A thermocouple is a sensor for temperature measurement. Water heaters use either a thermocouple or an alternative control device to regulate water temperature.
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|Bradford White Thermocouple 24" 233-46501-24|
Many gas-fed heating appliances such as ovens and water heaters make use of a pilot flame to ignite the main gas burner when required. If it goes out, gas may be released, which is a fire risk and a health hazard. To prevent this, some appliances use a thermocouple in a fail-safe circuit to sense when the pilot light is burning. The tip of the thermocouple is placed in the pilot flame, generating a voltage which operates the supply valve which feeds gas to the pilot. So long as the pilot flame remains lit, the thermocouple remains hot, and the pilot gas valve is held open. If the pilot light goes out, the thermocouple temperature falls, causing the voltage across the thermocouple to drop and the valve to close. Some combined main burner and pilot gas valves (mainly by Honeywell) reduce the power demand to within the range of a single universal thermocouple heated by a pilot (25mV open circuit falling by half with the coil connected to 10~12mV @ 0.2~0.25A typically) by sizing the coil to be able to hold the valve open against a light spring, only after the initial turning-on force is provided by the user pressing and holding a knob to compress the spring during first lighting. These systems are identifiable by the 'press and hold for x minutes' in the pilot lighting instructions. (The holding current requirement of such a valve is much less than a bigger solenoid designed for pulling the valve in from closed would require.) Special test sets are made to confirm the valve let-go and holding currents as an ordinary milliameter cannot be used as it introduces more resistance than the gas valve coil. Apart from testing the open circuit voltage of the thermocouple, and the near short-circuit DC continuity through the thermocouple gas valve coil, the easiest non-specialist test is substitution of a known good gas valve.