MidNite Solar Classic 150 User manual

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MidNite Solar Classic
Owner’s Manual
Standard Classic Classic Lite
This Manual covers models Classic 150, 200, 250 &
250KS as well as the Classic 150, 200, 250 & 250KS LITE

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The MidNite Solar Classic charge controller conforms to UL 1741, Safety for Inverters, Converters,
Controllers and Interconnection System Equipment for Use With Distributed Energy Resources,
Second Edition, May 7, 1999 with revisions through January 28, 2010 and
CAN/CSA C22.2 No. 107.1: 2001/09/01 Ed: 3 (R2006)
Notice of Copyright
MidNite Solar's Classic charge controller User’s Manual
Copyright ⓒ 2010 all rights reserved.
MidNite Solar Inc. reserves the right to revise this document and to periodically make changes to the
content hereof without obligation or organization of such revisions or changes unless required to do so
by prior arrangement.
Disclaimer
Unless specifically agreed to in writing, MidNite Solar Inc.
(a) Makes no warranty as to the accuracy, sufficiency or suitability of any technical or other
information provided in its manuals or other documentation.
(b) Assumes no responsibility or liability for loss or damage whether direct, indirect, consequential or
incidental, which might arise out of use of such information. The use of any such information will be
entirely at the user's risk.
Contact Information
Telephone: [phone]
Fax: [phone]
Email: [e-mail]
Web: www.midnitesolar.com
YOUR MIDNITE SOLAR DISTRIBUTOR
SOLIGENT
800-967-6917
www.soligent.net

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Table of Contents
Glossary of Terms.....................................................................................................................................5
Scope..........................................................................................................................................................7
Introduction..............................................................................................................................................7
Classic Power Curves...............................................................................................................................9
Unpacking the Classic............................................................................................................................11
Removing and installing the front cover on the Classic .....................................................................12
Mounting the Classic .............................................................................................................................13
Alternative Mounting.......................................................................................................................... 15
Dimensions...................................................................................................................................... 15
Sealed or Vented.................................................................................................................................. 16
Battery Temperature Compensation ....................................................................................................16
Classic Stacking Cable Routing and Installation Guidelines.............................................................17
Battery Temperature Sensor Installation.............................................................................................18
Chassis Grounding.................................................................................................................................20
DC System Grounding........................................................................................................................ 20
DC GFP (Ground Fault Protection) .....................................................................................................21
Disabling GFP..................................................................................................................................... 21
Wiring the Classic ..................................................................................................................................22
DC Terminal Connector ...................................................................................................................... 25
Over Current Protection and Wire Size Requirements......................................................................25
Current Rating..................................................................................................................................... 25
Over Current Protection ...................................................................................................................... 26
Long Distance Wire Runs ................................................................................................................... 26
Connecting the Classic to the Clipper................................................................................................. 26
Maximum and Minimum Wire Size.................................................................................................... 27
Equalization Manual and Auto.............................................................................................................28
Equalization with the Classic Lite ...................................................................................................... 28
Equalization with the standard Classic ............................................................................................... 29
Standard Classic programming ............................................................................................................30
Commissioning the Classic (Quick Start)........................................................................................... 30
Battery Charge Stages and Meanings ................................................................................................. 30
Resting ............................................................................................................................................ 30
Mode is OFF ................................................................................................................................... 31
Adjusting Absorb, Equalize and Float Voltages.................................................................................. 31
Current Limit....................................................................................................................................... 31
LED Modes and the “Blinking Red LED”.......................................................................................... 31
Calibrating Battery and PV Voltage .................................................................................................... 32
Configuring DC Input Source............................................................................................................. 32
Configuring the Classic for Wind Input Source.................................................................................. 34
Setting the Date and Time................................................................................................................... 35
Setting Longitude and Latitude........................................................................................................... 35
Configuring Auxiliary Input/Output ................................................................................................... 35
Aux 1 Function................................................................................................................................ 39
Aux 2 Function. Output/Input......................................................................................................... 40
Setting the MNGP features ................................................................................................................. 41
Navigating the Menu's ........................................................................................................................ 41

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Viewing Other MidNite Products on the Display ............................................................................... 42
Connecting Classic to Two MNGPs/Network cable........................................................................... 42
Arc Fault ............................................................................................................................................. 43
View Faults and Warning's.................................................................................................................. 44
View Logged Data .............................................................................................................................. 44
Graphical Logging Display modes ..................................................................................................... 47
Dealer Information Screen .................................................................................................................. 49
Classic Lite Programming.....................................................................................................................50
LED explanations................................................................................................................................ 50
Programming....................................................................................................................................... 51
Dip Switches ....................................................................................................................................... 51
Section 1 Switch settings explained................................................................................................. 53
Section 2 Switch settings explained................................................................................................. 54
Battery voltage and time settings.................................................................................................... 57
Using MNGP Remote to program a Classic Lite................................................................................ 58
Programming the Lite with a Networked Standard Classic................................................................ 58
Programming the Lite with the Local App.......................................................................................... 59
Clearing Faults .................................................................................................................................... 59
Notes on the Lite................................................................................................................................. 59
Explanations of Solar and Legacy ...................................................................................................... 59
Uploading New Firmware to the Classic..............................................................................................60
Connecting the Classic to the Internet .................................................................................................63
Networking.......................................................................................................................................... 63
Network Setup Through the MNGP ................................................................................................... 64
Web Access ......................................................................................................................................... 66
Local Network..................................................................................................................................... 66
Positive Ground systems........................................................................................................................66
HyperVOC ™.........................................................................................................................................67
Troubleshooting......................................................................................................................................68
Specifications Electrical.........................................................................................................................69
Specifications Mechanical .....................................................................................................................70
Default Battery charge set points .........................................................................................................71
Optional accessories...............................................................................................................................71
Regulatory Approval..............................................................................................................................71
Warranty.................................................................................................................................................72
Appendix .................................................................................................................................................73
Aux 1 and Aux 2 Graphs/Jumpers ...................................................................................................... 73
Aux 1 Voltage-Time Relation (Relay/12v) ......................................................................................... 74
............................................................................................................................................................. 74
Aux 2 Voltage-Time Relation (PWM) ................................................................................................ 74
Classic Breaker sizing......................................................................................................................... 75
Label Set from Classic ........................................................................................................................ 77
MODBUS............................................................................................................................................ 78
RS232 Jack Pin Out .......................................................................................................................... 102

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Glossary of Terms
Absorb –Constant voltage charge stage to fill the batteries. The controller is regulating so maximum power will
not be seen at this time. The Absorb timer is also counting down to the switch to Float.
A-EQ-R –This will reload the Auto Equalize counters, basically it will start the counters from day 1.
AF –Arc Fault, See page 43 for more info on arc fault protection.
Arc Adjust –This menu is where you adjust the Arc Fault sensitivity. For info on Arc Fault see page 43.
A-RST –Auto reset of the Classic controller, The Classic will reboot around Midnight every night when this is
enabled. This is useful for very remote sites where a loss of internet capability for example would be a hard ship.
Aux –Auxiliary relays. The Classic has 2 relays: Aux 1 can be configured as a 12 volt signal or a dry relay, Aux
2 can be used as a PWM signal output. Refer to page 35 for more Aux info.
BLK –Bulk MPPT Mode. By using the up arrow in Tweaks under BLK you can force the Classic into Bulk
mode.
Bulk MPPT - Maximum current charge stage, the Classic is trying to bring the batteries to the Absorb voltage
set point. We are basically putting all available power into the batteries.
Comm –This Menu allows adjustment of things like Mod Bus port, USB Mode and MNGP address.
DvrtCnt –When enabled, allows the charge stage timers to continue to run when the diversion modes are hold-
ing the battery voltage just below the actual set point.
Equalize - Constant voltage charge stage to equalize the batteries. The controller is regulating so maximum
power will not be seen at this time. The Equalize timer is also counting down to the switch to Float.
EQ MPPT - Maximum current charge stage, the Classic is trying to bring the batteries to the Equalize voltage
set point. We are basically putting all available power into the batteries.
Float –Constant voltage charge stage with a lower voltage than the Absorb charge point. The controller is regu-
lating so maximum power will not be seen at this time.
Float MPPT –Maximum current charge stage, the Classic is trying to bring the batteries to the Float voltage set
point. We are basically putting all available power into the batteries.
FLT –Float mode. By using the up arrow in Tweaks under FLT you can force the Classic into Float mode.
GF –Ground Fault, See page 21 for more info on ground fault protection.
Got Comm –Indicates a lack of communication between the display and the Classic. Consult Troubleshooting
for information page 68.

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Insomnia –This when enabled, will keep the Classic from going to Resting. This is intended for hydro mode
only where you may need time to open water valves and do not want to wait for the Classic to wake up.
LED-MODE –This selection lets you pick the function of the 6 visible LED’s on a standard Classic.
LMX –LoMax, This enables the Classic to track the input voltage all the way down to Battery voltage. When
disabled the Classic will stop tracking the input around 5 volts above the battery voltage. When the input voltage
is within a couple volts of the battery voltage the inductors can “Sing” this is usually not very loud and will do
no harm.
Local App –Monitoring software included with the Classic for monitoring over the Local Network or Internet.
MNGP –Midnite Graphical interface Panel. This is the graphical display included with the standard Classic
controller.
MNLP –MidNite LED interface Panel. This is the LED display that comes standard with the Classic Lite.
Mode –This menu lets you turn the charging ability of the controller On / Off as well as lets you select the DC
input source. See page 30 for info on the Mode menu.
Mod Bus –a standard protocol used for communications. We have published our protocol to allow users to in-
terface with the Classic. See page 78 for our Mod Bus protocol.
My MidNite –Web based monitoring for the Classic. (Not available yet)
NiteLog –When enabled allows the Classic to log data in the evening when the Classic is Resting.
PV Shading –This indicates the Maximum power point voltage is less than half the open circuit voltage.
Pwr Save –Allows you to adjust the time the Backlight stays on.
Resting –The Classic is not charging the battery due to low light. For reasons Resting will appear please see
page 30.
Shade –When enabled the Classic will show PV Shading on the display when the Maximum power point volt-
age is less than half the open circuit voltage.
T-Comp –Temperature compensation using a temperature sensor to measure the ambient temperature of the
battery bank and will adjust the voltage set points up or down accordingly to ensure a full battery. There are 3
parameters to set Minimum and Maximum adjusted voltage as well as volts per degree C per Cell. Typically this
is -.05 mV but please consult your battery manufacturer. See page 16 for Temperature compensation info.
Tweaks –This menu has all the advanced adjustments for the Classic. For example: Voltage off set adjustments
etc.
VBatt –Battery voltage, measured at the battery terminals of the Classic.
VOC –Open Circuit Voltage, unloaded voltage measurement.
Vpv –Input voltage, measured at the input terminals of the Classic.

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Web Access –When enabled allows the Classic to send data over the internet to My MidNite’s Server for you to
view when wanted.
Scope
This Manual provides safety guidelines and installation information for the Classic charge controller. It
does not provide brand specific information about photovoltaic panels, batteries etc. Contact the
manufacturer of other components in the system for relevant technical data.
Introduction
The MidNite Classic charge controller is unique in its ability to be used for a great variety of DC input
sources. The Classic is designed to regulate DC input from PV, and Approved Hydro and Wind turbines
for other DC sources please contact MidNite Solar tech support.. The Classic 150, 200 and 250 are
designed to work with 12, 24, 36, 48, 60 and 72 volt battery banks.
The Classic250KS is designed to charge up to a 120V nominal battery bank.
The Classic can be installed stand alone or as a multi-unit networked installation.
Standard features of the Classic charge controller include:
*3 input operating voltage ranges 150, 200 and 250 VDC
*Multiple DC input options (example Solar, Wind or Hydro)
*Wizard driven setup interface including voice and help screens
*Graphical display
*Previous 180 days of operational data logged
*Internet ready
This Manual covers Classic 150, Classic 200 Classic 250 and the Classic 250KS. It covers the
installation, wiring and use of the Classic charge controller.
WARNING Warnings signs identify conditions or practices that could result in personal injury or loss of
life.
CAUTION Cautions identify conditions or practices that could result in damage to the unit or other
equipment.
MIDNITE SOLAR CHARGE CONTROLLER INSTALLATION GUIDELINES AND SAFETY
INSTRUCTIONS
This product is intended to be installed as part of a permanently grounded electrical system as shown in the
system configuration sections. The following important restrictions apply unless superseded by local or national
codes:

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•The System's DC Negative conductor must not be bonded to earth ground. The Classic does this with its
internal Ground Fault Protection circuitry. The battery negative and ground are not bonded together directly but
are connected together by the Classic’s internal GFP device. All negative conductor connections must be kept
separate from the grounding conductor connections. The equipment ground terminal inside the Classic must be
connected to Earth Ground for the internal DC-GFP to work. Continue
• With the exception of certain telecom applications, the Charge Controller should never be positive grounded.
• The Charge Controller equipment ground is marked with this symbol:
• If damaged or malfunctioning, the Charge Controller should only be disassembled and repaired by a qualified
service center. Please contact your renewable energy dealer/installer for assistance. Incorrect reassembly risks
malfunction, electric shock or fire.
• The Charge Controller is designed for indoor installation or installation inside a weatherproof enclosure. It
must not be exposed to rain and should be installed out of direct sunlight.
For routine, user-approved maintenance:
• Turn off all circuit breakers, including those to the solar modules, batteries and related electrical connections
before performing any maintenance.
Standards and Requirements
All installations must comply with national and local electrical codes; professional installation is recommended.
The NEC in the USA requires a DC ground fault interrupter for all residential PV installations. NEC2011
requires an ARC FAULT detector on all charge controllers and inverters operating above 80VDC. Both of these
devices are built into the Classic.
DC and Battery-Related Installation Requirements:
All DC cables must meet local and national codes.
Shut off all DC breakers before connecting any wiring.
Torque all the Charge Controller’s wire lugs and ground terminals to the specs found on page 19.
Copper wiring must be rated at 75° C or higher.
Keep cables close together (e.g., using a tie-wrap) as much as possible to reduce inductance.
Ensure both cables pass through the same knockout and conduit to allow the inductive currents to
cancel.
DC battery over-current protection must be used as part of the installation on the input and output.
Breakers between the battery and the Classic must meet UL489 standards.
Breakers between the DC source and the Classic must meet UL1077 or UL489 standards.
Design the battery enclosure to prevent accumulation of hydrogen gas at the top of the enclosure. Vent the
battery compartment from the highest point to the outside. A sloped lid can also be used to direct the flow of
hydrogen to the vent opening. Sealed (AGM, Gel etc) batteries do not normally require ventilation. Consult your
battery manufacturer for details.
WARNING: PERSONAL PRECAUTIONS DURING INSTALLATION
WARNING BATTERIES PRESENT RISK OF

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ELECTRICAL SHOCK, BURN FROM HIGH SHORT CIRCUIT CURRENT, FIRE OR
EXPLOSION FROM VENTED GASES. FOLLOW PROPER PRECAUTIONS.
Someone should be within range of your voice to come to your aid if needed.
Keep plenty of fresh water and soap nearby in case battery acid contacts skin, clothing, or eyes.
Wear complete eye protection. Avoid touching eyes while working near batteries. Wash your hands with
soap and warm water when done.
If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters an eye,
flood the eye with running cool water at once for at least 15 minutes and get medical attention
immediately following.
Baking soda neutralizes lead acid battery electrolyte. Keep a supply on hand in the area of the batteries.
NEVER smoke or allow a spark or flame in vicinity of a battery or generator.
Be cautious to reduce the risk of dropping a metal tool onto batteries. It could short the batteries or other
electrical parts that can result in fire or explosion.
Never wear metal items such as rings, bracelets, necklaces, and watches when working with a battery or
other electrical circuits. A battery can produce a short circuit current high enough to weld a ring or the
like to metal, causing severe burns.
Classic Power Curves
Figure 2.1
Figure 2.2

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Figure 2.3
Figure 2.4