Symptoms of a bad thermocouple include a controller displaying 'b.o' (burn out), inaccurate temperature readings, and the thermocouple being an open circuit when checked for resistance.
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Controller Displaying 'b.o' (Burn Out): If the controller displays 'b.o', it indicates that the thermocouple is probably dead. This is a clear sign that the thermocouple is no longer functioning correctly and needs to be replaced. The 'b.o' message is typically a programmed response in the controller to indicate a failure in the thermocouple.
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Inaccurate Temperature Readings: Thermocouples generate a small electrical signal in millivolts when heated, which is used by the electronic controller to determine the temperature. Over time, the wires used to form a thermocouple degrade with each thermal cycle, causing the electrical signal to change. This degradation can lead to the signal degrading to the point where the temperature read by the electronic controller is no longer accurate. The furnace readout may continue to display a temperature value, but the actual temperature can be off by over 100 degrees, leading to incorrect process temperatures.
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Open Circuit When Checked for Resistance: After removing the thermocouple, checking the resistance can reveal if it is an open circuit, indicating that the thermocouple is broken. This test involves measuring the resistance of the thermocouple wires to determine if there is a continuous electrical path. An open circuit suggests a break in the thermocouple, which prevents it from functioning correctly.
These symptoms are critical indicators that the thermocouple is failing or has failed, necessitating immediate inspection and potential replacement to ensure accurate temperature control and prevent process failures or safety issues.
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