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VC150SDD Installation & Technician’s Manual

Page 13 of 47

9.

Solar Array Assembly

PLEASE READ ALL OF THE INSTRUCTIONS THOROUGHLY BEFORE COMMENCING

These instructions apply to all variants of the Dulas mounting system: 2 and 3 module systems in

both portrait and landscape orientation.

Tools required to assemble the mounting structure:



Deep reach 18mm socket (supplied)



Torx T30 key (supplied)



Torx T45 key (supplied



Ratchet socket handle (not supplied)

If this is your first time installing the Dulas mounting system it is highly recommended to do a test

assembly at ground level prior to working on the roof top. This will ensure you are familiar with how

the system goes together and can work out any problems in a safe environment.

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Summary of Contents for VC150SDD

Page 1: ...DULAS Solar Direct Drive VC150SDD Refrigerator and Freezer Installation Technician s Manual Ref M VC150SDD ENG D ...

Page 2: ...AY INSTALLATION 20 12 SOLAR MODULE CONNECTIONS 22 13 COMMISSIONING SOLAR ARRAY 23 14 ADVICE ON LIGHTNING PROTECTION 24 15 ADVICE ON SURGE PROTECTION 24 16 SOLAR ARRAY EARTHING 25 17 REFRIGERATOR INSTALLATION 26 18 SYSTEM COMMISSIONING 27 19 REFRIGERATOR LOADING 28 20 FREEZER OPERATION 29 21 GREEN COMPRESSOR STATUS LED LIGHT 30 22 USER TRAINING 31 23 MAINTENANCE TASKS 32 24 SPARE PARTS 32 25 TROUBL...

Page 3: ...ctor Branch Plug 2 Solar Connector Branch Socket 2 Earthing Kit incl Earth Rod 25m Earth Cable Earth Clamp 1 MOUNTING SYSTEM see page 14 for references A to G A End Clamp 34 43mm Set 4 B Mid Clamp 28 42mm Set 4 C Front fixed leg 3 D C Rail 47 3 1530mm 4 E C Rail 47 3 750mm not used with VC150SDD system 0 F Rear adjustable leg 3 G Rail connector set 47 2 Coachscrews Rawlbolts Washers 3 packs Screws...

Page 4: ...een given supervision or instruction Children must be supervised not to play with the appliance This refrigerator is for professional use only It is not designed for household use Refrigerator and power system are heavy please observe good manual handling procedures when moving the refrigerator and solar power system Only use suitable transport equipment Safe working Please observe safe working at...

Page 5: ...nly Do not expose it to rain WARNING This unit s cooling system contains flammable refrigerant Due to this fact the following information is particularly important Warning Do not damage the refrigeration circuit Ensure that sharp or pointed objects do not come into contact with the refrigeration circuit Warning Do not use mechanical devices or other means to accelerate the defrosting process other...

Page 6: ...xact temperatures required for safe vaccine storage and acts as a cold store storing energy that keeps the temperatures stable all day and night In order to store sufficient energy to keep vaccines safe for prolonged periods without any sunshine the refrigerator must be allowed time to charge its cold store Under normal sunlight conditions 8 hours day of solar irradiance 200W m the refrigerator wi...

Page 7: ...VC150SDD Installation Technician s Manual Page 7 of 47 4 Refrigerator Components ...

Page 8: ...crewdriver Slot head Screwdriver Pliers Wire Cutters Wire Strippers Craft Knife Drill and Bits Hammer and Punch Deep reach 18mm socket supplied Torx T30 key supplied Torx T45 key supplied Ratchet socket handle not supplied Adjustable Spanner Multimeter 20A rated Tape measure Spirit level Compass supplied ...

Page 9: ...d in large tanks secured inside the walls of the refrigerator In normal use the user will never be aware of its presence This PCM is classified under regulation EC No 1272 2008 as a category 1 aspiration hazard and is classified under regulation 67 548 EWG 1999 45 EG as having the potential to cause physical harm R65 R66 At normal ambient temperatures this product will be unlikely to present an in...

Page 10: ...s of the refrigerator contain an organic phase change material that can be harmful and must be disposed of safely Please contact Dulas for advice Worn out devices must be professionally disposed of in accordance with local regulations and legislation Potentially hazardous components materials are Refrigerant gas R600a Phase change material PCM paraffin normal C5 20 Electrolytic capacitor Electroni...

Page 11: ...pproved recycling facility Any device that you no longer require must be returned to our agent or find out about the approved collection and recycling facilities in your area Ignoring this European Directive may have potentially adverse effects on the environment and your health Solar modules contain materials that can be recovered and reused in either new PV modules or other new products Industri...

Page 12: ... of the installation 3 Discuss and decide a position for the refrigerator ensuring that it is out of direct sunlight and in a well ventilated dry place The cooler the room the better the performance Note avoid locations where room temperature may fall below 5 C 4 Identify a safe position for the solar array ensuring that it faces the correct direction and is mounted at the correct tilt angle for t...

Page 13: ...andscape orientation Tools required to assemble the mounting structure Deep reach 18mm socket supplied Torx T30 key supplied Torx T45 key supplied Ratchet socket handle not supplied If this is your first time installing the Dulas mounting system it is highly recommended to do a test assembly at ground level prior to working on the roof top This will ensure you are familiar with how the system goes...

Page 14: ...g system is supplied in pre assembled parts See below for a pictorial guide to identifying these individual parts refer to the parts list in Section 1 for the exact quantity of parts you should have B Mid clamps x 2 or x 4 A End clamps x 4 C Front fixed leg x 2 or x 3 ...

Page 15: ...al Page 15 of 47 The mounting system can be assembled to allow the modules to be attached in either portrait or landscape configuration The decision between which option to use is usually guided by which direction the joists run on your roof ...

Page 16: ...VC150SDD Installation Technician s Manual Page 16 of 47 ...

Page 17: ...VC150SDD Installation Technician s Manual Page 17 of 47 Attaching solar panels to the rails ...

Page 18: ...are supplied with three front legs and three back legs The outer two should be positioned as described previously but the third leg should be positioned approximately in the middle of the rail The mounting system is made from aluminium and is adaptable to a wide variety of mounting options If your mounting area cannot be level e g you have a sloping roof then the correct angle must be made by adju...

Page 19: ...RE AND NOT TWISTED ACCESSIBLE FOR CLEANING WELL VENTILATED SAFE FROM SEVERE WEATHER CONDITIONS NOT SHADED BETWEEN 7 am 5 pm The solar array should face towards the equator i e South in the Northern Hemisphere North in the Southern Hemisphere Use the compass provided with the refrigerator to ensure the array is facing the correct direction The tilt angle of a solar array is dependent on the country...

Page 20: ...gle at which to install the solar array The tilt angle should be equal to the locations latitude to a minimum of 10 The minimum 10 tilt ensues that rain will help to clean the modules For example Latitude 15 Latitude 5 use 10 array tilt The mounting system is made from aluminium and is adaptable to a wide variety of mounting options If your mounting area cannot be level e g you have a sloping roof...

Page 21: ...lay store to set the array tilt Alternatively a triangle may be cut from a piece of card and used with a spirit level to set the array angle correctly Refer to the table below for the dimensions necessary to produce a triangle of the correct size Required Angle A Length of Y Length of Z Required Angle A Length of Y Length of Z 10 9cm 50cm 30 29cm 50cm 15 16cm 60cm 35 35cm 50cm 20 22cm 60cm 40 42cm...

Page 22: ...ctices when installing the cables Route the cables where they cannot be damaged or subjected to excessive heat Do not install the cable around tight bends Ensure that the cable is supported along the full length of its route to the refrigerator using the cable ties and bases supplied Use the supplied length of conduit to protect the solar array cables as they enter the building or as it passes ove...

Page 23: ...strong sunshine 1 Measure the Short Circuit Current Isc of the individual solar panels before connecting them together You should measure approximately 9A refer to PV module data label for the exact value 2 Connect all the panels together and connect them to the solar array output cable 3 Cover all the solar panels with either cardboard or a thick blanket and ensure they remain covered for the dur...

Page 24: ...r array it is important to also connect the refrigerator cabinet to earth This protects the equipment and any people who may be touching the refrigerator from electric shock during fault conditions Dulas SDD cabinets have a dedicated earthing block on the rear of the cabinet for this purpose see Section 4 This earth block can be connected to the same earth rod as the solar array if a separate eart...

Page 25: ...ng where the full length of the earth rod can be completely sunk into the ground within easy reach of the earth cable Run the earth cable in the shortest and straightest route from the solar array to the earth rod ensuring it is securely attached to the building and or support structure Using the clamp supplied connect the earth rod to one end of the earth cable and connect the solar array and mou...

Page 26: ...rn the PV isolator on by switching it to 1 Within 1 minute the compressor will start if there is sufficient sunlight solar irradiance of 125W m You will be able to hear the compressor operating and feel the condensers getting warm 6 Turn the freezer switch to 1 Within 1 minute the second compressor will start if there is sufficient sunlight solar irradiance of 250W m You will be able to hear the c...

Page 27: ...er location adjusting the solar and earth cable accordingly When the refrigerator compartment temperature display reads 4 5 C or less by 4pm in the afternoon then the cold store is sufficiently charged this may take a few days depending on the level of sunshine Follow our instructions for loading vaccines in Section 19 below Only store vaccines in the refrigerator Leaving space for air circulation...

Page 28: ...ntains stacking baskets designed to make stock management easier and encourage air circulation within the compartment Do not remove these baskets and do not store vaccines outside of these baskets The wire baskets encourage the circulation of air by maintaining a small gap between the basket and the cabinet wall Good air circulation will help the refrigerator to maintain an even temperature throug...

Page 29: ...be used to build up a store of up to 23 x 0 6L water packs allowing multiple outreach trips to take place in a short time Simply add 2 4kg of water packs each day until the desired amount of ice has been accumulated The VC150SDD has an intelligent controller that automatically ensures the operation of the freezer never endangers the safe storage of the vaccines in the fridge There is also an on of...

Page 30: ...sufficient solar power Normal operation The refrigerator warms up slightly overnight It is usual for the compressor to start running shortly after sunrise It will run continuously for a few hours to cool the refrigerator After this time the compressor will begin cycling on and off to maintain the correct internal temperature This will continue until the sun sets at the end of the day At night ther...

Page 31: ...temperature display on the front of the refrigerator reads 4 5o C or less by 4pm in the afternoon Daily Routine Keep the lid closed open only when required and lock after use Store the most frequently used vaccines in the top baskets for easy access Do not keep food or drink in the refrigerator Vaccine Storage Only store vaccines in the refrigerator Use the baskets provided Do not store vaccines o...

Page 32: ... not shaded between 7am and 5pm Defrost the freezer if there is a build up of ice on the walls of the compartment Every 6 months Check all mechanical fixings and electrical connections including the array 24 Spare parts Listed below are the most likely spare parts required by the VC150SDD over the course of its lifetime It is recommended that one set of these spares is purchased for every 10 refri...

Page 33: ...acitor etc The capacitor provides a short term energy store to keep the compressor running during brief reductions in light intensity It s also required for starting of the compressor There is a bleed resistor connected in parallel with the capacitor to ensure that it discharges when the PV is disconnected However this takes some time wait one minute after power has been removed The switch circuit...

Page 34: ...VC150SDD Installation Technician s Manual Page 34 of 47 ...

Page 35: ... short circuit current This will depend on the light level on the array In bright sun each module will produce up to 9A of current Two modules will produce 18A and so forth Even in low light the short circuit current should be more than a few amps Caution Make sure that the current rating of the meter can withstand the likely current The current measurement should be made quickly and the wires dis...

Page 36: ...Check the open circuit voltage and short circuit current of the PV array 6 Temporarily connect the PV cables to the compressor cables and capacitor cables The circuit board has labels by the connector PV cable should be connected to F1 cable and C cable These three cables should be the same colour PV cable should be connected to F1 cable and C cable These three cables should be the same colour 7 D...

Page 37: ...nd side at the top and bottom of the fridge cabinet When there is sufficient light for the PV array the controller ensures that the average fridge is maintained at 3 5C As a fail safe the compressor will have turned off if the lower temperature is below 3C even if the average temperature is higher than 3 5C Control of the green LED on the front panel The front panel LED will illuminate to signify ...

Page 38: ...the control board 3 Check that the thermostat is set to the correct temperature There is no adjustment of the thermostat temperature but it can be checked as follows Run the refrigerator and wait until the compressor stops running Don t open the cabinet lid The temperature on the display on the front of the refrigerator should be between 2 5 and 4 0C The thermostat has been factory set to ensure t...

Page 39: ...eezer off using the freezer switch Put some water packs in with water at room temperature and leave them in until the freezer temperature is 15 degrees C or above Remove the ice packs replace the foam lid and turn the freezer on If there is sufficient sunshine the freezer will run The freezer temperature should drop to below zero degrees C within one or two hours Once the temperature drops below 1...

Page 40: ...ard for signs of damage or discolouration 6 Use a multi meter set to the lowest resistance range to measure the resistance from connection J1 PV to J2 This should be less than 0 15 ohms It is sometimes necessary to measure the resistance of the multimeter leads shorted together and subtract this zero reading from the measured resistance of the circuit board 7 Use a multi meter set to the lowest re...

Page 41: ...THINK Select a suitable location for the refrigerator Select a suitable location for the solar array Check for orientation should be towards equator Check for shading between 7am and 5pm Check for ease of access for installation and cleaning Check for length of cable to refrigerator You may need to negotiate with the user You may need to re think the refrigerator location if the solar array locati...

Page 42: ...ed Complete solar module interconnection wiring and connect solar cable Check that the connections are tight Measure and record Voc of the solar array Voc Check that array Voc is similar to the Voc for individual modules Measure and record Isc of the solar array Isc Check that array Isc is similar to the sum of the Isc for the individual modules Install the assembled solar array on the roof Route ...

Page 43: ...ing circuit is working condensers should get warm Check the freezer cooling circuit is working condensers should get warm Check the freezer fan is working Allow the temperature to stabilise this may take up to 7 days Check that the refrigerator compartment is 4 C to 6 C and the freezer compartment is less than 10 C 5 Finally STOP AND THINK Have we done a good job Is it good quality Check that all ...

Page 44: ...llation Technician s Manual Page 44 of 47 27 VC150SDD Electrical Schematic VC60SDD 1 and VC150SDD production wiring with dual compressor controller inc Vaccine Guard USB connector Dulas Ltd Drawn by JG Date 05 06 18 ...

Page 45: ...VC150SDD Installation Technician s Manual Page 45 of 47 28 VC150SDD Refrigeration Schematic 29 VC150SDD Freezer Schematic VC150SDD freezer ...

Page 46: ...VC150SDD Installation Technician s Manual Page 46 of 47 30 VC150SDD System Layout ...

Page 47: ...lation Technician s Manual Page 47 of 47 For more information contact DULAS Ltd Dyfi Eco Park Machynlleth Powys SY20 8AX UK tel 44 0 1654 705055 fax 44 0 1654 703000 email solar dulas org uk website www dulassolar org ...

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