Commissioning the solar controller
A solar monitor is located on the front of the solar controller
and houses a green and a red LED.
Remove the covering on the collector(s) to allow them to
begin receiving solar radiation and heating water in the
system. Plug in and switch on the power supply to the solar
controller. Once the electrical supply is switched on to the
solar controller it will start up and the green and red LED’s
will emit a constant glow for 2 seconds. If the solar hot water
system is operating correctly the green LED marked “solar”
will stay on and emit a constant glow.
SOLAR
ATTENTION
NOTE: The solar controller will monitor the temperatures
at the collector array and the storage tank in order to
determine the correct conditions to begin circulating the
water efficiently. As such it may not begin circulating water
immediately through the collector array.
If power to the solar controller is available and the green LED
is off or the red LED is flashing, this indicates that there may
be a fault with the hot water system. The red LED may emit
up to five flashes every two seconds indicating the relevant
fault mode. See the chart below for descriptions of the
operating modes:
Flashes
Operational modes
green & red constant glow power on initialization
green constant glow
(remains on)
standby mode, or circulating
water through collectors
Flashes
Fault modes
4 x red
sensor in storage tank –
open circuit or short circuit
5 x red
sensor in collector – open
circuit or short circuit
red rapid flash
temperature difference
between collector and
storage tank higher than 40°C
for more than 10 minutes
during circulating
no green & red
(remains off)
power outage or call for service
If any of the fault modes occur, check that the temperature
sensors are installed correctly, connected to the solar
controller and that the cables have not been damaged. If
the red LED is emitting continuous flashes, this indicates
that water is not circulating through the collectors and the
storage tank correctly and that the temperature difference
between them has been greater than 40°C for ten minutes.
There may be air in the system that still needs to be bled
in order for the water to circulate correctly. Reset the solar
controller by cycling power to the controller at the power
outlet and bleed the air out of the collector array “flow” and
“return” lines.
Optimising circulating water flow through the
collector array
In order to optimise the energy performance of the hot
water system, it is recommended to check and adjust the
circulating flow rate through the collector array. In order to
achieve this install an appropriate flow restrictor (control
valve or orifice plate) and non intrusive flow sensor on the
piping to the collector array. It is recommended that the flow
sensor be installed at the outlet of the check valve connected
to the solar controller. The flow restrictor should be installed
at the outlet to the flow sensor.
The pump should start to circulate automatically if there
is sufficient sunlight, however if not, it may be necessary
to force circulation by artificially warming the collector hot
sensor probe. This can be achieved by covering the probe
with a plastic cover and placing it in a cup of hot water
(please do not directly expose the sensor probe to water
ingress). Adjust the valve or flow restrictor until the circulating
flow rate registered on the flow sensor is as per the table
below, depending on the number of collectors installed in
the hot water system:
Number of collectors
installed:
1
2
3
Optimal circulating flow
rate (L/min):
1.0L/min
1.5L/min
2.0L/min
Commissioning
26 commissioning
Kelvinator solar hot water systems
