GAS SMART

Explanation of millivolt systems.

Service and trouble shooting guide.
Millivolts system This valve is similar to the thermocouple only valve,
Many gas appliances are fitted with millivolt systems however it has a pilot which heats up BOTH a thermocouple
and a thermopile. The thermocouple still acts to prove that
to protect and/or control the burner operation.
the pilot flame is on and allows this flame to continue after
The millivolt system is powered by a thermopile that
start-up. The thermopile is used to power a second circuit
operates a millivolt valve. Before explaining any which is used to open the main valve. This second circuit is
further let’s have a look at a thermopile. powerful enough (300-600 millivolts) to allow the use of a
thermostat, wall switch or control switch to operate the main
Thermopile valve. Control of the valve is obtained simply by hooking a
Thermopile or Thermo-electric generators, converts heat pair of wires to two terminals located on the valve.
directly into electricity, using the voltage generated at an in-
series connected array of thermocouples known as a
“thermopile”. The history begins in 1821 when Thomas This valve has the thermo-
Johann Seebeck found that an electrical current would flow couple circuit connected to the
in a circuit made from two dissimilar metals, with the thermopile. When heated the
junctions at different temperatures. thermocouple acts to prove
that the pilot flame is on and
The Thermopile was initially used for measurements of allows this flame to continue
temperature and infra-red radiation, but was also rapidly put after start-up. At the same time
to use as a stable supply of electricity for other physics the thermopile is used to
experimentation. power a second circuit which
is used to open the main valve
This Markus' thermopile Gas valve with and allow the use of a
won a prize in 1864/5 thermopile only
thermostat, wall switch or
from the Vienna Society control switch to operate the
for the Promotion of main valve. You can recognise this type by having a pilot
Science and generated with only a thermopile.
55 mV.
Gas Pilots

This pilot is often

used in gas fryers
Today’s thermopiles are much and gas heaters with
smaller and generate about a high gas input. It
750 mV- enough to actuate a reacts quickly when
small solenoid that keeps the the gas pilot has
gas valve open. gone out and shutoff
the gas. (B) See
wire diagram

Millivolt Gas Valves

Many manufacturers producing millivolt gas valves
for the gas appliance industry. It was recognised
that with a millivolt system, gas appliances could be
controlled and protected. Several valves are used in This pilot is used in gas
today’s gas appliances, some are; appliances were the
safety valve and the
control valve are
electrically connected
together. This system
uses 600-700mV for
proving the pilot flame.
(A) See wire diagram
Gas valve with thermo-couple
and thermopile

Arie de Kort - Mar 06

 Basic Wire diagram
Thermostat
On-Off
Switch
Gas Valve
Gas Valve
A
Trouble shooting
Millivolt systems with both a thermocouple and thermopile
(B), it is important first to isolate where the potential problem
may be. If the pilot can be lit and stays on after the knob is
released, then the problem is probably with the thermopile
side of the valve.
Millivolt systems where the safety valve is operated by the
thermopile (A), check where the potential problem is by
lighting the pilot and if it stays on with the knob released,
then the problem is probably with the control side of the
valve; e.g. loose connections, switches or thermostats.
Here are the most common problems and solutions;
1. Common problem is loose or poor connections or
circuits to your appliance switch or thermostats. This
can be isolated by simply using a small piece of wire to
jump the "TP" and "TH" terminals located on these
valves. If the appliance turns on when these terminals
are jumped, then you can be sure that your problem is
not in the appliance itself, but further down the switch
circuit. Make certain you have used the suggested
gauge of wire and that the length for your control runs
does not exceed the specs given by the manufacturer.
2. Check the milli-voltage between the connections
“TP/TH” and “TP” on the gas valve with the switch and
thermostat in the “ON” position and the pilot burning.
The voltage should be approximately 190mV DC. Main
burner may not light if readings are less than 145mV
DC.
Arie de Kort - Mar 06
Gas Burner
Pilot flame
Thermopile Thermocouple
B
3. The milli-voltage between the connectors “TP/HP” and
“TP” on the gas valve with the switch in the “OFF”
position should be around 500 mV DC. If readings are
low check the pilot burner is clean and operates as per
manufacture’s specification.
4. With a clean pilot and a low milli-voltage reading, check
the gas connection to the heater. The inlet pressure
should be in the range as specified by the
manufacturer.
5. If all the above fails renew the thermopile and check the
voltage.
Please Note
Never short out or remove a safety device in a
control system. That can lead to catastrophic
problems.
Never replace a thermocouple in a millivolt system
with a wire from the thermopile.
Appliances are designed for safety reasons with;
• a millivolt system with thermocouple or;
• a millivolt system without a thermocouple.
Altering systems could affect the appliance safety
and therefore should not be carried out without
authorisation of the manufacturer.
If not sure ask help from the manufacturer or
suitable qualified service agent.