DULAS Solar Powered VC150 Refrigerator/Freezer Installation & Operation Manual June 2010
VC150 Installation and Operation Manual CONTENTS SECTION Page KNOW YOUR SYSTEM te c a SOLAR Component checklist 3 Battery safety 4 Preparation Completed system 5 6 SOLAR ARRAY Photovoltaic module assembly 7 Support structure orientation Support structure assembly 8 10 Lightning protection 12 ELECTRICAL SYSTEM Photovoltaic controller information and installation Battery commissioning 13 - 18 19 THE REFRIGERATOR / FREEZER Positioning and starting Loading 20 21 Fridge temperature controlle
VC150 Installation and Operation Manual COMPONENTS – CHECK LIST REF PRODUCT QUANTITY SOLAR ARRAY (either 270W or 405W) a. 1 a. 2 KD135 Solar Modules 10m Array Output Cable a. 3 a. 4 0.5m Module Interconnect Cable Assembly 1 or 2 Bolt, Plain Washer, Nylon Washer, Penny Washer a. 5 2 or 3 1 & Nut Pack Silicon Sealant 1 REFRIGERATOR b. 1 DULAS VC150 Refrigerator / Freezer 1 b. 2 4m Refrigerator Cable 1 SUPPORT STRUCTURE c. 1 Unirac rail kit 2 c. 2 Unirac high profile tilt leg kit 2 c.
VC150 Installation and Operation Manual BATTERY SAFETY Observe operating instructions and position them within sight of the battery! Work only on batteries under instruction of skilled personnel! The electrolyte (diluted sulphuric acid) is extremely corrosive When working on batteries wear safety glasses and protective clothing! Acid splashes in the eyes or on the skin must be washed out or off with plenty of water. Then see a doctor immediately.
VC150 Installation and Operation Manual KNOW YOUR SYSTEM PREPARATION Before commencing, some time should be dedicated to working out all the aspects concerned in the system installation. By following these simple instructions and spending a little time on each, the whole installation process should be easier. 1) Check that all components are present, familiarise yourself with them and make sure that everything has been identified.
VC150 Installation and Operation Manual KNOW YOUR SYSTEM COMPLETED 1 2 3 t eca 6 7 5 4 8 1 SOLAR MODULE ARRAY 2 SUPPORT STRUCTURE 3 CHARGE REGULATOR 4 5 BATTERY PACK REFRIGERATOR 6 SOLAR ARRAY ACCESS 7 GOOD VENTILATION 8 NO DIRECT SUNLIGHT ON REFRIGERATOR Page 6 of 34
VC150 Installation and Operation Manual SOLAR ARRAY KYOCERA MODULE ASSEMBLY PLEASE READ ALL OF THE INSTRUCTIONS THOROUGHLY BEFORE COMMENCING (FOR 12V WIRING LAYOUTS SEE ‘JUNCTION BOX WIRING DIAGRAMS’) After ensuring that all the components are present, remove the solar modules (a.1) from their cardboard boxes and lay them next to each other on top of the cardboard, with glass facing down. Do not step on the glass modules. BROKEN MODULES CANNOT BE USED.
VC150 Installation and Operation Manual SUPPORT STRUCTURE ORIENTATION The solar array must be permanently positioned where the modules will receive the maximum amount of sunshine, however they are very fragile and should not be located where they may be damaged. 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.
VC150 Installation and Operation Manual SUPPORT STRUCTURE ORIENTATION CONTINUED The support structure is made from pre-drilled galvanised steel angle. If your mounting area cannot be level e.g. you have a sloping roof, then the correct angle must be made by adjusting the foot mounting holes. Use the ratios below to calculate your appropriate angle and follow the diagrams to position the structure accurately. Required Angle (A) Approx. Ratio (x : y) Required Angle (A) Approx.
VC150 Installation and Operation Manual SUPPORT STRUCTURE ASSEMBLY 1. Assemble the UniRac TLH High Profile Tilt Legs as shown in the drawing below. The UniRac can easily be assembled in any order appropriate to the job site requirements. TILT LEG 2. Use 3/8” hardware to assemble the UniRac and ¼” hardware to attach the PV modules to the UniRac. 3. UniRacs must be securely attached to roof rafters, ground footings or other secure structural features.
VC150 Installation and Operation Manual SUPPORT STRUCTURE LOCATING MOUNTING FEET 5. The drawing below shows two options for setting the width of the Mounting Feet. If possible, mount a PV module to the UniRails to determine the best attachment method for obtaining the proper distance between the Mounting Feet. TILT LEG 6.
VC150 Installation and Operation Manual LIGHTNING PROTECTION MEASURES LEVEL 1 – NO PROTECTIVE MEASURES – NOT RECOMMENDED BY DULAS LTD Failure to provide protection measures against lightning strike risks damage to the equipment. In the event of lightning striking the roof mounted Solar Array, high voltage may be conducted towards the refrigerator system. This high voltage may damage the electronic components of the system.
VC150 Installation and Operation Manual PHOTOVOLTAIC CONTROLLER INFORMATION When using Lead-Acid batteries in photovoltaic systems it is important to protect them against overcharging which would otherwise cause permanent damage. The Charge Controller is installed in the system to perform this task. Over-charge is prevented by limiting the battery voltage to a maximum of around 13.7 Volts at 25°C. The battery can be left charging at this ‘float’ voltage for long periods.
VC150 Installation and Operation Manual PHOTOVOLTAIC CONTROLLER – STECA PR SERIES STECA PR SERIES CHARGE CONTROLLER OPERATION The PR series controller is fully automatic in operation. See Steca manual for full information.
VC150 Installation and Operation Manual PHOTOVOLTAIC CONTROLLER – STECA PR SERIES INSTALLATION The unit should be installed in a dry location with clear space around it, to allow heat generated at the rear of the unit to be dissipated. The unit is fixed to the wall so that the terminals are at the bottom and the fins running vertically. INSTALLATION INSTRUCTIONS: 1. Fix the Photovoltaic Controller to the wall with plugs and screws. 2.
VC150 Installation and Operation Manual PHOTOVOLTAIC CONTROLLER – STECA TAROM SERIES STECA TAROM SERIES CHARGE CONTROLLER OPERATION The Photovoltaic Controller is fully automatic in operation. See manufacturer’s manual for information. CONTROLLER FUNCTIONS 1. STATE OF CHARGE: Indicated by a percentage at the top left of the display. When the state of charge is 50% or less, icepacks should not be frozen. 2. LOAD DISCONNECTION: The refrigerator is disconnected when the state of charge drops below 30%.
VC150 Installation and Operation Manual PHOTOVOLTAIC CONTROLLER – STECA TAROM SERIES 3.
VC150 Installation and Operation Manual PHOTOVOLTAIC CONTROLLER – STECA TAROM SERIES INSTALLATION The unit should be installed in a dry location with clear space around it, to allow heat generated at the rear of the unit to be dissipated. The unit is fixed to the wall so that the terminals are at the bottom and the fins running vertically. Installation Instructions 1. Fix the Photovoltaic Controller to the wall with plugs and screws. 2.
VC150 Installation and Operation Manual COMMISSION THE BATTERIES CONNECT THE BATTERIES THE BATTERY BOX MUST ALWAYS BE LOCATED IN A VERY WELL VENTILATED AREA AS THE BATTERIES GENERATE HYDROGEN, WHICH IS AN EXPLOSIVE GAS. 1. After choosing a final location, carefully place the batteries into the empty box, ensuring not to lift by the terminal points. THE BATTERIES ARE NOW EXTREMELY HEAVY. 2.
VC150 Installation and Operation Manual THE REFRIGERATOR / FREEZER POSITIONING DO NOT POSITION THE VC150 REFRIGERATOR / FREEZER IN DIRECT SUNLIGHT ENSURE THAT THE REFRIGERATOR IS WELL VENTILATED, ESPECIALLY THE VENTILATION GRILLES AND CONDENSER.
VC150 Installation and Operation Manual THE REFRIGERATOR / FREEZER LOADING IN ORDER TO KEEP INTERNAL TEMPERATURES OPTIMUM AND MINIMISE ENERGY CONSUMPTION, ONLY OPEN THE LID WHEN STRICTLY NECESSARY AND ALWAYS REPLACE INNER FOAM LIDS The VC150 Refrigerator / Freezer has two compartments, see General Layout Diagram: 1) The smaller Freezer (ice pack) compartment to the left. 2) The larger Refrigerator (vaccine) compartment to the right.
VC150 Installation and Operation Manual FRIDGE TEMPERATURE CONTROLLER Does the controller on your fridge/freezer look like this? If so go to page 23 Does the controller on your fridge/freezer look like this? If so go to page 24 Page 22 of 34
VC150 Installation and Operation Manual FRIDGE TEMPERATURE CONTROLLER INSTRUCTIONS The temperature controller has four buttons: SET, <<-<, >->> and AUX. TO BE DONE ONCE ONLY The electronic controller is adapted to control the appliance by setting parameters that have been developed by our engineers to ensure the correct internal operating temperatures. The setup is accessed by pressing the buttons + SET + in succession and keeping them pressed simultaneously for 3 seconds.
VC150 Installation and Operation Manual FRIDGE TEMPERATURE CONTROLLER Light (T1) indicates refrigerator compressor is running Temperature Alarm (1) Light (T2) indicates freezer compressor is running The controller normally displays vaccine temperature.
VC150 Installation and Operation Manual APPENDIX A: TECHNICIAN’S INSTRUCTIONS The temperature controller settings have been developed by our engineers to ensure that the vaccine and freezer temperatures are correct for a wide range of ambient temperature environments. Adjusting these settings may result in the refrigerator not working correctly and may result in damaged vaccine. (1) (2) (3) (4) To adjust the vaccine storage temperature setpoint, adjust parameters SPL, SPH and SP1.
VC150 Installation and Operation Manual ROUTINE MAINTENANCE CHECK TEMPERATURES The temperature inside the refrigerator should be checked each morning and afternoon. The temperature must be between 2°C and +8°C. If the temperature i s not within this range then something is wrong and the vaccines will be unusable. Consult the W.H.O. Fault Finding and Repair of Photovoltaic Refrigerators (provided with each refrigerator).
VC150 Installation and Operation Manual ROUTINE MAINTENANCE CHECKING THE LID SEAL The lid seal is the most likely area of heat penetration. If the lid hinges are wrongly aligned or the lid seal damaged, the system will have to work harder to maintain the vaccine temperature. When the batteries run out of energy the system will fail, therefore the lid seal must be checked regularly.
VC150 Installation and Operation Manual MODULE AND BATTERY WIRING DIAGRAMS 3 x KD135 - 12 VOLT MODULES 2 x KD135 - 12 VOLT MODULE LAYOUT 2 x 6 VOLT BATTERIES Page 28 of 34
VC150 Installation and Operation Manual SYSTEM WIRING DIAGRAM (Version 1) VC150 REFRIGERATOR / FREEZER Module interconnect cable Solar Module Array Module Interconnect Cable Array Output Cable ! Photovoltaic Controller 3530A or 45A Photovoltaic charge controller.
VC150 Installation and Operation Manual SYSTEM WIRING DIAGRAM (Version 2) VC150 REFRIGERATOR / FREEZER Page 30 of 34
VC150 Installation and Operation Manual GENERAL LAYOUT DIAGRAM VC150 REFRIGERATOR / FREEZER Refrigerator Condenser Freezer Condenser Freezer Switch (in ‘ON’ position) Power Connection Cable Entry Fuses Freezer Compartment VIEW FROM BEHIND Refrigerator Compartment VIEW FROM ABOVE Page 31 of 34
VC150 Installation and Operation Manual ELECTRICAL SCHEMATIC VC150 REFRIGERATOR / FREEZER Parts List Compressors C1147 Compressor Controllers Thermostats Switch on Freezer only Fan BD 35 101N0210 AT-5BQ8L-1PS CV465 E2076 Page 32 of 34
VC150 Installation and Operation Manual REFRIGERATION CIRCUIT DIAGRAM VC150 REFRIGERATOR Capillary (120’ x 0.031”) Evaporator (Assy No: EV8661) Accumulator (Part No: E L1027) Suction 46” x 5/16” Drier (Part No: N1184) Condenser (Part No: N1111 or N1235) M Compressor C1147 (Part No: BD 35) VC150 FREEZER Capillary (120’ x 0.
VC150 Installation and Operation Manual For more information contact: DULAS Ltd, Dyfi Eco Park, Machynlleth, Powys, Wales SY20 8AX tel: +44(0)1654-705000 fax: +44(0)1654-703000 e-mail: solar@dulas.org.uk website: www.dulas.org.
