MidNite Classic 150-SL User manual

ATTENTION: Please Read this cover letter
BEFORE installing the Classic-SL
For help with the Classic, Classic Lite or Classic-SL please see
our how to videos and extended documentation. Please visit
this website: www.midnitesolar.com/classic
Before calling tech support, we recommend visiting this
website for some of the most common issues.
DANGER OF DEATH TO YOUR CLASSIC
Warning with Tigo modules Solar Mode must not be used or the Classic will not survive.
MidNite does not recommend the use of Tigo Module Optimizers with the Classic. If
Tigo modules must be installed Legacy P&O MUST be used.
When the Classic is used with Wind or Hydro a Clipper type device will most likely be
needed to protect against over voltage. A battery based diversion load WILL NOT keep
the Classic safe from over voltage. High input voltage is recorded and over voltage is not
covered under warranty.
Never hook a Pump or other load to the Input side of the Classic. If a Load must be
hooked to the input side of the classic the load and Classic need to have blocking diodes
on them.

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Never Parallel 2 Classics onto one PV array. If 2 Classic’s have to be paralleled for wind
or hydro (NOT SOLAR) there must be blocking diodes on each Classic.
For Larger systems with Large inverters and or multiple inverters (like the Radian or
XW+ for example) it is important to use appropriate sized cables and bus bars or
damage to the inverters or charge controllers can occur. Take a single XW+ E-Panel for
example, it has a positive bus bar for Charge controller battery side connections. This
bus bar is sufficient for 2 charge controllers, so if you needed 3 or more then you need
to look at the best way to handle the amperage. Or a Dual Radian, for example, is
actually 4 separate inverters. Proper size cables become very important as well as large
enough battery banks. Most manufacturers of Battery based inverters recommend
100AH of battery per KW of solar modules. (Please consult the inverter manufacture for
assistance with cable sizing etc)

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This Manual covers models Classic 150-SL, 200-SL & 250-
SL

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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)
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
Contents
Scope............................................................................................................................................................................. 5
Introduction................................................................................................................................................................. 5
Classic SL Power Graphs & Sizing the Solar Array................................................................................................ 8
Unpacking the Classic SL......................................................................................................................................... 10
Removing and installing the front cover on the Classic SL................................................................................... 10
Mounting the Classic SL........................................................................................................................................... 11
Wiring the Classic SL............................................................................................................................................... 13
DC Terminal Connector.......................................................................................................................................... 17
Maximum and Minimum Wire Size ....................................................................................................................... 17
Over Current Protection and Wire Size Requirements ........................................................................................ 17
Current Rating......................................................................................................................................................... 18
Over Current Protection.......................................................................................................................................... 18
Long Distance Wire Runs....................................................................................................................................... 18

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Battery Temperature Compensation....................................................................................................................... 19
Battery Temperature Sensor Installation............................................................................................................... 19
Chassis Grounding.................................................................................................................................................... 21
DC System Grounding............................................................................................................................................ 21
DC GFP (Ground Fault Protection)........................................................................................................................ 22
Disabling GFP......................................................................................................................................................... 23
Commissioning the Classic SL (Quick Start) ......................................................................................................... 23
Equalization............................................................................................................................................................... 23
Battery Charge Stages and Meanings ..................................................................................................................... 23
Resting ................................................................................................................................................................ 24
Mode is OFF ....................................................................................................................................................... 24
Adjusting Absorb, Equalize and Float Voltages..................................................................................................... 24
Current Limit........................................................................................................................................................... 25
Calibrating Battery and PV Voltage ....................................................................................................................... 25
Configuring DC Input Source................................................................................................................................. 25
Setting the Date and Time....................................................................................................................................... 26
Troubleshooting / FAQs ........................................................................................................................................... 27
Electrical Specifications............................................................................................................................................ 35
Specifications Mechanical ........................................................................................................................................ 36
Classic Breaker sizing............................................................................................................................................. 37
Scope
This Manual provides safety guidelines and installation information for the Classic SL 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 SL charge controller was designed as a SOLAR only charge controller. The Classic 150-SL,
200-SL and 250-SL are designed to work with 12, 24, 36, 48, 60 and 72 volt battery banks.
The Classic SL can be installed stand alone or as a multi-unit networked installation.
Standard features of the Classic SL charge controller include:
*3 input operating voltage ranges 150, 200 and 250 VDC
*Graphical display
*Previous 380 days of operational data logged

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This Manual covers Classic 150-SL, Classic 200-SL and the Classic 250-SL. 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.
• 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. The GFP (Ground Fault
Protection) device is built into the Classic.

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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
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.

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Classic SL Power Graphs & Sizing the Solar Array
Table 1
Table 2
Table 3

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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
NOTE:
A typical solar module around 250 watts will be a 60 cell module so it’s open circuit voltage will be about
37 volts. So for a Classic 150-SL you could put 3 in series, A Classic 200-SL you could put 4-5 in series
and a Classic 250-SL you could put 5-6 in series. PLEASE NOTE this is not intended to be a sizing tool
but a general guide. Please follow the link above and size your array properly.
WARNING:
*VOC is a term you will hear a lot it stands for Volts Open Circuit, This is what is
used to determine how many modules can go in series. VOC will be printed on the
actual solar panel as well as on the spec sheet for the solar panel (For questions on the
values found on the solar panel please consult the panel manufacturer or the
distributor)
*NEVER connect any loads or other stuff to the PV input on the Classics (Or any
charge controller)
*Classics that have exceeded their HyperVOC voltage (safe voltage) will not be under
warranty.
*A Classic needs a MINIMUM Input voltage to turn on. To calculate this take the
highest voltage the battery will be at and multiply it by 1.33 if the PV input voltage is
lower than that value the Classic will not come out of resting.

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Unpacking the Classic SL
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
*Knock out covers 3 screened
*Parts bag with stickers, Terminal block cover and silicone grease
*User’s manual printed
Email [e-mail] for more information or if anything is missing or damaged.
Figure 1
Removing and installing the front cover on the Classic SL
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.

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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.
Figure 2
Mounting the Classic SL
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.
CLASSIC SL does NOT have Ethernet or USB!
Wiring the Classic SL
WARNING: Shock hazard. Disconnect the batteries and input power before opening the
Classic front cover. ALWAYS use proper Over current devices and disconnects on the PV+ and Battery +
at the Classic (MidNite DC breakers work well for both).
WARNING to comply with Australian/New Zealand code:
Any connection to the Classic SL will require double/reinforced insulated wire.
The Battery circuits are not isolated from hazardous PV circuits so proper cover/barrier must be in place to
ensure user cannot access battery circuits without a tool.

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The Classic SL 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 E-Panel and terminate on either (or both)
common neutral terminal. This negative conductor should be sized to match the battery + cable. 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 cables or auxiliary input/output wires
Torque terminal connector screws to the following specs
The Torque specs on the DC terminal connector (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.
HyperVOC ™
HyperVOC is a unique feature the Classic has built in. HyperVOC refers to when the DC Input Voltage
raises above the maximum operating voltage (150V, 200V, 250V, depending on the Classic model).
HyperVOC gives you the flexibility to go up to the maximum operating voltage PLUS the nominal battery
voltage. For example, the Classic 150 has an input voltage rating of 150 operating volts, if the Classic 150
is connected to a 48 volt battery bank, the HyperVOC voltage limit will be: 150V + 48V a total of 198
Volts that the Classic can withstand without damage. When the Classic input voltage rises above 150 volts
it will switch off (stop outputting power). As long as the Classic is in HyperVOC mode, the
microprocessor and all other functions like AUX will continue running. When the input voltage comes
back down below 150v (or the rated operating voltage of the Classic, depending on model) the Classic
will wake up and start charging again automatically. This could happen in a really cold morning with a
system that has a Voltage Open Circuit (VOC) close to the maximum operating input voltage.
Note 1. A HyperVOC message will be displayed on the bottom right side of the Status screen.
Note 2. Max nominal battery voltage to be added is 48v

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Diagram 1 Explanations
10 = Solar Modules (PV)
11 = DC Combiner (Like our MNPV6 or MNPV12 for example)
12 = MNSPD300-DC (Surge protection)
13 = MNSPD300-AC (Surge protection)
14 = MNSPD300-DC (Surge protection)
15 = DC breaker for the Inverter (Also serves as a disconnect for the Inverter)
16 = DC breaker for the PV into the Classic (Also serves as a disconnect for the Classic)
17 = DC breaker for the Battery into the Classic (Also serves as a disconnect for the Classic)
18 = AC L1 Input Bus Bar. (This is where the generator L1 input gets wired)
19 = AC Neutral Bus Bar. (This is where ALL AC Neutrals get wired)
20 = AC L1 Output Bus Bar. (This is where the L1 Output to the Load center for the building would connect)
21 = Battery Positive Bus Bar. (This is where we would wire the Battery positive side of the Classic, as well as
where we would wire up DC loads. Do NOT wire the battery cable to this bus bar).
22 = Earth Ground Bus Bar. (This is the common Earth Ground bus bar where all the grounds get wired back to and
it needs to be connected to the building’s ground rod system )
23 = PV Positive Bus Bar. (This is where the Solar Panels positive lead connects.)
24 = Battery negative Bus Bar. This is where the solar panel negative lead would go as well as the Classics negative
lead and any negatives from the loads. Do NOT connect the battery negative cable to this bus bar
25 = DC Shunt. (The Shunt measures the amperage in or out of the battery. You connect the battery to one side and
everything else to the other side.)
26 = Earth Ground system of the building
27 = Classic Charge controller.
28 = AC Generator
29 = Batteries. (The Voltage must match the voltage of the inverter. Typically 2-3 strings of batteries would be
considered the max.)
30 = Optional Battery temperature sensor. (This is used to compensate for the temperature of the battery. If a battery
is cold it has to be charged to a slightly higher voltage and when it is hot it will be charged to a slightly lower
voltage.)
31 = DC Cables to Inverter

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Diagram 1

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DC Terminal Connector
Figure 7
The Classic's DC terminal connector is located on the circuit board as shown in figure 17. The connector
will take up to a #4 AWG. #4 AWG THHN when installed in the Classic and MidNite E-Panel is rated for
over 100 amps and is therefore suitable for the highest power available from the Classic 150-SL. After
installing the wires for the last time snap in the blue cover that is included in the parts bag.
Maximum and Minimum Wire Size
The Classic’s Blue DC terminal connector will accept wire from #14-#4 AWG
The Classic’s Aux 1 and 2 terminal connector will accept wire up to #18 AWG
WARNING: Extra fine Stranded wire is actually larger in diameter than standard stranded wire
like THHN therefore #4 extra fine strand (Welding cable) will not fit in the terminal block.
Over Current Protection and Wire Size Requirements
The over current devices, wiring, and installation methods used must conform to all electrical codes
applicable to the location of installation. Wiring needs to be protected with proper strain relief clamps and
or conduit. See page 49 for a breaker and wire size chart.

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The USB cable, BTS cable and auxiliary input/output cables should run in a different conduit to preserve
their signal. When installing the Classic in a MidNite E-Panel, it is acceptable to run all wiring through the
same knockout hole. It is legal to run signal and power wires together as long as all wiring is listed for the
highest voltage to be encountered. (Follow all local code)
Current Rating
The Classic limits the output current based on the model you have.
The Classic current ratings are:
Classic 150-SL - 96 amps maximum
Classic 200-SL - 79 amps maximum
Classic 250-SL - 62 amps maximum
Over Current Protection
The Classic must have over current protection to protect wiring from over current events. A means of
disconnect must be installed on the DC in and DC out of the Classic. Consult your local codes to
determine over current ratings. The breaker between the battery bank and the Classic must conform to
UL489. The breaker between the DC source and the Classic must conform to UL1077 or UL489. The
NEC requires 1.56 times short circuit current for PV over current protection. This is reduced to 1.25 times
when using a breaker rated for continuous duty. All MidNite Solar breakers are hydraulic/magnetic and
are rated for continuous duty (100% rating). No de-rating is required for the output breaker when using
MidNite Solar breakers.
PV in particular will be capable of producing more current than its name plate rating in extreme situations,
so the safe minimum wire size should be selected for the PV array maximum short circuit current. Please
consult PV manufacturer for specifications. The US National Electrical Code requires 1.56 times the PV
short circuit current for wire size on the PV input. Output wire size follows the NEC guidelines. Typical
wire size for output is 6AWG for the Classic 250-SL and 4AWG for the Classic 200-SL and 150-SL but
check all de-ratings for your wire type and installation method.
Long Distance Wire Runs
The Classic offers some unique opportunities if you are faced with longer than normal wire runs between
the DC source and the Classic. The Classic comes in 3 input voltage ranges letting you design a DC
source at a higher voltage if it is beneficial. For example, let’s say you have a 300 ft run from a PV array
to the Classic. You could wire for an open circuit voltage close to 250vdc accounting for the coldest
temperature you will encounter. This will allow you to run a smaller gauge wire than with a lower voltage
charge controller. The efficiency of a high voltage Classic is less than the lower voltage versions, so you
need to weigh the benefit. If this sounds too complicated use this rule of thumb in selecting the proper
Classic. PV runs up to 100 feet, use the Classic 150; runs up to 180 feet, use the Classic 200; or above 180
feet use the Classic 250.
If the wire size between the DC source and the Classic is larger than the Classic's DC terminal connector
you can use a splicer block or similar connector to reduce down to #4 AWG close to the Classic. The
MidNite E-Panels are supplied with a PV input bus bar that accepts up to 2/0 wire

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Battery Temperature Compensation
A remote battery temperature sensor (BTS) can be purchased separately. 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.
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.
An optional Battery temperature sensor is available 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.

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Figure 8
Insert BTS to the jack labeled BATTERY TEMP on the control board.
Figure 9