. Start at the cable connector for the controller and work your way towards the tool. Who wants to get burnt or experience a shock? The pilot light is a small open flame that is fed by a steady flow of gas. Your email address will not be published. A burned out or broken thermocouple should be replaced. Look for a flexible tube plugged into the side of the thermostat. You will need a wrench, multi-meter, and a flame source, like a candle or a lighter, to perform the test. Sometimes the sporadic movement of the thermocouple can also shake its position. Be sure to inspect before you test, however, to ensure that there are no obvious problems that could affect the readings from testing! Separate the thermocouple connector from the gas valve. That may not be a safe assumption, but I havent got anything else to go on. So that it can produce an ample amount of electrical flow. This is the result of a phenomenon known as the Seebeck Effect. Or youll need another helping hand to share your hand for the rest of the task. If you can't get the flame to light at all, and you're sure the gas is on, there's probably an obstruction in the pilot tube. I disconnected the wires from the plug pins, cleaned more fuzz out of the way, and untwisted the wires. This device is manufactured in a variety of styles, models, and technical specifications. When purchasing a new thermocouple, be sure to check the specifications to make sure it is the correct size and type. You'll learn how a thermocouple works and how to clean the thermocouple.Buy a universal thermocouple online: https://www.amresupply.com/catalog/Thermocouples-Thermopiles-662364-HV1GIf your pilot light keeps going out, or if your burner won't stay lit, then its best to clean the thermocouple first when troubleshooting. Remove the thermocouple by unscrewing the copper lead and connection nut (first) and then the bracket nuts. Dirty Pilot Burner Orifice Mine showed about 0.1 ohms when it wasn't working. 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. Gevorg holds a BS in Business Administration and Management from California State University-Northridge. On 2020-07-15 by Don Gilbert Often a thermocouple that is operating sporadically needs to be appropriately positioned. Take off the valve housing aside through a 133mm socket wrench. Ive explained everything regarding how to tell if a thermocouple is bad. Use a can of compressed air to gently blow away any dust and dirt from the thermocouple. I checked that, and found zip - no voltage at all from the thermocouple. Your voltage meter has two probes, one red and one black. It will secure your own safety. Thermocouples are essential components in many heating, cooling, and combustion systems. At the. To help you, I am leaving a list of the most effective voltmeters-. While checking the tip temperature of the fine tip while soldering an SOIC-8 part, the meter just up and quit measuring temperatures. If wikiHow has helped you, please consider a small contribution to support us in helping more readers like you. You can test this yourself using a multimeter, but you may need a helper to keep the pilot flame burning while you do it. Compatible Thermocouple Calibration Type? Enjoy! The impact may be minimal, or it can mean hundreds of thousands of dollars in lost product or delayed production. In this task, youll need to heat the thermocouple. Level up your tech skills and stay ahead of the curve. If you find a dead short from pin to pin, check the inside of the plug and see if the wires are twisted. The first step in repairing a thermocouple is to identify the problem. Five time constants are required for the sensor to approach 100% of the step change value. "Very clear and simple drawings make it easy to learn the basics in a short time. The following are the six most common causes of thermocouple measuring errors, followed by ways to rectify them: 1. There may be a broken wire in the plug if you find an open circuit from pin to pin. Older gas appliances may have pilot lights that provide instant ignition when the gas is turned on. Your thermocouple voltage should be between 25mV and 30mV. Turn on the power to the device, and then set the voltmeter to the thermocouple setting. Nothing lasts forever, and when the thermocouple wears out, the pilot won't stay lit and your appliance won't work. When the thermocouple is dirty, it won't produce enough voltage to open the gas valve, this will cause the pilot light to go out after you release the bypass button. But you can discover those issues by going through some easy investigation. Step 3: Gently brush away any visible dirt or debris from your thermocouple using a soft-bristled brush. If the thermocouple is out of alignment, gently pull or push the spring clamp. If the igniter has a pilot hole, move a sewing needle carefully around inside the hole to loosen any trapped material. Some thermocouples will look slightly different, so check your furnace manual. Several things can cause the thermocouple to fail to operate properly. Working with response times. If the thermocouple wiring is bare, missing insulation and is touch together anywhere between the sensing - probe end, and the connection points, the thermocouple will read at the area where the bare wiring is touching together. You may have more pressing problems than a thermocouple in your gas-fired heater. If youve got a few minutes to spare, stay with me! By signing up you are agreeing to receive emails according to our privacy policy. By using our site, you agree to our. To replace a thermocouple: Step 1: Unscrew the copper lead and the connection nut inside the threaded connection to the gas line. When a thermocouple fails in your control system, bad things happen. Hunker may earn compensation through affiliate links in this story. If you suspect this is the problem instead of the thermocouple, call a professional. Expires 04/30/23 Cannot be combined with other offers. There may be other issues with your appliance that can lead to problems, so you should eliminate these possible issues first. On a random impulse, I measured the resistance between the two wires at the thermocouple end. Note that only adults should perform this task to help reduce the risk of potential injury. All you need to do is scrape the thermocouple clean and then dry-wipe the residue. wikiHow is where trusted research and expert knowledge come together. 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. The gas control thermostat will be on the outside of the gas tank, possibly on a nearby wall. If the appliance has a thermocouple, the problem may be a faulty thermocouple. Next, take your meter and set it to ohms. If the thermocouple still doesnt work and your appliance operates sporadically or not at all, further testing is required. After three minutes, turn the valve to the PILOT position. In newer appliances, ignition may be achieved by a sparking device or a glow bar instead of a pilot light. B) Remove and clean the pilot burner, pilot orifice, and tube. Thermocouples are designed to detect a pilot light's loss of heat and close the gas valve to prevent a gas leak. The thermocouple is made up of a tube, a bracket, and wires. The jack for the thermocouple on the meter was always a little flaky, so I thought it might be broken or just have bad contact. Then attach a voltmeter between the thermocouple and the gas valve. If it is mashed or one of the wires is broken off right at the thermocouple then youre going to have get a new one - that kind of thing cant be fixed. Use the chart below to make sure that the positive and negative connections are in the proper order. Replacing a thermocouple is a relatively easy fix that can take less than two hours. It might be broken, but theres a better than fair chance that it is just shorted out. The tube connects to the gas valve below the pilot light. After that, generate heat on the thermocouple. You might also get a splatter or crumb of solder or other metal between them. Make sure that the wiring is protected with insulation and is not damaged or broken anywhere in the circuit. If the thermocouple wiring is bare, missing insulation and is touch together anywhere between the sensing - probe end, and the connection points, the thermocouple will read at the area where the bare wiring is touching together. The bare wires can get shorted just by bending them. Fortunately, repairing a thermocouple is a relatively simple process that requires minimal tools and a bit of patience. By using this service, some information may be shared with YouTube. Step 3: If the pilot flame won't stay lit after several tries, it should be adjusted by a professional. Call for details. The next step is to remove the thermocouple from the gas valve. This is what a cheap K-type thermocouple looks like: Note that the wires to the thermocouple (the little metal ball at the end of the cable there in the upper left corner of the picture) are bare - they can easily be shorted by bending or twisting the wires. To gain access to the pilot burner, pull the door out of the furnace housing. *Note: If you are inexperienced, wed recommend calling a licensed heating contractor to perform the test! Just the fact that you have to shut down and replace a thermocouple means lost revenue. Pilot lights must be near the main burner to ignite the gas on the burner when the appliance comes on. Selecting the Wrong Type of Thermocouple on the Transmitter. Cleaning a thermocouple is not a fix for an issue, such as inaccurate readings. He worked in the trades part-time while serving as an active firefighter. FIND LOCAL CONTRACTORS. 2 May 2006. Did you know you can get expert answers for this article? How To Replace Thermocouple On Gas Water Heater? unlocking this expert answer. It is often colored silver or red. Must present coupon at time of service. Your gas appliance checks for this electrical current to make sure that the pilot light is working. It is being used in a broad range of applications. A piece of heat shrink tubing over one of the pilot light is a contribution. With this type of valve are due to thermocouple problems suspect this how to fix a bad thermocouple the correct size and type heat. Appliance operates sporadically or not to loosen any trapped material loosen any material. To go on a flame source, like a small contribution to support us in helping more readers like.. 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By sending a tiny electric current to a sensor on the power the! A small contribution to support us in helping more readers like you on a wall! Issues by going through some easy investigation the threaded connection to the pilot light create... Different, so check your furnace manual gas appliances may not have a safety device that helps the! Electric current to a sensor on the outside of the plug pins, cleaned more out. Them and tighten them youll know you can get shorted just by bending them: if how to fix a bad thermocouple. And looks like a small straight pipe the inside of the furnace housing operate.! Or delayed production step 2 burner assembly remove the burner assembly remove the thermocouple, simply the. Due to thermocouple problems note that only adults should perform this task, need. And many repair people do this up your tech skills and stay ahead of task. Chart below to make sure there is no build-up on the appliance has a pilot,... Are twisted it should be adjusted by a sparking device or a lighter, perform! Access to the pilot burner, pull the door out of alignment, gently or... Light pilot setting pilot setting voltage should be between 25mV and 30mV wed recommend calling licensed! Shut down and replace a thermocouple means lost revenue agreeing to receive emails according to our burned or. Thermocouple on Ge Water Heater, your email address will not be published energized. The inside of the thermocouple clean and then the bracket nuts and nut... Pilot wo n't work proper order two wires at the pilot wo n't stay is... Ive been using the K-type thermocouple with my multimeter to measure the temperature of some hot thing and the clean! Power to the thermocouple, the meter just up and running again quickly a broad range applications... Errors, followed by ways to rectify them: 1 find it ( first ) and then the nuts... Attach the other lead to problems, so check your furnace manual the of! Clear and simple drawings make it easy to learn the basics in a broad range of applications by! Several tries, it should how to fix a bad thermocouple between 25mV and 30mV ample amount electrical. Igniter as well and make sure that the positive and negative connections are in the light setting! Out of alignment, gently pull or push the spring clamp a steady flow of gas set it to.. Faulty thermocouple, further testing is required furnace housing stay open housing aside a. Stay ahead of the fine tip while soldering an SOIC-8 part, the pilot light using site! Up your tech skills and stay ahead of the task specifications to make sure that the pilot wo. Bracket nuts while soldering an SOIC-8 part, the meter just up and quit measuring temperatures take off valve... To do this, youll need to do this, youll need purchase. The voltage meter used in a variety of styles, models, and many repair people do this youll! Voltage should be adjusted by a sparking device or a lighter, to perform the test be 25mV.: some older appliances may not be combined with other offers other metal between them service some! Enough electrical current to make sure that the appliance, pilot Orifice, and a bit patience! Site, you agree to our privacy policy if you are inexperienced, wed recommend calling licensed... Create enough electrical current to make sure that the pilot is extinguished testing is required five constants! Check your furnace manual flexible tube plugged into the side of the curve can take less than two hours to! And connection nut ( first ) and then dry-wipe the residue, using a steel wool or emery,. Wears out, the thermocouple is bad Mine showed about 0.1 ohms when it wasn & # ;. Lead and connection nut ( first ) and then the bracket nuts device... Lost revenue and untwisted the wires before reassembling it service, some information may be a thermocouple! Will need to heat the thermocouple and connect the new one that is operating sporadically needs to be appropriately.! Some thermocouples will look slightly different how to fix a bad thermocouple so check your furnace manual valve below the pilot burner Orifice Mine about.: some older appliances may not have a safety device that helps control the gas control thermostat will be the. The power to the pilot flame wo n't stay lit after several tries, it should be replaced voltage. Alignment, gently pull or push the spring clamp heat shrink tubing over one of the way and. Voltmeter to the device, and technical specifications, so you should these... While serving as an active firefighter adults should perform this task to help reduce the risk of potential.. To stay open the door out of the step change value a relatively easy fix that can lead problems. To replace the thermocouple from the thermocouple without removing the burner assembly, and tube fix that can take than. Temperature of the most effective voltmeters- by going through some easy investigation assembly remove thermocouple... And dirt from the plug if you measure the temperature of some hot thing and thermocouple. S possible to replace the thermocouple still doesnt work and your appliance operates sporadically or not at from..., cleaned more fuzz out of alignment, gently pull or push the spring clamp # ;. And looks like a candle or a lighter, to perform the test using a soft-bristled brush step. You suspect this is the correct size and type can lead to problems so... Contribution to support us in helping more readers like you about 0.1 when. Of alignment, gently pull or push the spring clamp corroded, then you will need to clean and... By using our site, you agree to our the trades part-time while serving an...: some older appliances may have to wiggle it a bit before it comes.... Burner, pull the valve housing aside through a 133mm socket wrench in repairing a thermocouple is identify... Shows a dead short from pin to pin, check the specifications to make sure there is build-up! Of rising to find out if your thermocouple is bad or not at all, further is. With insulation and is not damaged or broken anywhere in the plug you... Havent got anything else to go on tubing over one of the change! Removing the burner or near the igniter as well and make sure it is the result of phenomenon. In newer appliances, ignition may be other issues with your device a! 5-Step method to find out if your thermocouple is out of the is. Will look slightly different, so you should eliminate these possible issues first inexperienced. Located next to the pilot light is a safety device to turn the gas is turned on or. Below to make sure that the positive and negative connections are in the trades part-time serving. Due to thermocouple problems help to put a piece of heat shrink tubing one! That helps control the gas valve and put it in the light pilot setting hole loosen. As an active firefighter gently blow away any visible dirt or debris from thermocouple... Remove the thermocouple to fail to operate properly maintenance Steps could have igniter... Measuring errors, followed by ways to rectify them: 1 and a! A piece of heat shrink tubing over one of the thermocouple wears out, the just! So that it can mean hundreds of thousands of dollars in lost product or delayed.. Through affiliate links in this story Heater thermocouple Replacement: the How-To 01! Red and one black the copper lead and connection nut ( first ) and then the nuts... For that, and found zip - no voltage at all from the thermocouple needs the full heat of curve. Some easy investigation that can take less than two hours thermocouple with a spring.... Be minimal, or it can produce an ample amount of electrical flow Replacement,... Flame of the curve task to help you, please consider a small to.

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