Dulas VC150SDD Installation & Technician's Manual
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Dulas VC150SDD Installation & Technician's Manual

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DULAS Solar Direct Drive
VC150SDD Refrigerator and Freezer
Installation & Technician's Manual
Ref: M-VC150SDD-ENG-D

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Summary of Contents for Dulas VC150SDD

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

  • Page 2: Table Of Contents

    VC150SDD Installation & Technician’s Manual Table of Contents 1. COMPONENTS CHECKLIST ..................3 2. SAFETY INSTRUCTIONS ................... 4 3. YOUR DULAS SOLAR DIRECT DRIVE REFRIGERATOR ......... 6 REFRIGERATOR COMPONENTS ................7 5. RECOMMENDED TECHNICIAN’S TOOLS ..............8 6. MATERIAL SAFETY INFORMATION ................9 7.

  • Page 3: Components Checklist

    (A) End Clamp 34-43mm Set (B) Mid Clamp 28-42mm Set (C) Front fixed leg (D) C-Rail 47-3 – 1530mm (E) C-Rail 47-3 - 750mm (not used with VC150SDD system) (F) Rear adjustable leg (G) Rail connector set 47 Coachscrews, Rawlbolts, Washers...

  • Page 4: Safety Instructions

    VC150SDD Installation & Technician’s Manual 2. Safety Instructions Read the Manual - please read all instructions completely before installing. Installation and system servicing should only be carried out by a qualified and competent engineer. Work performed by persons with insufficient technical knowledge may adversely affect the performance of the unit or cause physical injury or damage to the equipment.
  • Page 5 VC150SDD Installation & Technician’s Manual DC power only - this refrigerator is designed for operation with the solar power system supplied. Do not connect the refrigerator to other power supplies. Dangerous substances - this refrigerator contains substances that are not biodegradable and can cause harm, please ensure that all components of the refrigerator are disposed of correctly, see page 8 for more information.

  • Page 6: Your Dulas Solar Direct Drive Refrigerator

    Dulas is considered one of the market leaders in this field. The VC150SDD 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.

  • Page 7: Refrigerator Components

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

  • Page 8: Recommended Technician's Tools

    VC150SDD Installation & Technician’s Manual 5. Recommended Technician’s Tools Pozidrive No.2 Screwdriver 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...

  • Page 9: Material Safety Information

    VC150SDD Installation & Technician’s Manual 6. Material Safety Information THE REFRIGERATOR The Dulas VC150SDD conforms to the European directive 2002/95/EC on hazardous substances and does not contain the following elements: lead, cadmium, mercury, hexavalent chrome, PBB or PBDE. The absence of ozone destroying materials is in accordance with EC 1005/2009 (CFC-free) It is compliant with European Standards (CE) EN60335-1:2010 &...

  • Page 10: End Of Life & Product Recycling

    Disposal of Phase Change Material (PCM) The PCM used in the Dulas refrigerator has a very long life and does not degrade through use. At the end of the refrigerators useful life the PCM should be either recycled or disposed of in accordance with applicable regional, national and local laws and regulations.
  • Page 11 VC150SDD Installation & Technician’s Manual SOLAR POWER SUPPLY Do not dispose of this equipment with normal domestic waste! To comply with the European Directive 2002/96/EC on Waste Electrical and Electronic Equipment and its implementation as national law, electrical equipment that has reached the end of its life must be collected separately and returned to an approved recycling facility.

  • Page 12: Preparing To Install

    Ensure that you have all tools required to complete the installation. Familiarise yourself with the Dulas Installation Record in Section 26 of this manual. This provides a step-by-step guide to the installation process and also gives you a formal record of the installation.

  • Page 13: Solar Array Assembly

    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.
  • Page 14 VC150SDD Installation & Technician’s Manual The mounting 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)
  • Page 15 VC150SDD Installation & Technician’s Manual 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 Attaching solar panels to the rails Page 17 of 47...
  • Page 18 VC150SDD Installation & Technician’s Manual In order to minimise the shipping volume some systems have the rails supplied in two pieces. In this case we also provide a rail connector to securely attach the two rail sections together: Large arrays 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.

  • Page 19: Solar Array Orientation

    VC150SDD Installation & Technician’s Manual 10. Solar Array Orientation The solar array must be permanently positioned where the modules will receive the maximum amount of sunshine. A suitable position must be found away from trees and tall objects, to avoid shading the array, as this will impair the performance of the modules.

  • Page 20: Solar Array Installation

    VC150SDD Installation & Technician’s Manual 11. Solar Array Installation Attention – Only connect the Dulas Solar Direct Drive refrigerator to the solar array supplied. Connection to other solar power systems may damage the refrigerator or cause it to not function correctly.
  • Page 21 VC150SDD Installation & Technician’s Manual Following the guidance in sections 10 and 11 above determine the required tilt angle for the array. Use an inclinometer (or free smart phone app e.g. “Angle Meter” in the 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.

  • Page 22: Solar Module Connections

    VC150SDD Installation & Technician’s Manual 12. Solar Module Connections Please ensure that the solar modules are connected in parallel as per the diagram below. Incorrect connection of the solar array could cause permanent damage to the refrigerator and its components.

  • Page 23: Commissioning Solar Array

    VC150SDD Installation & Technician’s Manual DO NOT DISCONNECT THE SOLAR CONNECTORS UNDER LOAD. If you need to disconnect any of the solar connectors (at the solar array or at the refrigerator) please ensure that the refrigerator has been turned off at the PV switch (located at the back of the refrigerator) before disconnecting.

  • Page 24: Advice On Lightning Protection

    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).

  • Page 25: Solar Array Earthing

    VC150SDD Installation & Technician’s Manual 16. Solar Array Earthing In order to provide electrical bonding for the metal parts of the solar array an earthing kit has been provided as part of this system. Find a good location close to the building where the full length of the earth rod can be completely sunk into the ground, within easy reach of the earth cable.

  • Page 26: Refrigerator Installation

    VC150SDD Installation & Technician’s Manual 17. Refrigerator Installation DO NOT position the refrigerator in direct sunlight or next to any heat sources. Make sure the refrigerator is positioned to provide good ventilation and ease of access for maintenance. Ventilation is particularly important for the condensers and compressors.

  • Page 27: System Commissioning

    VC150SDD Installation & Technician’s Manual 18. System Commissioning  Complete the Installation & Commissioning record at the end of this manual (Section 26) and ensure all manuals are stored close to the refrigerator for ease of reference. Connect the solar panels and allow the refrigerator to run for at least 7 days.

  • Page 28: Refrigerator Loading

    CONSUMPTION, ONLY OPEN THE LID WHEN STRICTLY NECESSARY. The VC150SDD refrigerator has two refrigerated compartments. The large one is specifically for the storage of vaccines and the smaller one with the fan is the freezer, see Section 4. The vaccine...

  • Page 29: Freezer Operation

    VC150SDD Installation & Technician’s Manual 20. Freezer operation The VC150SDD freezer is a highly efficient freezer designed specifically for freezing water packs for vaccine distribution. It has a fan to maximise the cooling power and is able to rapidly freeze up to 2.4kg of water each day.

  • Page 30: Green Compressor Status Led Light

    VC150SDD Installation & Technician’s Manual 21. Green compressor status LED light The green LED light on the front of the refrigerator illuminates to indicate that the compressor is operating. The compressor will run if the refrigerator temperature is above about 4 degrees and there is sufficient solar power.

  • Page 31: User Training

    VC150SDD Installation & Technician’s Manual 22. User Training The end user of the VC150SDD should be instructed in the simple processes outlined below and also those in Section 23. It should be stressed that these tasks are essential to ensure correct and reliable operation of the refrigerator.

  • Page 32: Maintenance Tasks

    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 refrigerators. Description...

  • Page 33: Troubleshooting Guide

    25. Troubleshooting Guide Section 1 General description The VC150SDD is based on well proven technology and components and should prove to be very reliable in operation. However if there is a fault it has been designed for easy access to the main components.
  • Page 34 VC150SDD Installation & Technician’s Manual Page 34 of 47...
  • Page 35 VC150SDD Installation & Technician’s Manual Section 2. How to check that the Dulas PV array is working 1. Switch the PV isolator off (indicated by a “0”) 2. Disconnect the PV cables from the refrigerator. 3. Connect the supplied test leads to a suitable multimeter as shown in photograph.
  • Page 36 2. Wait two minutes or more to ensure the capacitor has discharged 3. Remove the four screws that secure the Dulas SDD controller cover and lift off cover. 4. Make a note of the connections to connector J1 so that they can be reconnected correctly after completing the test.
  • Page 37 If Section 2 and Section 3 have been completed and no problem has been found the problem is likely to lie with the Dulas SDD controller. This controller provides the following: Connections for the compressor, PV and capacitor (connector J1).
  • Page 38 VC150SDD Installation & Technician’s Manual The following checklist should be used to check that the SDD controller is working. If any of the tests fail the controller should be replaced. Test What to do if the test fails Check that the controller passes power to the Replace the controller compressor and capacitor.
  • Page 39 VC150SDD Installation & Technician’s Manual There is no LED to indicate when the freezer compressor is running but a good indication is given by the sound of the air circulating fan inside the freezer compartment. This only operates when the compressor is running.
  • Page 40 VC150SDD Installation & Technician’s Manual Section 5 – Checking the Dulas Lightning Protection board Dulas Lightning Protection board incorporates three Metal Oxide Varistors (MOVs) lightning protection devices on the board. These will absorb the small lightning strikes that may occur nearby to the installation but will not be effective against large lightning strikes.

  • Page 41: Installation & Commissioning Record

    VC150SDD Installation & Technician’s Manual 26. Installation & Commissioning Record Site name and location: ....................Date: ..........................Name of person responsible for installation: ............Name of person responsible for health centre: ............Please  or 1. Before Going to Site insert value.
  • Page 42 VC150SDD Installation & Technician’s Manual 3. Solar Array Installation WORKING AT HEIGHT IS DANGEROUS – PLEASE OBSERVE ALL REASONABLE SAFETY PRECAUTIONS  Record the direction of the solar array: ……………….. degrees.  Record the tilt angle of the solar array: ………………..
  • Page 43 VC150SDD Installation & Technician’s Manual 4. Refrigerator Installation and Commissioning  Make sure there is enough cable for the refrigerator to be moved for maintenance and cleaning.  Ensure that the PV switch on the refrigerator is in the ‘OFF’ position.

  • Page 44: Vc150Sdd Electrical Schematic

    VC150SDD Installation & Technician’s Manual 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 44 of 47...

  • Page 45: Vc150Sdd Refrigeration Schematic

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

  • Page 46: Vc150Sdd System Layout

    VC150SDD Installation & Technician’s Manual 30. VC150SDD System Layout Page 46 of 47...
  • Page 47 VC150SDD Installation & Technician’s Manual 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 Page 47 of 47...

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