Your controller should be set up with a temperature differential detector ( a "differential") which does not turn the pump on unless the exit temperature from the manifold is higher than the inlet temperature at the point where the system is drawing water from inside the tank. Assuming that the pipes from the panel back to the tank are well insulated, this should guarantee that you are getting a net increase of the heat inside the tank. But because it also will do some mixing of the tank contents, it could also result in the temperature at the top of the tank actually going down a bit.
You generally do not want to lock out the solar system from heating the cold water at the bottom of the tank just because the stratified temperature at the top of the tank is higher than the panel output. But this is why the solar is set up to return to the middle of the tank rather than the top unless it is the only heat source. Your situation, with a high temp heat source which is only sometimes available, is a difficult one to design for and I would like to see comments about this specific problem from those who have more design or use experience in this area.
The proper operation of the differential depends on the placement and accuracy of the two temperature sensors.
If the return pipe temperature at the heater is lower than the inlet temperature (the pipe at the heater going up to the panels) as measured by moving a single thermometer or with two calibrated/matched thermometers, then your controller should not be turning the pump on. If it does, then you need to look at your control system setup.
You generally do not want to lock out the solar system from heating the cold water at the bottom of the tank just because the stratified temperature at the top of the tank is higher than the panel output. But this is why the solar is set up to return to the middle of the tank rather than the top unless it is the only heat source. Your situation, with a high temp heat source which is only sometimes available, is a difficult one to design for and I would like to see comments about this specific problem from those who have more design or use experience in this area.
The proper operation of the differential depends on the placement and accuracy of the two temperature sensors.
If the return pipe temperature at the heater is lower than the inlet temperature (the pipe at the heater going up to the panels) as measured by moving a single thermometer or with two calibrated/matched thermometers, then your controller should not be turning the pump on. If it does, then you need to look at your control system setup.
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