Top 11 How Long Should A Thermocouple Last The 125 New Answer

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Thermocouples can last up to 10 years if properly installed and maintained, while furnaces can last 15-20 years, although either may wear out sooner in multifamily units.A good thermocouple is going to be used, and that can lead to metal fatigue. Changes in temperature can cause regular expansion and contraction in metal, which will cause thermocouples to weaken over time. After enough time, metal fatigue can cause a thermocouple to break.How Long Should a Water Heater Thermocouple Last? If properly installed and maintained, thermocouples can last for up to 10 years.

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What causes thermocouples to go bad?

A good thermocouple is going to be used, and that can lead to metal fatigue. Changes in temperature can cause regular expansion and contraction in metal, which will cause thermocouples to weaken over time. After enough time, metal fatigue can cause a thermocouple to break.

How long should a thermocouple last on a hot water heater?

How Long Should a Water Heater Thermocouple Last? If properly installed and maintained, thermocouples can last for up to 10 years.

How long does a gas fire thermocouple last?

The fireplace has thermocouples and switches. The thermocouples should last for a long time. According to experts, a four-year check cycle is all that is needed.

How do you know when to replace 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.

How often do thermocouples go bad?

Thermocouples can last up to 10 years if properly installed and maintained, while furnaces can last 15-20 years, although either may wear out sooner in multifamily units.

What are the symptoms of a bad thermocouple?

Failed Thermocouple Symptoms

Signs of contamination on the tube, e.g. discoloration, cracks, or pinholes.
Signs of wear or corrosion of the wirings, e.g. missing insulation or bare wire.
Physical damage to the connectors which can have an effect on the reliability of the test reading.

Can thermocouple be cleaned?

Yes, you can clean a thermocouple, but the task must be done with a light touch. Remove the thermocouple from the process assembly, using a steel wool or emery cloth, lightly clean the tip removing any build up. Cleaning a thermocouple is not a fix for an issue, such as inaccurate readings.

How much does a thermocouple cost?

The No. 1 cause of pilot lights that won’t stay lit is a worn-out thermocouple. 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.

What happens if a thermocouple fails?

Normally when the thermocouple malfunctions or isn’t working, it simply shuts off the gas to your heater. This is important, particularly if the pilot light is out, because it prevents harmful gas from leaking into your home.

How much does it cost to replace a thermocouple on a gas fireplace?

When replacing a thermocouple or thermopile with the help of a professional, you can expect to pay between $150 and $250.

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 much does it cost to replace a thermocouple on a furnace?

Replacing a thermocouple costs $150 to $250, mostly due to labor time. On older models without an ignitor, it checks to make sure your pilot light is lit. If it’s not, it’ll shut the gas off.

What is the most common thermocouple failure mode?

The most common failure mode for thermocouples is for them to fail open, this is known as thermocouple burnout. Burnout can result from a variety of reasons including the thermocouple experiencing a temperature in excess of that for which it was designed, metal fatigue, and oxidation.

What factors affect the response time of a thermocouple?

The factors that affect response times and accuracy are the thermowell’s material, thickness, and overall size.

How do you maintain a thermocouple?

THERMOCOUPLE MAINTENANCE

Do not allow excessive bending of the thermocouples. …
Use protection tubes for corrosive atmospheres.
Always inspect protection tubes when changing thermocouples. …
Do not locate the thermocouple too close to a heating element.

What’s the maximum lead wire length for a thermocouple or RTD?

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CAUSES OF THERMOCOUPLE FAILURE, PART 1

A malfunctioning thermocouple can lead to incorrect measurements and create big problems. Thermocouples are built to be resilient, but there are a few factors that can cause thermocouple failure. This week, we’ll go into how metal fatigue and oxidation are both potential threats to your thermocouples.

METAL FATIGUE

Like everything, thermocouples can’t stay new forever. A good thermocouple is going to be used, and that can lead to metal fatigue. Changes in temperature can cause regular expansion and contraction in metal, which will cause thermocouples to weaken over time. 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.

OXIDATION

Oxygen is great for people, but it doesn’t always extend the life of a thermocouple. The presence of oxygen causes a reaction in the thermocouple that can wear down the part and make the wires become thinner and more brittle.

Oxidation can be caused by a small amount of oxygen making its way into a sealed environment and reacting with the pure metal of the thermocouple. Make sure to check your sealed thermocouples regularly to ensure that the integrity of their seals haven’t been compromised and can continue to operate without fear of oxidation.

HIGH-QUALITY THERMOCOUPLES FROM GEOCORP

Thermocouple failure can lead to incorrect readings and unplanned downtime. GeoCorp can provide you with high-quality thermocouples that are designed to meet your needs and are built to resist factors like metal fatigue and are sealed properly to prevent oxidation.

Give us a call at 419-433-1101 or contact us online today to talk to one of our experienced sales technicians about how our thermocouples can benefit your business.

Gas Water Heater Thermocouple Possible Issues

A thermocouple is a sensor that is used to measure temperature and detect whether or not the water heater’s pilot light is lit. You certainly wouldn’t want this element to fail as it’s an important safety device.

The most common gas water heater thermocouple issues include a pilot light that keeps going out, a burner that won’t light, and the absence of hot water. This might happen, in case the thermocouple is dirty, faulty, worn down, or improperly positioned.

How Do You Know If You Have a Bad Thermocouple?

To find out for sure whether your gas water heater has a bad thermocouple or another problem, you can perform this test:

Unscrew the thermocouple. Set your multimeter to millivolts. Start the pilot (you might want to ask someone to help you as the gas control knob needs to be held to keep the flame burning while you’re testing the thermocouple). Give the unit a minute and then place the lead on the shaft and the other one – on the connector. The reading has to be over 25 millivolts. If it’s less, then your thermocouple had gone bad and you would have to replace it. You can try reversing the leads if you are not getting a reading. Give the device around 30 seconds; if the thermocouple is not giving at least the minimum rated millivoltage, then you need a new one.

Bear in mind that some thermocouples do not have dual wire leads. You are going to need special equipment to test those, that’s why calling a professional might be the best idea.

What Happens If You Have a Bad Thermocouple?

If the thermocouple had worn out, then:

The pilot light will go out

The burner won’t light

The water heater won’t be able to produce hot water

An obstruction in the pilot tube and some other issues might lead to such problems as well. However, if the flame goes out once you release the gas control knob (after holding it for 20-30 seconds), then the chances are high that there’s an issue with the thermocouple.

Read: What Is Water Heater Heat Pump? Everything You Need To Know

What Causes a Thermocouple to Fail?

The thermocouple or the ‘flame sensor’ is a safety device that will shut the gas off, if the pilot light goes out. The element is, basically, a metal rod that should be touching the flame when the water heater is operating.

The main things that can cause the thermocouple to fail include:

General wear and tear – this important component has to deal with extremely high temperatures on a regular basis. Throughout the years, it can wear down.

– this important component has to deal with extremely high temperatures on a regular basis. Throughout the years, it can wear down. Damage – the thermocouple can easily get damaged as the component is quite fragile.

– the thermocouple can easily get damaged as the component is quite fragile. Soot buildup – even a slight residue can make the thermocouple malfunction.

– even a slight residue can make the thermocouple malfunction. Improper positioning – the element has to be lined correctly, otherwise, it won’t be able to sense the flame.

Read: Does HVAC Include Water Heater?

Will a Pilot Light Stay Lit with a Bad Thermocouple?

The thermocouple is the component in your gas water heater that allows gas to flow to the burner. If the thermocouple had gone bad, it will shut off the gas to the burner and pilot, so the pilot won’t be able to stay lit.

How Do You Fix a Thermocouple?

At times, the simplest thing that you can do is replace the thermocouple. It is a relatively easy job that won’t take you too long.

Moreover, thermocouples are not expensive, so getting a new one won’t make a huge hole in your wallet.

If you have confirmed that the thermocouple has not gone bad, but it is still failing to sense the flame, then you can try cleaning the element or adjusting it.

To adjust a bent thermocouple or move it closer to the flame, you should:

Shut off the gas. Locate the thermocouple (under the burner). Gently pull or push the probe.

Hint: if the pilot flame is too small and is not able to reach the thermocouple, then try turning the pilot adjustment screw counterclockwise. Also, do make sure that there are no obstructions in the pilot tube.

Read: Ideal Temperature Of The Water Heater

Can You Clean a Thermocouple?

You can certainly clean a thermocouple as this element will get covered in soot and/or dirt over time.

Cleaning the thermocouple every 6 months or so should be enough.

How to Clean Thermocouple on Water Heater?

Prepare a multiway wrench, a screwdriver, an emery cloth, a lint-free fabric, and fine-grit sandpaper (or steel wool). Turn off the gas supply. Remove the burner assembly from the control center. Sand the end of the thermocouple and then wipe it with a lint-free cloth. If you have to – detach the thermocouple from the assembly. Reconnect the burner assembly. Open the gas valve and light the pilot.

Hint: before removing any part of the unit, take a picture of how it was assembled.

Read: The Best Temperature For The Water Heater And Why?

How Long Should a Water Heater Thermocouple Last?

If properly installed and maintained, thermocouples can last for up to 10 years.

Gas water heaters, in their turn, have a general lifespan between 8 and 12 years, so if you manage to take great care of your unit, you might not have to replace the thermocouple at all.

Water Heater Thermocouple Replacement

Make sure to disconnect all the connections to the gas control valve before you begin (disconnect the thermocouple, the burner supply tube, and the pilot supply tube).

Turn the gas control valve to ‘off’ and close the shutoff valve (on the gas supply pipe).

If the water heater has been running, give the unit around 30 minutes to cool down.

If you have an electronic ignition water heater or a standing-pilot unit:

Remove the burner assembly cover and then remove the actual burner assembly. Around the manifold cover plate, you’ll find the cover plate gasket – remove it. Locate the thermocouple’s mounting bracket and carefully remove the thermocouple by pulling and twisting the element. Insert the new thermocouple. Make sure that the tip is positioned right – it should get enveloped in the pilot flame by around 3/8-1/2 of an inch. Reinstall the rest of the water heater’s components. Reattach the gas tubes. Bear in mind that the mounting nut on the new thermocouple shouldn’t be more than a ¼ of a turn beyond hand-tight. Turn on the gas and test the water heater.

For an electronic ignition unit, you would have to remove and then reinstall the igniter.

For a standing-pilot water heater, you would have to relight the pilot before setting the gas control valve back to ‘on’.

How Much Is a Thermocouple for a Gas Water Heater?

Thermocouple replacement is one of the most common repairs needed for gas water heaters. It will cost you anywhere between $100 and $325 to have the element replaced by a professional.

If you have the necessary skills and equipment, you might want to replace the thermocouple on your own. In such a case, you would have to pay only for the actual part – that’s between $5 and $20.

Are Water Heater Thermocouples Universal?

Generally, thermocouples are interchangeable as the majority of them have standard connectors. Universal components are compatible with clamp-type, push-in, and screw-in pilot burners.

By the way, even the length of the thermocouple doesn’t really matter as it has no effect on the element’s accuracy.

However, do bear in mind that older water heaters with standing pilot lights utilize a thermocouple, while the more modern units with electronic ignition have a flame sensor.

The devices are pretty much the same, but you should still take the model of your water heater into consideration.

Read: How Many Amps Does Water Heater Use?

Can You Bypass a Thermocouple on a Water Heater?

You should not bypass a thermocouple as it is an extremely important safety device.

Without this element, your water heater might continue supplying the unit with gas even if the pilot light is out. In such a case, the gas is going to escape into your house – and that is a very serious safety hazard.

If you need to urgently use the water heater, the chances are high that you’re not going to be next to the unit all the time to keep an eye on the pilot light. So, in the worst-case scenario, gas might end up accumulating close to your floor.

In any case, cleaning the thermocouple or getting a new one and replacing the faulty element would require less effort (and, of course, is a much safer option).

How to Know If Your Thermocouple Is Malfunctioning

Like the other component parts in your furnace, the thermocouple can wear down over time, producing lower voltage than it should when heated. And the worst part is that you can have a bad thermocouple without even knowing.

Therefore, inspecting and testing your thermocouple should be part of your furnace maintenance. Be sure to inspect before you test, however, to ensure that there are no obvious problems that could affect the readings from testing!

If you’re uncomfortable performing this test yourself, be sure to call a licensed HVAC contractor who can help you.

How Does a Thermocouple Work?

The thermocouple is a small electrical device, but it is a critical safety component on your furnace. 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.

How to Inspect Your Furnace’s Thermocouple

You will need a wrench, multi-meter, and a flame source, like a candle or a lighter, to perform the test.

Step 1: Inspect the thermocouple

What does a thermocouple look like and how do you find it? Your furnace’s thermocouple is usually located right in the flame of the furnace’s pilot light. Its copper tubing makes it easy to spot.

The thermocouple is made up of a tube, a bracket, and wires. The tube sits above the bracket, a nut holds the bracket and wires in place, and underneath the bracket, you will see the copper lead wires that connect to the gas valve on the furnace.

Some thermocouples will look slightly different, so check your furnace manual.

Failed Thermocouple Symptoms

Once you have located the thermocouple, do a visual inspection. You are looking for a few things.

The first is signs of contamination on the tube , which can include discoloration, cracks, or pinholes.

, which can include discoloration, cracks, or pinholes. Next, check the wiring for any signs of wear or corrosion like missing insulation or bare wire.

like missing insulation or bare wire. Finally, visually inspect the connectors for physical damage because a faulty connector can affect the reliability of the test reading.

If you cannot see or detect problems proceed with the test.

Step 2: Open circuit test of the thermocouple

*Note: If you are inexperienced, we’d recommend calling a licensed heating contractor to perform the test!

Before the test, turn off the gas supply because you must first remove the thermocouple.

Remove the thermocouple by unscrewing the copper lead and connection nut (first) and then the bracket nuts.

Next, take your meter and set it to ohms. Take the two leads from the meter and touch them—the meter should read zero. Once this check is done, turn the meter back to volts.

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.

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.

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.

Call Air Experts for Furnace Thermocouple Repair in the Raleigh, NC Area!

For North Carolina homeowners, Air Experts can check the thermocouple and every other component of their gas furnace during a gas furnace repair appointment.

Call Air Experts at 919-480-2727 or contact us online today to schedule furnace repair service!

Related Reading

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So you have finished reading the how long should a thermocouple last topic article, if you find this article useful, please share it. Thank you very much. See more: how long should a thermocouple last on a water heater, furnace thermocouple, thermocouple water heater, thermocouple replacement, rheem thermocouple, thermocouple boiler, how to trick a thermocouple, how long does a kiln thermocouple last

Top 11 How Long Should A Thermocouple Last The 125 New Answer

What causes thermocouples to go bad?

How long should a thermocouple last on a hot water heater?

How long does a gas fire thermocouple last?

How do you know when to replace thermocouple?

How often do thermocouples go bad?

What are the symptoms of a bad thermocouple?

Can thermocouple be cleaned?

How much does a thermocouple cost?

What happens if a thermocouple fails?

How much does it cost to replace a thermocouple on a gas fireplace?

Can I bypass a thermocouple?

How much does it cost to replace a thermocouple on a furnace?

What is the most common thermocouple failure mode?

What factors affect the response time of a thermocouple?

How do you maintain a thermocouple?

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CAUSES OF THERMOCOUPLE FAILURE, PART 1 – News

CAUSES OF THERMOCOUPLE FAILURE, PART 1 – News

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