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Replacing thermocouple can't remove thermocouple from bracket

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replacing thermocouple - 0232f209-db10-4fb0-a02f-33d53f99836e.png
A thermocouple actually slides into a keeper that it can be withdrawn from with some steady pulling with needle nose pliars at the base of the thermocouple. Some mounts are screwed and the sleeved thermocouples, keeper is mounted in this.
I almost always just pull it out from it's base.

Posted on Oct 19, 2013

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My pilot light won't stay light


Most often, this is a faulty thermocouple. Replace it, but first be sure the pilot flame is actually heating the thermocouple. If it is not, it will not stay lit. Sometimes they fall down out of it's holding bracket or just go bad. A lazy yellow pilot flame means the pilot orifice is dirty and needs to be cleaned. If the pilot flame is a string blue color, then replace the thermocouple.

Mar 17, 2015 | Heating & Cooling

Tip

Sunjoy L-PH 018PS Patio Heater pilot failure repair


What is likely happening is that the pilot flame cannot reach the thermocouple. This is usually caused by corrosion or other blockage of the gas to the area where the pilot lights. Thus resulting in a small flame or no flame on the side the thermocouple is located. Fix this by cleaning out the corrosion or other blockage in the pilot assembly. I have found that small spiders like to make their homes here which causes the blockage of the gas for the pilot. The pilot assembly has three parts to it. The ignitor electrode, the pilot light tower, and the thermocoupler. The ignitor electrode has a wire that goes from it to the push button ignitor. The pilot tower is located in the middle and has a gas line going to it from the gas valve (control knob). The thermocoupler stands next to and on the opposite side of the ignitor electrode. It also has a copper line from it to the gas valve.

Unfortunately, the Sunjoy you have, which is the same model of two I have to keep running, is difficult to service. Parts are not readily available either so be careful when you take it apart. They do not sell the individual smaller parts in this model and therefore make you buy complete assemblies.

To clean and service the pilot assembly, remove the screws holding the front plate on where your control knob is. Once that is removed you can see the back of the ignitor, it is black and has one wire coming from it leading up to the ignitor electrode. You will also be able to see the small gas line from the gas valve going up to the pilot tower and the small copper line from the gas valve to the thermocoupler. That assembly is what you need to get to, to clean.

You do that by removing the top canopy by removing the three screws holding it down. Once that is removed, remove the center nut on the heat exchanger (the part that heats up with all of the little holes). It is located on the top and in the center of the heat exhanger. Then remove the three screws that are located around the bottom of the heat exchanger that connects the collar to it. You should be able to remove the heat exchanger now. Tilt the whole heater2_bing.gif down and prop the neck on something so you can work on it.

If you look in the top you will be able to see small metal box covering the pilot assembly. This is held onto the pilot assembly with two screws. Remove those screws and carefully remove the box. Now remove the two screws that holds the pilot assembly to the collar (located on the outside of the collar). The gas and copper lines will hold it up. If you look at the pilot assembly from the top you will see one screw holding the ignitor electrode to the pilot assembly bracket. Remove that screw, unplug the wire from the ignitor and remove the ignitor electrode from the assembly. Be careful not to break this and I am having you remove it so that you do not break it.

Now remove the nut that holds the thermocoupler onto the pilot assembly bracket and pull it out of the bracket. The copper line will hold it up and be careful not to kink the copper line. Take a piece of sandpaper and clean the outside surface of the thermocoupler. Corrosion on the thermocoupler could cause it to fail which will cause the pilot not to stay lit. I have not had one do that yet but it could happen.

Now, remove the gas line from the bottom of the pilot tower so that the tower and bracket are in your hands. Put it down and put the heater back up straight. Hook up your gas and turn the gas on. Now, press the control knob on the pilot setting to make sure you have gas coming out of the gas line that feeds the pilot. You should be able to hear, feel and smell it. If not you have a regulator problem or an empty tank. Turn off your gas, remove it from the heater and tilt the heater back down.

Take your pilot assembly, you will see a circular top to the pilot tower that is held down with really small metal ears. Carefully bend the ears back with a needle nose pliers so that you can bend the top of the tower back. Only bend it back far enough to clean the inside of it with a bent wire and compressed air or something. If you look on the lower side of the bracket, above where the gas line is threaded on you will see a hole that goes all the way through the assembly. This hole regulates the pilot gas pressure and allows the gas to mix with the air before it burns. Make sure that hole is clear of debris and take wire or something and thread it through the hole up through the top side of the tower.

When you have it clean, reconnect the gas line, thermocoupler and ignitor electrode. Once reconnected and before screwing the assembly back to the collar, I set the heater back up right and reconnect the gas. I then light the pilot to make certain you have a good strong pilot light generously touching the thermocoupler. The pilot should stay lit after holding the button in for a few seconds. Do not turn the heater on past the pilot area without the heat exchanger on or you might singe your hair. If the pilot works the way it is supposed to, turn it off, disconnect your gas, tilt the heater back down and reassemble it following the intructions in the opposite manner.


on Mar 24, 2010 | Heating & Cooling

1 Answer

Where can I find helpful instructions for replacing (removing old and installing new) thermocouple on Pentair 250k minimax ch NG mv? Thank you.


Simple:
  • Insecure bracket holding the pilot assembly to the burner tray
  • now, remove the pilot assembly from bracketry
  • unscrew old pilot generator/thermo pile or thermocouple
  • new may have a clip instead of threaded nut
    • diameter of hole is same so it should just snap into place
  • in reverse order resecure the pilot bracket to burner tray


24539435-iwrnrkacomuoeuyhvucmvd0t-2-0.jpg

24539435-iwrnrkacomuoeuyhvucmvd0t-2-2.jpg

May 30, 2014 | Pentair 250k Minimax Ch Ng Mv Heater

1 Answer

My heil furnance comes on but no hot air or air at all


see this causes and fix it. God bless you
o light the pilot on a standing-pilot (always on) ignition system, follow the lighting instructions located near the control. Otherwise, try these steps: Light the pilot:
  1. gasfurnace1.jpg Press and hold the pilot control knob to start the pilot. Set the control knob to the pilot position. Hold a long match under the pilot gas port.
  2. Press the control knob; the pilot should light. Hold the control knob down until the flame is burning brightly (about 30 seconds). Release pressure on the knob, and turn it to the on position.
  3. If the pilot goes out when you release the control knob, try relighting, holding the control knob down longer. If the pilot again goes out, check the thermocouple (below).
Adjust the pilot:
  1. Remove any cap covering the pilot adjusting screw on a combination control.
  2. Turn the adjusting screw counterclockwise to increase the flame or clockwise to decrease it. It is correctly adjusted when the flame envelops the thermocouple bulb by 1/2 inch and appears dark blue with a small yellow tip.
Test and replace a thermocouple:
  1. Hold the control knob to pilot and light the pilot as above.
  2. Unscrew the thermocouple fitting with an open-ended wrench.
  3. Set a multimeter to the DVC (lowest voltage) scale.
  4. Clip one multimeter lead to the end of the thermocouple tube nearest the pilot and the other lead to the fitting on the other end of the tube.
  5. If the multimeter shows a reading besides zero, the thermocouple is functioning. Replace the thermocouple tube.
  6. If there is no reading, you will need to clean or replace the thermocouple following steps 7 through 11.
  7. Release the control knob and shut off the main gas valve on the gas-supply pipe that leads into the burner. Shut off power to the burner at the electrical service panel .
  8. Remove the thermocouple from its mounting bracket.
  9. Wipe the combination control clean and install a new thermocouple, tightening it by hand, then give it a one-quarter turn with a wrench.
  10. Insert the thermocouple into the pilot bracket, being careful to not crimp the tubing.
  11. Turn on power to the furnace and relight the pilot (above).
Adjust an adjustable burner air shutter:
  1. Set the thermostat to its highest setting to keep the burner running. Once the furnace has heated up, remove the burner access panel and loosen the locking screw.
  2. Open the shutter by turning it to the right until the blue base of the flame appears to lift slightly from the burner port surface. Then close the shutter until the flame reseats itself on the surface.
Clean removable burner tubes and ports:
  1. Shut off gas and power to the furnace.
  2. Unscrew or loosen and remove the tubes from the supporting bracket.
  3. Carefully clean the tubes with a brush or vacuum, making sure not to damage the burner ports.
  4. Use a stiff wire to clear any debris from clogged ports.

Oct 08, 2012 | Honeywell Icp Heil Tempstar Furnace Spark...

1 Answer

RHFE Rinnai 551FT gas heater is not working after 7 years


see this steps and fix it. God bless you
.
If there is no heat, check the electrical service panel for a burned fuse or tripped breaker. Relight the pilot light (see below).
If there is not enough heat, adjust the burner air shutter (see below); and clean the burner ports (see below).
If the pilot light does not light or does not stay lit, clean the pilot orifice carefully with a toothpick, test the thermocouple and replace it if it is faulty (see below).
If the flame flickers, adjust the pilot (see below).
If there is an exploding sound when the burner ignites, adjust the pilot to a higher setting and clean the pilot orifice and the burner ports.
If the burner takes more than a few seconds to ignite, clean the pilot orifice and adjust the pilot light.
If the burner flame is uneven, clean the burner ports. If the burner flame is very yellow, clean the burner; open vents in the furnace room to provide more air; adjust the burner air shutter.
To light the pilot on a standing-pilot (always on) ignition system, follow the lighting instructions located near the control. Otherwise, try these steps:
Light the pilot:
  1. gasfurnace1.jpg Press and hold the pilot control knob to start the pilot. Set the control knob to the pilot position. Hold a long match under the pilot gas port.
  2. Press the control knob; the pilot should light. Hold the control knob down until the flame is burning brightly (about 30 seconds). Release pressure on the knob, and turn it to the on position.
  3. If the pilot goes out when you release the control knob, try relighting, holding the control knob down longer. If the pilot again goes out, check the thermocouple (below).
Adjust the pilot:
  1. Remove any cap covering the pilot adjusting screw on a combination control.
  2. Turn the adjusting screw counterclockwise to increase the flame or clockwise to decrease it. It is correctly adjusted when the flame envelops the thermocouple bulb by 1/2 inch and appears dark blue with a small yellow tip.
Test and replace a thermocouple:
  1. Hold the control knob to pilot and light the pilot as above.
  2. Unscrew the thermocouple fitting with an open-ended wrench.
  3. Set a multimeter to the DVC (lowest voltage) scale.
  4. Clip one multimeter lead to the end of the thermocouple tube nearest the pilot and the other lead to the fitting on the other end of the tube.
  5. If the multimeter shows a reading besides zero, the thermocouple is functioning. Replace the thermocouple tube.
  6. If there is no reading, you will need to clean or replace the thermocouple following steps 7 through 11.
  7. Release the control knob and shut off the main gas valve on the gas-supply pipe that leads into the burner. Shut off power to the burner at the electrical service panel .
  8. Remove the thermocouple from its mounting bracket.
  9. Wipe the combination control clean and install a new thermocouple, tightening it by hand, then give it a one-quarter turn with a wrench.
  10. Insert the thermocouple into the pilot bracket, being careful to not crimp the tubing.
  11. Turn on power to the furnace and relight the pilot (above).
Adjust an adjustable burner air shutter:
  1. Set the thermostat to its highest setting to keep the burner running. Once the furnace has heated up, remove the burner access panel and loosen the locking screw.
  2. Open the shutter by turning it to the right until the blue base of the flame appears to lift slightly from the burner port surface. Then close the shutter until the flame reseats itself on the surface.
Clean removable burner tubes and ports:
  1. Shut off gas and power to the furnace.
  2. Unscrew or loosen and remove the tubes from the supporting bracket.
  3. Carefully clean the tubes with a brush or vacuum, making sure not to damage the burner ports.
  4. Use a stiff wire to clear any debris from clogged ports.

Sep 30, 2012 | Heating & Cooling

1 Answer

Tappen furnace pilot will not light.status light keeps blinkink


If the light keeps blinking, its not getting the signal back from the thermocoupler. Look to make sure the flame is touching the thermocoupler. If it is not bend the bracket so that the thermocoupler tip is inside the flame of the pilot. If it is, the thermocoupler is bad and need to be replaced.

Dec 12, 2010 | Heating & Cooling

1 Answer

I WOULD LIKE TO REPLACE MY THERMO CUPPLING


In simplest terms, a thermocouple is a temperature sensor. Normally inexpensive, a thermocouple is standard on hot water tanks. If your thermocouple breaks or you feel it is not working properly, consider replacing it b?p=y23r90wnbq7oglkvtnbuhgyhrktxauzqpeoaddsf&t=18g7grtjm%2fx%3d1290445898%2fe%3d2143440281%2fr%3dacont%2fk%3d5%2fv%3d8.1%2fw%3d0%2fy%3dyahoo%2ff%3d2680761980%2fh%3dcg49imfjb250iibzzxj2zulkpsjzmjnsotb3tkjxn09nbgtwve5ivuhnewhys1r4yvv6cxbfb0fezfngiibzaxrlswq9ijq4mtmwnteiihrtdg1wpsixmjkwndq1odk4ota5njiwiia-%2fq%3d-1%2fs%3d1%2fj%3d6f060d4c&u=13gohjn6b%2fn%3df8a.bkwnpkw-%2fc%3d715481.14405591.14260180.13829426%2fd%3dlrec%2fb%3d6235626%2fv%3d1 lg.php?category_id=6&content_type=article&content_type_id=584031&key_page=1721642411054458764&site_id=1&bannerid=10089&campaignid=2945&zoneid=2&loc=1&referer=http%3a%2f%2fwww.associatedcontent.com%2farticle%2f584031%2fhow_to_change_a_thermocouple_on_your.html%3fcontent_type_id%3d584031&cb=ebe6534afeavw.php?zoneid=2&cb=1721642411054458764&source=&n=a14de4a9&slice=-1060-&dma=-0-&cty=-us-&content_type=article&content_type_id=584031&category_id=6&key_ad=1045292919&site_id=1&ad_pos=2&key_page=1721642411054458764&ac_url=http%3a%2f%2fwww.associatedcontent.com%2farticle%2f584031%2fhow_to_change_a_thermocouple_on_your.html rather than installing a new gas hot water heater.

Begin this project by shutting off the gas control knob on your hot water heater. Once you are sure that the gas is off, you should use a wrench to remove the nut that attaches the thermocouple to the gas hot water tank. This nut should appear to be securing a piece of copper tubing or other type of tubing. With the nut removed, you should also pull down on the tubing, dislodging it from the thermocouple.

Sometimes there is another nut that attaches the end of the thermocouple to the pilot bracket, if this is the case you should unscrew this nut as well. You can slide it down the tubing and keep it there until you need to replace it.

With the nuts that were holding the unit in place removed, you should be able to slide the old thermocouple out of the brackets that hold it to the hot water heater. You should then take it to a hardware or home improvement store and find a suitable replacement. Then follow these steps to install the new part and fix the hot water heater.

To change the thermocouple, you should press the end of the thermocouple into the pilot bracket as far as you can. If you had to remove a second nut to remove the old thermocouple, now is the time to replace that nut securely.

With the thermocouple in place, you should connect the lead to the control unit. Use the nut you removed in the beginning steps to secure the lead. You should then tighten it at least a quarter turn with a wench to make sure the lead is securely attached to the control unit of the gas hot water heater.

Now that the new thermocouple is installed on your gas hot water heater, turn on the gas shut off valve that you turned off earlier. You should be able to relight the pilot and the functionality of your gas hot water heater should be restored.

Dec 06, 2010 | Heating & Cooling

1 Answer

I have old rheem ruud hot water tank. it's down for 4 day's, i would like to get it started, but the thing i would like to find out is can i get it going by lighting it up by using lighter or not. The...


Yes you can light it with a BBQ type lighter (long enough).
If it lights and stays lit then you need to change the thermocouple (looks like a little pipe off gas valve)

In simplest terms, a thermocouple is a temperature sensor. Normally inexpensive, a thermocouple is standard on hot water tanks. If your thermocouple breaks or you feel it is not working properly, consider replacing it b?p=y23r90wnbq7oglkvtnbuhgyhrktxauzqpeoaddsf&t=18g7grtjm%2fx%3d1290445898%2fe%3d2143440281%2fr%3dacont%2fk%3d5%2fv%3d8.1%2fw%3d0%2fy%3dyahoo%2ff%3d2680761980%2fh%3dcg49imfjb250iibzzxj2zulkpsjzmjnsotb3tkjxn09nbgtwve5ivuhnewhys1r4yvv6cxbfb0fezfngiibzaxrlswq9ijq4mtmwnteiihrtdg1wpsixmjkwndq1odk4ota5njiwiia-%2fq%3d-1%2fs%3d1%2fj%3d6f060d4c&u=13gohjn6b%2fn%3df8a.bkwnpkw-%2fc%3d715481.14405591.14260180.13829426%2fd%3dlrec%2fb%3d6235626%2fv%3d1 lg.php?category_id=6&content_type=article&content_type_id=584031&key_page=1721642411054458764&site_id=1&bannerid=10089&campaignid=2945&zoneid=2&loc=1&referer=http%3a%2f%2fwww.associatedcontent.com%2farticle%2f584031%2fhow_to_change_a_thermocouple_on_your.html%3fcontent_type_id%3d584031&cb=ebe6534afe avw.php?zoneid=2&cb=1721642411054458764&source=&n=a14de4a9&slice=-1060-&dma=-0-&cty=-us-&content_type=article&content_type_id=584031&category_id=6&key_ad=1045292919&site_id=1&ad_pos=2&key_page=1721642411054458764&ac_url=http%3a%2f%2fwww.associatedcontent.com%2farticle%2f584031%2fhow_to_change_a_thermocouple_on_your.html rather than installing a new gas hot water heater.

Begin this project by shutting off the gas control knob on your hot water heater. Once you are sure that the gas is off, you should use a wrench to remove the nut that attaches the thermocouple to the gas hot water tank. This nut should appear to be securing a piece of copper tubing or other type of tubing. With the nut removed, you should also pull down on the tubing, dislodging it from the thermocouple.

Sometimes there is another nut that attaches the end of the thermocouple to the pilot bracket, if this is the case you should unscrew this nut as well. You can slide it down the tubing and keep it there until you need to replace it.

With the nuts that were holding the unit in place removed, you should be able to slide the old thermocouple out of the brackets that hold it to the hot water heater. You should then take it to a hardware or home improvement store and find a suitable replacement. Then follow these steps to install the new part and fix the hot water heater.

To change the thermocouple, you should press the end of the thermocouple into the pilot bracket as far as you can. If you had to remove a second nut to remove the old thermocouple, now is the time to replace that nut securely.

With the thermocouple in place, you should connect the lead to the control unit. Use the nut you removed in the beginning steps to secure the lead. You should then tighten it at least a quarter turn with a wench to make sure the lead is securely attached to the control unit of the gas hot water heater.

Now that the new thermocouple is installed on your gas hot water heater, turn on the gas shut off valve that you turned off earlier. You should be able to relight the pilot and the functionality of your gas hot water heater should be restored.

Nov 22, 2010 | Heating & Cooling

1 Answer

My reliance 606 hot water tank pilot wont stay on soon i release it it goes out and no hot water what do i need to do to solve the prolem myself?


You need to replace the thermocouple. It unscrews from the thermostat on one end, and the other one hooks in a bracket. After replacment make sure the thermocouple bulb is in the pilot flame.

Apr 08, 2010 | Reliance & 40 Gal Electric Mobile Home...

1 Answer

Where would I find install instructions for a thermopile (lennox 11450097) to go into a gas earth stove model TG300DV


Hi and welcome to FixYa. I am Kelly

You do not even have to turn off the gas to the stove to change the thermocouple.

It is a matter of unthreading the fitting from the gas valve and routing the new thermocuple in the same matter as the old one. There usually are 2 -3 mounting screws for the thermocouple head. Remove the screws and install the new thermocuple head in the same place as the old one.

Before you screw the new thermocouple into the gas valve make sure the mating area inside the gas valve is clean then thread the thermocouple fitting into the gas valve.

Sometimes the igniter is also mounted on the same bracket as the thermocouple just be careful not to damage it if yours is installed in the same manner.

It should not take more than 20 minutes......

That is it.... simple as that.

Thanks for using FixYa

Kelly

Feb 18, 2010 | Napoleon 36" Zero Clearance Top/Rear Vent...

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