Basic Classic-SL Manual
Contents
1. 226 150V Classic Power Graph 96A 1380W 94A 2700 951 13 ss 5955 864 5022W mum Saa 4847W so MPPT Input Operating Voltage 4672w 2353W 75 P 120V 110V PV 76A 100v Pv smm 90V PV 4438W 70 m 70V PV 14 4 28 7 55 4 azv Nominal Battery Voltage 24V 48V Table 1 ax 200V Classic Power Graph so 79A 1137W 75A 2235W TAG 78A 4550W rO K _pq 75 e 74A 2123W zT zo 73A 1050w er 74A 1065W cue 685A 5414W 65 E 6 PET Operating Velas 63A 5247W 160V PV 140V PV ns 120 70 PV as 53A 4414W a sun 14 4 28 7 58 4 83 3 VoMage Me 12V 24V 48V 72v Table 2 s 250V Classic Power Graph 61A 8578W 62A 1779W 60 P Vi 60A 55 58A 1722W 835W so 5 845 MPPT Input Operating Voltage 40 I 180v 40A s 200V PV 3468W 14 4 28 8 43 2 57 6 72 86 4 Nominal Battery av 45 72M Table 3 6 Page XX XXX XX REV A Classic SL owner s manual continued 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 hig2. tenete tenente tenentes Error Bookmark not defined DC GFP Ground Fault Protection 20 __ __ _ _ ____ 21 Commissioning the Classic SL Quick _ _ ________ 21 9 3 gt 3 gt _ 21 Battery Charge Macer 2 2 2 _ 21 _ 22 _ _3 gt gt gt 22 Adjusting Absorb Equalize and Float Voltages _ lt _ _ 22 _ ___ 0 2 lt _ _ _ _ 23 Calibrating Battery oni PY Volt ge usns efe ri fn ne RT Di da rire d 23 Configuring DC Input Source aient nd tete ia tc 23 Setting The Date __ 24 Uploading New Firmware to the 46 25 2 2 2 25 Electrical Specifications re penetret TAEA 26 Specifications Mechanical 2223 22 2 lt lt lt 27 Classic Breaker icio suscite tic d bait nh E Pitra le BETE 28 Scope This Manual provide
3. TWEAKS MENU LMX 0 On Off WB Jr Neg Amp Hours Blk hold up arrow to force bulk Fit hold up arrow to force float HiFetT d ups On off HiVpv q Followme On Off Hi Vbatt BTS NET Master Follow KW Hours PSWD On Off Float T WBRST Yes On Hi Power Powel B Symbolizes pushing the Right Soft Key 2 Symbolizes pushing the Left Soft Key ru hl www midnitesolar com 17722 67th Ave NE Arlington WA 98223 PH 360 403 7207 Fax 360 691 6862 Table 8 32 Page XX XXX XX REV A Classic SL owner s manual continued Glossary of Terms Absorb Constant voltage charge stage to fill the batteries The controller is regulating so maximum power will not be seen at this time The Absorb timer is also counting down to the switch to Float Aux Auxiliary relays The Classic has 2 relays Aux 1 can be configured as a 12 volt signal or a dry relay Aux 2 can be used as a PWM signal output Refer to page Error Bookmark not defined for more Aux info BLK Bulk MPPT Mode By using the up arrow in Tweaks under BLK you can force the Classic into Bulk mode Bulk MPPT Maximum current charge stage the Classic is trying to bring the batteries to the Absorb voltage set point We are basically putting all available power into the batteries Comm This menu allows adjustment of things like Mod Bus port USB Mode and MNGP address DvrtCnt When enabled allows the charge stage timers to continue to run when the di
4. A 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 5 Page XX XXX XX REV A Classic SL owner s manual continued Classic SL Power Graphs amp Sizing the Solar Array
5. MidNite Solar Classic SL Basic Owner s Manual Firmware revA 19xx A SOA amp This Manual covers models Classic 150 SL 200 5L amp 250 SL Classic SL owner s manual continued 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 360 403 7207 Fax 360 691 6862 Email customerservice midnitesolar com Web www midnitesolar com Contents Scope Introduction Classic SL Power Graphs amp Sizing the Solar Arra Unpacking the Classic SL
6. Removing and installing the front cover on the Classic 5 Mounting the Classic gt gt 9 9 2 9 6 9 Wiring M 11 _ ____ _________ _________ _ _____ 15 0 ow w Maximum and Minimum Wire Size Over Current Protection and Wire Size Requirement 15 3 _ _ _ 16 L _2 2 2 lt _ _ 16 Distance Wire 9 6 16 2 Page XX XXX XX REV A Classic SL owner s manual continued Battery Temperature 17 _ gt 17 Chassis Grounding 66606C 19 DC System Groundilg assess ce bae te ad Feo A T De ra re XE WAR dede Peg 19 Positive Ground 5
7. during the day SOLAR mode is best suited for shaded or un shaded PV arrays that are at least one nominal voltage above the battery voltage For severe partial shading or PV arrays with nominal voltage equal to battery voltage you may also want to try Legacy P amp O Perturb and Observe MPPT mode Legacy P amp O Legacy P amp O Perturb and Observe mode is a slow tracking mode similar to the Micro Hydro mode but with the difference that it is slightly faster and will shut off if the power source goes off It has two settings that are user adjustable Sweep Interval is the time between mini sweeps in minutes and sweeps around the present i e the last found MPP Voltage The range of this sweep is determined by the Sweep Depth user adjustment and is expressed as a percentage of Watts that the sweep started from For example if in Legacy P amp O mode the Classic was outputting 500 Watts and the Sweep Depth percentage was set for 1096 50 Watts the sweep will bring the input voltage DOWN until the output power drops down to 450 Watts then will sweep UP in voltage until the power drops again down to 450 Watts and then go back to the newly found MPP Voltage waiting for the next sweep Note Mode must be manually turned ON after changing the mode To turn the mode ON highlight the OFF under ON OFF and switch it to ON Press enter to save this change Setting the Date and Time To set the date and time manually on the Classic follow the steps b
8. II6 88II u SIOJONPUOD ejBuis 10 reu st 1 OLEOINs A00 10 5MMV9 V09 DMYOL YOE A00 Jo SMY9 V0G OMVOL VOE AQOE 20 5MIV9 V08 OMVOLATOE A00 10 5MMV8 V09 A00 JO 9 05 OMVOLAOE A00 10 08 DMYOL VOE AO00 10 OMVS VOS OMVOL VOE A00 10 ONV9 V0S A00 10 DMV9 VOS A00 Jo 5MV9 V09 A00 10 5MIV9 V0 A00 10 DAWIS VOS A00 OMY 10 OMV9 VOG AO00 S AV9 10 MM9 808 A00 40 OAAV9 V0S OMVOLATOE A00 Jo ONV9 V0S OMVOLAYOE AO00 10 MVM9 808 M008 10 5MMV9 9086 A00 Jo DAAVO VOS OMVOLAOE A00 Jo VVIV9 V098 OMVOLATOE M008 5MXL V08 A00 10 DMV9 VOG M00 10 OMV9 V0S OMVOLATOE ASL V99 9MV8 V06 AOSL OMV9 V 9 OMVOV YOE AOS 9MV9 VEO OMVOV YOE AOSL OMWS NED OMVSIVOG AOSL OMV9 VES OMVOV YOE M9L 9MV9 VE9 OMVOV VOE AOSI v 9 OMVS VOG 9 OMV9 VE9 OMVOV YOE AOSL 9MV9 9 OMVOV VOE AOSL WE AOSI NES OMVS VOG AOSL OMV9 9 OMVOV YOE AOSL SMVvATOS AOSI OMY V 9 AOSL OMV9 V 9 OMVOL YOE 10190 9592 UJ II V0X6910 dul 21 C4L 99 969 90v 28tc 296 1801 NS 26 VC 79 9L6C 8c gv E 90729 89C SS eL vog 6 Bb ee vest
9. The battery is considered full at the end of the absorb charge cycle 21 Page XX XXX XX REV A Classic SL owner s manual continued Float A Float cycle follows after the Absorb cycle is completed Float is displayed on the screen Battery voltage is held at the float voltage set point Equalize The Equalization function can be manually initiated or can be set up to Auto Equalize The intent of an Equalization charge is to bring all battery cells to an equal voltage by a controller deliberate overcharge The goal is to return each battery cell to its optimum condition through a series of voltage controlled chemical reactions inside the batteries Resting Resting will show on the display when the Classic is not charging the batteries this is typically due to low light If the Classic is resting and should not be make sure Aux2 is not set to a logic input that is forcing it into resting Mode is OFF The Classic has a software ON and OFF feature This software Switch basically turns the relay off effectively disconnecting the input source so the Classic will not charge the battery If you see Mode is Off in the bottom right corner of the display then the Mode may have been turned off To turn the mode back ON push the Main Menu button several times until Charge is highlighted Scroll to the right until Mode is highlighted and press Enter On this screen OFF should be hig
10. enables the Classic to track the input voltage all the way down to Battery voltage When disabled the Classic will stop tracking the input around 5 volts above the battery voltage When the input voltage is within a couple volts of the battery voltage the inductors can Sing this is usually not very loud and will do no harm MNGP Midnite Graphical interface Panel This is the graphical display included with the standard Classic controller 33 Page XX XXX XX REV A Classic SL owner s manual continued Mode This menu lets you turn the charging ability of the controller On Off as well as lets you select the DC input source See page 21 for info on the Mode menu Mod Bus a standard protocol used for communications We have published our protocol to allow users to interface with the Classic See www midnitesolar com for our Mod Bus protocol Pwr Save Allows you to adjust the time the Backlight stays on Resting The Classic is not charging the battery due to low light For certain reasons Resting will appear Please see page 22 T Comp Temperature compensation using a temperature sensor to measure the ambient temperature of the battery bank and will adjust the voltage set points up or down accordingly to ensure a full battery There are 3 parameters to set Minimum and Maximum adjusted voltage as well as volts per degree C per Cell Typically this is 5 mV but please consult your battery manufacturer See page 17 for Temperat
11. 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 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 15 Page XX XXX XX REV A Classic SL owner s manual continued 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
12. to the Classic s USB port is either isolated from ground and the Classic s negative or that the computer s USB negative is common with the Classic s negative and ground WARNING You cannot turn a Classic 150 into a Classic 200 for example using new software the internal components are also different Troubleshooting Classic will not power on No self test on power up Check for voltage between the Battery and the common on the blue terminal block inside the Classic If voltage is present and above 10vdc contact customer service If no voltage is present back step through the and to find the fault Classic Display is blank but Classic is on Check that the blue cable is plugged in between the display and the top most jack on the circuit board Try another cable A standard short 4 conductor phone cable will work Classic says Resting but the sun is out Resting indicates a lack of power available to the Classic Verify there is voltage on the display under IM that is at least 30 greater than battery voltage Verify the Charging mode is correct for the source as well as the Mode is ON Classic switches between Resting and Bulk MPPT repeatedly but produces 0 watts This can be normal during low light conditions Watch the IN voltage and see if it is setting stable and does not change when the Classic goes from Resting to Bulk MPPT if so call customer service Watch the I
13. 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 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 GAWG 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 nor
14. 9L0L 9V g 281 YO 9 vv 9092 8CL 1 69 c 99 V Indu 21 0L 926 JAA OGAOSL DUGNANO Y Mdno oel Moul 50A 100 A Idd AE 9MV9 8 OMYo SMa 9MV3 SNVr 9 9MV9 9MVv9 9MV3 9MV9 9 0V or 909 eg 02 09 09 02 09 89 8 09 r 8 09 99 07 69 29 07 9 19 709 s 0804 99 06 08 e 06 08 z 07 9 9 08 02 99 06 08 ZL 06 08 08 0 99 03 02 OL 06 08 06 08 2 06 08 92 06 08 87 06 08 06 08 9 001 06 29 00L 26 06 08 92 001 06 ve 00L 6 06 09 08 00 16 00L 26 001 06 8 00 v6 00 96 001 06 98 00 v6 00 96 Buizis Jeyeeig 2I9550 2 2 9rv 668 991 GZ 91 GL SL c eee 999 e e vel cec 88 99 991 G2 9 ol 6 tes s E OL 622 99 916 802 9rv 8 181 97 94 Sri CBS 89 002 00C 002 002 08L 081 09 08L 09 09 091 091 Or Ovl Or 01 081 Ozh Oct 02 0 0 061 Oz Oc OL 14 Ort 00 00 00 06 06 06 0 0 0 cL er ve e cL er ve CL cL er ve e cL gy ve 2 c 8r ve CL 8r ve c 8r ve CL 9r ve CL 9r ve c 14 ve CL 8r ve CL osz 215520 092 218520 092 515592 097 218520
15. B L High Toe Symbolizes pushing the Right Soft Key D Symbolizes pushing the Left Soft Key www midnitesolar com 17722 67th Ave NE Arlington WA 98223 PH 360 403 7207 Fax 360 691 6862 30 Page XX XXX XX REV A Classic SL owner s manual continued CLASSIC SL MENU MAP 285 MidNite Solar Inc Continued from previous page AUX MENU Aux 2 Manual Off Manual On MISC MENU LED Mode Off Diversion Hi Te ea NES Waste Not Hi TS Waste Not Low TES Toggle Test PV VOn High Oque PVV On Low Night Light Day Light Float High Float Low Logic Input 1 Logic Input 2 Force Float In Whizbang Junior Symbolizes pushing the Right Soft Key Time PWRSV www midnitesolar com 17722 67th Ave NE Arlington WA 98223 PH 360 403 7207 Fax 360 691 6862 Rick Mode Blinky LED 1 Comm Test Backlight Adjust Backlight Contrast 6 Adjust Contrast Volume Adjust Volume Play MNGP Address USB Mod MB Port Phone Jack Routing To enable SMA mode Time 00 00 00 Date 00 00 0000 Off Backlite Short Backlite Long XX XXX XX REV A Classic SL owner s manual continued 4 4 CLASSIC SL MENU MAP MidNite Solar Inc LOGS MENU TEMPS MENU History L Remote FETS Clear Daily Logs Hourly Logs Lifetime LW Hours Lifetime Amp Hours WB Jr Net Amp Hours WB Jr Pos Amp Hours
16. C 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 12 Page XX XXX XX REV A Classic SL owner s manual continued 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 LI 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
17. N voltage and see if it slowly drops to battery voltage Or Close when the Classic goes to Bulk MPPT if so this is usually a sign of a High resistance connection Loose Connection between the Classic and DC source The Display shows 0 volts in or real close but the battery voltage looks correct If this is a new install or recently altered install check for reverse polarity on the DC input of the Classic If this just happened out of the blue or reverse polarity has been eliminated call customer service The Display is showing Mode is Off Enter into the main menu and select Mode Turn the Mode ON and press Enter to save 25 Page X XXX XX REV A Classic SL owner s manual continued Stuck in the or Quick Do a hardware factory restore There are 4 sets of jumpers directly above the Start blue terminal block For the purpose of this we will call the left most jumper JP1 and the right most JP4 actually labeled Boot Step l Turn the PV and Battery power off to the Classic and remove the front cover Step 2 Locate the 2 jumpers 7 1 and BOOT JP4 Take the actual jumpers and keep them in your hand Step 3 Turn the Battery power on to the classic e Step 4 within 1 minute place jumper JP4 on its two pins and then place jumper 1 1 on its two pins at this point the 3 leds on the top of the circuit board should flash back and forth for about 60 seconds Step 5 Af
18. 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 4 Page XX XXX XX REV A Classic SL owner s manual continued DC and Battery Related Installation Requirements gt gt 4 te 4 te gt 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
19. com 17722 67th Ave NE Arlington WA 98223 PH 360 403 7207 Fax 360 691 6862 29 Page CHARGE MENU Volts EQ Volts Absorb Volts Float Volts ChgTime Absorb Hrs Mins Time 00 00 EQ 00 00 B Timer View MinSec B Timer View HrsMin T Comp Comp Mv Deg C Cell Disable Mv EQ Comp D Temp Comp Set Point Volts EQ L Equalization Menu EQ Stopped EQ Started Advanced Ending Amps Rebulk Volts 5 Days Clasc Shunt Limits Output Amps Mint Comp Volts Max Volts HiBatt Tempc Right Soft Key Directional Arrow Keys CLASSIC KEY PAD ni XX XXX XX REV A Classic SL owner s manual continued CLASSIC SL MENU MAP MidNite Solar Inc AUX MENU Aux 1 Manual Off Manual On SOC High Les s Ie 8 Delay Lisa Off Trip High Fan Low Volts FL Vent Fan High 8 Vots Float Low Float High Day Light Nite Light Toggle Test L VOnLow Delay Mt Lo V OnHigh To Hold Waste Not Low Le V Low V High Y K 2 Delay To Aux 2 on next page AUX 1 CONTINUED nis 2of4 MODE MENU ON OFF ON OFF Function Legacy P amp O L B interval Minutes Depth Watts Solar L 8 interval Minutes AUX 1 CONTINUED Waste Not High L High Te Delay Low Bat Discon B L High T Hold Diverson
20. dards Connect the DC source and Battery wire to the Classic Connect any communications cables or auxiliary input output wires lt 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 VO
21. elow Push the Main Menu button repeatedly until Charge is highlighted Scroll left or right to highlight MISC and push the Enter button Scroll to Time and push Enter Now scroll left or right to highlight the data you want to manually change Use the up and down buttons to change the data When you have all the data changed push the Enter button to save the changes The Classic includes a battery CR1216 in the MNGP portion to keep the time running even when the power is disconnected To replace the battery refer to the Installation Manual 24 Page XX XXX XX REV A Classic SL owner s manual continued Uploading New Firmware to the Classic The Classic has the ability to have its firmware updated with a standard USB cable and a Windows based PC The USB cable is Standard to Mini B Please see www midnitesolar com and click on the Software tab for the firmware and instructions Due to the various different Windows configurations we will not go into detail in the Classic Manual The Firmware upgrade is fail safe so if the wrong code is installed the Classic simply says Wrong code prompting you to load the correct code Also if the upload is interrupted for whatever reason simply start over WARNING The Classic s USB port is NOT isolated from battery negative This is typically only an issue on positive ground systems or systems with a tripped ground fault protection device Care must be taken that a computer connected
22. erenced to battery negative that can complete a short circuit of the battery bank These items include but are not limited to the USB Cable and RS232 serial data lines 19 Page XX XXX XX REV A Classic SL owner s manual continued DC GFP Ground Fault Protection The Classic has internal ground fault protection GFP built in Since 2008 the NEC 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 grounding jumper is installed in a Classic 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 In a network with multiple Classics connected in Follow Me only one Classic should have its internal grounding jumper installed and all should have GFP enabled 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 Positive ground or an ungrounded DC system Figure 11 Figure 12 The Ground fault device is simple to understand and use It detects a fault between battery PV negative and earth ground just like the breaker DC GFP system The difference with the Classic is that it turns off the charge ability and sounds a loud warning when a ground fault is detected The Classic s system consists of a PTC that is be
23. her 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 y
24. hlighted use the up or down arrow to change it to ON and press Enter Press the Status button once to return to the main status screen Adjusting Absorb Equalize and Float Voltages The table below describes the default preset voltages for the different nominal battery voltages This means that if you set the Classic from the QUICK START to a different battery voltage the Classic will take the default voltage set points Note If you manually adjust the absorb float or equalize voltage set points and then nominal battery voltage is changed to a different nominal voltage e g from 24v to 12v or to 48 etc manual adjustments may be required 8301 2 12v 24v 36v 48v 60v 72 Voltage Bulk MPPT 14 3v 28 6v 42 9 57 2 71 5 85 8 Float 13 6v 27 2 40 8v 54 4v 68 0v 81 6v Equalize 14 3 28 6v 42 9v 572v 71 5V 85 8v Table 4 To adjust these voltage set points follow these steps Absorb Equalize and Float voltages are fully adjustable You will need to get the actual voltages from the 22 Page XX XXX XX REV A Classic SL owner s manual continued battery manufacturer To adjust these voltages follow the steps below Press Main Menu to enter the Main Menu Scroll right or left until Charge is highlighted and push the Enter button Highlight Volts and press the Enter button Use left and right arrow keys to highlight the set point voltage to adjust Use up and down arrow key
25. mal 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 16 Page XX XXX XX REV A Classic SL owner s manual continued 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 thi
26. 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 13 Page XX XXX XX REV A Classic SL owner s manual continued CLASSIC WIRING FLOW DIAGRAM REVB 10 3 14 a AAAAAAA 31 Diagram 1 14 Page XX XXX XX REV A Classic SL owner s manual continued 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
27. osz 218520 082 215580 097 218500 002 215520 002 218580 ooz 218520 002 DISSED 007 asse 008 215520 002 218580 002 218580 008 215520 002 218580 002 218580 008 21852 002 218589 002 218580 008 21858 ooz 215520 081 218580 OS 215520 091 218580 OSL 218580 OS 218520 091 218880 OSL 2185817 OS 215520 091 218580 OG 215500 OS 218520 OS 218520 081 218587 OS 21850 05 218520 1900VL Table 7 Classic SL owner s manual continued CLASSIC SL MENU MAP MidNite Solar Inc Classic SL Menu Items Status Charge Mode Aux Misc Logs Tweaks and Temps STATUS MENU Main Status One KWH IN Main Status Two Ahr IN BAT Main Status Three VOC V Amps IN BAT Whizbang Junior Shunt B Capacity gt I D Lifetime AH Reading Short Term History Power w 00 00 Log Moon Scope Vin V Battery About Classic Software Version Nominal Battery V Classic Version R Symbolizes pushing the Right Soft Key D Symbolizes pushing the Left Soft Key WARNING Tho Classic s USB port is NOT isolated from battery negative This is typically only an issue on positive ground systems or systems with a tripped ground fault protection device Caro must be taken that a computer connected to the Classic s USB port is either isolated from ground and the Classic s negative or that the computer s USB negative is common with the Classic s negative and ground www midnitesolar
28. ou 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 7 Page XX XXX XX REV A Classic SL owner s manual continued 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 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 customerservice midnitesolar com 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 no
29. re to Factory Default follow these steps to initiate a Quick Set With the power off to the Classic Hold the left and right arrow buttons down Turn the power on to the Classic and continue to hold the arrow buttons until the setup screen is displayed Answer the questions on the next few screens to complete the Quick Set Equalization To do a manual Equalization charge go into the Charge menu and highlight EQ and press Enter Now EQ Stopped will be highlighted Scroll up to select Eq Started Press the Status button to return to the home screen To stop a manual EQ in progress simply reverse the steps above A manual EQ when started will last for that day Battery Charge Stages and Meanings Bulk MPPT This stage of the Classic means that the Classic will be putting out as much current as it can to raise the battery voltage to the absorb voltage set point This is also known as Constant Current Mode Absorb This stage means that the Classic will maintain the Absorb set point voltage until the batteries are charged This stage is terminated at the end of the Absorb time or the End Amps set point whichever is reached first At this stage the Classic is not putting out maximum current as that would increase the battery voltage over the Absorb set point This is also referred to as Constant Voltage Mode The absorb time is proportional to the bulk time i e the time bulk takes to reach the absorb voltage
30. rers 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 17 Page XX XXX XX REV A Classic SL owner s manual continued Insert BTS to the jack labeled BATTERY TEMP on the control board 18 Page XX XXX XX REV A Classic SL owner s manual continued Chassis Grounding In all installations the Classic chassis should be connected to ground For systems with a battery breaker sized 60 amps and smaller 10 AWG 6 mm copper is generally sufficient For systems with a battery breaker sized 100 amps and smaller 8 AWG 10 mm copper is required For grounding conductor requirements on your specific installation please consult your local electrical code The chassis rounding terminal is in the upper right corner of the electrical connection compartment Figure 10 DC System Grounding The Classic charge controller is designed to work with Negative Ground Positive Ground or Ungrounded power systems In grounded systems dc negative may be connected to ground either externally or by using the Classic s internal grounding jumper shown on figure 15 on Page 21 The internal grounding jumper should only be installed when the Classic s GFP is enabled In Positive ground or Ungrounded systems the GFP jumper must be removed See Figure 15 Also note that with Positive ground there will be items still ref
31. s 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 A 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 manufactu
32. s 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 3 Page XX XXX XX REV A Classic SL owner s manual continued 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 A WARNING Warnings signs identify conditions or practices that could result in personal injury or loss of life A 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 unles
33. s 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
34. s to lower or raise the voltage Press the Enter button to save the new voltages Current Limit The Classic has a current limit component which interacts with the temperature of the charge controller If the Classic is exposed to extremely hot ambient conditions the output current will be reduced automatically to keep the charge controller safe If the orange LED comes on the MNGP it means that the Classic is in current limit mode If you believe the Classic is not hot and the orange LED is on most likely the current limit set point is too low To check this follow steps below Press Main Menu Highlight the CHARGE menu and press the Enter Button Scroll to LIMITS and press the Enter Button Press the right arrow key to highlight the Out Amps column Use the up and down arrow keys to change the current limit then press the Enter Button to save this data Calibrating Battery and PV Voltage To calibrate the Classic battery and PV voltage reading you will need a Volt meter to check the actual battery bank voltage or input PV voltage Using the volt meter measure the voltage on the DC terminal connector of the Classic refer to Screenshot 1 compare this reading to the reading on the Status screen in the Classic press Status if not in this screen To adjust the reading of the Classic to the one in the volt meter follow these steps Press Main Menu scroll to TWEAKS and press Enter Highlight VBatt and use the up and down arrow keys to ma
35. t 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 9 Page XX XXX XX REV A Classic SL owner s manual continued 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 A Charge controller bracket mounted to the E Panel The bracket comes with every E Panel 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 10 Page XX XXX XX REV A Classic SL o
36. t 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 8 Page XX XXX XX REV A Classic SL owner s manual continued 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 uprigh
37. tch both of the readings Press the Enter button to save Note Use the description below to help complete the calibration of the Classic voltages TWEAKS screen Battery voltage adjust Input voltage adjust Input voltage _ attery voltage offset offset 12 6 VOLTS 0 0 B Displayed MASTER Ha Displayed Input battery voltage Screenshot 1 voltage Configuring DC Input Source To select the Mode the Classic will run in follow the steps below Push the Main Menu button Scroll left or right until Mode is highlighted and then push the Enter button 23 Page XX XXX XX REV A Classic SL owner s manual continued Scroll to the right and highlight the current Mode than use the up and down arrows to set the mode you want lt Take note of the Right soft key most modes have some set points that can be adjusted Press the Main Menu button until you get back to the Mode Menu Set the ON OFF to ON and press Enter The following Modes will appear in this order in the MODE Menu Solar This is the default mode for PV systems and has a very fast sweep typically 1 2 second or less that will re sweep at user adjustable sweep intervals unless the Classic finds that it needs to do a sweep on its own because of changing conditions The timed sweep interval is user adjustable and is in units of minutes SOLAR mode is typically best for PV systems especially if there is partial shading at times
38. ter the flashing stops power down the classic and remove 1 1 and JP4 and stow them back on a single pin like they where Step 6 Put the front cover on and power up the Classic Lite If you have the MNLP set to Custom you will need to go to the local app and reset the battery voltage and setpoints etc Table 5 Electrical Specifications Classic150 SL Classic200 SL Classic250 SL Operating Volts in 150VDC 200VDC 250VDC Max Hyper VOC 150 battery 250 battery Battery Charge Volts 12 93 volts 12 93 volts 0 Absolute Current Dd Output at 25 C 48v haler De rate current B ameres at 40 C Environment Dimensions of Classic Dimensions of Box Shipping Weight NOTE Current output ratings were measured with 75 of the PV array s VOC Open Circuit Voltage NOTE Calculated by adding battery voltage to the maximum input operating voltage 48V battery max NOTE Measurement Accuracies 0 12v offset calibration adjustment maybe necessary Table 6 26 XX XXX XX REV A Classic SL owner s manual continued Specifications Mechanical Figure 13 27 Page XX XXX XX REV A Classic SL owner s manual continued Classic Breaker sizing ey pue Jayeeug Indu o sejdde osje e oqe I0 2CI Ajayes 9 95 ambaa jou op pue eK 95001 40 pae siayeaug Jejog PIN ss Jeueg 3 PNPIN e M DGZ PEYI SIY uo peseq SI HEYD SIUL
39. tween the Negative and Ground internally in the Classic A PTC is basically a self healing fuse that will open when current exceeds its rating and reclose when current is dropped below its rating The Classic will monitor this PTC and disable the charging when it senses it go open When the fault is cleared the Classic will restore charging To disable the internal Ground Fault Protection function the jumper labeled GFP needs to be removed and the GFP function needs to be disabled in the TWEAKS menu See Disabling GFP for instructions To reset the internal GFP function after detection has occurred fix the actual ground fault then turn OFF the Classic and turn it back ON Do this by turning the external battery breaker to OFF position and then to ON position 20 Page XX XXX XX REV A Classic SL owner s manual continued Disabling GFP The GFP feature should only be disabled to operate the Classic in an ungrounded power system or in systems where GFP is not required Press Main Menu Scroll to the right or left until TWEAKS is highlighted and press ENTER In TWEAKS press the right soft key to get to the MORE menu In MORE scroll until GFP is highlighted Use the up and down arrow keys to toggle between on and off Press ENTER to save VVVVVV Commissioning the Classic SL Quick Start The Classic will enter into the Quick Set screens upon initial power up If the Classic does not enter into the quick set or you want to resto
40. ure compensation info Tweaks This menu has all the advanced adjustments for the Classic For example Voltage off set adjustments etc VBatt Battery voltage measured at the battery terminals of the Classic VOC Open Circuit Voltage unloaded voltage measurement Input voltage measured at the input terminals of the Classic 34 Page XX XXX XX REV A
41. version modes are holding the battery voltage just below the actual set point Equalize Constant voltage charge stage to equalize the batteries The controller is regulating so maximum power will not be seen at this time The Equalize timer is also counting down to the switch to Float EQ MPPT Maximum current charge stage The Classic is trying to bring the batteries to the Equalize voltage set point We are basically putting all available power into the batteries Float Constant voltage charge stage with a lower voltage than the Absorb charge point The controller is regulating so maximum power will not be seen at this time Float MPPT Maximum current charge stage The Classic is trying to bring the batteries to the Float voltage set point We are basically putting all available power into the batteries FLT Float mode By using the up arrow in Tweaks under FLT you can force the Classic into Float mode GF Ground Fault See page 20 for more info on ground fault protection Got Comm Indicates a lack of communication between the display and the Classic Consult Troubleshooting for information page 25 Insomnia This when enabled will keep the Classic from going to Resting This is intended for hydro mode only where you may need time to open water valves and do not want to wait for the Classic to wake up LED MODE This selection lets you pick the function of the 6 visible LEDs on a standard Classic LMX LoMax This
42. wner s manual continued 13535 Figure 6 14 905 Install locknut here to act as a spacer 0 989 Wiring the Classic SL AN WARNING Shock hazard Disconnect the batteries and input power before opening the Classic front cover ALWAYS use proper Over current devices and disconnects the PV and Battery at the Classic MidNite DC breakers work well for both 11 Page XX XXX XX REV A Classic SL owner s manual continued 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 shoule 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 stan
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