Editing Thermocouple (section)

===Gas appliance safety===
[[File:Burner assembly of a water heater.jpg|thumb|A thermocouple (the right most tube) inside the burner assembly of a [[water heating|water heater]]]]
[[File:Thermocouple connection.JPG|thumb|Thermocouple connection in gas appliances. The end ball (contact) on the left is insulated from the [[Compression fitting|fitting]] by an insulating [[Washer (hardware)|washer]]. The thermocouple line consists of copper wire, insulator and outer metal (usually copper) sheath which is also used as [[Ground (electricity)#Electronics|ground]].<ref>{{cite book|title=Flammable Vapor Ignition Resistant Water Heaters: Service Manual (238-44943-00D)|publisher=Bradford White|url=http://waterheatertimer.org/pdf/44943-D-FVIR-Brad-White.pdf|pages=11–16|access-date=11 June 2014}}</ref>]]
Many [[Natural gas|gas]]-fed heating appliances such as [[oven]]s and [[water heating|water heaters]] make use of a [[pilot light|pilot flame]] to ignite the main gas burner when required. If the pilot flame goes out, unburned gas may be released, which is an explosion 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.

Where the probe may be easily placed above the flame, a [[Flame detector#Ionization current flame detection|rectifying sensor]] may often be used instead.  With part ceramic construction, they may also be known as flame rods, flame sensors or flame detection electrodes.

[[File:Flame-igniter(top)-and-flame-sensor.jpg|thumb|Flame-igniter(top)-and-flame-sensor]]

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 (25 mV open circuit falling by half with the coil connected to a 10–12 mV, 0.2–0.25 A source, typically) by sizing the coil to be able to hold the valve open against a light spring, but only after the initial turning-on force is provided by the user pressing and holding a knob to compress the spring during lighting of the pilot. 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 a closed position would require.) Special test sets are made to confirm the valve let-go and holding currents, because an ordinary milliammeter 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.

Some systems, known as millivolt control systems, extend the thermocouple concept to both open and close the main gas valve as well. Not only does the voltage created by the pilot thermocouple activate the pilot gas valve, it is also routed through a [[thermostat]] to power the main gas valve as well. Here, a larger voltage is needed than in a pilot flame safety system described above, and a [[thermopile]] is used rather than a single thermocouple. Such a system requires no external source of electricity for its operation and thus can operate during a power failure, provided that all the other related system components allow for this. This excludes common [[forced air furnace]]s because external electrical power is required to operate the blower motor, but this feature is especially useful for un-powered [[convection heater]]s. A similar gas shut-off safety mechanism using a thermocouple is sometimes employed to ensure that the main burner ignites within a certain time period, shutting off the main burner gas supply valve should that not happen.

Out of concern about energy wasted by the standing pilot flame, designers of many newer appliances have switched to an electronically controlled pilot-less ignition, also called intermittent ignition. With no standing pilot flame, there is no risk of gas buildup should the flame go out, so these appliances do not need thermocouple-based pilot safety switches. As these designs lose the benefit of operation without a continuous source of electricity, standing pilots are still used in some appliances. The exception is later model instantaneous (aka "tankless") [[tankless water heater|water heaters]] that use the flow of water to generate the current required to ignite the gas burner; these designs also use a thermocouple as a safety cut-off device in the event the gas fails to ignite, or if the flame is extinguished.