MidNite Solar Barcelona User manual

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MidNite Solar Barcelona
Owner’s Manual
This entire manual is printed without color but is available for download—with many of the
diagrams available in color—on our website at midnitesolar.com.

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Table of Contents
Introduction ...............................................................................................................................3
Safety Instructions................................................................................................................. 4
How To KILL Your Batteries.................................................................................................... 6
Wiring Requirements............................................................................................................. 7
Installation.......................................................................................................................... 10
Barcelona Connections ........................................................................................................ 12
Options Board............................................................................................................................ 12
Bypass Switch ............................................................................................................................ 13
Arc Fault..................................................................................................................................... 14
Ground Fault.............................................................................................................................. 14
Rapid Shutdown System............................................................................................................ 15
Battery Temperature Sensor..................................................................................................... 16
Whiz Bang Jr .............................................................................................................................. 17
Battery Sense Circuit ................................................................................................................. 18
Barcelona Wiring................................................................................................................. 18
Energizing the Barcelona ..................................................................................................... 19
Operation............................................................................................................................ 20
System and Device Naming....................................................................................................... 20
Battery Charge Stages ............................................................................................................... 22
Advanced Settings and Concepts ......................................................................................... 23
Barcelona Programming ...................................................................................................... 24
Auxiliary Modes .................................................................................................................. 28
Firmware Update ................................................................................................................ 30
Troubleshooting.................................................................................................................. 31
Technical Drawings & Specifications ................................................................................... 34
Warranty............................................................................................................................. 39
PV Voltage Correction Factors ............................................................................................. 41

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INTRODUCTION
The Barcelona charge controller regulates a DC input source from solar to properly charge a
48VDC battery bank. The Barcelona can be installed stand-alone or as a multi-unit, networked
installation with any CANBUS MidNite product using our latest graphical interface, the MNGP2.
Standard Features:
•200A of charging current: 100A per MPPT
channel
•Min/Max MPPT range: 185V to 550VDC
•Two independent MPPT input channels
•Installed Options Board for:
oArc Fault Protection, UL1699B
oGround Fault Protection, NEC2020
oSunSpec compliant Rapid Shutdown
Transmitter
•Compatible with flooded lead-acid, sealed,
AGM, Gel, NiFe, Lithium, and virtually any
other battery chemistry
•Two AUX circuits for remote triggering
•Dedicated Whiz Bang Jr input terminal
•Remote Battery Voltage Sense Circuit
•MidNite Graphics Panel (MNGP2)
•Operating voltage: 29V to 65VDC
•Battery Temperature Sensor
•CANBUS communications
•Data logging for 365 days
•Voice annunciations
•48VDC battery bank
•Bluetooth
•ETL Listed
Pre-Wired Barcelona and Breaker Box …
Includes PV and Battery breakers, SPDs (not
shown), and mounting backplate.

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IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
THIS MANUAL CONTAINS IMPORTANT INSTRUCTIONS FOR THE MIDNITE SOLAR BARCELONA
MPPT CHARGE CONTROLLER THAT SHALL BE FOLLOWED DURING INSTALLATION AND
OPERATION.
If you do not fully understand any of the concepts, terminology, or hazards outlined in these
instructions, please refer installation to a qualified dealer, electrician, or installer. These
instructions are not meant to be a complete explanation of a renewable energy system. Before
using the Barcelona, read all instructions and cautionary markings. The installation instructions
are for use by qualified personnel only. Do not perform any installation other than that
specified in this manual unless you are qualified to do so. Incorrect installation may result in a
risk of electric shock, fire, or other safety hazard.
Safety Symbols
The following safety symbols have been placed throughout this manual to indicate dangerous
and important safety instructions.
SAFETY PRECAUTIONS
•Over-current protection for the DC wiring is not provided as an integral part of this charge
controller. Over-current protection of the DC wiring must be provided as part of the
system installation.
WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
WARNING!
CAUTION indicates conditions or practices that could result in damage to
the unit or other equipment.
CAUTION!
INFO: Indicates information that emphasizes or supplements important
points of the main text.

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•System grounding is the responsibility of the system installer and must comply with local
and national electrical codes and standards.
•This product is designed for indoor/compartment installation. It must not be exposed to
rain, snow, moisture, or liquids of any type.
•Listed or labeled equipment shall be installed and used in accordance with any instructions
included in the listing or labeling.
•All work must be performed in accordance with local and national electrical codes.
•The DC negative conductors are not connected (bonded) to the charge controller’s chassis.
•Use Class 1 wiring methods for field wiring connections to terminals of a Class 2 circuit.
oBarcelona’s Class 2 terminals: WBJr, AUX, Current Transformers, BTS, CANBUS.
•Use insulated tools to reduce the chance of electrical shock or accidental short circuits.
•Torque all wiring and cable connections to the required torque values.
•Use only copper wires with a minimum temperature rating of 90°C.
•There are no user-serviceable parts contained in the Barcelona.
•Always verify proper wiring prior to energizing the Barcelona.
•Battery cables should be no less than #2/0 AWG.
•Properly mount the Barcelona.
BATTERY SAFETY
•Wear eye protection and avoid touching your eyes and face when working with batteries to
keep any fluid/corrosion on the battery from contact with eyes and skin. Have plenty of
fresh water and soap nearby and thoroughly wash in case battery acid contacts skin,
clothing, or eyes. In the event of exposure to the eyes, flood them for at least 15 minutes
with running water and seek immediate medical attention. Baking soda neutralizes lead
acid battery electrolyte and vinegar neutralizes spilled NiCad and NiFe battery electrolyte;
depending on your battery type, keep a supply on hand near the batteries.
•Read and follow the battery manufacturer’s safety precautions before installing the inverter
and batteries. Always verify proper polarity and voltage before connecting the batteries to
the Barcelona. Once the batteries are connected, ensure the maintenance and charging
requirements (i.e., charge voltage and charge rate) provided by the battery manufacturer
are followed to extend the life of the batteries and to prevent damage to the batteries
while charging.
•The battery bank should be installed in a clean, dry, ventilated environment that is
protected from high and low temperatures. If installed in a vehicle/boat, the batteries must
be mounted upright (if using liquid batteries) and securely fastened. The location must be
fully accessible and protected from exposure to heat producing devices, and away from any
fuel tanks.
•Batteries can produce explosive gasses, so install batteries in a well-ventilated area. For
compartment or enclosure installations, always vent batteries from the highest point to the

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outside. Design the battery enclosure to prevent accumulation and concentration of
hydrogen gas in pockets at the top of the compartment.
•Remove all jewelry such as rings, watches, bracelets, etc., when installing or performing
maintenance on the batteries and inverter. A battery can produce a short-circuit current
high enough to weld metal jewelry, causing severe burns.
•Use insulated tools and be very careful when working around batteries, they can produce
extremely high currents if short-circuited (e.g., dropping a metal tool across the battery
terminal), which could cause a fire or explosion.
•To prevent a spark at the battery and to reduce the chance of explosion, turn off (open) the
DC battery breaker, install/connect the positive DC cable to the breaker, then connect the
positive DC cable to the battery bank. With the DC breaker off/open, connect the negative
DC cable to the battery bank and the Barcelona.
•Never work alone. Always have someone within the range of your voice or close enough to
come to your aid when working around batteries.
•Never use old or untested batteries. Check each battery’s label for age, type, and date code
to ensure all batteries are identical.
•Batteries are sensitive to changes in temperature. Install batteries in a stable environment.
•Provide at least one inch of air space between batteries to provide optimum cooling.
•Use proper lifting techniques when working with batteries.
•Never smoke or allow a spark near batteries.
•Never charge a frozen battery.
STANDARDS
The MidNite Solar Barcelona charge controller conforms to UL 1741, Safety for Inverters,
Converters, Controllers and Interconnection System Equipment for Use with Distributed Energy
Resources, UL 1741:2010 Ed.2+R:15Feb2018; CSA C22.2#107.1:2016 Ed.4.
HOW TO KILL YOUR BATTERIES
Batteries are delicate and require proper attention, especially when off-grid. Think of your
batteries and solar equipment as a small nuclear power plant, hydro dam, or natural gas-fired
power plant. Just like any of those, your system needs DAILY attention to ensure it is performing
correctly and safely. We recommend the use of an independent battery monitor/alarm if you
have an expensive battery bank. Below is a list of some of the most common ways we have
seen people kill their battery bank.
•Using more than three parallel strings and not using common bus bars. With lead-acid
batteries, when you use more than three strings, it is very hard to properly charge the
middle strings. The only safe way to do this is to wire each string with equal length cables
to a common bus bar. Connect inverter cables to the farthest points on the busbars.
•Not watching to verify the Absorb or EQ times are set properly and that the equipment

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actually charges for that period of time. Some equipment will have settings like “End Amps”
that can terminate Absorb early and, if set up wrong, can damage a battery.
•Not using ALL EQUAL LENGTH interconnect cables on each string. It is important that ALL
strings be wired EXACTLY the same. Any variance in resistance on one string versus another
will cause an imbalance and the batteries will suffer a shortened lifespan.
•Trusting a State of Charge (SOC) meter, which can lose calibration over time and give you
false readings. You need to verify specific gravity and or verify the charge voltage is being
met. Never fully rely on the SOC %; it is just a good, quick reference.
•Routinely using more than 50% of the capacity of the lead acid battery. Using more than
half the battery capacity drastically shortens the batteries life; occasionally is fine, but daily
will kill lead acid batteries in months.
•Not leaving ample space between cells for cooling. We recommend at least one inch
between the cells for cooling. Ask the battery manufacturer what they recommend.
•Not having enough charge current to properly charge the size of the battery you have.
Consult the battery manufacturer for the minimum charge current.
•Using tap water or other liquids instead of distilled water in a flooded battery. The minerals
in the tap water will destroy a battery.
•Not verifying the temperature compensation neutral point (typically 25°C) and the milli volts
per degree C per cell (typically -5mV).
•Not verifying you are charging to the voltage supplied by the battery manufacturer.
•Not fully charging your lead acid batteries at least once a week.
•Failing to keep all connections clean.
WIRING REQUIREMENTS
•The NEC (National Electric Code, ANSI/NFPA 70) for the United States and the CEC
(Canadian Electrical Code) for Canada provide standards for safely wiring residential and
commercial installations. The NEC/CEC lists the requirements for wire size, overcurrent
protection, and installation methods.
•Do not mix AC and DC wiring in the same panel unless specifically approved/designed for
both AC and DC wiring. Where DC wiring must cross AC or vice-versa, try to make the
wires at the crossing point perpendicular (90 degrees) to one another.
•DC wires to and from the Barcelona must be protected as required by code. This can be
done by using jacketed wires or by feeding the wires through conduit or a conduit box. The
optional Barcelona Breaker Box satisfies this requirement.
•Always check for existing electrical, plumbing, or other areas of potential damage prior to
making cuts in structural surfaces or walls.
•Wiring should meet all local codes and standards and be performed by qualified personnel
such as a licensed electrician.
•DC over-current protection must be provided as part of the installation.
•Use only copper wires with a minimum temperature rating of 90°C.

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•The equipment ground is marked with this symbol:
DC Wiring
•Minimize the number of connections between the Barcelona and the battery bank.
Exceptions are the DC breaker —required at the battery to protect the DC wiring—in the
positive line, and a DC shunt—to allow battery charge state monitoring—in the negative
line. Additional connections will contribute to voltage drops, and these extra connection
points may loosen during use.
•The DC cables/wires must be color coded with colored tape or heat shrink tubing: RED for
positive (+); WHITE for negative (-) if solidly grounded ; BLACK if reference grounded (using
a GFP breaker); and GREEN for DC ground.
•All wiring to the battery terminals should be checked monthly for proper torque/tightness.
If you don’t have a torque wrench, ensure all DC terminals are tight and cannot move.
•Use the correct DC cable and corresponding circuit breaker to achieve maximum efficiency
from the system and reduce fire hazards associated with overheating.
•The DC cables must be fine strand, super flexible, such as Cobra cable (or equivalent) and be
approved for residential wiring per the NEC (THW for example).
•Do not use the Barcelona chassis in place of the battery negative connection for grounding.
A reliable return path directly to the battery is required.
•PV negatives must stay isolated from Battery negative. Wire PV negative directly to the
Barcelona’s MPPT PV input terminal block.
•Install a 200A DC breaker between the Barcelona and the battery bank on the positive
cable. Use #2/0 AWG battery cables.
•A readily accessible battery disconnect is required and must be located within sight of the
battery system (NEC 480.7).
•Ensure both DC cables pass through the same knockout and conduit to allow the inductive
currents to cancel.
The Barcelona 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.
CAUTION!
Ensure all sources of DC power (i.e., batteries, solar, wind, or hydro) are
de-energized (i.e., breakers opened, fuses removed) before proceeding—to prevent
accidental shock.
WARNING!

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•All wiring to the battery terminals should be checked periodically (once a month) for proper
tightness.
•Ensure cables have a smooth bend radius and do not become kinked.
•Limit cable length to 6’ or less from Barcelona to battery bank.
•The battery bank voltage MUST be 48V!
DC Over-Current Protection
•The NEC requires both over-current protection (UL489 standards) and a disconnect switch.
If a circuit breaker is used as the over-current protection device, it can also be used as the
required DC disconnect. If a fuse is used as an over-current device, a Class-T type or
equivalent is highly recommended. This fuse type is rated for DC operation, can handle high
short-circuit currents, and has a time delay that allows for momentary current surges
without opening the fuse. Because the fuse can be energized from both directions, the NEC
requires that it be installed in a manner that the power must be disconnected on both ends
of the fuse before servicing.
•The DC over-current protection device must be installed on the positive DC cable and it
must be correctly sized according to the size of DC cables being used, which means it is
required to open before the cable reaches its maximum current carrying capability.
•Use a 200A DC breaker.
Grounding
•The negative battery conductor should be
solidly bonded to the grounding system at
only one point in the system. The size for
the conductor is determined by the size of
the largest phase conductor, per the
NEC/CEC.
•Use #6 AWG grounding electrode conductor.
Arc Fault - The NEC requires any PV system DC circuit operating at 80VDC or greater must be
protected by an arc fault (AF) circuit interrupter.
Ground Fault - Since 2008 the NEC requires a DC Ground Fault (GF) Protection device on all
PV systems to indicate when a GF condition exists.
Verify correct polarity with a multimeter BEFORE connecting battery cables to Barcelona.
WARNING!
The Barcelona may be used in a positive,
negative, or ungrounded system. For a
grounded system, bond either Battery Negative
to Ground, or bond Battery Positive to Ground
(but not both at the same time!!).
CAUTION!

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Protecting Wire –Barcelona Breaker Box (MNBCLNA BB)
DC wires to and from the Barcelona must be protected as required by code. This can be done
by using jacketed wires or by feeding the wires through conduit. Midnite offers a breaker box
that includes the necessary DC breakers that allow the PV wires and DC battery cables to be
routed via conduit and connected to the Barcelona.
PV Array
•The PV array connected to the Barcelona must be designed to present enough voltage to
operate, yet not enough to damage the unit. The Barcelona needs a minimum of 240Voc
from the PV array; otherwise, the controller will remain in a Resting state on a hot day.
Thus, when you design the PV layout, ensure you wire enough PV modules in series to
present at least 240Voc. Since this is a 600V controller, you will more than likely wire many
modules in series to take advantage of the 600V input. Be mindful of the effects of cold
temperatures on PV string voltages. DO NOT PRESENT MORE THAN 600VDC TO THE
CONTROLLER!! The MPPT range of the Barcelona is 185V –550VDC. Page 41 shows an
ambient temp chart to help size the PV string voltage.
EXAMPLE - Assume the coldest weather in your locale is -4F. Referencing the chart gives a
factor of 1.18. 600Voc / 1.18 = 508Voc. Thus, wire the PV modules in series so as not to
exceed 508Voc and the MPPT will continue charging down
to -4F.
•The PV negative wire from the PV array must be isolated
from ground. Ensure the PV negative is wired from the
array directly to the PV negative input terminal in the
Barcelona.
INSTALLATION
Before installing, read the entire installation section to determine how you are going to install
your Barcelona. The more thoroughly you plan in the beginning, the better your overall system
needs will be met.
The installation begins by selecting a wall. The Barcelona is indoor rated and should not be
placed outside unless precautions are taken to keep rain and moisture off the system.
The NEC requires 30” clear on the wall. The Barcelona may be located anywhere within this
30”. The NEC also requires 36” free and clear of obstructions in front of the charge controller.
The 36” clear area in front of all electrical panels is to provide a space to fall back into in case of
electrical shock.
The PV negative from the
PV array must be wired
directly into the Barcelona.
Do NOT bond PV negative
to ground. Do NOT exceed
600V IN!
CAUTION!