Dulas VC150SDD User manual

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

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Table of Contents
1. COMPONENTS CHECKLIST ...................................................................................... 3
2. SAFETY INSTRUCTIONS ........................................................................................... 4
3. YOUR DULAS SOLAR DIRECT DRIVE REFRIGERATOR ......................................... 6
4. REFRIGERATOR COMPONENTS ............................................................................ 7
5. RECOMMENDED TECHNICIAN’S TOOLS ................................................................. 8
6. MATERIAL SAFETY INFORMATION .......................................................................... 9
7. END OF LIFE & PRODUCT RECYCLING ..................................................................10
8. PREPARING TO INSTALL .........................................................................................12
9. SOLAR ARRAY ASSEMBLY ......................................................................................13
10. SOLAR ARRAY ORIENTATION ..............................................................................19
11. SOLAR ARRAY INSTALLATION .............................................................................20
12. SOLAR MODULE CONNECTIONS .........................................................................22
13. COMMISSIONING SOLAR ARRAY ........................................................................23
14. ADVICE ON LIGHTNING PROTECTION ................................................................24
15. ADVICE ON SURGE PROTECTION .......................................................................24
16. SOLAR ARRAY EARTHING ....................................................................................25
17. REFRIGERATOR INSTALLATION ..........................................................................26
18. SYSTEM COMMISSIONING ...................................................................................27
19. REFRIGERATOR LOADING ...................................................................................28
20. FREEZER OPERATION ..........................................................................................29
21. GREEN COMPRESSOR STATUS LED LIGHT.......................................................30
22. USER TRAINING .....................................................................................................31
23. MAINTENANCE TASKS ..........................................................................................32
24. SPARE PARTS ........................................................................................................32
25. TROUBLESHOOTING GUIDE ................................................................................33
26. INSTALLATION & COMMISSIONING RECORD .....................................................41
27. VC150SDD ELECTRICAL SCHEMATIC .................................................................44
28. VC150SDD REFRIGERATION SCHEMATIC ..........................................................45
29. VC150SDD FREEZER SCHEMATIC ......................................................................45
30. VC150SDD SYSTEM LAYOUT ...............................................................................46

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1. Components Checklist
DESCRIPTION QUANTITY
REFRIGERATOR
VC150SDD Refrigerator Cabinet 1
Refrigerator Baskets 6
Refrigerator Key 2
SOLAR ARRAY
250W minimum Solar Modules 3
20m Pre-terminated Solar Cable (+ve & -ve) 1 pair
Solar Connector – Branch Plug 2
Solar Connector – Branch Socket 2
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 4
(C) Front fixed leg 3
(D) C-Rail 47-3 – 1530mm 4
(E) C-Rail 47-3 - 750mm (not used with VC150SDD system) 0
(F) Rear adjustable leg 3
(G) Rail connector set 47 2
Coachscrews, Rawlbolts, Washers 3 packs
Screws 1 pack
Wall Plugs 1 pack
Cable Ties 1 pack
Cable Tie Bases 1 pack
Silicon Sealant 1

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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.
The refrigerator is not to be used by persons (including children)
with reduced physical, sensory or mental capabilities, or lack of
experience and knowledge, unless they have been 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 height practices
when installing the solar array.
Live electrical components – solar modules are live when
exposed to sunlight. Isolate the array (using the PV isolator on the
back of the refrigerator) before disconnecting any components.
Electrical danger – under fault conditions high electrical
currents can occur. Never bypass a circuit breaker and always
replace with the same type and rating.

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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. Do not damage the internal side
panels of the compartment.
Keep Dry – This refrigerator is for indoor use only. 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 than those recommended
by the manufacturer.
Warning: Keep ventilation openings, in the appliance enclosure
or in the built-in structure, clear of obstruction.
Warning: Do not use electrical equipment inside the appliance.
Warning: Do not store explosive substances such as aerosol
cans with a flammable propellant inside this appliance.

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3. Your Dulas Solar Direct Drive Refrigerator
Congratulations on choosing the Dulas VC150SDD vaccine refrigerator and water pack freezer.
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 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. With this new technology we can offer the same renowned 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 shining 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 its cold store. Under normal
sunlight conditions (8 hours/day of solar irradiance >200W/m²) the refrigerator will take
approximately 7 days to fully charge the cold store and be ready for vaccine storage.
In the VC150SDD the freezer compartment is secondary to the vaccine compartment. It has its
own separate refrigeration circuit and we prioritise the operation of the vaccine compartment. The
freezer only runs when there is enough solar energy to power first the fridge compressor and then
the freezer. This means that in periods of very low sunshine you may not be able to freeze water
packs.
Recommended solar array
The VC150SDD has been designed to meet the World Health Organisations 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 between +5C and +43C. For use in such Hot Zone environments it should be powered by
a minimum 600W solar array with a Voc not exceeding 45Vdc.

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4. Refrigerator Components

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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
Ratchet socket handle (not supplied)
Adjustable Spanner
Multimeter (20A rated)
Tape measure
Spirit level
Compass (supplied)

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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 & EN60335-2-24:2010.
R600a refrigerant – Isobutane, is highly flammable when mixed with air. Do not inhale, ingest, and
avoid contact to skin. Ensure that any work carried out on the refrigeration circuit is done by a
competent refrigeration engineer.
THE PHASE CHANGE MATERIAL (PCM)
The refrigerator contains an organic phase change material (PCM) that provides the energy store
for the refrigerator. This PCM material is a paraffin wax that is liquid at room temperature and is
stored in large tanks secured 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 because of its low volatility. At high
temperature aerosol/mist can cause an irritation of the respiratory tract.
H304 May be fatal if swallowed and enters airways.
P301 + P310 IF SWALLOWED: Immediately call a POISON CENTRE or
physician.
P331 DO NOT induce vomiting.
R65: Harmful: may cause lung damage if swallowed.
R65: Repeated exposure may cause skin dryness or cracking.
In the event of a PCM spillage:
 Wear suitable protective clothing, gloves and safety glasses when clearing up spillages.
 Use an absorbent substance such as sand to contain any escaping material.
 Do not allow to enter drains / surface waters / groundwater. In case of the leakage of a
large amount inform the responsible authorities.

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7. End of Life & Product Recycling
PACKAGING
The packaging is made from recyclable / reusable materials and should be brought to an official
recycling centre. The materials used are:
 Heat treated (HT) timber, certified by UK Forestry Commission (ISPM No. 15 Mark)
 Corrugated cardboard / Cardboard
 Polyethylene plastic
 Moulded polystyrene parts
 Steel reinforcing straps
WARNING – Keep packaging away from children - danger of suffocation from plastic!
WORN OUT REFRIGERATOR
The refrigerator still contains valuable materials and is not to be disposed of in the normal
household waste.
 Ensure that the cooling circuit of the worn out device is not damaged when being
transported.
 Information on the coolant used is on the type plate on the back of the refrigerator.
 The walls 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) - paraffin, normal C5-20
 Electrolytic capacitor
 Electronic components – SDD controller
Compressor controller
Refrigerator compartment temperature display
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. Contact your local
waste disposal authority for advice. The product can be incinerated in accordance with local
regulations. In the EU it has a Waste Disposal Code (EWC): 13 08 99 oil waste not otherwise
specified.

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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. 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. Industrial recycling processes exist for both thin-film and silicon modules.
Materials such as glass, aluminium, as well as a variety of semiconductor materials, are valuable
when recovered.

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8. Preparing to Install
Before starting the installation please read through the complete installation manual. By taking the
time to follow these simple instructions the whole installation process will be much easier.
1) Carefully unpack the system and check that all components are present, familiarise
yourself with them and make sure that everything has been identified. Ensure that you
have all tools required to complete the installation.
2) 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.
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 the system location. Ensure that the solar array is
not, and will not become, shaded in the future and that it is accessible for cleaning
and maintenance.
5) Work out the best route for the solar array output cable and the earthing cable, ensuring
that there is sufficient length to reach the refrigerator and that our advice on lightning
protection is followed (see Section 14).
Each component should have a sensible, well thought out, safe location, allowing access for
routine maintenance.

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9. Solar Array Assembly
PLEASE READ ALL OF THE INSTRUCTIONS 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 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.

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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)
B) Mid clamps x 2 (or x 4)
A) End clamps x 4 C) Front fixed leg x 2 (or x 3)

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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.

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Attaching solar panels to the rails

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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.
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.

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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. Remember that the modules
are very fragile and should not be located where they may be damaged.
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.
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 in which it is located. The front of the
solar modules must be cleaned every week or when necessary in dusty areas.
PV Modules near the Equator should be p ositioned
with a slight (10-15 ) tilt facing North o r So uth in order
to allow rain to run off them also keeping them clean.
30
o
30
o

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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.
The solar array must be permanently located in a safe and unshaded position, orientated to face
the equator to guarantee maximum energy generation. A compass has been supplied to assist
with optimum positioning.
The final country of location will dictate the optimal 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°, use 10° array tilt.
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.
Please ensure that the supporting structure (i.e. roof) can support the weight of the array and that
the fixings sufficiently penetrate a solid sub-structure. Simply screwing the mounting system to roof
decking is not adequate to withstand high wind loads.