MidNite Solar Classic 150 User manual

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MidNite Solar Classic
Owner’s Manual
This Manual covers models Classic 150, 200 and 250

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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----------------------------------------------------------------------------------------------------------------- 5
Introduction--------------------------------------------------------------------------------------------------------- 5
Installation guidelines and safety instructions------------------------------------------------------------------- 6
Battery safety----------------------------------------------------------------------------------------------- 7
Installing the Classic------------------------------------------------------------------------------------------------ 7
Classic power curves-------------------------------------------------------------------------------------- 7
Classic labels----------------------------------------------------------------------------------------------- 9
Unpacking the Classic----------------------------------------------------------------------------------- 10
Removing and installing the front cover------------------------------------------------------------- 10
Mounting the Classic-------------------------------------------------------------------------------------- 12
Alternative Mounting-------------------------------------------------------------------------------------- 13
Sealed or Vented------------------------------------------------------------------------------------------- 13
Network cables and network layout--------------------------------------------------------------------- 14
Battery temperature sensor installation----------------------------------------------------------------- 16
Grounding------------------------------------------------------------------------------------------------------------ 18
Internal Ground Fault Protection------------------------------------------------------------------------ 18
Wiring the Classic--------------------------------------------------------------------------------------------------- 19
Connecting multiple units--------------------------------------------------------------------------------- 20
Basic Hook up Diagram----------------------------------------------------------------------------------- 20
DC Terminal Connector----------------------------------------------------------------------------------- 21
Over current protection and wire size requirements--------------------------------------------------- 21
Current Ratings -------------------------------------------------------------------------------------------- 23
Current Limit ---------------------------------------------------------------------------------------------- 21
Over current protection------------------------------------------------------------------------------------ 22
Long distance wire runs----------------------------------------------------------------------------------- 22
Maximum and minimum wire size---------------------------------------------------------------------- 22
Connecting the Classic to the Clipper------------------------------------------------------------------- 23
Commissioning the Classic------------------------------------------------------------------------------- 24
Using the Classic user setup screens-------------------------------------------------------------------- 24
Configuration--------------------------------------------------------------------------------------------------------- 25
Configuring battery menus-------------------------------------------------------------------------------- 25
Setting battery nominal voltage----------------------------------------------------------------- 25
Calibrating battery voltage---------------------------------------------------------------------- 25
Battery size and chemistry---------------------------------------------------------------------- 25
Battery charge set points and times------------------------------------------------------------ 25
Battery temperature compensation------------------------------------------------------------- 25
Configuring Classic input source------------------------------------------------------------------------- 25
Solar 1---------------------------------------------------------------------------------------------- 25
Solar 2---------------------------------------------------------------------------------------------- 25
Legacy mode--------------------------------------------------------------------------------------- 25
U Set PV------------------------------------------------------------------------------------------- 25
Hydro----------------------------------------------------------------------------------------------- 25
Configuring the Classic for wind--------------------------------------------------------------- 25
Adjusting and changing wind curves------------------------------------------------- 25
Wind learn------------------------------------------------------------------------------------------ 25
Boost Mode----------------------------------------------------------------------------------------- 25
Setting Date and time--------------------------------------------------------------------------------------- 26
Setting Longitude and Latitude--------------------------------------------------------------------------- 26
Configuring Auxiliary input/output's------------------------------------------------------------------------------ 26

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Aux 1 Function------------------------------------------------------------------------------------ 45
Auxiliary 2 (OUTPUT)-------------------------------------------------------------------------- 27
Auxiliary 2 (INPUT)----------------------------------------------------------------------------- 27
Back light--------------------------------------------------------------------------------------------------- 60
Restore factory default settings-------------------------------------------------------------------------- 29
Operating the Classic----------------------------------------------------------------------------------------------- 29
Display and buttons---------------------------------------------------------------------------------------- 29
Navigating the display menus------------------------------------------------------------------ 31
Viewing other Midnite products---------------------------------------------------------------- 31
Charge stages and meanings------------------------------------------------------------------------------ 31
View active faults and warnings-------------------------------------------------------------------------- 32
View logged data-------------------------------------------------------------------------------------------- 33
Equalization mode------------------------------------------------------------------------------------------- 71
Uploading firmware to the Classic and Display------------------------------------------------------- 72
Retrieving firmware level------------------------------------------------------------------------ 74
Connecting the Classic to the internet------------------------------------------------------------------ 75
Trouble Shooting--------------------------------------------------------------------------------------------------- 100
Resetting the Ground Fault detection---------------------------------------------------------------------------- 110
Specifications-------------------------------------------------------------------------------------------------------- 111
Electrical specifications---------------------------------------------------------------------------------- 112
Default battery charge settings------------------------------------------------------------------------- 113
Mechanical Specifications----------------------------------------------------------------------------- 114
Optional accessory---------------------------------------------------------------------------------------- 116
Regulatory approvals------------------------------------------------------------------------------------- 118
Warranty and Return information-------------------------------------------------------------------------------- 119
End of warranty tune up----------------------------------------------------------------------------------- 120
Technical information---------------------------------------------------------------------------------------------- 122
Typical array sizes---------------------------------------------------------------------------------------- 123
Wire and disconnect sizing------------------------------------------------------------------------------ 124
Wire distance charts-------------------------------------------------------------------------------------- 125

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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, Hydro, Wind and other DC sources..
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)
*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 and the Classic 250. It covers the installation, wiring and
use of the Classic charge controller.
WARNING Warnings 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 eq-
ment.
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:
•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

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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.
• 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 XX.
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.
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 SHORTCIRCUIT 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.

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• 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 current. 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
The graphs above represent the max power output for a given input for each Classic. Using and understanding
these power graphs will help maximizing Classic’s output power and aid in selecting wire and
breaker/disconnects. The built in set up wizard also helps select breakers and wire sizes. 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.
Below are the labels present on the Classic.

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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 1.1. Included in the Classic package should be:
*Classic charge controller
*Battery temperature sensor
*Snap on upper vent cover
*Knock out covers 4 screened and 4 solid

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*User’s manual CD, printed installation instructions
*1 ten foot custom USB cable
If anything is missing or damaged please refer to Page 2 for details on contacting us.
Figure 1.1
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 there is a cable connecting the cover to the electronics. Do not pull hard or fast.
Damage will result.
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 10” long 6 conductor phone cable.
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 1.2 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.
Figure 1.2

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Mounting the Classic
The following section covers typical mounting arrangements. If you require additional details that are
not covered here please contact us at technical support. The Classic is designed to be directly mounted
onto the MidNite Solar E-Panel as well as other installation methods. Mount in an upright position out

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of direct sunlight when possible. The Classic has four one inch knock outs for your convenience they
are pre cast. The Classic has mounting and conduit location similar to other brands to facilitate ease of
upgrading older technologies to features available only on the Classic.
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 1.3.
*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 1.3B Classic Mounted to side of E-Panel Figure 1.3C Nipple, locknuts and bushings
that come with every E-Panel
Figure 1.3D Classic mounted to the side of a MidNite Solar E-Panel
Figure 1.3A Charge controller
bracket mounted to the E-Panel. The
bracket comes with every E-Panel

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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 40 for more details.
Sealed or Vented
The Classic ships with the parts to convert it to a sealed unit. If you
live in a dusty or salt air environment you may wish to seal the Classic.
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

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seen in the photo below. Note that the Classic will be slightly derated (puts out less power) by sealing
it. Refer to the owner’s manual for the specifications of the Classic in the sealed mode. Refer to Figure
1.4 and 1.5
figure 1.4 figure 1.5
Figure 1.6 Power wire hook up between the Classic and E-Panel
Network Cable routing and installation guidelines
The Classic uses a network cable to communicate with other Classic's or other MidNite products. This cable is a
standard 6 conductor phone cable and simply plugs into the jack on the Classic labeled slave and then plugs into
the master jack on the second device. There is a plastic clamp located on the circuit board for routing the
network cables above the USB jack so they stay tied down out of the way. Refer to figure 1.7A and 1.7B

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Figure 1.7A Master / Slave methods of hook up

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figure 1.7B
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 Terminal
block labeled “Battery Temp”. Refer to Figure 1.8 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 them please refer to the battery manufacturer's recommended procedure.
Battery Temp Sensor
Cable Clamp for
network cables
USB connector
10 foot USB cable is
include
d
Ethernet connector

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Figure 1.8
Insert BTS to the jack labeled BATTERY TEMP on the control board.
Figure 1.9
Before placing the Battery Temperature Sensor make sure battery surface is clean from any dust or
acids. Placement is not very critical.

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Grounding
The Classic charge controller is designed to work with negatively grounded or ungrounded systems.
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 see figure 2.0
Figure 2.0
Internal Ground Fault Protection
The Classic has internal ground fault protection (GFP) built in. NEC 2008 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 GFP is enabled 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. Only one Classic is to have the GFP function enabled. If more than one GFP
device is enabled the feature may not work as designed. 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 an ungrounded DC system.
To disable the internal Ground Fault Protection
function, jumper labeled GFP needs to be
removed, or it can be disabled in the TWEAKS
menu. See page 40
To reset the internal GFP function after
detection has occurred, fix the actual ground
fault, then turn OFF Classic and turn it back
ON. Do this by turning the external battery
breaker to OFF position and then to ON
position.

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Wiring the Classic
WARNING: Shock hazard. Disconnect the batteries and input power before opening the Classic
front cover
The Classic should be wired by a qualified professional and needs to meet all applicable electrical
codes. Always make sure all source and battery circuits are de energized and wait 5 minutes before
working on the wiring in the Classic. The Classic has 2 common neutral (negative) terminals.
Therefore, only one neutral conductor is required to run from the Epanel and terminate on either (or
both) common neutral terminal. The Positive DC source wire goes to the PV+ Turbine+ screw. The
Positive Battery DC wire goes to battery + terminal. Torque the terminal screws to the specs below.
To connect the wiring to the Classic:
*Ensure the DC source and Battery are disconnected
*Connect a grounding conductor between the Classic and system ground
*Ensure the breaker between the battery and Classic meets UL489 standards.
*Ensure the breaker between the dc source and Classic meets UL1077 standards.
*Connect the DC source and Battery wire to the Classic
*Connect any communications cable or auxiliary input/output wires
*Torque terminal connector screws to the following specs
The Torque specs on the big blue terminal connector are:
Up to #10 AWG torque to 25-35 inch pounds.
#8 AWG torque to 30-40 inch pounds.
#6 AWG or above. Torque to 40-50 inch pounds.
Refer to next two diagrams for Classic Basic Hook Up Diagram

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