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VC50SDD Installation &

Technician’s Manual

Page 7 of 46

Your Dulas Solar Direct Drive Refrigerator

Congratulations on choosing the Dulas VC50SDD vaccine refrigerator. With over 30 years of

engineering experience in the production of solar powered vaccine refrigerators, Dulas is

considered one of the market leaders in this field.

The VC50SDD is

Dulas’ latest innovation in solar refrigeration. Using our new solar direct drive

technology we have replaced the traditional battery energy store with a ground breaking phase

change solution. With this new technology we can offer the same renown Dulas quality and

reliability that have always kept your vaccines safe, but in a simpler and more efficient package.

How does solar direct drive work?

When the sun shines the solar panels generate electricity which directly drives the refrigerators

compressor, cooling down the refrigerator and its contents. As a result the compressor only

operates during the day. To 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 refrigerator must be allowed time to charge

it’s cold store. Under normal

sunlight conditions (8 hours/day of solar irradiance >250W/m²) the refrigerator will take

approximately 7 days to fully charge the cold store and be ready for vaccine storage.

Recommended solar array

The VC50SDD has been designed to meet the World Health

Organisation’s Performance, Quality

& Safety (PQS) standards. The refrigerator has been independently tested to the PQS standard

WHO/PQS/E03/RF05 and is a Hot zone rated appliance with an ambient operating temperature

range of b5C and +43C. For use in such Hot Zone environments it should be powered by

a minimum 260Wp solar array with a Voc not exceeding 45Vdc.

Содержание VC50SDD

Страница 1: ...DULAS Solar Direct Drive VC50SDD Refrigerator E003 078 Installation Technician s Manual Ref M VC50SDD ENG F ...

Страница 2: ... 11 SOLAR ARRAY ORIENTATION 21 12 SOLAR ARRAY INSTALLATION 22 13 SOLAR MODULE CONNECTIONS 24 14 COMMISSIONING SOLAR ARRAY 25 15 ADVICE ON LIGHTNING PROTECTION 26 16 ADVICE ON SURGE PROTECTION 26 17 SOLAR ARRAY EARTHING 27 18 REFRIGERATOR INSTALLATION 28 19 SYSTEM COMMISSIONING 29 20 REFRIGERATOR LOADING 30 21 GREEN COMPRESSOR STATUS LED LIGHT 31 22 USER TRAINING 32 23 MAINTENANCE TASKS 32 24 TROUB...

Страница 3: ...VC50SDD Installation Technician s Manual Page 3 of 46 ...

Страница 4: ...r Connector Branch Socket only required for 2 module systems 0 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 0 C Front fixed leg 2 D C Rail 47 3 1530mm 2 E C Rail 47 3 750mm only required for 2 module systems 0 F Rear adjustable leg 2 G Rail connector set 47 only required for 2 module sy...

Страница 5: ...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...

Страница 6: ...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...

Страница 7: ...ressor only operates during the day To 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 per...

Страница 8: ...lation Technician s Manual Page 8 of 46 4 VC50SDD Refrigerator Components Lockable Handle Basket Vaccine compartment solar powered temperature display and compressor status LED Temperature sensors Replaceable gaskets ...

Страница 9: ... No 2 Screwdriver 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 ...

Страница 10: ...ured 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 inhalation hazard beca...

Страница 11: ... 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 paraffins normal C5 20 Electrolytic capacitor Electroni...

Страница 12: ...proved 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 Industria...

Страница 13: ...in the vehicle Plan 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 duri...

Страница 14: ... 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...

Страница 15: ...ONS 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 ...

Страница 16: ...ntifying these individual parts refer to the parts list in Section 1 for the exact quantity of parts you should have Mounting system components for 1 or 2 module systems E 750mm rail x 2 2 mod only B Mid clamps x 2 2 mod only A End clamps x 4 C Front fixed leg x 2 D 1530mm rail x 2 F Rear adjustable leg x 2 G Optional Rail connector x 2 2 mod only ...

Страница 17: ...n 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 1 or 2 modules in Portrait orientation Front fixed legs Rear adjustable leg ...

Страница 18: ...UM WIND LOADING Solar panel clamping guidance 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 ...

Страница 19: ...VC50SDD Installation Technician s Manual Page 19 of 46 Attaching solar panels to the rails How to attach the modules to the rails Mid clamps x 2 2 mod Only End clamps x 4 ...

Страница 20: ...ail connector to securely attach the two rail sections together Joining two rails together with the rail connector 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 adjusting the position of the mounting feet and the leg lengths ...

Страница 21: ...E 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 ...

Страница 22: ...l tilt angle 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 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...

Страница 23: ...Google Play 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 2 1 15 16cm 60cm 35 1 75 1 20 22cm 60cm 40 1 5 1...

Страница 24: ... 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 over sharp edges The cond...

Страница 25: ...trong 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 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 o...

Страница 26: ... 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 earth...

Страница 27: ...g 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 moun...

Страница 28: ...Plug the solar connectors into the refrigerator Check that there is sufficient slack in the cable 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 250W m You will be able to hear the compressor operating and feel the condensers getting warm 5 Check that the re...

Страница 29: ...r location adjusting the solar and earth cables 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...

Страница 30: ... vaccine compartment that drop below freezing and thus no danger of freezing vaccines The single wire basket encourages 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 the lid open for as short a time as possible St...

Страница 31: ...ufficient 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 there...

Страница 32: ... in the afternoon Daily Routine Keep the lid closed open only when required and lock after use 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 basket Always store vaccine in its original packaging Always keep the same type of vaccine together and store your vaccine neatly Always use old...

Страница 33: ...ompressor capacitor etc The capacitor provides a short term energy store to keep the compressor running during brief reductions in light intensity It 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 swi...

Страница 34: ...VC50SDD Installation Technician s Manual Page 34 of 46 ...

Страница 35: ...t less than 45V 6 Measure the PV array 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 2 modules will produce 18A and so forth 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 the meter from ove...

Страница 36: ... voltage and short circuit current of the 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 3 cables should be the same colour PV cable should be connected to Comp cable and Cap cable These 3 cables should be the same colour 6 Disconnect connector J4...

Страница 37: ...vaccine storage compartment 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 5C 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 5C Control of the green LED on the front panel The front p...

Страница 38: ...mpressor should stop and the LED should be OFF Replace the control board 4 Check that the thermostat is set to the right temperature There is no adjustment of the thermostat temperature but it can be checked as follows Run the fridge and wait until the compressor stops running Don t open the fridge lid The temperature on the display on the front of the fridge should be between 2 5 and 3 5C The the...

Страница 39: ...rd 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 res...

Страница 40: ...HINK 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 locatio...

Страница 41: ...d 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 equal to the sum of the Isc s for the individual modules Install the assembled solar array on the roof Route t...

Страница 42: ...a torch if natural light 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 u...

Страница 43: ...VC50SDD Installation Technician s Manual Page 43 of 46 26 VC50SDD Electrical Schematic ...

Страница 44: ...ulated according to the stocking rate listed 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 Condenser fan G5001 10 Compressor BD35K 101Z0211 5 Solar thermometer 56SD 5 Gasket Inner PD11016 5 Gasket Outer PD11015 5 Any other parts required can be obtained by contact...

Страница 45: ...VC50SDD Installation Technician s Manual Page 45 of 46 29 VC50SDD System Layout 1 module system Diagram showing two modules in parallel illustrative purposes only ...

Страница 46: ...ation Technician s Manual Page 46 of 46 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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