- Buy an exact replacement for the old thermocouple from a plumbing supply center that carries your brand or the plumber who installed your water heater.
- Push the tip of the new thermocouple into the pilot bracket clip as far as it will go.
- If there is a hexagonal nut at its tip, screw it to the bracket.
- Run the lead out and bend it up into a gentle curve.
- Screw the nut on the end of the thermocouple to the control unit by hand, then give it a quarter-turn with an open-end wrench.
- Relight the pilot (instructions for relighting a pilot on all major brands is here).
- If it does not stay lit, close the gas shutoff valve, and call for service.
Full Answer
How to make a water heater thermocouple last longer?
- Make sure the thermostat is in heat mode.
- Locate the pilot valve. …
- Always turn the valve knob to the off position and make sure to wait at least several minutes for any residual gas to clear away.
- Get your match ready. …
- Once the pilot stays lit, turn the pilot valve to the on position.
How to bypass thermocouple?
- Remove the two screws holding thermal fuse in place
- Flip over the old fuse so that it’s upside down
- Twist clockwise and pull out of socket
- Remove one screw holding thermal fuse in place
- Push new thermal fuse into place
How to bypass your thermocouple on a propane heater?
What you’ll need for the test :
- Make sure to turn off your gas flow before conducting the test since you’ll have to remove the thermocouple.
- To remove the patio heater thermocouple, unscrew the connection nuts, and copper leads, followed by the bracket nuts.
- Set your meter to ohms. ...
- Turn the flame source on to conduct the actual test.
Can you repair a thermocouple?
Can you repair a broken thermocouple wire? If it is mashed or one of the wires is broken off right at the thermocouple then you’re going to have get a new one – that kind of thing can’t be fixed. If so, strip back some of the insulation, cut both bare wires to the same length, and reattach the wires. ...
Can a thermocouple be repaired?
Thermocouples are designed to detect a pilot light's loss of heat and close the gas valve to prevent a gas leak. Replacing a thermocouple is a relatively easy fix that can take less than two hours.
How do you fix a thermocouple on a water heater?
2:329:44Water Heater Thermocouple - Voltage Test & Replacement - YouTubeYouTubeStart of suggested clipEnd of suggested clipIf the multimeter under 20 millivolts then the pilot might have trouble staying lit. Over time aMoreIf the multimeter under 20 millivolts then the pilot might have trouble staying lit. Over time a buildup of carbon will act as an insulator.
Can you replace a thermocouple yourself?
It's easy to replace and a new one costs $5 to $10. Rather than trying to unfasten the thermocouple inside the water heater's burning chamber, it's easier to remove the whole burner and thermocouple assembly.
How do I know if my thermocouple is broken?
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. If the reading is less than 25 millivolts, the thermocouple is bad and needs to be replaced.
Can I bypass a thermocouple?
Realistically, you have just disabled the thermocouple, but you can also reach in and unclip it from its holding bracket where it meets the pilot light. In most cases it will be held on with a gravity clip, but some are held on with a screw that must be removed with a small screwdriver.
How do you fix a bad thermocouple?
2:345:18Furnace - Thermocouple | Repair and Replace - YouTubeYouTubeStart of suggested clipEnd of suggested clipUse a soft abrasive pad or emery cloth to gently clean the outside of the thermocouple. Be carefulMoreUse a soft abrasive pad or emery cloth to gently clean the outside of the thermocouple. Be careful not to scratch the coating. Next insert the thermocouple into the pilot assembly.
Are water heater thermocouples universal?
Universal thermocouples come in lengths from 15 to 36 inches. An 18 or 24 inch will suffice for all residential water heaters using universal kits. Almost all older waters heaters and many of the newer style units with a sealed burner compartment and a viewing window will use this thermocouple.
How do I know if my thermocouple is bad on my water heater?
If the pilot lights but the flame goes out as soon as you release the button after holding it for 60 seconds, then the thermocouple is bad. It's possible to replace the thermocouple without removing the burner assembly, and many repair people do this.
How long does a thermocouple last on a water heater?
How Long Should a Water Heater Thermocouple Last? If properly installed and maintained, thermocouples can last for up to 10 years.
What causes a thermocouple to fail?
After enough time, metal fatigue can cause a thermocouple to break. Thermocouples that are regularly exposed to extreme heat stress or extreme conditions are more likely to go through metal fatigue. If thermocouples start to give out unusual readings, it may be suffering from metal fatigue.
How do I know if I need a new thermocouple?
A working thermocouple will give a reading of between 25 and 30 millimeters. If the reading is less than 25 millimeters, it should be replaced.
What happens when thermocouple goes bad?
This means that if the thermocouple goes bad, there is no way of detecting if the pilot light is burning or not. And when the pilot light goes out, you will not have hot water supply in your plumbing system. To test if the problem is with the thermocouple, try to relight the pilot.
How do you know if your thermocouple is bad on your hot water heater?
If the pilot lights but the flame goes out as soon as you release the button after holding it for 60 seconds, then the thermocouple is bad. It's possible to replace the thermocouple without removing the burner assembly, and many repair people do this.
How much does it cost to replace a thermocouple on a water heater?
Thermocouple – $20 to $150 The thermocouple is an apparatus that senses whether the pilot light is lit and triggers the gas control valve. Repairs typically cost about $150 to have it done professionally, though a new thermocouple itself only costs about $20 on average.
What happens when thermocouple goes bad?
This means that if the thermocouple goes bad, there is no way of detecting if the pilot light is burning or not. And when the pilot light goes out, you will not have hot water supply in your plumbing system. To test if the problem is with the thermocouple, try to relight the pilot.
What does it mean when your hot water heater won't stay lit?
Thermocouple Issues If it senses that your water heater pilot light keeps going out, the thermocouple will shift off the gas supply to the heater. Over time, thermocouples can malfunction, accumulate dust buildup, or the device can get bent away from the pilot light's flame.
What is a thermocouple in a water heater?
The thermocouple is an essential safety feature of many gas-powered water heaters. It works like a temperature sensor that shuts off the gas supply to the burner if there is no heat in the pilot light.
How to prevent thermocouple from bending?
Apply firm pressure when twisting and pulling the thermocouple from its mount. It would be best to do this slowly to avoid deforming, bending, or damaging the thermocouple-pilot tube connection.
Why remove the manifold cover?
It is essential to remove the manifold cover to access the combustion chamber that accommodates the electronic ignition, thermocouple, pilot, burner, and burner supply tube.
How far should a pilot flame engulf a thermocouple?
It is essential to place the thermocouple in the correct position. Ideally, the pilot flame should engulf the thermocouple’s upper half to 3/8 inch. If you do not position the thermocouple properly, your efforts to replace a thermocouple will be in vain.
Can you reinstall a gasket around a manifold?
Place a new gasket around the manifold cover if the old one is no longer practical . Otherwise, you can reinstall the old lining to create a perfect seal around the combustion chamber.
Can you replace a thermocouple?
You need the correct thermocouple replacement for this activity. Unfortunately, you can only ensure you have the right replacement part by removing the old thermocouple and bringing it to the store.
Can I replace a water heater thermocouple?
Pro Tip: I advise you to bring the old water heater thermocouple to the store to buy the correct water heater thermocouple replacement. It will also be an excellent idea to consider buying a new manifold cover gasket if you intend to change the old one.
What is thermocouple in water heater?
Thermocouples are part of a pilot burner assembly connected to a gas control valve outside the water heater. This is a simple device that converts the heat from the burning flame into a small current, allowing you to act as a switch to control the gas flow of the gas supply valve.
Where to insert thermocouple?
Insert the new thermocouple externally into a ring or opening in the collector cover of the burner assembly.
How far away from the tip of a thermocouple should the pilot flame be?
Place the tip of the thermocouple so that the pilot flame surrounds 3/8 to 1/2 inch from the tip of the thermocouple.
What is the combustion chamber of a water heater?
The combustion chamber of a water heater with electronic ignition seals, gaskets. #N#To get into the combustion chamber, you need to remove the collector cover from the burner assembly, which includes the supply pipe of the burner, burner, electronic ignition, pilot and thermocouple.
How to release manifold and pilot tube?
Take the burner feed tube and push slightly down to release the manifold, pilot tube, and thermocouple connection.
What is the first step in maintaining the electronic ignition or standby pilot water heaters?
Disconnecting the gas control valve is the first step in maintaining the electronic ignition or standby pilot water heaters:
Can you disassemble a water heater foot indicator?
For old water heaters with foot indicators, it is very simple to disassemble and replace the thermocouple:
Step1
Before performing any maintenance it is important to turn off the supply to the water heater at the manual shut-off valve.
Step3
1. Using a 1/4” nut driver or socket loosen the two screws securing the manifold door assembly until they are free.
Step4
In this step, the thermocouple, manifold tube, pilot tube, and igniter wire can be disconnected from the mix control valve/thermostat.
Step5
1. Grasp the manifold tube and push down slightly to free the manifold tube, pilot tube, and thermocouple from the combination gas control valve/thermostat.
Step7
1. find the retainer clip securing the two-piece wire connector to the manifold door. (Note the orientation of the retainer clip).
Step9
1. Locate the clip holding the thermocouple to the pilot tube. (If your mannequin doesn’t have a clip, proceed to the following step).
Step10
1. Locate the thermocouple to the place it connects to the rear of the pilot meeting.
What is a Water Heater Thermocouple?
A water heater thermocouple is a sensor that turns off the gas supply when the pilot light goes out. This operational and safety feature is also known as a flame or heat sensor and its function is to control the flow of gas into the burner.
How Do You Know if Your Water Heater Thermocouple is Bad?
A bad thermocouple is the most common reason for a water heater pilot light that won’t stay lit. And it’s not unusual for it to wear out.
Final Thoughts
A gas water heater thermocouple replacement is a project you can do yourself. But it is important that you follow the safety rules: (1) turn off the gas is priority number one, and (2) don’t touch the thermocouple until it has cooled down.
Call 1-Tom-Plumber
Don’t hesitate to contact us here or call us at 1-Tom-Plumber (1-866-758-6237) if you need help safely maintaining, repairing, or replacing your gas water heater.
What is a thermocouple and why does my water heater need one?
Gas water heaters which use a pilot to light the burner will also have a thermocouple or thermopile to monitor the pilot (a thermopile is, essentially, multiple thermocouples connected in a series making the component more sensitive than a single thermocouple). If the pilot light goes out, the thermocouple acts as a safety device by preventing the gas valve from opening and potentially filling the area surrounding the water heater with natural gas. A faulty thermocouple, or one that is simply dirty, may consistently prevent the gas valve from opening or the pilot from staying lit. The end result is the burner assembly doesn’t produce a flame and the water in the tank is left unheated.
Where is the thermocouple located on a water heater?
The thermocouple is usually mounted on the burner assembly located near the bottom of the water heater tank . The steps required to access the thermocouple will vary depending on the water heater model, but here are some general guidelines you can follow:
What happens if the pilot light goes out on a water heater?
If the pilot light goes out, the thermocouple acts as a safety device by preventing the gas valve from opening and potentially filling the area surrounding the water heater with natural gas. A faulty thermocouple, or one that is simply dirty, may consistently prevent the gas valve from opening or the pilot from staying lit.
What to do if your water heater pilot light goes out?
Be aware, if the pilot light goes out, you will need to relight it following the water heater manufacturer’s instructions. Newer model water heaters will have a pilot setting on the gas valve and a spark electrode to light the pilot. Older models will have the pilot setting, but you will need to manually relight the pilot with a long match or lighter.
What happens if my water heater is not heating?
If the water heater is still failing to heat the water, the thermocouple may be completely defective, the pilot itself could be restricted, the igniter could be faulty, the gas valve could be malfunctioning, or the pressure switch in the power vent blower housing may have failed. All of these parts can be found at Repair Clinic by entering ...
How to secure burner plate to tank?
Thread and tighten the mounting nuts or screws to secure the burner plate to the tank.
How to clean a thermocouple?
Be aware, you may need to detach the thermocouple from the burner assembly to clean it thoroughly. Use a lint-free cloth to wipe the component clean of any remaining debris . Secure the thermocouple to the burner assembly if required .
What is a thermocouple in a gas water heater?
The thermocouple is an essential element of your gas water heater’s pilot light, ensuring more efficient water temperature management. Unfortunately, it can rust or wear out over time.
How to clean a thermocouple?
Ensure you do not see any dirt, soot, or residue after cleaning. Check the area between the thermocouple terminal and the power wire for any sign of corrosion. Remove the rust if any. Finish cleaning by wiping the thermocouple ends with a clean microfiber cloth or any other type of lint-free cloth.
How to remove a burner cover?
If your burner has an access cover, unthread the mounting screws first. Loosen and remove the screws or nuts that secure the burner plate. Loosen the nut that connects the burner supply line to the control center.
Why is my water heater not producing hot water?
A dirty thermocouple is one of them, but one that many people overlook. Now that you know how to clean your gas water heater ’s thermocouple, you may want to share this knowledge with your friends.
What is the best cloth to clean thermocouples?
Lint-free Cloth. This type of cleaning cloth is ideal as a finishing touch to the thermocouple cleaning process. Its main advantage is that it will not leave any fluff on the surface. We recommend a microfiber cloth for cleaning the thermocouple. 4. Small Brush or Steel Wool.
How to set water temperature in a water heater?
Open your water heater’s gas supply line and plug the power cord of your unit if it has one. Turn on the pilot light and adjust the thermostat to your desired temperature. It would be best to dial in a temperature not higher than 120 degrees Fahrenheit. Check your water if it is in your desired temperature.
Can you take a picture of a thermocouple before disassembly?
Pro Tip: If this is your first time removing the burner assembly, it would be best to take a picture of it before disassembly. The image serves as a guide for you to reassemble the unit after cleaning the thermocouple.
