Product Installation: Solar Array

Installation:
Solar array and cabling
Safety instructions
Read the manual
Please read all the 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.

Safe working
Before assembly, ensure the roof is large enough and stable enough for multiple installers. Scan for hazards including
sharp items or edges. Ensure there is safe access to the roof, including suitable room for safely raising the solar array
components onto the roof. Please observe safe working at height practices when installing the solar array. Installers
must wear appropriate footwear.

Handling
The system is heavy and fragile – please observe good manual handling procedures when moving the solar power
system. Only use suitable transport equipment. Do not put anything on top of the solar array, and do not lean on or step
on any part of the system.
Safety instructions
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.

DC power only
This refrigerator is designed for operation with the solar power system supplied. Do not connect the refrigerator to other
power supplies.
Planning
You will need to consider the following aspects
before installing any equipment:

+ Date and time of delivery

+ People and responsibilities

+ Weather considerations
+ Clear space and site planning
+ Tools and power supply
+ Hazard review and management
Planning
Delivery date and time
Ensure you are aware of when the equipment will be delivered, and who will be available to move equipment into the
health facility. You may need permission in advance from the health facility for deliveries.

People and responsibilities

Understand and organise who is responsible for leading the delivery and installation teams. The Dulas In-country Partner
can be contacted for queries about equipment supply.

Weather considerations
The electrical equipment needs to be kept dry. It is advised that precautions are prepared before equipment arrives.
Consider the weather and prepare a safe dry space for the equipment. Do not install the solar array during rainfall.
Planning
Clear space and site planning
Make sure you have a large, clear area where the equipment can be temporarily stored and installed. Measure doorways
and corridors where required, before moving equipment. Ensure the equipment never blocks doors, walkways or
healthcare equipment.

Tools and power supply

It is advised that installers have as many tools at their disposal as possible, ready for equipment installation on site. There
is a list of recommended technician’s tools in section 5 of the installation manual. Store tools safely and securely, and
take extra care with cables and blades.

Hazard review and management

Conduct a thorough hazard review for every stage of the delivery and installation phases, from road safety and access
requirements. Consider the risks installers may encounter and take steps to make the installation safe. Dulas equipment
is fragile and heavy. It should always be carefully manoeuvred by multiple people. Take extreme care when working at
height, with electrical components and with power tools.
Solar array installation:

Preparation
Please refer to the Installation & Technician’s Manual for detailed
instructions. We recommend that the installer uses the Installation &
Commissioning Record as a checklist during installation.
 Before starting the installation, please read through the complete installation
Preparation manual. By taking the time to follow these simple instructions, the entire
installation process will be much easier.

1. Unpack
Carefully unpack the system and check that all components are present. Familiarise yourself with them and make sure everything has
been identified. Ensure that you have all the tools required to complete the installation.

2. Installation Record
Familiarise yourself with the Dulas Installation Record in Section 25 of the Installation & Technician’s Manual. This provides a step-by-step
guide to the installation process and also gives you a formal record of the installation.

3. Refrigerator location
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 the temperature may fall below +5ºC.

Continued on next slide…

Preparation

4. Solar array location

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. It also needs to be accessible for cleaning and maintenance.

5. Cable routing
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 Dulas’s advice on lightning protection is followed (Section 14 of the Installation & Technician’s Manual).

All components should have a sensibly planned, safe location that allows access for routine maintenance.
Solar array installation:

Assembly

WORKING AT HEIGHT IS DANGEROUS.

PLEASE OBSERVE SAFE WORKING PRACTICES

FRAGILE ROOFS – ENSURE THAT THE ROOF WILL HOLD YOUR WEIGHT
PLUS THAT OF THE ARRAY BEFORE YOU CLIMB ONTO IT.

FRAGILE COMPONENTS – BROKEN MODULES CAN NOT BE USED.

DO NOT DROP TOOLS OR LEAN ON THE MODULES.
 PLEASE READ ALL OF THE INSTRUCTIONS THOROUGHLY BEFORE
Assembly COMMENCING. These instructions apply to all variants of the Dulas mounting
system: 2 and 3 modules in both portrait and landscape orientation.

Tools required
+ Deep reach 18mm socket
+ Torx T30 key
+ Torx T45 key
+ Ratchet socket handle (not supplied)

If this is your first time installing the Dulas mounting

system, it is highly recommended to complete a
test assembly at ground level prior to working on
the rooftop. This will ensure that you are familiar
with how the system fits together and can work
out any problems in a safe environment.
Assembly
A
Components
The mounting system is supplied in pre-assembled B
parts. This guide will help you to identify the
individual parts.

For exact quantities, please refer to the

Components Checklist, Section 1 of the Installation
C E
and Technician’s Manual.

A End clamps (x4)

B Mid clamps (x2, x4 for 3 module system)
C Front fixed leg (x2, x3 for 3 module system) F
D 1530mm rail (x2, x4 for 3 module system)
D
E 750mm rail (x2, none for 3 module system)
F Rear adjustable leg (x2, x3 for 3 module system) G
G Optional rail connector (x2 if required)
Assembly

Orientation
The mounting system can be assembled to allow
the modules to be attached in either portrait or
landscape configuration.
ê
The decision between which option to use is
usually guided by which direction the joist run on
your roof.
2 modules in
portrait orientation

Rear adjustable leg

Front fixed leg

Assembly 2 modules in
landscape orientation

Orientation
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 3 modules

usually guided by which direction the joists run on in portrait orientation
your roof.
Assembly

How to attach the modules to the

rails

Mid clamps affix the modules to the centre of the rails.

End clamps affix the modules to the end of the rails.

For maximum strength (550kg/m2), clamp

the modules in the green area as shown opposite.

Where required, you can clamp

in the yellow area (244kg/m2).

Do not clamp in the red area.

Assembly

Joining with a rail connector

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.
Assembly

Solar array position

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 placed where they may be damaged.

Ensure that the support structure is:

+ Secure and not twisted

+ Accessible for cleaning
+ Well ventilated
+ Safe from severe weather conditions
+ Not shaded between 7am and 5pm
 PV modules near the equator should be positioned with a slight tilt (10-15º)
Assembly facing North or South, in order to allow rain to run off them, also keeping them
clean.

Solar array orientation

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 the solar array is dependent on the

location. The front of the solar modules must be
cleaned weekly in dusty areas.
 Warning: Only connect the Dulas Solar Direct Drive refrigerator to the solar array
Assembly supplied. Connection to other systems may damage the refrigerator.

Required Length Length

Solar array tilt angle A of Y of Z Z

Determine the required tilt angle for the array 10º 9cm 50cm
installation on your roof. Use an inclinometer Y
15º 16cm 60cm
(or free smartphone app e.g. ‘Angle Meter’ in
the Google Play Store) to set the tilt.
20º 22cm 60cm
A
Alternatively, a triangle may be cut from a piece 28cm 60cm
25º
of card and used with a spirit level to correctly set
the array angle. 30º 29cm 50cm

Refer to this table and diagram for the dimensions 35º 35cm 50cm
needed to produce a triangle of the correct size.
40º 42cm 50cm

45º 50cm 50cm

Assembly 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.

Solar module connections

Only use the solar cable and solar connectors

provided. Follow good electrical installation
practices when installing the cables:

+ Route the cables where they cannot be

damaged or subjected to excessive heat.

+ Do not install the cable around tight bends.

Use the supplied length of conduit to protect the solar array cables as they enter
+ Ensure that the cable is supported along the full the building or as it passes over sharp edges. The conduit is slit so that it can be
length of its route to the refrigerator, using the clipped over both cables. Once applied, cable tie it in and if necessary, fill the
cable ties and bases provided. external end with the supplied silicon sealant to seal the hole.
Assembly

Solar module connections

DO NOT DISCONNECT THE SOLAR

CONNECTORS UNDER LOAD.

If you need to disconnect any of the solar

connects (at the solar array end of the
refrigerator) please ensure that the refrigerator
has been turned off at the PV switch (located at
the back of the refrigerator) before
disconnecting.
Assembly
Lightning protection
In order to reduce the risk of damage from a lightning strike
on any part of the system, please take note of the following:
+ Keep all cable routes as short and straight as possible
+ If an existing lightning protection system is present, please
bond the array directly to this and check whether the Dulas
array earthing kit is required
+ Keep the solar cable and earthing cable separate
by at least 1.5 metres
Ensure that all fastenings on the array earthing kit are secure
and check them annually.
For a Solar Direct Drive installation where the refrigerator is
directly connected to the solar array, it is important to also
connect the refrigerator cabinet to earth. This protects the
equipment and any people who may be touching the
refrigerator from electric shock during fault conditions.
Dulas SDD refrigerators have a dedicated earthing block on
the rear of the cabinet for this purpose. The earthing block
can be connected to the same earth rod as the solar array if a
separate earth connection is not available.
Which checks do I
need to perform?
In order to find out what is wrong with the
refrigerator, we need to ask the right questions.

There are four main symptoms:

 The refrigerator is The refrigerator is The refrigerator is
The refrigerator sometimes too warm too warm and too warm but
is always too and sometimes at the the compressor the compressor
cold correct temperature never runs does run
Check the solar array for Check the solar array and cables Check the Dulas SDD controller
Check the Dulas SDD shading and cleanliness ê
controller Check the PV isolator ê
ê ê
ê Check the Dulas SDD controller Check the temperature sensors
Check the solar array ê
Check the temperature and cables Check the temperature sensors ê
sensors ê
ê Check the compressor controller Check the thermostat accuracy
ê ê
Check the compressor and Check the compressor and ê
Check the thermostat refrigeration system refrigeration system
accuracy ê ê Check the compressor and
Check the capacitor refrigeration system
Check the capacitor ê
Check the thermostat accuracy
Other factors

In addition to the previous symptoms, there are two other areas that need to be considered if experiencing a fault:

Lightning protection
The lightning protection systems can prevent failure of the refrigerator caused by electrical storm activity, but may be degraded over a
period of time. In areas of frequent lightning storms, the lightning protection circuits will need periodical checking even though the system
may be working normally. If fault finding or work carried out on the refrigerator, it is advised that the lightning protection systems are checked
at the same time.

Vaccine Guard failure

Some Dulas vaccine refrigerators are fitted with the ‘Vaccine Guard’ remote temperature monitoring system. If you are experiencing problems
with the Vaccine Guard you should check that it is being properly charged.