1. COOLER CONTROLLER
2. COMPRESSOR CONTROL
3. EVAPORATOR FANS
4. OUTSIDE AIR SYSTEM
5. DOOR HEATERS

1. COOLER CONTROLLER
2. COMPRESSOR SYSTEM (This includes both the evaporator fans and the compressor control.)
3. OUTSIDE AIR SYSTEM
4. DOOR HEATERS

Programming the Cooler Controller. The LCD (liquid crystal display) window and the three white buttons next to it at the top of the Cooler Controller are for you to communicate with and control, or program, your Freeaire System. Once all the system components are in place and wired, it is time to check the controller's program. The controller is already pre-programmed to control a typical walk-in cooler or freezer. The installer will want to verify the default settings and perhaps enter custom settings for the particular installation. If any of the settings in the Cooler Controller will be different from the default settings, use an erasable pencil to record them on the SETTINGS stickers and attach them to the front of the Cooler Controller. The single white button on the left is the SCROLL button, and is used to advance to the next display window. Recessed inside the rubber grommet just above the scroll button is the programming switch. The white "+" and the "-" buttons on the right are used to make adjustment to what can be changed on the screen. There are three levels of access, or menus, for the Cooler Controller:

1. Main Menu. No code is needed to access this as no programming is done at this level, and the scroll button is the only button used. No settings can be changed without first entering a code, that will allow access to one of the other two menus.
2. User Menu. Access is gained by holding down all three buttons (the scroll, the "+", and the "-" buttons) for 5 seconds. This prevents accidental or mischievious alteration of certain settings by unauthorized person without this basic knowledge. The user menu allows access to energy use information and simple changes such as raising or lowering of the temperature. As a further protection against unwanted changes to any setting but the time, the programming switch must first be switched on. This is the small slide switch accessible just above the scroll button. Use a ballpoint pen or a small screwdriver to slide the switch from run mode (up position) to programming mode (down position). Programming is then accomplished by entering instructions into the controller by pressing the 3 white buttons.
3. Installer Menu. This menu is to be accessed by authorized persons only by use of a password. This is to ensure that critical settings are altered only by someone having a thorough understanding of the controller's logic and the operation of the refrigeration systems.

• INSIDE COOLER TEMP 35.0° or: INSIDE FREEZER TEMP 35.0°F
• OUTSIDE TEMP -6.0°F The Outside Temperature appears only if OUTSIDE AIR SYSTEM has been selected in the Installer Menu (more on this later).
• EVAPORATOR #1 TEMP 28.0°F
• EVAPORATOR #2 TEMP 29.0°F If either the evaporator #1 or #2 sensor is not connected, that reading for the sensor that is connected will be used for all internal calculations and actions based on evaporator temperature. There is no window for an un-connected sensor.
• NOVEMBER 18, 2001 FRI 2:00 PM

• DEFROST CYCLE IN PROGRESS
• HOURS TO NEXT DEFROST 04:49:42
• WARM-UP PERIOD IN PROGRESS
• WARNING COOLER TOO COLD
• WARNING COOLER TOO WARM

USER MENU: This is accessed by pressing all three buttons continuously for five seconds. It is where the user can program some of the basic operations of the Cooler Controller. To exit this menu just keep pressing the scroll button. DEFAULT SETTINGS are shown in ITALICS, and can be changed with the + and - buttons.

• ENERGY INFO? YES + (NO-) You can find out what percentage of the time each of the loads connected to the Cooler Controller has been energized, also known as duty cycle. This information can be recorded using our unique "Graphite Download" system. That means you write the runtimes down on a piece of paper with a pencil! You or your Freeaire dealer can then determine how much money your Freeaire system has saved you and compare it to what was projected for it to save. Remember that energy info is not available for longer ago than the last year. When (NO-) is selected the next window takes you to the installer access code. If (YES+) is selected the next window asks for the desired time period:
• TIME PERIOD: +/- LAST: (DAY) MO YR Use the + and - buttons to select the last day, month, or year. If the controller has not been connected for a whole year, select only as many days as it has been connected. Selecting a longer period than the time it has been connected will give misleading figures since it counts pre-installation figures as off time. Select (DAY) for the time period since midnight or for 1 to 29 days, (MO) for multiples of 30 days, and (YR) for a whole year. Once the time period has been selected, you can scroll through the following windows to find out the percentage runtimes of each load since that period of time: Press the scroll button and then the + button to reach the desired number of days:
• DISPLAY DATA LAST: 24 DAYS
• % ON LAST 24 DAYS COMPRESSR: 12.0%
• % ON LAST 24 DAYS EVAP#1: 16.1%
• % ON LAST 24 DAYS EVAP#1: 16.3%
• % ON LAST 24 DAYS CIRC. FANS: 83.7%
• % ON LAST 24 DAYS DOOR HEATERS: 0.0%
• % ON LAST 24 DAYS OUTSIDE SYS: 23.7%
• MORE INFO? YES+ (NO-) This window allows you to get energy information for a different time period without having to go to the end of the User Menu.
• ADJUST TIME? YES+ (NO-) If (YES+) is selected, the various components of the time begin flashing once a second. Each component is adjustable with the + and - buttons, as they cycle through their possible settings. Once the correct value is set, press the scroll button to move on to the next setting. (The Model 2001 Cooler Controller has a 10-year battery back-up so the time should be correct as soon as it is installed. Power failures will not affect the time, nor any of the stored settings. The clock even knows when daylight savings time is scheduled, so there should never be a need for adjustment.)
• TO MAKE CHANGES SET TO PGM MODE This is a reminder that you must first set the programming switch (recessed just above the lefthand white scroll button) from the run mode (up position) to the programming mode (down position) for any setting changes to be retained.
• LOW LIMIT +35.0°F The Low Limit is the coldest inside temperature that the Cooler Controller will allow in the walk-in. It is the temperature to which several of the settings in the Installer Menu are compared in order to make decisions about when to switch various equipment on and off. If there is an outside air system installed, then the Low Limit is the temperature at which the outside air fans are automatically switched off, while the compressor will be switched off at least 1°F warmer than the Low Limit. If there is no outside air system, the Low Limit is the temperature at which the compressor is automatically switched off. The default setting is +35.0°F. for a cooler and 0°F. for a freezer.
• WARM-UP SCHEDULE? YES+ (NO-) Having a warm-up schedule can save energy by allowing the temperature of the walk-in to rise to a higher level for a period of time, usually overnight. NOTE: There should be consideration of the variability of business hours, length of the warm-up period that will be used, the amount of time needed to bring the walk-in back down to a suitable temperature, the timing of off-peak periods under time-of-day electric rates, and the suitability of warming up the particular product being stored (do not warm-up dairy products!). If there is an outside air system installed, this warm-up period will not apply to its operation. In general, frozen food lasts longer if consistently cold temperatures are maintained in a freezer, so a warm-up period is usually not recommended for a freezer. If (YES+) is selected the next window will be:
• CHANGE SCHEDULE? YES+ (NO-) When (NO-) is selected, the next press of the scroll button take you to the alarm settings. If (YES+) is selected the next window will be:
• WARM-UP SCHEDULE (DAILY+) WEEKLY- If (DAILY+) is chosen, the following windows, with their adjustable parts blinking, will appear after each press of the scroll button:
• WARM-UP START 11:00 PM
• WARM-UP END 5:00 AM But if (WEEKLY-) is selected then 42 windows will appear in succession that will start here:
• WARM-UP START SUN 11:00 PM .....and end here:
• WARM-UP END SAT 5:00 AM This will allow a different schedule every day of the week.
• ALARM: TOO WARM 45.0°F This is the temperature the inside of the box must rise to in order for the alarm, if there is one connected, to be activated. If there is no alarm connected, a warning message will still appear in the readout window. The alarm will stop when the inside temperature falls 2°F (1°C) below the Alarm: Too Warm setting. The default setting for the ALARM: TOO WARM for a cooler is 45°F. and 10°F. for a freezer.
• ALARM: TOO COLD 32.0°F This is the temperature the inside of the box must drop to for the alarm, if there is one connected, to be activated. If there is no alarm connected, a warning message will still appear in the display window. The alarm will stop when the inside temperature rises 2F° (1°C) above the ALARM: TOO COLD setting. The default setting for the ALARM: TOO COLD for a cooler is 32°F. and -10°F. for a freezer.
• INSTALLER ACCESS CODE? YES+ (NO -) This window allows the Freeaire installer or technician to gain access to the Installer Menu. This menu is designed to be less accessible than the User Menu so that critical settings are not disturbed by people who do not, and who do not have to, understand them. NOTE: ADJUSTMENTS TO THE INSTALLER MENU ARE TO BE MADE BY QUALIFIED SERVICE TECHNICIANS AFTER CONSULTATION WITH THE FACTORY. Normally, there is no need to adjust any of the settings by which the Cooler Controller makes its decisions to energize and de-energize the various components of the different refrigeration systems. However, there may be special conditions for which the settings made at the factory are not optimum. Give us a call if you think that a special adjustment to the Cooler Controller might improve its performance. If (NO-) is selected or the scroll button is pressed, the User Menu is complete, and the Main Menu returns, as soon as the programming switch is reset to the run mode (up position of the slide switch). If (YES+) is selected, the code must be entered now in the display window. The code is entered by pressing the + or - buttons to make letters appear in alphabetical order. When the correct letter appears in a position, push the scroll button and move on to the next letter. Continue until the complete access code is entered.

For a cooler the correct code is: _________

For a freezer the correct code is: _________

Once the correct code is entered, press the scroll button twice and you will be in the Installer Menu. If an incorrect password is entered by two successive presses of the scroll button, the display will read:

• ACCESS DENIED RETRY? YES+ (NO-) If (YES+) is selected the code entry window will reappear as before, and you have another chance to enter the correct code. If (NO-) is selected and the scroll button is pressed, the User Menu is complete, and the Main Menu returns.

INSTALLER MENU: To exit this menu just keep pressing the scroll button. The Cooler Controller will not permit certain settings that would cause problems in the operation of the system.

• (FAHRENHEIT +) CELSIUS - Whichever temperature scale is selected here causes all temperatures to be displayed in that scale.
• OUTSIDE AIR SYSTEM ? (YES+) NO- What is selected here will determine whether display windows having to do with an outside air system will appear elsewhere.
• OUTSIDE SYS ON LL + 2.0°F This is the ON setpoint for the outside air system and appears only if OUTSIDE AIR SYSTEM (above) has been selected. It is the number of degrees the inside temperature must rise above the Low Limit to begin operating the outside air fans. To eliminate short-cycling of the outside air fans, OUTSIDE SYS ON cannot be set less than 2°F (1°C) .
• COMPRESSOR OFF LL + 3.0°F This is compressor system OFF setpoint, and appears only if OUTSIDE AIR SYSTEM (above) has been selected. It is the number of degrees above the Low Limit at which the compressor is automatically switched off. When OUTSIDE AIR SYSTEM (above) is not selected the compressor switches off at the Low Limit, and this setting does not appear.
• COMPRESSOR ON LL + 5.0°F This is the ON setpoint for the compressor system, and is the temperature the inside of the walk-in must rise to in order for the compressor to be switched on. To prevent short cycling, COMPRESSOR ON will always be at least 2.0°F warmer than COMPRESSOR OFF (above). When OUTSIDE AIR SYSTEM (above) is selected, the outside air fans are allowed to switch on at a lower temperature than the compressor, so COMPRESSOR ON will always be at least 1°F (.5°C) higher than OUTSIDE SYS ON (above).
• OUTSIDE SYSTEM �T OFF 4.0°F (�T stands for "temperature differential" between the inside and outside.) This is the OFF temperature differential for the outside air system, and along with OUTSIDE SYSTEM �T ON (see next setting below), appears only if OUTSIDE AIR SYSTEM (above) has been selected. OUTSIDE SYSTEM �T OFF is the number of degrees that the outside temperature is cooler than the air inside the walk-in when the outside air fans stop operating. To ensure that only colder outside air is delivered to the walk-in it will always be at least 2°F(1°C).
• OUTSIDE SYSTEM �T ON 6.0°F (�T stands for "temperature differential" between the inside and outside.) This is the ON temperature differential for the outside air system, and is the the number of degrees that the outside temperature must be cooler than the air inside the walk-in for the outside air fans to begin operating. It will always be at least 2°F (1°C) more than OUTSIDE SYSTEM �T OFF, to eliminate short cycling of the outside air fans.
• EVAPORATOR FANS OFF DELAY 1 MIN This is the number of minutes that the evaporator fans operate after the compressor control has been de-energized. This is to drive some of the cold out of the evaporator coils, before the circulating fans begin operating. Keeping this period of time short is helpful in saving energy.
• COMP OP TO START DEFROST 06:00 H This is short for "compressor operation time to start defrost, 6 hours." When the compressor reaches a cumulative run-time since the last defrost cycle equal to this setting, a new defrost cycle begins. The higher this setting is the greater the frost build-up on the evaporator coils will be at the start of a defrost cycle. In a defrost cycle in a walk-in cooler the compressor is kept off, and the evaporator fans are kept on, until the evaporator temperature has risen to one degree less than the inside temperature of the walk-in, a level that indicates that all coil frost has melted. In a walk-in freezer defrost cycle the evaporator fans are kept off and the electric heaters are kept on until the frost has been removed.
• EVAP TEMP TO END DEFROST 38.0°F This stands for "evaporator temperature to end defrost." In a walk-in freezer this is the evaporator temperature at which the installer is sure that all frost is melted from the coils and the defrost cycle can be safely terminated. In a cooler this setting ends the defrost cycle even if the evaporator temperature has not reached one degree less than the inside temperature.
• MAX TIME FOR DEF PERIOD 2 H 00 MIN This is the maximum time a defrost period is allowed to last. We recommend that each defrost period be ended by the rise in temperature of the evaporator coils as explained under EVAP TEMP TO END DEFROST (above). However, there are special situations in which a maximum length of time for the defrost period is useful as a "failsafe" setting. When a defrost period occurs while outside air is being used, the temperature rise that would end the defrost period sooner may be prevented. A malfunctioning evaporator sensor, or a too-high temperature setting for EVAP TEMP TO END DEFROST (above) could also make the defrost period drag on too long. Having a maximum allowable defrost time period provides an alternative method of ending defrost when the temperature is not doing the job, allowing the compressor to get back to work. Keep this setting as high as you think the evaporator defrosting would ever need to last, but keep it short enough to keep the unnecessary use of energy to a minimum. A longer setting for COMP OP TO START DEFROST (above) means more time for ice to form on the evaporator coils, requiring a longer MAX TIME FOR DEF PERIOD setting. The Cooler Controller model 2001 will allow a defrost period of up to 24 hours in a cooler and 1 hour in a freezer. (Because this is not the best way to end defrost, a warning message will appear in the window whenever a defrost period has "maxed-out" on time: MAX TIME ENDED LAST DEFROST. See the Trouble-shooting section for what to do if this message appears.)
• DEFROST NOW? YES+ (NO-) If there is frost build-up on the evaporator coils this setting can start a defrost cycle to remove it immediately upon exiting the installer menu. This setting can also end a defrost cycle already in progress.
• EXTRA DEFROST TIME: 0 H 15 MIN This is the number of hours to be added to the end of a defrost cycle to be sure all ice is melted, even ice not surrounding the sensor. Even though the installer of a Freeaire system should always take care to locate the evaporator sensor(s) in the place(s) where the most ice is likely to form, sometimes it is inconvenient to get access to the evaporator coils. Sometimes there is not a consistent place where ice forms on a set of evaporator coils. If the sensor is not always in the right place to detect the last remaining frost on the coils, there is can be residual ice left somewhere on the coils after the defrost period ends. This setting allows the defrost period for the evaporator circuits to be extended until all ice is gone, but it is best to be sure the evaporator sensor is located in the correct location first. Any extra evaporator fan operation in a cooler (or electric defrost heater operation in a freezer) at the end of a defrost cycle that happens after all the ice is gone is an unnecessary waste of energy and can allow unacceptable warming of the walk-in. However, an evaporator coil that is left with ice remaining at the end of a defrost cycle will not operate at top efficiency. As a humid summer day with a large product load is likely to be the time when the most ice will form on the evaporator coils, it is important to monitor the coils at that time and adjust this setting to the minimum that will keep the them ice-free. You can add up to 4 hours of extra defrost time, in half-hour increments, but the overall length of a defrost period is limited to the setting for MAX TIME FOR DEFROST (see above).
• WARMUP TEMP RISE COMPRESSR 5.0°F This stands for "warm-up temperature rise for the compressor system", and is the amount of warming, due to decreased compressor operation, allowed in the walk-in during any warm-up period, if there is to be a warm-up schedule. It is the number of degrees that the settings for COMPRESSOR OFF and COMPRESSOR ON (above) are increased. It does not apply to outside air system operation. See NOTE under WARM-UP SCHEDULE? under the User Menu.
• EVAPORATOR FANS ON TEMP 10°F (Freezers only). This is how cold the evaporator coils must be before the evaporator fans begin operating again. At the end of a defrost periodin a freezer it gives time for the compressor to operate and to carry away excess heat from the coils without having the evaporator fans blow that heat out into the freezer. The end of this delay period marks the end of the defrost period.
• OUTPUT TESTING? YES+ (NO-) This is to be used by the installer to test whether the various outputs of the controller are working. If (NO-) is selected, the Installer Menu is complete, and the Main Menu returns. If the (YES+) selected, the output loads may now be tested individually. All toggle switches on the front of the Cooler Controller should be switched ON, but no loads will operate until instructed by the installer. They will operate whether the normal functioning of the controller would call for them to or not. Select (ON+) or (OFF-) to control the load. The scroll button switches the load off and advances to the next load. The testable loads appear in this order: COMPRESSOR CONTROL, EVAP FANS #1, EVAP FANS #2, OUTSIDE AIR FANS, DOOR HEATERS, CIRCULATING FANS, ALARM CIRCUIT, and ELECTRIC DEFROST HEATER. The installer should check and correct the wiring of any load that does not operate when tested.
• MAIN MENU? (YES+) NO- When this window appears you can select (NO-) to return to the beginning of the Installer Menu and avoid having to re-enter the password, or if (YES+) is selected, the Installer Menu is complete.
• SET SWITCH TO RUN MODE This is a reminder that you must reset the programming switch from the programming mode (down position) to the run mode (up position) for the Main Menu to return.

Specifying Planning Installing Wiring Cooler Controller Commissioning & Troubleshooting Maintaining

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