MidNite Classic User manual

For help with the Classic or Classic SL, please see our how-to videos and extended documentation at
www.midnitesolar.com/documentIndex.php . Before calling tech support, we recommend visiting
this website for some of the most common issues.
WARNING: Arc Fault protection is not ON by default.
NOTE: The National Electrical Code article 690.11 requires Arc Fault protection. The Classic has
this built-in as standard equipment and will need to be enabled, if so desired. The Classic SL does
not have Arc Fault built-in.
NOTE: The Arc Fault protection has adjustable sensitivity and may require some tuning for your
particular system to avoid nuisance tripping. Some house loads like table saws and well pumps and
other motor loads can be seen on the PV circuit in the Classic appearing similar to DC arcs. We have
started with a general average we have found to work reliably but in some cases this sensitivity
level is too high causing false Arc Fault alarms. When the Classic goes into Arc Fault, it goes to
Resting and will not charge the batteries. Please consult the Classic Manual for enabling and fine-
tuning of the Arc Fault system.
DANGER OF DEATH TO YOUR CLASSIC!
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 wire a pump or other load to the input side of the Classic. If a load must be wired to the input
side of the Classic, the load and Classic need to have blocking diodes on them.
Never parallel two Classics onto one PV array.
IMPORTANT –Per UL1741 and NEC 690.12, this device must be located where the PV input
conductors are not required to be controlled.
For larger systems with large inverters and or multiple inverters (i.e., Radian or XW+), it is
important to use appropriately 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 the
charge controller battery side connections. This bus bar is sufficient for two charge controllers; if
you need three or more, then you need to look at the best way to handle the amperage. A dual
Radian, for example, is actually four separate inverters. Properly sized cables as well as a large
enough battery bank is very important. Most manufacturers of battery-based inverters recommend
100Ah of battery per kW of solar modules. Please consult the inverter manufacturer for assistance
with cable sizing.
Classic SL
This Owner’s Manual covers both the Classic and the Classic SL models.
The Classic SL performs the same functions as the regular Classic, but WITHOUT the following
features: 1) No Arc Fault circuit; 2) No AUTO EQ function; 3) No Ethernet port; 4) No wind or hydro
programming; and 5) The Classic SL does not include the Battery Temp Sensor, sold separately.

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Classic 150 Classic 200 Classic 250

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Table of Contents
Introduction..................................................................................................................................................... 5
Safety Instructions............................................................................................................................................ 6
Standards and Requirements.................................................................................................................................... 6
DC and Battery-related Installation Requirements................................................................................................... 7
How to KILL Your Batteries........................................................................................................................................ 7
Classic Power Curves ........................................................................................................................................ 8
Classic Installation .......................................................................................................................................... 10
Unpacking the Classic.............................................................................................................................................. 10
Removing and Installing Classic Front Cover........................................................................................................... 10
Mounting the Classic............................................................................................................................................... 11
Alternative Mounting.............................................................................................................................................. 12
Sealed or Vented..................................................................................................................................................... 13
Wiring the Classic ........................................................................................................................................... 13
Maximum and Minimum Wire Size......................................................................................................................... 13
To Connect Wiring to the Classic ............................................................................................................................ 14
DC Terminal Connector ........................................................................................................................................... 16
Current Rating ......................................................................................................................................................... 16
Over-current Protection.......................................................................................................................................... 16
Long Distance Wire Runs......................................................................................................................................... 17
Connecting the Classic to the Clipper ..................................................................................................................... 17
Grounding...................................................................................................................................................... 18
Chassis Grounding................................................................................................................................................... 18
DC System Grounding ............................................................................................................................................. 18
DC GFP (Ground Fault Protection) .......................................................................................................................... 18
Disabling GFP........................................................................................................................................................... 19
Positive Ground Systems......................................................................................................................................... 19
Networking .................................................................................................................................................... 20
Follow-Me –Charge Coordination .......................................................................................................................... 19
Ground Fault Sharing .............................................................................................................................................. 21
Naming the Classic .................................................................................................................................................. 21
Addressing Classics.................................................................................................................................................. 21
Connecting the Classic to Two MNGPs/Network Cable.......................................................................................... 22
Connecting the Classic to the Internet.................................................................................................................... 22
Network Setup through the MNGP......................................................................................................................... 23
DHCP........................................................................................................................................................................ 24

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Static IP.................................................................................................................................................................... 24
IP Address................................................................................................................................................................ 25
Subnet / Gateway / DNS 1 ...................................................................................................................................... 25
Web Access ............................................................................................................................................................. 25
Local Network ......................................................................................................................................................... 26
Battery Temperature...................................................................................................................................... 26
Battery Temperature Compensation ...................................................................................................................... 26
Battery Temperature Sensor (BTS) Installation ...................................................................................................... 26
Classic Programming....................................................................................................................................... 27
Commissioning the Classic (Quick Start) ................................................................................................................. 27
MNGP Features and Programming ......................................................................................................................... 27
Battery Charge Stages ............................................................................................................................................. 29
Mode is Off.............................................................................................................................................................. 30
Adjusting Absorb, Equalization, and Float Voltages ............................................................................................... 30
Current Limit ........................................................................................................................................................... 30
LED Modes............................................................................................................................................................... 31
Calibrating Classic and PV Voltage .......................................................................................................................... 31
Configuring DC Input Source ................................................................................................................................... 32
Programming the Classic for Wind Input Source .................................................................................................... 33
Equalization............................................................................................................................................................. 35
Setting Date and Time............................................................................................................................................. 36
Arc Fault .................................................................................................................................................................. 36
Programming for PV Bleed Down ........................................................................................................................... 37
Charge/Advanced Settings...................................................................................................................................... 38
Auxiliary Ports................................................................................................................................................ 39
Configuring the Classic’s AUX Ports ........................................................................................................................ 39
AUX Function Definitions ........................................................................................................................................ 40
AUX 1 Modes........................................................................................................................................................... 41
AUX 2 Modes........................................................................................................................................................... 43
AUX 1 and 2 Jumpers .............................................................................................................................................. 45
Logged Data ................................................................................................................................................... 47
Graphical Logging Display Modes ........................................................................................................................... 49
Classic Voice................................................................................................................................................... 51
Levels of Chattiness................................................................................................................................................. 51
Programming Classic Voice ..................................................................................................................................... 51
Updating New Firmware to the Classic ............................................................................................................ 52

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Preparing Classic for Update................................................................................................................................... 52
HyperVoc ....................................................................................................................................................... 54
Troubleshooting / FAQs.................................................................................................................................. 55
Mechanical Specifications............................................................................................................................... 64
Electrical Specifications .................................................................................................................................. 65
Default Battery Charge Set Points ................................................................................................................... 65
Regulatory Approval ...................................................................................................................................... 66
RS232 Jack Pin Out ......................................................................................................................................... 66
Classic Breaker Sizing...................................................................................................................................... 67
Classic Menu Maps......................................................................................................................................... 68
Classic Label Set ............................................................................................................................................. 72
Glossary of Terms........................................................................................................................................... 73
Warranty ....................................................................................................................................................... 75
New Turbo Fan Assembly ............................................................................................................................... 76

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Introduction
The MidNite Classic charge controller is designed to regulate DC input from PV, hydro, or wind
turbines. For other DC sources, please contact MidNite Solar Tech Support. The Classic 150, 200,
and 250 are designed to work with 12V, 24V, 36V, 48V, 60V, and 72V battery banks. Voice
annunciations of operating values are now available in English (French and Spanish coming soon).
The Classic can be installed stand-alone or as a multi-unit networked installation. Standard features
of the Classic charge controller include:
Three input operating voltage ranges: 150, 200, and 250V
Multiple DC input options (solar, wind or hydro)
Voice annunciations in multiple languages
Data logging for 380 days
Graphical display
Internet-ready
Scope
This manual provides safety guidelines, installation instructions, and usage information for the
standard and SL models of the Classic 150, 200, and 250 charge controllers. It does not provide
brand specific information about photovoltaic panels, batteries, et cetera. Contact the manufacturer
of other components in the system for relevant technical data.
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.
Notice of Copyright
MidNite Solar's Classic Charge Controller User’s Manual
Copyright ⓒ 2019 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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Safety Instructions
WARNING: Identifies conditions or practices that could result in personal injury or loss
of life.
CAUTION: Identifies conditions or practices that could result in damage to the unit or
other equipment.
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, rather battery negative and
ground are connected 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 Classic should never be positively
grounded.
The Classic equipment ground is marked with this symbol:
If damaged or malfunctioning, the Classic should only be disassembled and repaired by a
qualified service center. Please contact your renewable energy dealer/installer for
assistance. Incorrect re-assembly risks malfunction, electric shock, or fire.
The Classic 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.
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 NEC requires an ARC FAULT detector on all charge controllers and inverters
operating above 80VDC. Both devices are built into the Classic.
The MidNite Solar Classic 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).

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DC and Battery-Related Installation Requirements
All DC cables must meet local and national codes (Reference NEC Article 480).
Shut off all DC breakers before connecting any wiring.
Torque all Classic wire lugs and ground terminals to the specs found on Page 14.
Copper wire ONLY with a rating of 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 over-current protection must be used on the Classic input and output circuits.
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)
batteries do not normally require ventilation. Consult your battery manufacturer for details.
WARNING: Personal precautions during installation – 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, immediately flood the eye with running cool water for at least 15 minutes and
seek medical attention.
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. Doing so can short the
batteries or other electrical parts, resulting in fire or explosion.
Never wear metal 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.
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. For Lithium battery banks we highly recommend using the Logic input on the Classic which
allows the BMS to tell the Classic to stop charging if the BMS detects an issue brewing. We also
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.

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Not watching the charge voltages or verifying you are charging to the voltage supplied by the
battery manufacturer.
Not verifying the temperature compensation neutral point (typically 25° C) and the milli volts
per degree C per cell (typically -5mV).
Not watching to verify the Absorb or EQ time is set properly and that the equipment 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 having enough charge current (Solar Panels) 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.
Failing to keep all connections clean.
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 be dead in less than 6 months.
Using more than three parallel strings and not using common bus bars. 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.
Not making sure your lead acid batteries get a full charge at least once a week.
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 on a daily
basis will kill them 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.
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.
Classic Power Curves
Table 1

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Table 2
Table 3
Tables 1 through 3 above represent the max power output for a given input for each Classic. Using
and understanding these power graphs will help maximize the 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 common
battery bank configurations. Other voltages are also supported. The Classic battery voltage
parameters are fully user-adjustable.
Example: If you are using a Classic 250 and 48V battery bank, the maximum continuous output
power based on 25° C ambient is 55A when using a PV array that yields a maximum power voltage