MidNite Solar Classic 200 User manual

MidNite Solar Classic
Owner’s Manual Firmware rev 1933
Standard Classic Classic Lite
This Manual covers models Classic 150, 200 & 250 as well
as the Classic 150, 200 & 250 LITE
Este manual también está disponible en Español. La versión en Español puede encontrarse en nuestra
pagina web en la ficha Documentos y haga clic en Manuales.

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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

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Contents
Scope............................................................................................................................................................................. 6
Introduction................................................................................................................................................................. 6
Classic Power Curves.................................................................................................................................................. 8
Unpacking the Classic................................................................................................................................................. 9
Removing and installing the front cover on the Classic ........................................................................................ 10
Mounting the Classic ................................................................................................................................................ 11
Alternative Mounting.............................................................................................................................................. 13
Dimensions.......................................................................................................................................................... 13
Sealed or Vented..................................................................................................................................................... 14
Battery Temperature Compensation....................................................................................................................... 14
“Follow-ME” Charging coordination ..................................................................................................................... 15
Battery Temperature Sensor Installation............................................................................................................... 17
Chassis Grounding.................................................................................................................................................... 19
DC System Grounding............................................................................................................................................ 19
DC GFP (Ground Fault Protection)........................................................................................................................ 20
Disabling GFP......................................................................................................................................................... 21
Wiring the Classic..................................................................................................................................................... 21
DC Terminal Connector.......................................................................................................................................... 24
Over Current Protection and Wire Size Requirements ........................................................................................ 24
Current Rating......................................................................................................................................................... 24
Over Current Protection.......................................................................................................................................... 25
Long Distance Wire Runs....................................................................................................................................... 25
Connecting the Classic to the Clipper..................................................................................................................... 25
Maximum and Minimum Wire Size ....................................................................................................................... 27
Equalization Manual and Auto................................................................................................................................ 27
Equalization with the Classic Lite........................................................................................................................... 27
Equalization with the standard Classic ................................................................................................................... 28
Manual EQ.......................................................................................................................................................... 28
Auto EQ .............................................................................................................................................................. 28
Standard Classic programming............................................................................................................................... 29
Commissioning the Classic (Quick Start)............................................................................................................... 29
Battery Charge Stages and Meanings ..................................................................................................................... 29
Resting ................................................................................................................................................................ 29
Mode is OFF ....................................................................................................................................................... 30

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Adjusting Absorb, Equalize and Float Voltages..................................................................................................... 30
Current Limit........................................................................................................................................................... 30
LED Modes and the “Blinking Red LED”.............................................................................................................. 31
Calibrating Battery and PV Voltage ....................................................................................................................... 31
Configuring DC Input Source................................................................................................................................. 32
Configuring the Classic for Wind Input Source...................................................................................................... 33
Setting the Date and Time....................................................................................................................................... 34
Configuring Auxiliary Input/Output....................................................................................................................... 34
Aux 1 Function.................................................................................................................................................... 39
Aux 2 Function. Output/Input............................................................................................................................. 40
Aux 1 and Aux 2 Graphs/Jumpers.......................................................................................................................... 40
Aux 1 Voltage-Time Relation (Relay/12v)............................................................................................................. 41
Aux 2 Voltage-Time Relation (PWM).................................................................................................................... 42
Setting the MNGP features ..................................................................................................................................... 43
Navigating the Menu's ............................................................................................................................................ 43
Viewing Other MidNite Products on the Display................................................................................................... 44
Connecting Classic to Two MNGPs/Network cable............................................................................................... 44
Arc Fault ................................................................................................................................................................. 45
View Faults and Warning's ..................................................................................................................................... 46
View Logged Data.................................................................................................................................................. 46
Graphical Logging Display modes.......................................................................................................................... 49
Classic Lite Programming........................................................................................................................................ 51
LED explanations.................................................................................................................................................... 51
Programming........................................................................................................................................................... 52
Dip Switches........................................................................................................................................................... 52
Section 1 Switch settings explained................................................................................................................. 54
Section 2 Switch settings explained................................................................................................................. 55
Battery voltage and time settings........................................................................................................................ 58
Using MNGP Remote to program a Classic Lite.................................................................................................... 59
Programming the Lite with a Networked Standard Classic.................................................................................... 59
Programming the Lite with the Local App.............................................................................................................. 59
Clearing Faults........................................................................................................................................................ 59
Notes on the Lite..................................................................................................................................................... 59
Explanations of Solar and Legacy........................................................................................................................... 60
Uploading New Firmware to the Classic................................................................................................................. 60

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Connecting the Classic to the Internet.................................................................................................................... 63
Networking.............................................................................................................................................................. 63
Network Setup through the MNGP......................................................................................................................... 65
Web Access............................................................................................................................................................. 66
Local Network......................................................................................................................................................... 67
Positive Ground systems........................................................................................................................................... 67
Troubleshooting ........................................................................................................................................................ 69
Electrical Specifications............................................................................................................................................ 70
Specifications Mechanical ........................................................................................................................................ 71
Default Battery charge set points............................................................................................................................. 72
Optional accessories.................................................................................................................................................. 72
Regulatory Approval ................................................................................................................................................ 72
Warranty.................................................................................................................................................................... 73
Appendix.................................................................................................................................................................... 73
Classic Breaker sizing............................................................................................................................................. 74
................................................................................................................................................................................. 75
Label Set from Classic............................................................................................................................................ 76
RS232 Jack Pin Out ................................................................................................................................................ 77

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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 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)
*Graphical display
*Previous 380 days of operational data logged
*Internet ready
This Manual covers Classic 150, Classic 200 and the Classic 250. 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:
•To use the Classic’s built in DC GFP 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.
• With the exception of certain telecom applications, the Charge Controller should never be positive grounded.

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• 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. NEC 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 21.
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
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

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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
Table 1
Table 2

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Table 3
The graphs above represent the max power output for a given input for each Classic. Using and
understanding these power graphs will help maximize Classic’s output power and aid in selecting wire and
breaker/disconnects. Notice that lower battery voltages and lower PV input voltages result in higher
continuous output power. The PV voltages listed are for reference and are not intended to be the only PV
voltages supported. The battery voltages listed show the most used battery bank configurations. Other
voltages are also supported. The Classic battery voltage parameters are fully user adjustable.
For example: if you are using a Classic 250 and 48v battery bank, the maximum continuous output
power based on 25 degree C ambient is 55 amps when using a PV array that yields a Maximum Power
Voltage of 180 volts. The same set up using a bit higher voltage modules that result in a 200V Maximum
Power voltage will result in only 53 amps. Although 55 to 53 amps is not a significant change, it does give
you the idea that all things being equal, lower voltages are a bit more efficient, keeping in mind that an
MPPT controller needs to have the open circuit voltage of the array about 30% higher than the highest
battery voltage you plan to charge to.
NOTE: You can find the Classic string sizing tool on the web page www.midnitesolar.com
Unpacking the Classic
When you receive your Classic you will want to unpack it and make sure everything is there and in good shape.
Refer to Figure 1 Included in the Classic package should be:
*Classic charge controller
*Battery temperature sensor
*Knock out covers 3 screened
*Parts bag with stickers, Terminal block cover and silicone grease
*User’s manual printed
**Snap on upper vent cover
**Knock out covers 4 solid
**Note. These items are optional and do not ship as standard equipment. Email [e-mail]
for more information or if anything is missing or damaged.

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Figure 1
Removing and installing the front cover on the Classic
Removing the front art deco cover is required to gain access to the wiring compartment.
Be aware if this is not the first removal of this cover there is a cable connecting the cover to the
electronics. Do not pull hard or fast as damage could occur.
To remove the front cover of the Classic in preparation for installation, remove the 4 Phillips head screws
with a #2 Phillips screwdriver. Lift the front half of the Classic casting off. You will need to unplug the
display cable. It works the same as any phone cable.
When installing the cover for the final time, squeeze a small amount of Silicone grease (Included in the
parts bag) onto the metal pins of the male jacks on the Display cable before plugging them in.
To re-install the front cover of the Classic you will need to plug in the display cable and carefully route it
around the components on the circuit board as you set the cover in place. See Figure 2 Do not force the
cover if it does not seat into place easily stop and look for any cables or wires that may be interfering.
With the cover seated in place install the four Phillips screws with a #2 Phillips screwdriver.

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Figure 2
Mounting the Classic
The following section covers typical mounting arrangements. If you require additional details that are not
covered here please contact our technical support team. The Classic is designed to be directly mounted
onto the MidNite Solar E-Panel. The Classic can also accommodate other installation methods as well.
Mount in an upright position out of direct sunlight when possible. For your convenience the Classic has
four one inch knock outs that are pre cast. The Classic has mounting locations and conduit locations that
are similar to other brands of charge controllers to facilitate ease of upgrading older technologies.

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Mounting the Classic directly to the E Panel:
*Remove the front cover of the Classic.
*Install the mounting bracket on the E Panel and start the upper mounting screw into the bracket, leaving
it about half way out so you can hang the Classic on this screw.
*Install the 1 inch close nipple into the E Panel as shown in the E-Panel directions. The 1” close nipple, 3
locknuts and 2 plastic bushings are included with each E-Panel. One locknut acts as a spacer.
*Carefully hang the Classic on the screw in the bracket and slide it over the close nipple (see figure 4).
*Install the lock nut and bushing on the close nipple and tighten the screw in the mounting bracket.
*Don't install the front cover until you complete the wiring of the Classic.
Figure 3
Classic Mounted to side of E-Panel Nipple, locknuts and bushings that come with
every E-Panel
Figure 4 Figure 5
Classic mounted to the side of a MidNite Solar E-Panel
Figure 3 A Charge controller bracket
mounted to the E-Panel. The bracket
comes with every E-Panel

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Figure 6
Install locknut here to act as a spacer.
Alternative Mounting
To mount the Classic to a plywood surface, use 1 1/2” wood screws
in the top key hole slot hole and the holes in the wiring
compartment. Taking care to make sure the Classic is Plumb and
Level.
Dimensions
See page 71 for more details.
Figure 7

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Sealed or Vented
The Classic has the ability to be sealed for protection from salt air or dust. It comes from the factory
Vented. If you live in a dusty or salt air environment you may wish to seal the Classic. Sealing the Classic
does not make the unit water resistant. To seal the Classic install the solid plastic knock out covers into
any unused knock outs and snap the upper vent cover onto the Classic as seen in the photo below. Note
that the Classic will be slightly de-rated (will put out less power) by sealing it. Refer to the specifications
page of this manual for the ratings in the sealed mode. To obtain the parts necessary to seal the Classic
please contact our Technical Support Team. Refer to Figure 8 and 9
Battery Temperature Compensation
The Classic comes with a battery temperature sensor (BTS). This sensor raises or lowers charge voltage
based on temperature. Connect BTS to the BATT TEMP jack. (Refer to Battery Temperature Sensor
Installation 20) The Battery temperature menu appears as T-Comp in the BATTERY MENU. In this menu
you can change the voltage compensation as needed. If the BTS is disconnected or shorted the Classic will
automatically default to 25C on the Battery temperature.
Figure 8
Figure 9

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“Follow-ME” Charging coordination
Follow-Me will allow Classics to share charge stages, as well as Battery temperature info and Ground
fault coordination. Follow-Me also allows you to program a single Classic for Equalize charging and it
will instruct all the others to Equalize as well. You do need to set the Equalize parameters in each Classic.
For the Battery Temp sensor you will need one BTS only and it can be on any of the Classics.
WARNING: ALL FIRMWARE SHOULD MATCH ACROSS ALL CLASSICS
The Follow Me function basically is just what it is called. The Classic will simply ask the Classic to its
right “What do I do now” and this propagates around the loop continually. Whoever goes to Float first for
instance will simply tell everyone else it is time to go to float.
NOTE: Follow Me coordinates charge stage but the Classics will still vary in the amount of power
processed, Follow Me was not intended to make them all produce the same amount of current just
coordinate the stages
To enable Follow Me you need to wire the Classics network cables as shown below. You also need to
enable Follow-ME. To do this, go to the Tweaks Menu. Press the “Main Menu” button repeatedly until
“Charge” is highlighted. Scroll to the Right until “Tweaks” is highlighted and press “Enter”. Now press
the right soft key (Upper right button) 4 times until you see the screen with “Follow-ME” and “BTSNET”
on it. Here you need to highlight Follow-ME and turn it on using the up arrow. You will also need to
highlight BTSNET and turn it on if you want to share battery temperature data. After enabling these press
Enter to save this data.
Ground Fault sharing
To share Ground fault you need to remove all of the GFP Jumpers except one classic only. You then need
to make sure Ground Fault is Enabled in the Tweaks menu for any of the networked Classics you want to
shut down on detection of ground fault. For example say you have three solar Classics and one Wind
Classic and you do not want the wind Classic to shut down for GFP. Make sure in the tweaks menu of that
Classic GFP is Disabled.
Naming the Classic
The Local Application software (Available as a free download at www.midnitesolar.com) allows you to
issue a name to the Classic with upper and lower case letters, as well as numbers. This name can be up to
8 characters. This name will show up on the Display of the Classic instead of the word CLASSIC. It will
be shown in all upper case on the Classic’s display. The Naming process can be helpful for networked
Classics that use one MNGP (Display) to view multiple Classics.

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Addressing the Classics
You can assign unique addresses to each networked Classic. This is not necessary for Follow Me to work
but it is necessary if you want to view multiple Classics from a single MNGP. To address a Classic simply
use the MNGP that is plugged into that Classic, or plug the MNGP into that classic and hold the Left
arrow button down and tap the up or down button. The normal default address is 10 so going up will take
you to 11 and down to 9. When you get to the unused address you want for that Classic hold the left and
right arrows for a second until “Data Sent and Saved”shows up. Now this Classic has been re addressed
to the new address. Do this for all the Classics or Classic Lites on the network.
To view other Classics on the network use the same button strokes. Hold the left arrow down and tap the
up or down arrow depending on which number you are looking for. We suggest going from 10 up for
clarity. So if you had four Classics they would be 10,11,12 and 13. You would scroll up from the normal
position to find the other three.
Figure 10 Follow-Me diagram
When installing the Follow Me cables for the last time it is recommended you add a bit of the included
silicone grease on the metal contacts of the male ends of all the cables.

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Figure 11
Battery Temperature Sensor Installation
CAUTION - To reduce risk of injury, charge only deep-cycle lead acid, lead antimony, lead calcium,
gel cell or absorbed glass mat type rechargeable batteries. Other types of batteries may burst, causing
personal injury and damage. Never charge a frozen battery.
WARNING: RISK OF INJURY. To reduce the risk of injury, charge only properly rated (such as 6
V 12 V and 24 V ) lead-acid (GEL, AGM, Flooded, or Nickel Cadmium) rechargeable batteries. Other
battery types may burst, causing personal injury and damage.
WARNING: Explosion hazard during equalization, the battery generates explosive gases. Follow all
the battery safety precautions listed in this guide. Ventilate the area around the battery using ventilators
with brushless motors thoroughly and ensure that there are no sources of flame or sparks in the vicinity.
The Classic comes with a Battery temperature sensor which plugs into the jack beside the DC Terminal
connector labeled “Batt Temp”. Route the cable through the E-panel into the battery box. Pick a battery in
the middle of the bank and about half way up the side of the battery thoroughly clean a spot off on the
case. Then remove the protective tape from the sensor and adhere the temperature sensor to the battery.
Some manufacturers use a double wall case on the battery. For mounting a temp sensor to a double wall
battery case please refer to the battery manufacturer's recommended procedure.
Battery Temp Sensor
included
Cable Clamp for network
cables
USB connector
Ethernet connector

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Figure 12
Insert BTS to the jack labeled BATTERY TEMP on the control board.
Figure 13

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Chassis Grounding
In all installations the Classic chassis should be connected to ground. For systems with a battery breaker
sized 60 amps and smaller, 10 AWG (6 mm2) copper is generally sufficient. For systems with a battery
breaker sized 100 amps and smaller, 8 AWG (10 mm2) copper is required. For grounding conductor
requirements on your specific installation please consult your local electrical code. The chassis
grounding terminal is in the upper right corner of the electrical connection compartment.
Figure 14
DC System Grounding
The Classic charge controller is designed to work with Negative Ground, Positive Ground or Ungrounded
power systems. In grounded systems, dc negative may be connected to ground either externally or by
using the Classic’s internal grounding jumper, shown on figure 15 on Page 22. The internal grounding
jumper should only be installed when the Classic’s GFP is enabled.
In Positive ground or Ungrounded systems the GFP jumper must be removed. See Figure 15 Also note that
with Positive ground there will be items still referenced to battery negative that can complete a short
circuit of the battery bank. These items include, but are not limited to, the USB Cable and RS232 serial
data lines.
Please contact Technical Support for assistance on Positive ground systems.

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DC GFP (Ground Fault Protection)
The Classic has internal ground fault protection (GFP) built in. Since 2008, the NEC requires a DC-GFP
on all PV systems in the USA. The built in DC-GFP eliminates the need to purchase and install an external
DC-GFP. If the internal grounding jumper is installed in a Classic, the battery negative and DC source
negative must not be connected to the system grounding conductor anywhere in the system. Grounding of
these circuits will defeat the GFP function. In a network with multiple Classics connected in Follow Me,
only one Classic should have its internal grounding jumper installed and all should have GFP enabled. The
factory setting will make a DC negative to System Ground connection in the Classic charge controller.
The GFP function will need to be disabled for Positive ground or an ungrounded DC system.
Figure 16
The Ground fault device is simple to understand and use. It detects a fault between battery/PV negative
and earth ground just like the breaker DC-GFP system. The difference with the Classic is that it turns off
the charge ability and sounds a loud warning when a ground fault is detected. The Classic’s system
consists of a PTC that is between the Negative and Ground internally in the Classic. A PTC is basically a
self-healing fuse that will open when current exceeds its rating and reclose when current is dropped below
its rating. The Classic will monitor this PTC and disable the charging when it senses it go open. When the
fault is cleared the Classic will restore charging.
To disable the internal Ground Fault Protection function, the jumper labeled GFP needs to be removed and
the GFP function needs to be disabled in the TWEAKS menu. See “Disabling GFP” for instructions.
To reset the internal GFP function after detection has occurred: fix the actual ground fault, then turn OFF
the Classic and turn it back ON. Do this by turning the external battery breaker to OFF position and then
to ON position.
Figure 15