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VC88SDD Installation

Technicians’ Manual

Page 43 of 45

27.

VC88SDD Refrigeration Schematic

28.

Spare parts

Listed below are the most likely spare parts required by the VC88SDD over the course of its

lifetime. It is recommended that one set of these spares is purchased for every 10 refrigerators.

Spare Part Description

Spare Part No.

Stocking

Rate

(n/100)

Dulas SDD controller

SDD CONTROLLER

Temp probe

SN4B15P1

Compressor controller

101N0420

MCB Fridge

693-CBTWF060C0

Lightning board

5541

Compressor BD35K

101Z0211

Solar Thermometer

56SD

Gasket Outer

PD9915

Gasket Inner

PD9916

Any other parts required can be obtained by contacting Dulas on the details at the end of this

manual.

Summary of Contents for VC88SDD

Page 1: ...DULAS Solar Direct Drive VC88SDD Refrigerator E003 059 Installation Technician s Manual Ref M VC88SDD ENG G ...

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

Page 3: ...ch Plug 1 Solar Connector Branch Socket 1 Earthing Kit incl Earth Rod 25m Earth Cable Earth Clamp 1 MOUNTING SYSTEM see page 14 for references A to G A End Clamp 28 33mm Set 4 B Mid Clamp 28 42mm Set 2 C Front fixed leg 2 D C Rail 47 3 1530mm 2 E C Rail 47 3 750mm 2 F Rear adjustable leg 2 G Rail connector set 47 2 Coachscrews Rawlbolts Washers 2 packs Screws 1 pack Wall Plugs 1 pack Cable Ties 1 ...

Page 4: ...struction 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 height practices when inst...

Page 5: ...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 than those recommend...

Page 6: ...o maintain the temperature at night or when the sun is not shinning the refrigerator has a phase change lining This interior lining holds the exact 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 refrige...

Page 7: ...Page 7 of 45 4 Refrigerator Components ...

Page 8: ... Slot head Screwdriver Pliers Wire Cutters 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: ... 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 inhalation hazard because of its low volati...

Page 10: ... 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 paraffins normal C5 20 Electrolytic capacitor Electronic components SDD con...

Page 11: ...ility 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 Industrial recycling processe...

Page 12: ...any lifting or moving of the refrigerator in advance paying particular attention to steps gradients and doorways Ensure suitable moving and lifting equipment is used as required Make sure there is sufficient assistance to safely carry out any lifting and moving of the refrigerator Keep the refrigerator in its original packaging for as long as is practical to prevent damage during transit and unloa...

Page 13: ...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 the system location En...

Page 14: ...E 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 t...

Page 15: ...identifying these individual parts refer to the parts list in Section 1 for the exact quantity of parts you should have Mounting system components for 2 module systems E 750mm rail x 2 B Mid clamps x 2 A End clamps x 4 C Front fixed leg x 2 D 1530mm rail x 2 F Rear adjustable leg x 2 G Rail connector x 2 ...

Page 16: ...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 2 modules in Portrait orientation Front fixed legs Rear adjustable leg ...

Page 17: ...Page 17 of 45 2 modules in Landscape orientation ...

Page 18: ...ance Clamp here for maximum strength 550 kg m2 Extended clamping area 244 kg m2 Do not clamp here NOTE This diagram is for guidance only If you are uncertain of the correct way to install the solar panels in your system refer to the solar panel manufacturer s installation manual for more details L 8 L 4 L ...

Page 19: ...ays 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 ...

Page 20: ...CESSIBLE 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 in which it is locat...

Page 21: ... 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 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 b...

Page 22: ...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 50cm 25 28cm 60cm 45...

Page 23: ...bles 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 over sharp edges The conduit is slit so that it c...

Page 24: ...hort Circuit Current Isc of the individual solar panels before connecting them together You should measure approximately 9A per solar panel refer to PV module data label for the exact value 2 Connect the panel s together and connect them to the solar array output cable 3 Cover the solar panel s with either cardboard or a thick blanket and ensure they remain covered for the duration of the commissi...

Page 25: ...nt 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 earth connection is not a...

Page 26: ...gth 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 mounting system to the o...

Page 27: ...to allow access to the back of the refrigerator 4 Turn 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 5 Check that the refrigerator compartment temperature display on the front of the cabinet is operating If there is in...

Page 28: ... 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 around the contents ...

Page 29: ...t 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 throughout the compartment In order to save energy try to keep...

Page 30: ...r 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 there is no power to the ...

Page 31: ...quired 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 outside the baskets Always store vaccine in its original packaging Always keep the same type of vaccine together and store your vaccine neatly Always ...

Page 32: ...c 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 breaker ...

Page 33: ...Page 33 of 45 ...

Page 34: ...t 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 disconnected to prevent ...

Page 35: ...he PV array 5 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 COMP cable and CAP cable These three cables should be the same colour PV cable should be connected to COMP cable and CAP cable These three cables should be the same colour 6 Disconnect connector J5 make a short circuit between t...

Page 36: ...artment When there is sufficient light for the PV array to allow the compressor to run the Dulas SDD controller ensures that the average of these two temperature sensors is maintained at 3 7C As a fail safe the compressor will turn off if the lower temperature is below 3C even if the average temperature is higher than 3 7C Control of the green LED on the front panel The front panel LED will illumi...

Page 37: ...ould be OFF Replace 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 fac...

Page 38: ...ge 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 resistance range to mea...

Page 39: ...le 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 location is difficult Stop ...

Page 40: ...ule 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 the solar cable to th...

Page 41: ...ight is insufficient Check the refrigerator cooling circuit is working condensers should get warm Allow the temperature to stabilise this may take up to 7 days Check that the refrigerator compartment is 4 C to 6 C 5 Finally STOP AND THINK Have we done a good job Is it good quality Check that all cables are securely fixed and terminated Complete the user training Make sure the user understands How ...

Page 42: ...26 VC88SDD Electrical Schematic VC88SDD ...

Page 43: ...ares is purchased for every 10 refrigerators Spare Part Description Spare Part No Stocking Rate n 100 Dulas SDD controller SDD CONTROLLER 10 Temp probe SN4B15P1 10 Compressor controller 101N0420 10 MCB Fridge 693 CBTWF060C0 10 Lightning board 5541 10 Compressor BD35K 101Z0211 5 Solar Thermometer 56SD 5 Gasket Outer PD9915 5 Gasket Inner PD9916 5 Any other parts required can be obtained by contacti...

Page 44: ...29 VC88SDD System Layout ...

Page 45: ...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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