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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SOLAR

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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
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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
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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

VC150 Installation and Operation Manual
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KNOW YOUR SYSTEM
COMPLETED
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
SOLAR MODULE ARRAY
SUPPORT STRUCTURE
CHARGE REGULATOR
BATTERY PACK
REFRIGERATOR
SOLAR ARRAYACCESS
GOOD VENTILATION
NO DIRECT SUNLIGHT ON REFRIGERATOR
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VC150 Installation and Operation Manual
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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. Arrange the solar modules so that the junction boxes are all
on the same side.
Interconnect the modules with the cables provided (a.3). The
interconnect cable has a crimped ring terminal at each end which
are easily connected to the Kyocera junction boxes as illustrated
below in Figure 1, (remove plastic nut, screw gland in place,
replace plastic nut and connect cables.)
The array output cable (a. 2) must then be connected to the nearest
module (see System Wiring Diagram), brown or red wire to +, blue
or black wire to -. Ensure that there is sufficient cable to meet the
necessary distance then insert into the junction boxes as performed
previously.
Note : Due to new cable colour regulations brown or red can be
used for +ve and blue or black for –ve until 1/4/06 after which time
only brown and blue will be permissible.
Lift the cover of the junction box by
removing the four screws. Place the ring
terminal into position and tighten up the
terminal screw until it is gripped securely.
Replace the cover of the junction box with
the screws provided ensuring a moisture
proof seal.
Figure 1

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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.
Please ensure that the support structure is: SECURE 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.
The tilt angle of a solar array is dependent on the country in which it is located. Figure 2 demonstrates
common tilt angles. The front of the solar modules must be cleaned every week or when necessary in dusty
areas.
Figure 2
PVModulesnear the Equatorshould be positioned
with a slight (10-15 )tilt facing North orSouth in order
to allow rain to run off them also keeping them clean.

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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. Ratio (x : y)
10° 6 : 1 30° 2 : 1
15° 4 : 1 35° 1.75 : 1
20° 3 : 1 40° 1.5 : 1
25° 2.4 : 1 45° 1.4 : 1
Changing the position or length of the Tilt
legs can alter module angles.
Always ensure that all bolts are secured
tightly after alterations have been made.
A protractor can be used to determine
if the correct angle has been acquired.

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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.
Simply screwing the UniRac to roof decking is not adequate to withstand high wind loads.
4. Leaving as much space as possible at the bottom of the UniRac will minimize debris accumulation and
snow load.

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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. On UniRacs Tilt Leg Kits, rack tilt can be determined by:
A – Raising or lowering the Tilt Leg,
B – Moving the Tilt Leg up or down along the UniRail,
C – Adjusting the distance between the lower and upper Mounting Feet before final installation.
COMPLETED UNIRAC TLH HIGH-PROFILE TILT
LEGS INSTALLATION (ADJUSTABLE LEG)

VC150 Installation and Operation Manual
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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.
LEVEL 2 – LIMITED PROTECTIVE MEASURES (Normally Supplied)
We strongly recommend that at least this level of protection be installed – see figure 1.
Install an earth electrode (earth rod) (A) outside the building – the earth rod should be at least 2m long.
Connect the earth rod with good quality wire (at least 6mm²) to the Solar Array and support structure (wire
B). The earth wire should follow the shortest and straightest path between the support structure and the
earth rod.
LEVEL 3 - FULL LIGHTNING CONDUCTOR SYSTEM (Not Supplied)
Assess the risk of lightning strike. Look at other local buildings – are they fitted with lightning conductors?
Ask local people if TV aerials etc often get struck?
If the installation is at high risk of lightning strike then an additional lightning conductor and separate earth
rod should be installed – see figure 2.
In addition to level 2 protection, install a second earth electrode (D). The distance between the two earth
electrodes must be more than their length. Erect an Air Terminal or Lightning Conductor (D) next to the
second earth electrode. The Air Terminal must exceed the height of the Solar Array such that the Solar
Array falls within a 45º cone centred on the Air Terminal – this is the area that is protected by the Air
Terminal.
Figure 1. Figure 2.

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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. The battery float voltage
is temperature compensated. In order to measure the temperature, a temperature sensor is built in to the
charge controller. The Controller should therefore be mounted close to the batteries.
Similarly, the battery must be protected against over-discharge. The Controller has an automatic low voltage
disconnect facility. In the event of the battery becoming discharged, the refrigerator will be disconnected
before permanent battery damage occurs. Re-connection is automatic.
The Photovoltaic Controller is fully automatic in operation. See manufacturer’s manual for further
information.
Dulas supply one of two different models of Steca Charge controller: either the PR series or the Tarom
series. Please compare the charge controller you have to the pictures below to determine which model you
have been supplied. The instructions on pages 14 and 15 refer to the PR series and the instructions on
pages 16 to 18 refer to the Tarom series.
STECA PR3030 – go to pages 14 and 15
STECA TAROM 235 – go to pages 16, 17 and 18

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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.
CONTROLLER FUNCTIONS
The display window on the front panel shows system information and error messages, the left button on the
front panel can be used to switch display windows or calling up settings and the right button is used as a
manual load switch, or confirmation button in the programme mode. The three displays, which are the most
relevant to the operation of the refrigerator, are as follows:
1. CORRECT OPERATION: Indicated by a smiling face in the display window. A sad face indicates a fault.
The reference number in the display can then be looked up in the manual to give the meaning of the error
and the cause/remedy.
2. STATE OF CHARGE: Indicated by the bar graph (SOC:) and a percentage on the display. When the
state of charge is 50% or less, icepacks should not be frozen.
3. LOAD DISCONNECTION:The refrigerator is disconnected when the state of charge drops to 30%. The
SOC bar value, or the voltage value, flashes. The face looks sad until the reconnection set point is reached.
THE LCD ALSO PERFORMS VARIOUS OTHER FUNCTIONS. CONSULT THE MANUFACTURER’S
HANDBOOK FOR FURTHER INFORMATION.

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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. Connect the battery cable to the central pair of terminals on the unit (2). Taking care to ensure correct
polarity (brown or red to +, blue or black to -).
3. The array output cable (a.2) must be connected AFTER the batteries, to the left hand pair of terminals on
the unit (1) (brown or red to +, blue or black to -). BE AWARE OF LARGE VOLTAGES. Cover the array or
connect at night.
4. The refrigerator is connected to the right hand pair of terminals (3) on the regulator, taking care to ensure
correct polarity (brown or red to +,blue or black to -).
5. Support the cables using the clips provided.
2
1
3
Display window for
system information
and error messages
Button for switching
display windows or
calling up settings
Manual load switch, or
confirmation button in
programme mode

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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%.

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PHOTOVOLTAIC CONTROLLER
– STECA TAROM SERIES
3. DISPLAY FUNCTIONS (for 35a and 45a)
The rotating display goes through the following screens:
4. The display also indicates various system faults and other functions. Consult the manufacturer’s manual
for further information.
SOC:
Battery state of
BAT:
Battery voltage
IN:
Charge (PV) current
OUT
:
Discharge
(fridge) current
This section
SOC = xx % State of charge of the battery
U BAT = xx V Voltage of the battery
I accu = + xx A Battery current (charging is +ve)
I out = xx A Fridge current
I in = xx A Charge current
I mod = xx
A
Current available from PV
manual auto System is in automatic mode
normal charge Indicates ‘normal’ or ‘boost’ charge
fixed electrolyte Controller is pre-set for sealed gel battery

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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. Connect the refrigerator to the right hand pair of terminals (A) on the controller, taking care to ensure
correct polarity (brown or red to +,blue or black to -).
3. Connect the battery cable to the central pair of terminals on the unit (B), taking care to ensure
correct polarity (brown or red to +, blue or black to -).
4. Install the battery fuse.
5. Check the controller display is working, then connect the array output cable to the left hand pair of
terminals on the controller (C), (brown or red to +, blue or black to -).
6. Support the cables using the clips provided.
B
C
A

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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. Connect the battery-to-regulator cable to the regulator FIRST,
brown or red to + and blue or black to – THEN to the battery.
Secure in place using the nuts, bolts and washers provided. Insert
a spare fuse (d.7) into the fuse holder on the battery-to-regulator
cable. Any problems refer to the manufacturers handbook provided.
3. Apply petroleum jelly or similar to each battery terminal – this helps
avoid corrosion.
4. Commence charging of the batteries immediately by connecting the
solar array cable to the PV Controller. DO NOT CONNECT THE
REFRIGERATOR as the batteries need an initial charging of two
good sunny days for optimum performance.
5. Once the batteries are ready for operation (after two good sunny
days of charging), the refrigerator can be connected.

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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.
WE RECOMMEND LEAVING A 500mm GAP AT EACH END OF THE REFRIGERATOR
NEVER OBSTRUCT THE TEMPERATURE OR REGULATOR DISPLAYS
ENSURE THAT THE BATTERY BOX AND BATTERIES CAN BE INSPECTED WHEN NECESSARY
NEVER BLOCK THE CIRCULAR COMPRESSOR VENTILATION FAN AT THE FRONT
STARTING THE FRIDGE
The VC150 Refrigerator is designed for continuous operation, therefore an ON/OFF switch is not provided,
as it is not necessary. The VC150 Freezer however, does have an ON/OFF switch to allow for defrosting.
This is situated at the rear right of the cabinet, as viewed from the front, above the cable gland (see General
Layout Diagram).
The VC150 Refrigerator/Freezer is operational when the power cable is connected to the controller.
a) Strip the power cable to reveal 10 mm of brown or red (+) and blue or black (-) wire.
b) Insert the cable into the black strain relief gland, located at
the rear, see ‘Cable Entry’ in the General Layout Diagram.
c) Connect to + & - terminals on
opposite side of the strain relief
gland.
d) TIGHTEN THE TERMINALS SECURELY,
TIGHTEN THE STRAIN RELIEF GLAND SECURELY.