Testing the Thermocouple

1. Remove the thermocouple from the appliance. Make sure all safety protocols are followed. Make
sure that the multimeter to be used can read both ohms/resistance and millivolts.
2. Choose a test to assess the thermocouple. The three main tests used are the open circuit test,
closed circuit test and resistance test. While all three are useful, the closed circuit test will clearly
indicate whether the thermocouple performs properly under load and is often the primary test
conducted.
3. Select the ohms or resistance option on your multimeter. Place one test lead on the side of the
thermocouple and the other to the end that screws into the gas valve. If the thermocouple has
proper continuity, a small resistance reading should be visible on the multimeter. Many
multimeters also indicate continuity with an audio alert. If the reading on the multimeter indicates
an "OL" reading, the thermocouple does not have continuity and is therefore not usable. A high
resistance reading, such as 40 ohms, suggests that the resistance will cause problems and the
thermocouple should be discarded.
4. Turn your multimeter to millivolts to perform an open circuit test. Place one of the test leads of the
multimeter on the side of the thermocouple and the other to the end that enters the gas valve.
Ignite a lighter, or other heat source with a flame, at the opposite end of the thermocouple.
Thermocouples designed for residential gas appliances, such as fireplaces, water heaters and
furnaces, are made for 30 Millivolts. The reading should be between 25 and 30. Anything under or
hovering around the 20 millivolts mark means the thermocouple needs to be replaced. Discretion
should be used if the reading is between 21 and 25.
5. Perform a closed circuit test using the thermocouple adapter to achieve a true performance ability
under load. It is easier to perform this test using crocodile clips attached to the test leads. First,
attach the thermocouple adapter to the gas valve in the thermocouple's spot. Then attach the
thermocouple as normal with the exception that the end that would screw into the gas valve will
screw into the adapter.
6. Turn the appliance on and place a crocodile clip from the multimeter to the side of the
thermocouple. Attach the other crocodile clip on the screw that extends out of the side of the
adapter. The reading should be within 12 millivolts and 15 millivolts. Fewer than 12 millivolts
signifies that the thermocouple is defective.

Causes of failure
1. The use of lugs on TC cables, as time passes, the wire gets loose and there is an open loop.
2. The TC wire can also get broken due to vibration in the line, from the Junction
3.

Thermowell damage and subsequent ingress of process medium is also responsible for failure,
happens alot in corrosive service

4. The the TC module in the marshalling or the head cover can also get faulty. Or cause intermittent
error
5. Many times people do not use proper glands in the TC head which makes it more susceptible to
the ambient corrosive environment, hence oxidizing the contact area causing the failure.
Type K thermocouples have there own issues including instability in measurements, errors, hysterisis and
ultimately failure.
The reasons for the instability in Type K thermocouples are due to some inherent properties in the
chromel/alumel material. One problem that occurs with this thermocouple is an effect called short-range
ordering. It occurs in a temperature range of about 500F to 1020F when nickel and chromium atoms in
the chromel leg tend to form an ordered crystalline structure. The ordering produces a different
metallurgical structure and if a temperature gradient exists, an erroneous EMF is produced.
Another shortcoming of Type K thermocouples is the hysteresis effect that occurs when a Type K
thermocouple is cycled up and down in temperatures above and below 1800F. The re-ordering of the
crystalline structure changes with each cycle. After the first pass above this temperature, the Type K
temperature indication will probably be accurate. However,with each additional cycle after this one, the
error will increase more and more. The Type K thermocouple also experiences a cumulative drift after a
period of time at temperatures above 1650F. Finally, this thermocouple experiences a physical defect
called green rot which is caused due to preferential oxidation of the chromel leg.