BriskHeat TC4000 User manual

TC4000
Digital High Capacity
Outdoor Temperature
Controller
Instruction Manual
You must read and understand this manual before
installing, operating, or servicing this product. Failure to
understand these instructions could result in an
accident causing serious injury or death.
Keep these instructions for future reference.
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2
TC4000 Digital High Capacity
Outdoor Temperature Controller
Immediate hazards which WILL result in
severe personal injury or death.
Hazards or unsafe practices that COULD
result in severe personal injury or death.
Hazards or unsafe practices that COULD
result in minor personal injury or property
damage.
SAFETY ALERT SYMBOL
The symbol above is used to call your
attention to instructions concerning your
personal safety. It points out important
safety precautions. It means “ATTENTION!
Become Alert! Your Personal Safety is
involved!” Read the message that follows
and be alert to the possibility of personal
injury or death.
WARNING
CAUTION
DANGER
TABLE OF CONTENTS
Introduction...........................................................................................................................2
Safety Alert Symbol..............................................................................................................2
Important Safety Instructions................................................................................................3
Specifications and Part Number Matrix................................................................................4
Installation Instructions.........................................................................................................5
Power Input/Output Connections ........................................................................................6
Operation Overview..............................................................................................................9
Alarm Settings ................................................................................................................... 10
Glossary ........................................................................................................................... 11
Troubleshooting Guide ...................................................................................................... 12
Warranty Information......................................................................................................... 13
INTRODUCTION
BriskHeat®TC4000 digital temperature
controllers are designed for general purpose
use in outdoor or indoor environments to
control temperatures on applications
requiring automatic control.
For additional information concerning this, or
other BriskHeat®products, please contact
your local BriskHeat®distributor or contact
us toll free (U.S. / Canada only) at
1-800-848-7673 or 614-294-3376.
Save these instructions for future use.

© BriskHeat®Corporation. All rights reserved.
3
TC4000 Digital High Capacity
Outdoor Temperature Controller
IMPORTANT SAFETY INSTRUCTIONS
A person who has not read and understood
all operating Instructions is not qualified to
operate this product.
DANGER
 Do not immerse or spray any
component of the control system with
liquid.
 Keep volatile or combustible material
away from controller when in use.
 Use controller only in approved
locations.
 Keep sharp metal objects away from
controller.
 Do not rely on the controller as a
disconnect – only handle the output
wires if you know the power is totally
disconnected.
Failure to observe these warnings may result
in electric shock, risk of fire, and personal
injury.
DANGER
End User Must Comply With the Following:
 Disconnect all supply power at the source before making any power connections.
 Only qualified personnel are allowed to connect electrical wiring.
 All electrical wiring must follow local electrical codes. BriskHeat® highly recommends
following NEC Article 427.
 The person who performs the final installation / wiring must be qualified for this work.
 The end-user is responsible for providing a suitable disconnecting device.
 The end-user is responsible for providing suitable electrical protection device. It is highly
recommended that a ground fault circuit breaker is used.
Failure to observe these warnings may result in personal injury or damage to the product and/
or property.
WARNING
 Inspect all components before use.
 Do not use control and heater if any
component is damaged.
 Do not repair damaged or faulty
controller or heaters.
 Do not crush or apply severe physical
stress on any component of controller,
including cord assembly.
Failure to observe these warnings may result
in personal injury or damage to the product
and/or property.
CAUTION
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4
TC4000 Digital High Capacity
Outdoor Temperature Controller
Part Number Matrix for TC4000 Series
           
   TC4XXX
ProductSeries
        
        
TC4‐TC4000Series       
        
ControlZones
        
        
 11‐SingleZone        
 22‐DualZone        
          
VoltageRang
         
         
 1‐100‐240VACSinglePhase        
 2‐480VACSinglePhase        
 3‐100‐240VAC3‐Phase/Delta        
 4‐480VAC3‐Phase/Delta        
          
AmbientTemp
         
         
 N‐(0°Cto40°C)        
 (32°Fto104°F)        
          
SPECIFICATIONS
Maximum Controller Temperature Setting: 999 °F or 999 °C
Input Voltage: 100-240, 480 VAC; may be operated as single, or three-phase.
Accuracy: ±0.2% with sampling time of 60 ms
Sensor input options: Type J, K, thermocouples.
Product dimensions: 16.75 x 15.5 x 8.5 inches (H x W x D)
Maximum weight of #A#A

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TC4000 Digital High Capacity
Outdoor Temperature Controller
INSTALLATION INSTRUCTIONS
Figure 1: Mounting the Controller: Hole Pattern
MOUNTING THE CONTROLLER:
The following procedure should be used when installing the TC4000 temperature controller.
1. Choose an appropriate location considering the following:
a. Mounting location must provide strong, stable support.
b. Proximity to a suitable power supply.
c. Proximity to a means of disconnecting or switching equipment.
d. Proximity to heater load, in terms of sensors and monitoring. Thermocouples longer than 30m
are not recommended.
e. The mounted location must provide easy access for the operator.
f. Appropriate clearances
Example: clearance to open enclosure door at least 90°, clearance to allow easy connection of
power cords and sensors
g. Ambient operating temperature does not go beyond the range of:
32 °F to 104 °F (0 °C to 40 °C)
h. Humidity conditions within 20 - 85%, non-condensing temperatures
2. Mount the controller securely in the chosen location. All four mounting points must be used.
a. To mount from front (with the attached mounting brackets), simply hold the controller up to the
mounting area, orient the mounting brackets as desired, and mark the new hole locations.
Additional mounting hardware, suitable for the weight of the controller, may be required and is
not included.
3. Supply power (inlet voltage) to be hardwired into controller.
4. As supplied, TC4000 controllers are NEMA 4X. To maintain this, all external connections must be installed
with appropriate IP rated, liquid-tight fittings.
5. Ensure any heating elements connected to the controller are rated for the same voltage supplied to
controller.
6. For protective grounding, connect suitably sized ground conductor at location marked in panel.
Enclosure Openings
For maximum flexibility, TC4000 controllers are sold with no openings already made in the enclosure. Holes for conduit
and fittings may be made using a standard hole saw. Take care to avoid damaging components when making holes. Be
sure to clear debris completely.
Fire and shock hazard. This product is an
electrical device that must be installed correct-
ly to ensure proper operation and to prevent
shock or fire. Read these important warnings
and carefully follow all the installation instruc-
tions. Keep these instructions for future refer-
ence.
The customer is responsible for providing
suitable branch circuit protection for each
zone, as well as providing a suitable dis-
connect for each zone.
WARNING
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6
TC4000 Digital High Capacity
Outdoor Temperature Controller
Power Input/Output Connection
The TC4000 is compatible with single- or 3-phase connections, and there are 2 voltage
ranges offered: 100-240 VAC and 480 VAC, clearly labeled on the controller. Do not
exceed the voltages listed on the controller!
Mains power must supply a Safety Ground connection to the controller.
Connect Mains power to the screw type terminal block.
Single-phase power is supported by supplying mains power to N/L2 (DB1-1) and L1 (DB1-
2).
3-phase Y or Delta is supported by supplying power to L1 (DB1-1), L2 (DB1-2), L3 (DB1-3)
and N (DB1-4). This controller does not convert a Y feed into a Delta, or vice-versa.
Input Power is supplied through the modular terminal blocks. These are clearly labeled
DB1-1, DB1-2, DB1-3, DB1-4 inside the controller, and the blocks are individually marked
L1, L2, L3, N, Gnd as well. An allen wrench is required to insert connectors into the
distribution block, and to disconnect. See Figure 2, above.
Heater output connections are spring-type connections. Zone 1 is marked TB-1 and Zone 2
(if applicable) is marked TB-2. All that is needed is a small screwdriver to push deeply into
the terminal’s adjacent slot, to temporarily loosen each terminal clamp.
Each electrical supply conductor must be connected directly to its intended Input (for ex-
ample, Zone 1 Input). Also, because controller power is provided through the input power
connection for Zone 1, Zone 1 must be connected to an electrical feed. If Zone 1 loses
power, all control functionality will stop.
WARNING
Figure 2: LEFT: 3-Phase or Delta Input Power RIGHT: Single Phase Input Power

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7
TC4000 Digital High Capacity
Outdoor Temperature Controller
Each zone provides L1-L3, Neutral, and Ground (Gnd). The terminals are individually
marked L1, L2, and L3 as well. Connect the output Gnd wire directly to the terminal block
Gnd for that zone (Gnd terminal block is used as a pass-through). Customers using 3-
Phase Y connections should connect the output N wire directly to the terminal block N for
that zone (N terminal block is also used as a pass-through). The Neutral terminal block is
not switched, floating, and is provided as a pass-through connection for a 3-Phase Y
configuration.
Temperature Sensor Connection:
The TC4000 controller can directly accept thermocouples with mini-connectors. Supported thermocou-
ples are (J, K). The sensor type must be set in the controller. Be sure to observe correct polarity when
wiring thermocouples.
Sensor Placement:
Place the temperature sensor tip between the surfaces to be heated and the heater to be controlled.
The tip must be placed in a location which best reflects the application. Depending on the object’s size
and shape, there may be spots that are warmer or colder due to different thermal transfer parameters.
If all areas of the object must reach a minimum temperature, then place the sensor tip on the coldest
spot. If the temperature of any area of the object cannot go above the controller’s set point, then place
the sensor tip on the hottest spot. If a temperature differential is allowable, then place the tip on an
area where the temperature is between the hottest and coldest.
PRESS SCREW-
DRIVER HERE
CONDUCTORS
HERE
GND/N
HERE
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TC4000 Digital High Capacity
Outdoor Temperature Controller
BUTTON FUNCTIONS:
UP ARROW - SCROLL UP
Allows the operator to adjust temperature setting and parameter options (See PARAMETERS
section for more information).
Down arrow - Scroll Down and Quick Temperature Set Point Access.
Allows quick access to modify controller set point value when pushed once. Allows the operator to
adjust temperature setting and parameter options (See PARAMETERS section on Page 7 for more
information).
U button - Standby Mode
Press to toggle the temperature controller in/out of standby mode. While in standby mode, the
heater will de-energized and all heating and temperature monitoring operations cease until taken
out of standby mode.
P button - Programming Mode
Grants access to program the temperature controllers parameters (See PARAMETERS section on
Page 7 for more information).
QUICK START OPERATION:
1. Default temperature set-point is 0, default unit is °C.
2. Press Down Arrow to access / change the temperature set-point parameter.
3. Press Up/Down arrows to adjust the temperature to desired set-point.
4. Press and Hold the P button exit the temperature set-point parameter.
TO CHANGE TEMPERATURE UNITS (°C OR °F) OR ELEMENT TYPE:
1. Press and hold the P button for approximately 5 seconds.
2. Use (▲▼) buttons to select the “r.P.” (Restricted Parameters) parameter keyword on the controller.
3. Press the P button to select. The controller will alternately flash the parameter’s keyword (r.P.) and its
current value.
4. Use (▲▼) to adjust the parameter value from 0 to 1.
5. Press the P button to save the desired value. The display will return to flashing only the selected
parameter’s keyword.
6. Use (▲▼) buttons to select the “SEn” (sensor) parameter keyword on the controller.
7. Press the (P) button to select. The controller will alternately flash the parameter’s keyword (SEn) and
its current value.
8. Use (▲▼) to adjust the parameter value. See PARAMETERS section on page 8 for more information.
9. Press the (P) button to save the desired value. The display will return to flashing only the selected
parameter’s keyword.
10. Exit the programming mode by pressing and holding (▲) for approximately five seconds or wait 30 seconds for the
controller to automatically exit the programming mode. When the temperature displays, the controller is no longer
in the programming mode.

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9
TC4000 Digital High Capacity
Outdoor Temperature Controller
OPERATION OVERVIEW
NOTE: READ ALL INSTRUCTIONS PRIOR TO APPLYING POWER TO THE CONTROLLER
1. All TC4000 Controllers require temperature sensors, which may be Type-J, Type-K. Verify correct polarity of the
sensor connection prior to use.
2. Verify proper placement of the temperature sensor.
3. Properly connect power leads of each heater into the appropriate contactor(s).
4. Plug the selected thermocouple into the TC4000’s jack corresponding to the heating zone being controlled.
5. When all is ready, turn on the power feeding this system.
6. Press the key and use the and arrow keys for each zone controller to adjust the setpoint.
PARAMETERS
* Only select a parameter listed in the table that corresponds with the controllers model
number being used.
Parameter Descripon Range Units Default
SP1 Set Point
Desired heater
temperature 0 to 999 °C 0
°F
AL High limit
alarm Alarm set point 0 to 999 °C 999
°F
SEN Sensor/
Units
Change tempera-
ture units be-
tween ° C and °F
Type J JC (°C) _
JC
JF (°F)
Type K Ca.C (°C) _
Ca.F (°F)
d1 Hysteresis
Deviaon Be-
tween On-Off
cycle
1 to 999
°C
1
°F
AL.F Alarm
Funcon
Change of the
alarm funcon
AL - Automac reset
_ AL.n
AL.n - Latched
AL.A - Acknowledgea-
ble
r.P Restricted
Parameters
Factory Program-
ming Factory preset to 0
_
0
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10
TC4000 Digital High Capacity
Outdoor Temperature Controller
Stand - by:
Press and hold the U (Stand-by) button to turn on stand-by mode. The heater will not heat while the
controller is in this mode. To return the controller to normal operations, press and hold the U button
until the temperate displays on the screen.
ALARM SETTINGS
The alarm displays when the sensing element temperature extends past the High Limit Alarm. This
device’s alarm is identified by the illumination of the AL and OUT2 red LEDs. The alarm settings are
accessed under the Alarm Function (AL.F) parameter. The three available alarm settings are:
 AL - Automatic reset Alarm - When the temperature extends past the High Limit Alarm, the alarm
automatically disengages.
 AL. n - Latched Alarm - When the temperature extends past the High Limit Alarm, the alarm
display will remain engaged until it is manually reset. To manually reset the alarm, press and hold
both the U and P buttons for 5 seconds.
 AL.A - Acknowledgeable alarm - While the temperature is extends past the High Limit Alarm, the
alarm can be acknowledged and disengaged by pressing and holding both the U and P buttons for
5 seconds. The alarm will automatically reset when the temperature returns to within the High Limit
Alarm if it is not acknowledged prior.
Configuration of Parameters:
1. If the controller is in Stand-by mode, return the controller to normal operations.
2. Press and hold the P button for approximately 5 seconds. Use the UP and DOWN buttons to select the desired
parameter to change.
3. Press the P button to select the desired parameter. The instrument will alternatively visualize the parameter’s code
and its current value.
4. To modify the value of the parameter, press the UP and DOWN buttons.
5. Press the P button to save the new value. The display will return to visualize only the code of the selected
parameter.
6. Press the UP and DOWN buttons to select another parameter to modify using the steps above.
7. To exit the programming mode, press and hold the UP button for approximately five seconds or wait 30 seconds for
the controller to automatically exit the programming mode. When the temperature displays, the controller is no
longer in the programming mode.

© BriskHeat®Corporation. All rights reserved.
11
TC4000 Digital High Capacity
Outdoor Temperature Controller
Glossary
Alarm Output that trips when a certain condition is reached, for example, a defined
temperature. Note that the TC4000 only provides visual alarm capability, on the
controller display.
Control output Output that controls the process and is switched on and off as needed.
Hysteresis In the context of ON/OFF control of a heating system, Process Value (PV) must
exceed Setpoint Value (SV) by a certain quantity before the controller switches the
heater off, and PV must fall below SV by a certain quantity before the heater is turned
on. In each of these two cases, “certain quantity” could be equal or different,
depending on how the controller is set.
ON/OFF Control process based on full-power activation and deactivation of the output. Also
called “Bang/Bang” or “Hysteresis” control. See “Hysteresis.”
- This type of control is not intelligent, and is not very accurate, but is simple, effective,
and controls how often ON/OFF switchings of the output happen. Minimizing how often
ON/OFF switchings happen minimizes component wear and tear.
Overshoot Situation in which Process Value exceeds Setpoint Value because the control action
stopped too late. The ON/OFF controls have an overshoot greater than the PID
controls.
Process Value / PV The value that the process variable (temperature, valve opening, etc.) has at that
moment.
Sensor Device that translates physical phenomena (such as change in resistance based on
temperature) into electrical signals that can be measured and processed by the
controller
Setpoint Value / SV The value that the process variable (temperature, valve opening, etc.) has to reach
and maintain.
Thermocouple Sensor that transmits an electrical signal of a few millivolts. Cannot be tested for
galvanic continuity. It needs specially designed extension cables.
Undershoot Situation in which Process Value does not reach Setpoint Value because the control
action stopped too soon.
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12
TC4000 Digital High Capacity
Outdoor Temperature Controller
TROUBLESHOOTING GUIDE
Please read this guide prior to contacting BriskHeat®. This guide is designed to answer the
most commonly asked questions. If you are unable to identify the problem or need
additional assistance, please contact your local distributor or BriskHeat at 1-800-848-7673
(U.S. & Canada), 1-614-294-3376 (worldwide), or [email protected]om.
PROBLEM SOLUTION(S)
Does not heat Verify heater is connected to proper voltage. The identification label located on the
power cord displays the heater’s voltage requirement.
Using an ohm meter, check to see if there is a resistance reading (not an open circuit) in
the heater.
Many special heater plugs require special crimping tools. Ensure good connection
between the heater wiring, plug and input receptacle.
Use a Volt-Ohm meter to check the outlet receptacle.
Circuit breaker is tripping Validate that the circuit breaker is capable of handling the Amp requirement of heater.
The identification label located on the power cord displays the heater’s amperage
requirement.
Examine heater and cord for any damage.
Something has lightly
spilled on exterior or interior
of heater
Apply any general household cleaner, that does not contain any silicone rubber
dissolving type ingredients, with a clean cloth fabric. Do not connect any heater to a
TC4000 that is not clean and in good repair.
Controller is heating to an
incorrect Setpoint
Temperature
Controller will attempt to provide power to the heater whenever the PV is less than SV. If
thermocouple is not exposed to heater, the controller will operate at 100% in an attempt
to reach SV.
Controller Error Codes
If these error messages occur, contact Briskheat® for service.
EPr—If the controller displays EPr, this error message will disappear automatically. If
this error message occurs multiple times, please contact your Briskheat® representative
for service.
Replace sensor. If problem still exists contact Briskheat® for service.
Controller does not turn on Verify that the controller and heaters are connected to proper voltage, according to
product identification labels.
Controllers’ fuse blown – check with multimeter and replace.
MAINTENANCE AND CLEANING
UNPLUG DEVICE BEFORE CLEANING
After device is unplugged, wipe down with a damp rag. Examine cords and heaters for
wear or damage. If damaged, replace affected components immediately.

© BriskHeat®Corporation. All rights reserved.
13
TC4000 Digital High Capacity
Outdoor Temperature Controller
NOTE
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14
TC4000 Digital High Capacity
Outdoor Temperature Controller
WARRANTY INFORMATION
BriskHeat warrants to the original purchaser of this product for the period of eighteen (18)
months from date of shipment or twelve (12) months from date of installation, whichever
comes first. BriskHeat’s obligation and the exclusive remedy under this warranty shall be
limited to the repair or replacement, at BriskHeat’s option, of any parts of the product which
may prove defective under prescribed use and service following BriskHeat’s examination, is
determined by BriskHeat to be defective. The complete details of the warranty can be found
online at www.BriskHeat.com or by contacting us at 1-800-848-7673 (toll free, U.S. /
Canada) or 1-614-294-3376 (worldwide).
CorporateHeadquarters:
4800HiltonCorporateDr.
Columbus,OH43232,U.S.A.
TollFree:800‐848‐7673
Phone:614‐294‐3376
Fax:614‐294‐3807
Email:[email protected]
Europe:
P.O.Box420124
44275Dortmund,Germany
PN: 41336 Rev 0