Dulas Solar VC150 User manual

DULAS Solar Powered
VC150 Refrigerator/Freezer
Installation & Operation Manual
June 2010

VC150 Installation and Operation Manual
Page 2 of 34
CONTENTS
SECTION Page
KNOW YOUR SYSTEM
Component checklist 3
Battery safety 4
Preparation 5
Completed system 6
SOLAR ARRAY
Photovoltaic module assembly 7
Support structure orientation 8
Support structure assembly 10
Lightning protection 12
ELECTRICAL SYSTEM
Photovoltaic controller information and installation 13 - 18
Battery commissioning 19
THE REFRIGERATOR / FREEZER
Positioning and starting 20
Loading 21
Fridge temperature controller 22 - 24
Appendix A: technician’s instructions 25
Routine maintenance 26 & 27
SYSTEM DIAGRAMS
Photovoltaic module and battery layouts 28
System wiring diagram (Version 1) 29
System wiring diagram (Version 2) 30
General layout diagram 31
Electrical Schematic 32
Refrigeration circuit diagram 33
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VC150 Installation and Operation Manual
Page 3 of 34
COMPONENTS – CHECK LIST
REF PRODUCT QUANTITY
SOLAR ARRAY (either 270W or 405W)
a. 1 KD135 Solar Modules 2 or 3
a. 2 10m Array Output Cable 1
a. 3 0.5m Module Interconnect Cable Assembly 1 or 2
a. 4 Bolt, Plain Washer, Nylon Washer, Penny Washer
& Nut Pack
a. 5 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. 3 Feet 4
c. 4 Bolt, Plain Washer, Spring Washer & Nut Pack
c. 5 Screws & Wall Plugs Pack
c. 6 Cable Clips Pack
BATTERY PACK
d. 1 Battery 2
d. 2 Battery box 1
d. 3 Photovoltaic controller 1
d. 4 Battery to controller cable 1
d. 5 Spare Fuses Pack
d. 6 Cable Ties 5
d. 7 Padlocks 3
TOOLS REQUIRED FOR INSTALLATION
Pozidriv No.2 Screwdriver Slot-head Screwdriver
Pliers Wire Cutters
Wire Strippers Craft Knife
Drill and Bits Hammer and Punch
Adjustable Spanner Size 10, 11, 13, 14 & 17 mm Spanners

VC150 Installation and Operation Manual
Page 4 of 34
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. Clothing exposed to acid should be washed
out with water without delay.
Electrical Danger! In the case of a short circuit, extremely high currents can occur
which can cause severe burns.
Block batteries or cells are heavy! Ensure secure installation! Only use suitable
transport equipment!
Explosion and fire hazard due to explosive gases escaping from the battery.
Caution! Metal parts of the battery are always live, therefore do not place items or
tools on the battery! Avoid short circuits!
No smoking! Do not expose the battery to an open flame, a glowing fire or sparks as
explosion and fire hazards exists.

VC150 Installation and Operation Manual
Page 5 of 34
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.
2) Discuss and decide a position for the refrigerator, ensuring that it is well ventilated, dry and not in
direct sunlight. The colder the room, the better the performance.
3) Work out a position for the solar array ensuring that it faces the correct direction, is at the correct tilt
angle (see page on support structure orientation), no shading will occur, it will not be damaged and it
is accessible for cleaning and maintenance.
4) Work out the route for the solar array output cable, ensuring that there is sufficient length to reach
the charge regulator.
5) Choose a position for the batteries that is well ventilated, dry, safe, not in direct sunlight and
accessible for topping up with distilled water. The colder the room the better the performance.
The system, when completely installed should look similar to the drawing below. Each component should
have a sensible, well thought out, safe location, allowing access for routine maintenance.
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SOLAR