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.