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Excel 1 48 volt Owner Manual

1. Note These wire sizes have been engineered to provide optimum rotor loading for the BWC EXCEL 1 48 wind turbine Deviation from these recommendations can result in decreased performance from your machine and or unnecessary additional wire run costs The use of a wire gage one size larger than the recommended size is recommended if aluminum wire is used Before assembling the wind turbine the tower wiring must be in place though not necessarily permanent ly affixed We recommend that you leave at least 30 cm 12 in of free wire at the top of the tower for making the electrical connections to the wind turbine E Other System Components A complete remote power system will include other electrical components such as a solar array optional a battery bank required a dump load optional and an inverter optional These components are sometimes called the balance of system or BOS equipment The wind turbine and the other BOS equipment are electrically connected a DC bus architecture as shown in Figure 4 The DC bus architecture is robust and very flexible allowing endless options for mul tiple and differing components The unifying feature is that all of these components are electrically con nected to the positive and negative DC bus so they all experience the same DC voltage The DC voltage of the system is largely determined by the state of charge of the battery bank and to a lesser but
2. 27 Egua Zere 27 Adjusting Absorb Equalize and Float Voliagesasusnietenpesr 27 dpud Cels ES esser is ue xus Essa pq Daal st eu am G cus D Nu es ums aa uM 27 Battery Temperature CODES DOT nee a UE 27 Calibrating Battery and PV sep re oe eR e PES osea poe 27 DC Input SODEPE AER VS 28 Configuring the Classic for Wind Input So rce ie eese entre tota proe tesa sett poke eH VP Voto o PER ir 30 vog M O 30 Setting Che Date 30 Settimo Lougibude and Ue ys NER KI EE 30 Configuring 31 AM UM 35 Aux 2 Function Tpit M 36 Setting the MNGP features Access the Version of software and Restore factory defaults 36 MCI D 37 Navigating the MEG S eae cd cette Bere idit eR pad 37 Viewi
3. 29 ino ino A OVAOSY UA 1OHLNOO ANIGHNL SALON SISSVHO MV 1OS SLINGIN WV 769 ATOILYV O3N 04 WdAN 3ONVQOOOV NI GATIVLSNI 38 TIVHS LNAWdINOA L ASVE SHuooaino 1 pr V vI OVAOBL WSL ge INIJYNL ANIM 8t L71X SHONVLSIO SNOILVYNSISNOO S3HLO 304 TWANVW NOLLVTTV LSNI FHL OL X343 LHOI3H 1 lt 1334 00 OL 081 N33ML38 SNNY IAIM 9MVOLE X MidNite Solar Classic Owner s Manual Viipl ire L SEE XE This Manual covers models Classic 150 200 250 amp 250KS 1 Page 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 Note The Classic KS has not been evaluated by ETL Notice of Copyright MidNite Solar s Classic charge controller User s Manual Copyright 2010 all rights reserved MidNite Solar Inc reserves the right to revise this document and to periodically make changes to the content hereof without obligation or organization of such revisions
4. tute that installed divers vin vindon Vide Uae e jou celu een sae dade to windows Update lor drivers Hardware Profiles D dien a PE ENIM naan chen M conligushions Hardware Profiles 52 26 In the Device Manager expand the tree branch labeled Ports COM amp LPT1 Right click on USB CDC serial port emulation COMxx and select Properties Fie Action View Heb DMFS Disk drives Display adapters i DVD CD ROM drives ATA ATA controllers TEEE 1394 Bus host controllers Keyboards gt 7 Mice and other pointing devices Modems d Poets COM amp LPT 9 Coenurications Port COMI USB CDC serial port emulation COM6 Properties 53 Page 28 In the Port number drop down selection box select 8 and press to exit that window Advanced Settings for COMB Use FIFO buffers requires 16550 compatible UART Select lower settings to correct connection problems Select higher settings for faster performance Receive Butler Low 2 4 Transmit Butler Low 1 29 Click on the USB CDC serial port emulation COMS Properties to save changes Now close the Device Manager click on System Properties and then close the Control Pan el Uploading Classic Firmware 30 Turn OFF the battery br
5. 5 After saving the MidNiteSolarSetup 3 4 2011 file double click on it to start the installation Desktop view Favorites Tools 28 Name 1 31 12 2011 Current Linites Fixed 1 17 2011 1 12 2011_ S C Mario ca bite serva Cim Search amp Destroy 15 3 Windows Explorer 6 The Software License Agreement dialog box will appear Click Yes to except the terms Please read the following License Agreement Press the PAGE DOWN key to see the test of the soreement All files in this are copynght protected material Unautheazed or distnbution it prohibited None of the files in this installation may be altered or reverse engineered The same apples to installed copies of these fles Release of Liability UNLESS SPECIFICALLY AGREED TO IN WRITING MidNite Solar Inc MAKES NO WARRANTY AS TO THE ACCURACY SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN 175 MANUALS OR OTHER DOCUMENTATION 6 ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES NNNM PO Setup will close To proceed with the installation you have to accept this agreement 7 Inthe Select Program Folder dialog box make sure that MidNiteSolar is in the Program Folder field and then click Next 43 Page Setup will add program icons to the Program Folder
6. and push the Enter button 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 in the MNGP portion to keep the time running even when the power is disconnected To replace the battery refer to the Installation Manual Setting Longitude and Latitude With the built in virtual map you are able to select where you are in the world For a more precise setting you can manually enter the longitude and latitude coordinates geographic location is important because it 30 Page helps determine when the Classic wakes up and when it goes to sleep This setting tells the Classic when sunrise and sunset are to happen The Classic will use this information on future features also To set longitude and latitude coordinates you need to go thought the WIZARD that is the only way to gain access of this feature Configuring Auxiliary Input Output The Classic includes two auxiliary ports which can be configured to become inputs or outputs These aux ports can be used as a secondary power supply to be used for accessories such as vent fan anemometer and generator starter or even and anemometer The Aux output is limited to 200ma or less per channel These aux ports if used correctly could extend the system life Here is an explanation of how they work gt An internal re settable
7. 4 Remove the spinner Check the torque on the blade nuts the torque value is 45 ft Ibs Check the front bearing cover for seal integrity and grease loss Check the alternator bearings for lack of play a tiny amount of play is acceptable and normal if it appears excessive pop the front bearing cover off This will expose the bearing adjustment nut Remove the cotter pin and tighten the nut to just snug DO NOT USE A WRENCH if the cotter pin will go through one of the two holes in the alternator shaft then push it through if not BACK THE NUT OFF CCW until a cotter pin will go through Replace the front bearing cover Reattach the spinner and check that it is secure 5 Check the screws holding the nacelle rubber bumpers and tail fin in place 6 Check the cotter pins on the tail pivot pin 7 Check the torque on the tower mounting bolts the recommended value is 45 ft lbs 8 Check for cracks or loose hardware on the tail boom and fin 9 While descending the tower or before raising it inspect the following A Check that the tower wiring is properly secure B Check all tower fasteners C Look for any cracks in the tower structure D Check the condition of the guy wire attachments 18 10 Check the connection on all ground rods and hardware 11 Inspect the surge arrestor s Replace if there are signs of damage 12 Restart the turbine 13 Listen to the sound of the machine as it speeds up No mechanical sounds such as a
8. 63 Page Base Registers Address R W Name Conversion Notes 4101 R UNIT_ID PCB revision 4101 msg The PCB revision is a value Unit Type 4101 between 0 and 255 indicating the hardware revision of the PC board The Unit Type is an integer value indicating the voltage category of the Classic See Table 4101 1 4102 R UNIT SW DATE RO Year 4102 Software Build date 4103 Month 4103 msp Day 4 1 03 5 4104 R UNIT SerialNumber 4105 lt lt 16 4104 The serial number of the unit as 4105 appears on the label 4106 R UNIT MAC AddressI 4108 4108 1 58 The unit s Ethernet MAC 4107 4107 4107 rsn address 4108 4106 4106 4109 R UNIT IP Address 4110 uss 4110 15 The Unit s TCP IP Address 4110 41091 lt 4109 4111 UNIT Device ID 4112 16 4111 The device ID of the unit 4112 4113 RESERVED Do NOT Write 4114 R RestartTimerms 4114 Mili Seconds Time after which the Classic can wake up countdown 4115 R dispavgV batt 4115 10 Volts Average Battery Voltage 4116 R dispavgVpv 4116 10 Volts Average PV terminal input Voltage 4117 R IbattDisplaySi_mbus 4117 10 Amps Average Battery Current 4118 R kWhoursAdj 4118 10 kWh Average Energy to the Battery This is reset once per day 4119 R Watts 4119 10 Watts Average Power to the Battery 4120 R mbComboChrgStge Charge Stage 4120 msp_ See Table
9. LII Misc I Logs Tweaks Temps Net Solar Wind Hydro Volts L Quickset Right Soft Key ChgTime L View Right Soft Key T Comp L View Right Soft Key EQ EndAmps Limits Solar L Setup Right Soft Key Wind Track L Graph Right Soft Key Hydro Slow Track LL Setup Right Soft Key U Set VOC 96 E MPPV 96 Right Soft Key Aux 1 Aux 2 Led Mode Time Audio Volume Play Display Version Backlight Contrast Comm Dflts LL Password L Dealer Message More L Arc Adj Next L Advanced
10. 10 Volts Aux 1 Absolute High Voltage Threshold 4173 R W Aux2VoltsHiAbs 4173 10 Volts Aux 2 Absolute High Voltage Threshold 4174 R W AuxlVoltsLoRel Relative to 4174 10 Volts Aux 1 Relative Lower charge stage set point V Voltage Threshold Charge Stage Rel 4175 R W Aux1VoltsHiRel Relative to 4175 10 Volts Aux 1 Relative Upper charge stage set point V Voltage Threshold Charge Stage Rel 4176 R W Aux2VoltsLoRel Relative to 4176 10 Volts Aux 2 Relative Lower charge stage set point V Voltage Threshold Charge Stage Rel 4177 R W Aux2VoltsHiRel Relative to 4177 10 Volts Aux 2 Relative Upper charge stage set point V Voltage Threshold Charge Stage Rel 4178 R W Aux1VoltsLoPv absolute 4178 10 Volts Aux Lower PV Voltage Threshold 67 Page Address R W Name Conversion Notes 4179 R W Aux1VoltsHiPv absolute 4179 10 Volts Aux 1 High PV Voltage Threshold 4180 RESERVED Do NOT Write 4181 R W Aux2VoltsHiPv absolute 4181 10 Volts Aux 2 High PV Voltage Threshold 4182 RESERVED Do NOT Write 4183 ArcFaultSenstvty Time 4183 Arc Fault Protection Sense 4183 sensitivity response adjustments 4184 4185 RESERVED Do NOT Write 4186 4187 R W Enable Flags bits 4187 See Table 4187 1 4188 R W RESERVED 4188 RESERVED Do NOT Write 4189 R W O
11. 10 Volts Last Voc rea dins 4232 42 2 RESERVED Do NOT Write 4234 4235 4236 R W AbsorbTime 4236 seconds Absorb Time Counter DUP 4237 R W AntiClickSenstvty 4237 Best Left Alone 4238 SiestaTime 4238 seconds Sleep timer 4239 SiestaAbortVocA dj 4239 10 Volts Volts above last Voc reading to abort Siesta 4240 R flagsRD 4241 lt lt 16 4240 Internal Flags See Table 4241 4240 1 4242 4243 RESERVED Do NOT Write 4244 R VbattRegSetPTmpComp 42441 10 Volts Temperature compensated battery regulation target voltage 4245 R W VbattNominal 4245 12 1 thru 10 Nominal Battery bank 120 Max for 250 KS voltage 1 e 12V 24V etc 4246 R W EndingAmps 4246 10 Amps Goes to Float below this Batt I 4247 EndingSoc 4248 EndAmpSocMBaddress 4249 R W Rebulk Volts 4249 10 Volts Rebulks if battery drops below this for gt 90 Seconds 70 Page 4250 R BattMon Volts Address R W Name Conversion Notes 4251 R BattMonSOC 4252 R BattMonAmps 4253 R BattMonAHefficiency 4254 4255 RESERVED Do NOT Write 4256 4257 R W RebulkTimerSec 4257 seconds Rebulk interval timer Cleared if Vbatt gt Rebulk V 4258 4259 4260 RESERVED Do NOT Write 4261 4262 4263 4264 Voc Qualify Timer 1ms 4265 lt lt 16 4264 Timer msec qualifying time 4265 msec till turn on valid
12. 11 Figure 6 Tail Fin 12 Figure 7 Blade and Spinner Fasteners 4 1010 13 Figure 8 Nut Tightening Order 4240 00 13 Figure 9 Boom Attachment sessssssssssssssesseseeeee ener ener 14 Table of Tables Table 1 Variation in wind speed and expected relative energy output with tower height 25 Table 2 Recommended Wire Sizes for the EXCEL 1 28 1 Overview The BWC EXCEL 1 48 wind turbine system is a state of the art small generator designed to charge bat teries and supply electrical loads in a 48 VDC power system When used in conjunction with a suitable sine wave DC AC inverter and a 48 VDC battery bank the EXCEL 1 48 can also be connected to the power grid The EXCEL 1 48 turbine consists of an 8 2 75 Ib wind turbine rated at 1 000 watts and the Midnite Solar Classic controller The EXCEL 1 48 wind turbine features superior low wind speed performance very high system efficien Cy and low noise The BWC EXCEL 1 48 is offered with the optional guyed tubular Tilt Tower which comes in heights from 60 to 100 The Tilt Tower is shown in Figure 1 For installation procedures on this tower please refer to the BWC EXCEL 1 Tilt Tower Installation Manual This manual is available on line at ht
13. 48 60v 72v 25 Page DO YOU KNOW THE BATTERY BANK AMP HR Helps set Absorption time and EQ defaults CAPACITY YES NO WHAT IS THE VOLTAGE This is necessary for the set up software to help OF AN INDIVIDUAL figure out battery capacity BATTERY 6 SET CURRENT LIMIT Sets classic s max output current 80 ENTER TO CONTINUE CONTROLLER MODE Selects classic s mode This can be changed in SOLAR WIND HYDRO the mode menu SCROLL gt TO SELECT THEN PUSH ENTER STC Photovoltaic module power rating MODULE POWER 210 WATTS STC Photovoltaic module voltage rating VOC RATING 44 34 VOLTS STC Photovoltaic module current rating ISC RATING Setting Nominal Battery voltage Upon initialization the Classic will display battery To set up the Classic to a preset battery voltages e g 12v 24v 48 follow the steps below Press Main Menu Scroll to the left until Charge is highlighted and push the Enter button Highlight Volts and press the Enter button Press the Right soft key Scroll up and down to select the desirable battery voltage 9 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 trying to charge the batteries 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 poin
14. Noise data is occasionally required and will soon be available for the EXCEL 1 from Bergey Windpower Co If your property size is several acres or more then the turbine will likely be so far from the nearest neigh bor s house that they will not be bothered It is none the less strongly recommended that you contact your nearest neighbors well in advance of any construction to let them know that you are installing a wind turbine This is doubly good advice if your property size is less than several acres or you have to obtain a variance for a building permit Good neighbor relations boil down to treating your neighbors the same 24 way you would like to be treated and showing respect for their views An example of what not to do is to put the turbine on your property line so that it is closer to a neighbor s house than to your own and not give those neighbors any advance notice of your intentions In general we do not recommend that a BWC EXCEL 1 be installed on property of less than one half acre in size We say this because the impact of a wind turbine on the neighbors in such a tight area is significant and the potential for disputes is too great If you have questions about procedures requirements or tactics please contact us Since so few wind systems have been installed and communities are generally unfamiliar with them you may face some obstacles in gaining permission to install a unit We appreciate the pioneering spirit and resolve
15. Shift the value x binary digits to the left This is equivalent to multiplying the decimal number by 2 Ex 4116 0x0001 Then 4116 lt lt 1 0x0002 Binary shift right Shift the value x binary digits to the right This is equivalent to dividing the decimal number by 27 4116 0x0002 Then 4116 gt gt 1 0x0001 OR two numbers together aligned to LSB gt amp AND two numbers together aligned to LSB XOR two numbers together aligned to LSB String Concatenate 4116 0x4142 4116 mss 4116 15 gt 0x41 0x42 gt A gt AB Examples Using the example of the Average PV Voltage register dispavgVpv 4116 Suppose using a MODBUS scanner you retrieve the following integer value from the dispavgVpv register at address 4116 4116 1201 e The address itself 4116 Full 16 bit value at the address 4116 1201 0x04B1 hex The top most MSB octet of the register 4116 msp 0x04 hex The bottom most LSB octet of the register 4116 0xB1 hex Applying the Conversion 4116 10 Volts o 4116 1201 o 1201 10 120 1 Volts File Transfer and Function Execution modes Coming soon next revision of this document will be information on how to use the MODBUS File Transfer and Function execution commands File Transfer will be necessary for instance to transfer wind power curves to from the Classic or logging and audio data to from the Classic and or MNGP
16. To check this follow steps bellow e 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 Out Amps column Use the up and down arrow keys to change the current limit then press the Enter Button to save this data 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 01489 The breaker between the DC source and the Classic must conform to UL1077 UL489 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 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 Ty
17. clunking or banging should be heard Also watch for any new or significant vibration Some growling from the alternator is normal The turbine operation should be smooth 14 Inspect the wire run particularly all electrical connections 15 Check condition of all wiring connections into and out of the charge controller Preventive Maintenance The Bergey EXCEL 1 turbine and tower should be inspected 30 days after installation and then again 180 days after installation Following these two inspections the installation should be inspected every two years and after any partic ularly severe weather Inspections should be done on days when the wind is below 16 mph Check List for Inspections 1 Inspect the blades for A Cracks outboard of the hub pad in the blade pultrusion itself Cracks in the molded hub pad are normal after a few weeks of operation and will not affect the strength or reliability of the blade B Leading or trailing edge damage C Condition of the paint 2 Checkthe torque on the blade nuts the recommended value is 45 ft Ibs Check the bearings for seal integrity and grease loss e Inspect the mainframe for cracks 4 Check for cracks or loose hardware on the tail boom bushings and fin 5 Check the tail pivot pin and particularly its fasteners 6 Check the connection on all ground rods and hardware 7 Remove the alternator shorting connection Check the disconnect switch 8 Inspect the wire
18. 104 ft The Tilt Tower is cost effective and is designed to be installable by non experts The installa tion of these towers is covered in the BWC EXCEL 1 Tilt Tower Installation Manual BWC is working to expand the range of tower options including self supporting towers that do not require guy wires Customers can also supply their own towers These towers have to meet certain criteria for strength and blade clearance see Appendix and a mounting adapter for the EXCEL 1 wind turbine will need to be designed and fabricated Customer supplied towers are not covered by the BWC warranty and any dam age to the EXCEL 1 wind turbine resulting from a customer supplied tower is excluded from the turbine warranty coverage C Location The size and layout of the installation site may limit the tower location height or type More often than not however there are several potential sites In choosing the best one the following factors should be considered 1 The proximity of the proposed site to dwellings As noted before it is a good idea for you to consult with neighbors about the installation before proceed ing The rotor system and alternator do produce a certain amount of sound This is a low level whirring sound that usually can not be heard indoors From a noise standpoint the further the wind turbine is from a house the better In general we recommend that the turbine be installed at least 60 from the house Most often the tower is in
19. 4120 1 for battery State 4120 charge state See Table 4120 2 for State 4121 R PvInputCurrent 4121 10 Amps Average PV terminal input Current 4122 R VocLastMeasured 4122 10 Volts Last measured open circuit Voltage at the PV terminal input 64 Page Address R W Name Conversion Notes 4123 RESERVED 4124 R MatchPointShadow 4124 Instantaneous value of Wind curve being used Values 1 16 4125 R AmpHours 4125 10 Amp Hour Daily Amp Hours reset once per day 4126 R TotalkWhours 4127 lt lt 16 4126 Lifetime Energy Generation 4127 kWh 4128 R TotalAmpHours 4129 lt lt 16 4128 Lifetime Amp Hour Generation 4129 Amp Hours 4130 R InfoFlagsBits 4131 lt lt 16 4130 See Table 4130 1 4131 4132 R BATTtemperature 4132 10 C F Temperature measured at the external Battery Temperature Sensor if installed else 25C 4133 R FETtemperature 4133 10 C F Temperature of PWM FETs 4134 R PCBTemperature 4134 10 C F Temperature of the Classic Control top PCB 4135 NiteMinutesNoPwr 4135 minutes Nighttime Check 4136 4137 RESERVED Do NOT Write 4138 R TimeMinutesFloatToday 4138 minutes Number of minutes that the Batteries have spent in float today Reset next AM 4139 R W AbsorbTime 4139 seconds Absorb Time Up Down Counter 4140 R DaysSinceLastFloat
20. 4156 R W Minimum Battery 4155 10 Volts Lowest Charge Voltage is Temperature Compensation limited to this value when Voltage battery temp sensor installed 4157 R W Temp Comp Value 4157 10 mV degree Absolute value of the for each 2V cell C cell 0 5 mV steps 0 to 10 Temperature Compensation mV per 2V cell Value in mV C 2V cell 4158 R W Battery Type 4158 Type of Batteries See Table 4158 1 unimplemented as of May 2011 4159 RESERVED 4160 W Force Flag Bits 4161 lt lt 16 4160 See Table 4160 1 4161 66 Page Address R W Name Conversion Notes 4162 R W Equalize Time 4162 Seconds Initialize Time for Batteries to remain in Equalize Stage 4163 R W Equalize Interval Days 4163 Days Number of days between Equalize Stages Auto EQ 4164 R W Mppt Mode Solar Wind 4164 bit 0 On Off Maximum Power Point etc Mode See Table 4164 1 4165 Aux and 2 Function 4165 Combined Aux 1 amp 2 Functions On Off See Table 4208 4166 R W Aux VoltsLoAbs 4166 10 Volts Aux 1 Absolute Low Threshold Voltage 4167 Aux1DelayT 4167 Milli Seconds Aux Delay time before Asserting 4168 R W Aux1HoldT 4168 Milli Seconds Aux 1 Hold time before De asserting 4169 R W Aux2PwmVwidth 4169 10 Volts Voltage range over which PWM operates 4170 4171 RESERVED 4172 Auxl VoltsHiAbs 4172
21. Aux 1 Active Classic Yellow LED Aux 2 Active Classic Blue LED Unimplemented LED 2 Unimplemented LED 3 3 Unimplemented 75 Page Table 4240 1 Internal Flags bits Read Only flagsRD Name Value Description RESERVED 0x00000001 RESERVED RESERVED 0x00000002 RESERVED RESERVED 0x00000004 RESERVED RESERVED 0x00000008 RESERVED RESERVED 0x00000010 RESERVED RESERVED 0x00000020 RESERVED RESERVED 0x00000040 RESERVED AbsorbTimeRunf 0x00000080 Bulk Absorb Timer Counting is Enabled EqTimeRunf 0x00000100 EQualize Timer Run flag FloatTimeRunf 0x00000200 Float Time accumulate flag kWhAccumRunf 0x00000400 kiloWatt hour amp Amp Hour accumulate enabled RESERVED 0x00000800 RESERVED AbsorbCountUpf 0x00001000 Absorb Timer is counting UP if set OK2WriteIVtables 0x00004000 OK to write WindPowerTableV amp I WindLowflag 0x00008000 Indicates that we turned off because of low power SweepDwnEnabledf 0x00010000 Slowly Sweeping Down V input LowLightflag 0x00020000 State 2 detected low light May not be accurate RESERVED 0x00040000 RESERVED RESERVED 0x00080000 RESERVED RESERVED 0x00100000 RESERVED SweepUpEnabledf 0x00200000 Slowly Sweeping UP V input RESERVED 0x00400000 RESERVED RESERVED 0x00800000 RESERVED RESERVED 0x01000000 RESERVED BattFull 0x02000000 Battery Full Absorb c
22. CONTROLLER NOMINAL OPERATING ENVIRONMENT 25 40 DE RATED SEE MANUAL MAX PV VOLTAGE OPERATING 150V CONFORMS TO UL STANDARD 1741 MAX PV CURRENT OPERATING 96A 2ND EDITION MAY 7 1999 MAX PV VOC 150V BATTERY VOLTAGE WITH REVISIONS THROUGH MAX PV SHORT CIRCUIT CURRENT 96A vive ia BATTERY CHARGE CURRENT 96A nterisk CERT TO MAX BATTERY CHARGE VOLTAGE 93V 3084883 S19 022 2 ep J NOMINAL BAT VOLTAGES 12 72V MAX OUTPUT FAULT CURRENT 436A MIDNITE SOLAR CLASSIC 250 MPPT SOLAR WIND HYDRO BUCK BOOST CHARGE CONTROLLER NOMINAL OPERATING ENVIRONMENT 25 C 40 C DE RATED SEE MANUAL MAX PV VOLTAGE OPERATING 15 250V CONFORMS TO UL STANDARD 1741 MAX PV CURRENT OPERATING 62A 2ND EDITION MAY 7 1999 MAX PV VOC 250V BATTERY VOLTAGE pror MAX PV SHORT CIRCUIT CURRENT 62A See ea MAX BATTERY CHARGE CURRENT 62A intertek EET PANTER MAX BATTERY CHARGE VOLTAGE 93V 3084883 No 107120010901 J NOMINAL BAT VOLTAGES 12 72V MAX OUTPUT FAULT CURRENT 436A erza exe erm Wd em A dU AUX OUTPUT 1 13VDC 200mA RECONFIGURABLE AS 3 3VDC AUX INPUT AUX OUTPUT 2 500mA RELAY DRY CONTACT RECONFIGURABLE AS 13VDC 200mA OUTPUT MINIMUM INTERRUPT RATING 4000 AMPS DC FOR OVERCURRENT PROTECTION DEVICE TORQUE TERMINAL BLOCK AND GND TERMINAL TO 35 IN LBS 4Nm SUITABLE FOR USE WITH 75 C MINIMUM RATED COPPER CONDUCTORS THIS DEVICE IS PROVIDED WITH AN INTEGRAL PV DC GROUND FAULT INTERRUPTER IF TH
23. Ested below You may type a new folder name of select one from the existing Folders list Click Next to continue Program Folder 8 The Start Copying Files dialog box will appear click Next Files will begin to install on your computer Setup has enough information to start copying the program files If you want to review or change any settings click Back If you are satisfied with the settings click Next to begin copying files Target Directory MidNiteS olar Program Manager Group MidNiteSolat 9 Inthe Setup Complete dialog box click Finished A new MidNite Solar folder will be placed in your C drive We will refer to this folder in step 20 By default the View Readme check box is checked If you don t want to read the Readme file uncheck this box before clicking the Finish button 44 Page Setup has firsshed instaling Update on your computer Press Finish to ext setup Prepare Classic charge controller for update 10 Now go to your electrical panel and identify the input and output breakers for the Classic Turn them off Wait 3 minutes for the Classic to de energize 11 Remove the four screws holding the front cover of the Classic charge controller Do not let the front cover hang by the cable 45 Page 12 Holding the front cover with one hand place a screw in the top left hole of the front cover and screw it into the top right hole of the back
24. Off Auto On Selection WIND CLIPPER 10 PWM output Active High when V input is above PV input V plus headroom voltage NITE LITE HIGH 11 Active High indicating Night Time Inactive at Wakeup NITE LITE LOW 12 Active Low indicating Night Time Inactive at Wakeup Aux2Function Aux12FunctionS amp 0x3f00 gt gt 8 Digital Analog Input Output Table 4187 1 EnableFlags bits 4187 Name Value Description GroundFaultEn 0x0001 Ground Fault Protection Enabled when Set to 1 ArcFaultEn 0x0002 Arc Fault Protection Enabled when Set to 1 RESERVED 0x0004 RESERVED Do NOT set this bit PvPartialShadeEn 0x0008 Partial Shade reporting Enabled when Set to 1 RESERVED 0x0010 RESERVED Do NOT set this bit DefCon3ErrEn 0x0020 DefCon3 Error reporting enabled if set to 1 DefCon4ErrEn 0x0040 DefCon3 Error reporting enabled if set to 1 PwmLowMaxFlag 0x0080 Low Max Enabled if Set to Low Vin Vout RESERVED 0x0100 RESERVED Do NOT Set to 1 RESERVED 0x0200 RESERVED Do NOT Set to 1 Bump WindI 0x0400 When adjusting wind curve automatically bumps adjacent current set points out of the way if set to 1 DivrsnAbsEqTmrEn 0x0800 Enables Absorb amp EQ timer counting when Aux functions are diverting if set to 1 RESERVED 0x 1000 RESERVED Do NOT Set to 1 RESERVED 0x4000 RESERVED Do NOT Set to 1 RESERVED 0x8000 RESERVED Do NOT Set to 1 78 Page Table 4214 1 Consol
25. Point Tracking Seeking Float set point Voltage Equalize 7 Regulating battery voltage at Equalize Set point HyperVoc 10 Input Voltage is above maximum Classic operating Voltage EqMppt 18 Max Power Point Tracking Seeking Equalize set point Voltage Table 4120 2 Classic States LOWER Byte of mbComboChrgStge register Name Value Description Internal Resting state O 0 Internal state 1 through 6 1 2 3 4 5 6 7 Internal state machine states 72 Page e Table 4130 1 Info Flag Bits READ ONLY Flag Value Description Classic Over Temperature 0x00000001 Classic Over Temperature if set EEPROM error 0x00000002 Classic EEprom read write found an error if set RESERVED 0 00000004 RESERVED Equalize In Progress 0 00000008 Equalize Charge stage Active if set RESERVED 0 00000010 RESERVED RESERVED 0x00000020 RESERVED RESERVED 0 00000040 RESERVED EQ MPPT 0 00000080 Battery V is less than EQ Voltage EQ MPPT In V is Lower Than Out 0x00000100 Input Voltage PV is lower than Vbatt if set Current Limit 0x00000200 User current limit or internal temperature current limt reached HyperVoc 0x00000400 Hyper Voc PV input is between Vmax and Vmax Vbatt RESERVED 0x00000800 RESERVED RESERVED 0x00001000 RESERVED Battery Temp Sensor Installed 0x00002000 Battery temperature sensor installed if set Aux1
26. Primary Address lookup device D2 Secondary DNS Address Secondary Address lookup device optional Web Enables or disables the Classic s online web service feature Access MA MAC Address The hardware or Ethernet address of the Classic DI Device ID The unique MidNite Solar address of the Classic Table 5 1 Net Menu Details DHCP The Classic supports Dynamic Host Configuration Protocol DHCP in which all networking settings are derived from a DHCP enabled router This is the simplest configuration method and recommended unless you explicitly need a statically allocated IP address for your Classic In this mode all other settings are automatically configured and are read only informational with the exception of the Web Access feature e Press Main Menu e Scroll to NET menu and press the Enter button e Highlight and select DCHP 58 Please note that the Classic s DHCP protocol implementation usually takes a few seconds up to a minute to update the network settings If the network settings do not update within a minute please consult the troubleshooting section Static IP The Classic supports static IP address allocation In this mode you can assign the Classic a specific IP address This lets you set up things like port forwarding from your router or for networks with static IP allocations e Press Main Menu e Scroll to NET menu and press the Enter button e Highlight and select STATIC e Using the
27. State On 0x00004000 Aux 1 ON aux 1 connector has V or relay closed Aux2 State On 0x00008000 Aux 2 ON aux 2 connector has V present GroundFaultF 0x00010000 Ground Fault detected if set DefCon4ErrF 0x00020000 FET Drive Error if set lower priority than DefCon3 ArcFaultF 0x00040000 Arc Fault occurred if set NegBatCurrentF 0 00080000 Negative battery current if set DefCon3ErrF 0x00100000 FET error higher priority and DefCon 4 Xtralnfo2DsplayF 0x00200000 Extra info is available to display Shading etc PvPartialShadeF 0x00400000 Partial Shade detected during SOLAR sweep WatchdogResetF 0x00800000 watchdog reset flag indicator for debugging LowBatteryVF 0x01000000 VERY low battery Vbatt is lower than 8 0 Volts StackumperF 0x02000000 Stack Jumper is NOT installed if set EqDoneF 0x04000000 EQFinished Resets when mode changed or new day TempCompShortedF 0x08000000 Indication of shorted Temp Comp if set all fans should come on if this is true LockJumperF 0x 10000000 Lock Jumper is NOT installed if set XtraJumperF 0x20000000 Extra Jumper is NOT installed if set 73 Page Table 4158 1 Battery Type not used yet as of May 2011 Name Value Description Flooded 1 Lead Acid Flooded Gel 2 Lead Acid Gel AGM 3 Lead Acid AGM AGM2 4 Lead Acid AGM2 Lithium 5 Lilon Nicad 6 Nickel Cadmium VRLA 7 AGM AGM or 2 actually AbsolytellP 8 TBD
28. User1 9 TBD Table 4160 1 ForceFlagsBits can write to low or high 16 bits independently if wanted Name Value Description RESERVED 0x00000001 RESERVED Do NOT Set to 1 ForceRstDailyKwHrsF 0x00000002 Reset Daily kWh count ForceEEpromUpdateWriteF 0 00000004 Write all current settings to internal EEPROM ForceEEpromlnitReadF 0x00000008 Reset all values to EEPROM defaults MAY not work yet ForceResetInfoFlags 0x00000010 Force ALL Info Flags to zero when set to 1 Will reset info flags to 0 or course some may pop back to 1 after reset ting if applicable ForceFloatF 0x00000020 Force battery charge stage to Float ForceBulkF 0x00000040 Force new Bulk Absorb charge stage ForceEqualizeF 0x00000080 Force new Equalize stage ForceNiteF 0x00000100 Force a new night time Force25HrDayF 0x00000200 Otherwise it s a 24 Hour day ForcePandOsweepF 0x00000400 Force a Mini Sweep for Legacy P amp O mode ForceSweepF 0x00000800 Force a Sweep at least for U Set RESERVED 0x00001000 RESERVED Do NOT Set to 1 ForceGetTimeF 0x00002000 Set time from MNGP Remote Modbus CTIME RESERVED 0x00004000 RESERVED Do NOT Set to 1 RESERVED 0x00008000 RESERVED Do NOT Set to 1 RESERVED 0x00010000 RESERVED Do NOT Set to 1 RESERVED 0x00020000 RESERVED Do NOT Set to 1 RESERVED 0x00040000 RESERVED Do NOT Set to 1 RESERVED 0x00080000 RESERVED Do NOT Set to 1 RESERVED 0x0
29. 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 battery can produce a short circuit current high enough to weld a ring or the like to metal causing severe burns 7 Page Classic Power Curves 150V Classic Power Graph 96A 1380W 944 2700 4 120V A 110V 2 100v am 90V 70V ERI LU eum 1450190670 5 mol REIN eden Operating Voltage 160V PV 140V 120PV mm 70 Nominal Battery 14 4 Voltage 12V 180V ea 200V 14 4 Nominal Battery Voltage 12V 8 Page Figure 2 1 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 The built in set up wizard also helps select breakers and wire sizes Notice that lower battery voltages and lower PV input voltages result in higher continuous output power The PV voltages listed are for reference and are not intended to be the only PV voltages supported The batt
30. around the top of the tower so that the rotor will face into the wind The slip ring assembly is the electrical connection between the moving as it orients with the wind direc tion wind turbine and the fixed tower wiring The slip rings and yaw bearings are located just above the tower mount The tower mount attaches the EXCEL 1 turbine to the top of the tower D Tail Assembly and AutoFurl Operation The tail assembly composed of a tail boom and the tail fin keeps the powerhead and therefore the ro tor aligned into the wind at wind speeds below approximately 12 5 m s 28 mph At about 12 5 m s the AutoFurl action see Figure 3 turns the rotor away from the wind to limit its speed The tail appears to fold but in reality the tail stays stationary as the powerhead turns sideways to the wind The rotor does not however furl completely sideways This allows the turbine to continue to produce power in high winds When the high winds subside the AutoFurl system automatically restores the turbine to the nor mal straight position E MidNite Solar Classic The MidNite Solar Classic charge controller is used to charge the batteries The owner s manual for the Classic is included in the Appendix 5 SYSTEM OPERATION A Normal Operation The rotor of the BWC EXCEL 1 should begin to rotate when the wind speed reaches approximately 3 m s 7 mph For the first several weeks of operation however the start up wind speed will be highe
31. battery reaches that set point The voltage has to fall 2 tenths of a volt below the set point for 30 seconds before Aux 1 will turn back on Vent Fan High This mode will turn Aux 1 on above the voltage set point you program It allows you to run a vent fan for a battery bank based on battery voltage There is a voltage set point that you set and Aux 1 will turn on when the battery reaches that set point The voltage has to fall 2 tenths of a volt below the set point for 30 seconds before Aux 1 will turn off Float Low This mode will turn Aux 1 off whenever the Classic is in Float Aux 1 will stay off until the Classic falls 3 tenths of a volt below the float voltage set point Float High This mode will turn Aux 1 on whenever the Classic is in Float Aux 1 will stay on until the Classic falls 3 tenths of a volt below the float voltage set point Clipper Control This mode was intended to control the MidNite Clipper It will send out a PWM signal whenever the controller is unloading the turbine because the battery is full or close to it There are no adjustment in this mode the Classic is preprogrammed with the best parameters to control turbine RPM Day Light This mode will turn Aux 1 on at sunrise and turn it off at sunset based on the PV input voltage Nite Light This mode will turn Aux 1 on at sunset and turn it off at sunrise based on the pv input voltage Toggle Test This mode will cycle Aux 1 for 1 second off and 1 second on
32. be surprised if your batteries pop in and out of Absorb stage unexpectedly though Operators Indexing square brackets around an address indicate the value of the register specified 61 Page Iss Arithmetic Logical lt lt XxX 62 Page ex 4116 indicates the value of the register at address 4116 Square brackets followed by an means to use the most significant byte of the register ex if the value at register 4116 is 0x04B1 decimal 1201 4116 0x04B1 4116 0x04 Square brackets followed by an rsg means to use the least significant byte of the register ex if the value at register 4116 is 0 04 1 decimal 1201 4116 0x04B1 then 4116 15 OxBI Parentheses refer to bits within the register For example 4116 0 means Oth bit of the value in register 4116 So if 4116 held the value 1 0x0001 hex then 4116 0 would be a 1 4116 1 15 would all be Os Ellipses represent ranges of values or indices For example to refer to the first three bits of a register you may see 4116 0 3 which signifies the first three bits of the value of register 4116 You may also see spans of registers as 4116 4120 which refer to registers 4116 to 4120 inclusive Add two numbers together Subtract two numbers or negate the value on the right Divide two numbers integer implied Multiply two numbers integer implied Binary shift left
33. d MEO 60 MODBUS Preliminary 60 DISCLAIMER OE vant A 60 iE T NN TO TO TT 61 Dealer Information Sereen Pen 86 Positive Ground dax ida korea 86 Hyper e 86 VOC M Origins T 87 Piceno cer 87 Al information Me 88 SPECHICATIONS PLCCOMCAl m 88 MECHANICAL m 89 Default Battery Charge s t 90 Optional d6COSSOEIGSC ancha ixi sse IVa xU 90 Regulatory Approval csccciscscssvsscccssccssesscenssicssvssseusssesssestecessessonsosstseconsbssenscsessscssesssevedscsessnscsseassodessesassessass 90 Warranty soi PA 91 End or Warranty TANS Ub ao ices 91 Aux land Aus 2 Graphs Jumpers 92 Aux 1l Voltage Time Relation Relay T2N D Mnt Foi Cv
34. demon strated by our customers and we stand ready to help out in any way that we can B Towers The smooth flow of the wind over the land is interrupted by obstructions and topographical variations These interruptions bring about two important phenomena wind shear and turbulence Wind shear describes the fact that close to the ground the wind is slowed down by friction and the influence of obsta cles Thus wind speed is low close to the ground and increases with increasing height above the ground Wind shear is more pronounced over rough terrain and less pronounced over smooth terrain Turbulence is essentially rough air caused by the wind passing over obstructions such as trees buildings or terrain features Turbulent air reduces energy output and puts greater strain on the wind turbine The effects of both wind shear and turbulence diminish with height and can be largely overcome simply by putting the machine sufficiently high above the ground Taller towers usually will provide better eco nomics because the power in the wind increases as the cube of the wind velocity P V e g a 2696 increase in wind speed doubles the energy output A small increase in average wind speed will result in a large increase in long term energy output Table 2 shows the influence that tower height can have on annual energy output for the BWC EXCEL 1 wind turbine under typical DOE Class 2 inland site conditions with a shear exponent of 0 20 Wind speed may
35. go to the next character block Do this until your desired message is complete Press enter to save on the classic memory 9 9 9 Positive Ground systems When installing the Classic in a positive ground systems there are a few extra steps that need to be taken The Ground fault jumper needs to be removed and ground fault needs to be disabled in the menu Refer to page 19 for instructions on doing this The overcurrent protection needs to be done a little different as well The input and output breakers need to be double poles Battery negative and positive conductor both need to be protected Refer to Classic Breaker Sizing Table 6 1 IMPORTANT Do not connect both positive battery and positive PV input to ground One or the other positive normally battery but not both otherwise the Classic input and output will be shorted 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 breaking When the Classic input voltage
36. good abrasion resistance For ground runs we recommend THHN wire buried inside plastic conduit rated for electrical service A suitable watertight junction box should be installed at the base of the tower to en close the wire connections between the tower and underground wiring In some cases it will be possible to provide direct point to point wiring between the EXCEL 1 wind turbine and the charge controller For this purpose we recommend 3 conductor VNTC Vinyl Nylon Tray Cable which is suitable for outdoor and direct burial applications For rocky soils or runs underneath roadways we recommend that the underground wire run be installed in conduit If a wiring junction is made at the base of the tower then a watertight junction box should be installed for the connections The recommended wire sizes for the 48 VDC EXCEL 1 wind turbine are shown in Table 3 The listed distances include the height of the tower Maximum Current 60 amps Caution Installing wire sizes larger than those recommended will increase the maxi mum current produced by the turbine 27 Table 2 Recommended Wire Sizes for the EXCEL 1 DISTANCE FROM TURBINE TO CHARGE CONTROLLER METERS FEET 0 35 0 116 6 AWG 36 56 117 183 4 AWG 57 89 184 292 3 AWG 90 112 293 368 2 AWG 113 141 369 464 1 AWG 142 178 465 585 1 0AWG 179 225 586 739 2 0 AWG 226 287 740 940 3 0 AWG 288 361 941 1185 4 0 AWG 362 455 1186 1494
37. in performance If you need or want to go higher than the zoning height restriction you must apply for a variance A variance is essen tially permission to break a rule and it is granted following a public hearing before a Planning Board Ob taining a variance is a major undertaking costing 200 5 000 and taking several months so it is im portant to establish whether it will be necessary as soon as possible Bergey Windpower Co has experience in working with customers and BWC dealers in variance hearings and we offer advice and assistance to those who request it Generally in order to obtain a building permit you will be required to submit a plot plan and fill out an ap plication A plot plan is a map drawn to scale of your property showing the boundaries dwelling s and other structures major topographic features easements and most importantly the location and height of the proposed wind turbine tower Often you will be required to submit plans for the tower and information on the wind turbine In some cases you will also be required to submit a structural analysis of the tower to show that it is in compliance with the building code Sometimes a registered Professional Engineer PE must sign this analysis and occasionally the PE must be licensed in the State where the unit will be installed Bergey Windpower Co has engineering analyses PE Certified for most towers it offers and copies of these analyses are available to our customers
38. 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 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 Continue With the exception of certain telecom applications the Charge Controller should never be positive grounded S Page The Charge Controller equipment ground is marked with this symbol 3 If damaged or malfunctioning the Charge Controller should only be disassembled and repaired by a qualified service center Please contact your renewable energy dealer in
39. menus will be sub menus to adjust the parameters of the selected feature Here is an overview of these menus lt lt WIZARD CHARGE MODE AUX MISC LOGS TWEAKS TEMPS NET gt gt Below each of the menu names is a row with a description of the menu inside To enter a menu the name of the menu has to be highlighted Pushing ENTER will show the submenus The up and down arrow keys are enabled for easier navigation Highlighting a sub menu and pushing ENTER will take you inside 37 Page the submenu where you will be able to change the parameters of the unit To get out of the submenus push MAIN MENU this will take you out of the submenus one at a time every time you push it See page 44 for entire Menu Map Viewing Other MidNite Products on the Display The Classic is able to view other products or Classics connected to the network For example the MidNite Solar Clipper To view other products or Classics connected to the Classic network go to the Status screen and press the UP and DOWN arrows to scroll between the addresses of the different items The Classic is address 10 and labeled CLASSIC Connecting Classic to Two MNGPs Network cable The Classic can be controlled with two MNGPs at the same time This will help when the Classic is in a shop and there is a considerable distance between the Classic and the controlling point office inside house garage etc Instead of going to the Classic to check status or to change
40. not 2 useful 4266 R MinVpvTurnOn 4266 10 Volts Minimum Turn On Volts Best Left Alone Not too useful 4267 4268 4269 RESERVED Do NOT Write 4270 4271 4272 R RestartTimerms 4271 Milli Seconds Count Down Time until Wake Allowed 4273 R Ibatt 4272 10 Amps Battery Current Unfiltered 4274 4275 RESERVED Do NOT Write 4276 R ReasonForResting 4275 Reason number Reason Classic went to Rest See Table 4275 1 4277 R Output Vbatt 4376 10 Volts Battery Voltage Unfiltered 71 Page 4278 R Input Vpv 4377 10 Volts PV Voltage Unfiltered 4279 Address R W Name Conversion Notes 4280 Typeint 4279 lt lt 16 4278 TBD 4281 2252 RESERVED Do Write 4283 Table 4101 1 Device Type Name Value Description Classic150 150 Classic 150 Classic200 200 Classic 200 Classic250 250 Classic 250 Classic250 KS 251 Classic 250 with 120 V Battery bank capability lower current than 250 Table 4120 1 Battery Stage UPPER Byte of mbComboChrgStge register Name Value Description Resting 0 Off No Power Waiting for Power Source Battery V over set point etc Absorb 3 Regulating battery voltage at Equalize Set point BulkMppt 4 Max Power Point Tracking until Absorb Bulk Terminate Voltage reached Float 5 Battery is FULL and regulating battery voltage at Float Set point FloatMppt 6 Max Power
41. 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 2 Page 5 Classic 8 Huc the SL 10 Removing and installing the front cover on the Classic saco vis citer a ete Pa Pre ee Pel 11 Mounting the ClassiC 12 Altemative Mounting n TEE aeRO 14 A 14 Sealed ot Vented 14 Network Cable Routing and Installation Guidelines esee eren ee eren nera seen nae 15 Battery Temperature Sensor Installation s ccssscsc
42. repeatedly This mode is mostly for testing purposes Pv V on Low This Mode will turn Aux 1 off above a user set voltage based on the input voltage to the Classic V High and turn Aux 1 on when it hits a low voltage set point V Low It also allows you to set a delay time in seconds the Classic will wait before turning Aux 1 off after reaching the V High set point It also allows you to set a hold time in seconds the Classic will wait before turning Aux 1 on after reaching the V Low set point This mode can be useful for controlling a failsafe stopping system for Hydro or Wind 32 Page Pv V on High This Mode will turn Aux 1 on above a user set voltage based on the input voltage to the Classic V High and turn Aux 1 off when it hits a low voltage set point V Low It also allows you to set a delay time in seconds the Classic will wait before turning Aux 1 on after reaching the V High set point It also allows you to set a hold time in seconds the Classic will wait before turning Aux 1 off after reaching the V Low set point This mode can be useful for controlling a failsafe stopping system for Hydro or Wind Opportunity Lo This mode will turn Aux 1 off when the Classic gets within a certain range of the voltage set points for each charging stage V High and turn Aux 1 on when it gets to a low set point V Low These set points are user adjustable and will allow the Absorb Float and EQ timers to continue to run You will adjust these se
43. run particularly all electrical connections 9 Check condition of all wiring connections into and out of the charge controller We recommend that the bearings be re packed re greased every 8 12 years There are four tapered roller bearings two for the alternator and two for the tower adapter They are all the same size Timken L44643 L44610 except for the lower yaw bearing on EXCEL 1 s shipped after September 2003 There are two bearing seals and we recommend that these seals be replaced when the bearings are re packed 19 The strength of the blades particularly at the root inner end may degrade over time due to flexure and UV degradation of the fiberglass material The symptom of degradation is a reduction in blade stiffness fore and aft The blades have to become very flexible in the fore aft direction before there is any risk of tower strikes during severe weather We recommend that you check blade stiffness about every 10 years and replace the blades if they become extremely flexible Charge Controller Fuses The charge controller has four fuses If you blow fail one or more of these fuses you may replace them using the following specifications and parts identifiers P N means part number Battery Fuse 90 amps Buss P N JJN 90 or Little Fuse P N JLLN 90 Turbine Fuse 70 amp or 75 amp special order because of the L shaped mounting tabs but you can use a Buss P N JJN 70 or Little Fuse JLLN 70 by also installing 2 x M6 brass
44. still significant extent by the charging or discharging rates the rate at which DC current or amps is be ing created or consumed Charging components such as wind turbines solar arrays and inverter chargers powered by a back up generator or the power grid can be added to a DC bus system with separate charge regulators and the se regulators can operate completely autonomously e g they do not need to communicate with each other or be coordinated using a central system controller The separate charge regulators whether there is just one or if there are a dozen will respond to the DC bus voltage and control their generators charg ing current When putting together or adding to a DC bus remote power system there are a few pitfalls to avoid if pos sible e Battery banks that are too small so that battery voltage swings too much with high charging or discharging currents e Multiple charge regulators set to the same voltage so that there is one big step in charging cur rent rather than several smaller ones e Setting high voltage regulation points too low so that the batteries don t get fully charged 28 29 Setting the low voltage disconnect typically part of the inverter too high so that the battery bank capacity is underutilized How to Avoid the 6 Most Common Mistakes When Installing an EXCEL 1 30 DO NOT use the charge controller box lugs to connect wiring to the turbine There is not enough space for them so the
45. suitable for the highest power available from the Classic 150 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 The network cables 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 Current Rating The Classic limits the output current based on the model you have The Classic current ratings are Classic 150v 96 amps maximum Classic 200v 79 amps maximum Classic 250v 62 amps maximum 23 Page Temperature 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 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 15 on most likely the current limit set point is too low
46. sunrise based on the pv input voltage Clipper Control This mode was intended to control the MidNite Clipper It will send out a PWM signal whenever the controller is unloading the turbine because the battery is full or close to it There are no adjustment in this mode the Classic 15 preprogrammed with the best parameters to control turbine RPM Pv V on Low This mode is PWM based and is just reverse logic of Pv V High It would be comparable to using the NC contacts of the relay used in Pv V High It can be used that way with a solid state relay with NC contacts for a failsafe load Pv V on High This mode is PWM based and will PWM Aux 2 above a user set voltage V High based on the input voltage to the Classic and stop when it hits a low voltage set point V Low Toggle Test This mode will cycle Aux 2 for 1 second off and 1 second on repeatedly This mode is mostly for testing purposes Opportunity Lo This mode is PWM based and is just reverse logic of Opportunity Hi It would be comparable to using the NC con tacts of the relay used in Opportunity Hi It can be used that way with a solid state relay and NC contacts to do di version above a set voltage 34 Page Opportunity Hi This mode is PWM based and will PWM Aux 2 when the Classic gets within a certain range of the voltage set points for each charging stage V High and stop when it gets to a low set point V Low These set points are user adjustable and will allow the Absor
47. 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 Figure 2 1 OE pyi INPUT GROUND ROD ke 1 CLASSIC POWER WIRING ac O lt LLI ca 5 MS e D ie 2 ric a amp MIDNITE E PANEL BATTERY BUS BAR eee i accum pe pee 21 Page CLASSIC GENERATOR WITH BRANCH 16 BASIC HOOK UP DIAGRAM 18 BATTERY BANK MIDNITE Figure 2 2 22 Page BATTERY Figure 2 4 The Classic s DC terminal connector is located the circuit board as shown in 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
48. to its tower by a three sided six fastener cast ing shown in Figure 4 that is designed to fit inside a tube with an inner diameter of 108 mm 4 25 in Note EXCEL 1 s shipped prior to September 2003 were built to fit a tube with an 85 mm 3 35 in inner diameter If you are using the BWC Tilt Tower then the EXCEL 1 will bolt directly in place If you are mounting the EXCEL 1 to a different type of tower then you will need to ensure that the tower meets the requirements for EXCEL 1 towers see Appendix and that it has a proper adapter fitting for attaching the EXCEL 1 tower mount casting also defined in the Appendix Once you have the proper mounting arrangement you can proceed with assembly of the wind turbine The fasteners on the EXCEL 1 are all metric NS A ADAPTER OF LS TOWER Figure 4 Tower Mounting for the EXCEL 1 Tilt up Type Towers If you have a tilting tower such as the BWC Tilt Tower the following proce dure is recommended Tools Required e 17 mm box end wrench 17 mm socket and 300 mm 12 ratchet drive 8mm socket or wrench e for wiring terminals U shaped crimp preferred over straight crimp e thread locking compound like Loctite 242 e tape measure 12 ft Procedure Step 1 With the tower tilted down place the powerhead of the wind turbine near the top end of the tower The tower wiring is connected to the EXCEL
49. you system Press Main Menu Scroll to LOGS and 4 Press the Enter button Uploading New Firmware to the Classic There is also an Ethernet method for updating software in the Classic itself Ethernet for MNGP Remote coming soon Updating Classic Firmware Windows XP Requirements PC with Windows XP One available USB port Internet Connection 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 con nected 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 1 To retrieve the firmware go to www midnitesolar com then click on the link labeled Firmware in the top menu bar of the web site 40 Page The engineers at Michite Sater have been designing renewable anergy disconnect boxes for tweety years The majority of the existing disconnect boxes were Gesiqned by us We Bink we have finally got it right People in the industry have spent years teaching us what is important 10 them Our E Panels take care of the over current and disconnect requirements This allows you to devote more Of your hard eamed money to te performance components such as PV panels power electronics and balenes 2 Fil emm registration form with th
50. 0100000 RESERVED Do NOT Set to 1 RESERVED 0x00200000 RESERVED Do NOT Set to 1 RESERVED 0x00400000 RESERVED Do NOT Set to 1 ForceResetFaultsF 0x00800000 Just reset all of the faults RESERVED 0x01000000 RESERVED Do NOT Set to 1 74 Page c Table 4164 1 MPPT MODET Value Description PV Uset 0x0001 U SET MPPT MODE includes MPPT ENABLED On FLAG i e if 0 0000 mode is OFF DYNAMIC 0x0003 Slow Dynamic Solar Tracking old Solar 1 O amp P Legacy P amp O 0 0009 Legacy P amp O sweep mode SOLAR 0x000B Fast SOLAR track old PV Learn mode MICRO HYDRO 0x000D Micro Hydro mode similar to Legacy P amp O WIND TRACK 0x0005 Wind Track Mode WIND LEARN future mode 0x0007 Wind Learn Mode not implemented as of May 2011 PV COMBO 1 0 000 1 RESERVED 0x0011 RESERVED BOOST CHRG 0x0013 Boost Charge Mode Lower to Higher Voltage Unimple mented as of May 2011 0 is the ON OFF Enable Disable Table shows modes as ON NOTE MPPT MODE will automatically revert to OFF during mode change Table 4207 1 LED Mode Name Value Description Off 0 No LED activity except on startup Rick Mode 1 Minimal Activity Remote Yellow LED indicates Current Limiting or FET Temperature Limit Blinky 2 LEDs Active Lightshow MNGP Red LED MNGP gt Classic MODBUS active LED 1 2 Status Mode MNGP Green LED Battery Full Float Classic Red LED
51. 08 10007 this unit that failed 10009 forwarded 10010 lt lt 16 Number of packets forwarded through this 10010 10009 interface 10011 broadcast 10012 lt lt 16 Number of broadcast packets received 10012 10011 10013 dropped busy 10014 lt lt 16 Number of packets dropped due to the 10014 10013 interface being busy 10015 RESERVED 10016 Slave Out bus interface 10017 rx ok 10018 lt lt 16 Number of correctly received packets 10018 10007 10019 rx crc err 10020 lt lt 16 Number of packets received with crc errors 10020 10020 10021 requested ok 10022 lt lt 16 Number of transactions originating from 10022 10021 this unit that completed successfully 10023 requested err 10024 lt lt 16 Number of transactions originating from 10024 10023 this unit that failed 10025 forwarded 10026 lt lt 16 Number of packets forwarded through this 10026 10025 interface 10027 broadcast 10028 lt lt 16 Number of broadcast packets received 10028 10027 10029 dropped busy 10030 lt lt 16 Number of packets dropped due to the 10030 10029 interface being busy 10031 RESERVED 10032 83 Page Communication Statistics Remote bus interface 10033 ok 10034 lt lt 16 4 Number of correctly received packets 10034 10033 10035 crc err 1003
52. 1 wind turbine at the slip ring using two small screws and ring terminals crimped to the two conductors BWC does not supply these ring terminals Cut the outer insulation on the wire back about 60 mm 2 5 in Strip the insulation off the outer 12 mm 1 2 in of each conductor and crimp on the appropriate ring terminals Attach the two power conductors to the slip ring assembly with the screws provided The polarities of the connections are marked If your conductors are color coded we recommend making note of the colors connected to positive and negative leads Caution Do not use the box lugs supplied for the charge controller connections instead of ring terminals The box lugs could short circuit against the tower tube and dam age the alternator Caution Be very careful with the washers on the slip ring terminals DO NOT let them fall into the alternator If they do you must disassemble the alternator and remove them before completing the in stallation The slip ring assembly is not designed to support the weight of the down tower wire A strain relieving installation is required as shown in Figure 5 If possible put a loop in each wire to wrap around the wire ties Use the two nylon cable ties provided to secure the tower wiring to the tower adapter casting After completing the connections pull on the tower wire to make sure that it is secure before mounting the wind turbine on the tower Step 2 Raise the tower about 3 o
53. 183 4 AWG 57 89 184 292 AWG 90 112 293 368 2 AWG 118 141 369 464 1 AWG 142 178 465 585 1 0 AWG 2 0 AWG 3 0 AWG 179 225 226 287 288 361 586 739 740 940 941 1185 4 0 AWG BASIC TOWER REQUIREMENTS For the BWC EXCEL 1 Wind Turbine Customer supplied towers for the BWC EXCEL 1 Wind Turbine should meet the following mini mum requirements 362 455 1186 1494 Tower Height 9 m 30 ft minimum though we recommend 18 m 60 ft or higher Design Wind Speed 54 m s 120 mph Turbine Weight 34 kgs 75 165 Maximum Turbine Thrust Load 890 200 lbs 54 m s 120 mph 31 Blade Clearance Top 1 1 m 44 in of the tower must not exceed 12 7 cm 5 in radius from the tower center line Dynamics Not considered due to variable rotor speed Stiffness Tower top should not deflect more than 15 cm 6 in 54 m s 120 mph Turbine Mounting Cylindrical 108 mm 4 25 in Outside Dia See attached drawing Tower Climbing On non tilting towers provisions must be made to allow the tower to be climbed for inspections and possible maintenance Climbing pegs should be removable if they do not meet the blade clearance requirement On lattice type towers we recommend the use of horizontal laterals to facilitate climbing We recommend the use of anti fall devices for towers requiring climbing Materials We recommend low carbon stee
54. 4140 days Elapse days since battery was last in the Float stage 4141 R PWM ReadOnly 4141 0 to 1023 Duty Cycle command of PWM signal NOT a Percent 4142 R SunRiseTodayMsrd 4142 Minutes Minutes since first wakeup today for solar modes 4143 R Equalize Time 4143 Seconds Battery Stage Equalize Down Counter Time remaining in Equalize Stage 4144 4145 RESERVED Do NOT Write 4146 65 Page Address R W Name Conversion Notes 4147 R NoDoubleClickTimer 4142 Seconds Forced time space between manual MPPT sweeps 4148 R W Battery output Current Limit 4148 10 Amps Battery Current Limit Amps example 23 4 A 234 4149 R W Absorb Set Point Voltage 4149 10 Volts Battery Absorb Stage Set point Voltage example 28 3V 283 4150 R W Float Voltage Set Point 4150 10 Volts Battery Float Stage Set Point Voltage 4151 R W Equalize Voltage Set Point 4151 10 Volts Battery Equalize Stage Set Point Voltage 4152 R Sliding Current Limit 4152 Amps Sliding Current Limit changes with V Temp etc 4153 R W Minimum Absorb Time 4153 seconds Minimum time for Batteries to remain in Absorb Stage 4154 R W Maximum Absorb Time 4154 seconds Maximum time for Batteries to remain in Absorb Stage 4155 R W Maximum Battery 4155 10 Volts Highest Charge Voltage is Temperature Compensation limited to this value when Voltage battery temp sensor installed
55. 6 16 4 Number of packets received with crc errors 10036 10035 10037 requested ok 10038 lt lt 16 4 Number of transactions originating from 10038 10037 this unit that completed successfully 10039 requested err 10040 lt lt 16 4 Number of transactions originating from 10040 10039 this unit that failed 10041 forwarded 10042 16 4 Number of packets forwarded through this 10042 10041 interface 10043 broadcast 10044 lt lt 16 Number of broadcast packets received 10044 10043 10045 dropped busy 10046 lt lt 16 4 Number of packets dropped due to the 10046 10045 interface being busy 10047 RESERVED 10048 TCP bus interface 10049 rx ok 10050 lt lt 16 Number of correctly received packets 10050 10049 10051 crc err 10052 lt lt 16 Number of packets received with crc errors 10052 10051 10053 requested ok 10054 lt lt 16 Number of transactions originating from 10054 10053 this unit that completed successfully 10055 requested err 10056 lt lt 16 Number of transactions originating from 10056 10055 this unit that failed 10057 forwarded 10058 lt lt 16 Number of packets forwarded through this 10058 10057 interface 10059 _ broadcast 10060 lt lt 16 Number of broadcast packets received 10060 10059 10061 dropped busy 10062 lt lt 16 Number of packets dropped due to the 10062 10061 interface being busy 10063 RESE
56. AOSL OMV9 VE9 OMVOL WOE OMV9 WEI OMVOL YOE AOSL V 9 DOMV8S vOS OMV9 V 9 OMVOL YOE OMV9 V 9 OMVOL WOE AOSL AVES 06 OMV9 V 9 OMVOL YOE OMV9 V 9 OMVOL WOE V 9 V 9 06 AOSL OMV9 VEO OMVOL WOE AOSL OMVY vOS AOSL E9 06 AOSL OM V9 V 9 YOE 0108 62 1ndul vl vl GL cL 99 928 907 48752 cS 6L 801 27 92 veg 566 8c gv LE S0 cS 892 SSEL vOe SL ee ve 8 Sl OL 9786 21816 8 90 SZ 8 9 9 y ndu xeW 1 0 9 Dug DOA 1040 144 Aa 9 8 OMV9 9 OMWV9 SN V9 OMV9 ONT OMVY 69 0 69 09 0 09 02 09 69 04 68 09 07 89 07 69 9 09 08 02 06 08 06 08 01 69 08 07 06 08 06 08 08 07 08 02 06 08 06 08 06 08 06 08 06 08 06 08 001 06 001 06 08 001 06 001 06 08 001 001 001 06 001 001 001 06 001 001 B
57. C Terminal connector labeled Battery Temp Refer to Figure 1 8 Route the cable through the E panel into the battery box Pick a battery in the middle of the bank and about half way up the side of the battery thoroughly clean a spot off on the case Then remove the protective tape from the sensor and adhere the temperature sensor to the battery Some manufacturers use a double wall case on the battery For mounting a temp sensor to them please refer to the battery manufacturer s recommended procedure 17 Page Figure 1 8 Insert BTS to the jack labeled BATTERY TEMP on the control board Figure 1 9 FLUSH EYES IMMEDIATELY WITH WATER 18 Page 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 grounding terminal is in the upper right corner of the electrical connection compartment see Figure 2 0 Figure 2 0 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 jump
58. E PV GROUND FAULT PROTECTION IS TRIPPED THE NEGATIVE CONDUCTOR MAY BE ENERGIZED DANGER ELECTRICAL SHOCK AND BURN HAZARD SOLAR PANELS WILL CONTINUE TO PRODUCE VOLTAGE EVEN WHEN DISCONNECTED ENSURE THAT PV MODULES ARE COVERED TURN OFF PV ARRAY AND CHARGE CONTROLLER OUTPUT PRIOR TO SERVICE RISK OF ELECTRIC SHOCK DO NOT REMOVE COVER NO USER CAUTION SERVICEABLE PARTS INSIDE REFER SERVICING TO QUALIFIED SERVICE PERSONNEL DANGER DE CHOC LECTRIQUE ET DE RISQUE DE BRULURE LES PANNEAUX SOLAIRES CONTINUERONT DE PRODUIRE L LECTRICIT M ME SILS SONT ATTENTION D BRANCH S S ASSURER QUE LES PANNEAUX SOLAIRES SONT COUVERTS PENDANT L ENTRETIEN POUR TOUTE ACTION DENTRETIEN LA SORTIE DES PANNEAUX SOLAIRES ET DU CONTR LEUR DE CHARGE DOIVENT TRE D CONNECT ES RIEN D PANNER LINT RIEURE DU E PANNEAU NE PAS OUV CAUTION LE COUVER POUR TOUTE R PARATION OU SERVICE D ENTRETIEN CONSULTER UN AGENT SP CIALIS MIDNITE SOLAR INC WERE WWNW MIDNITESOLAR COM Unpacking the Classic When you receive your Classic you will want to unpack it and make sure everything is there and in good shape Refer to Figure 1 1 Included in the Classic package should be Classic charge controller Battery temperature sensor Snap on upper vent cover Knock out covers 4 screened Knock out covers 4 solid User s manual DVD printed installation instructions 10 ten foot custom USB cable Note These items are optiona
59. Input OUTPUT 12 0 Signal FLOAT LOW Aux2 off when in Float FLOAT HIGH Aux2 on when in Float DAY LIGHT Aux2 on at dawn off at dusk NITE LIGHT Aux2 on at dusk off at dawn CLIPPER CONTROL PWM Control for Clipper Pv VON LOW PWM sig below Pv in setpoint Pv V ON HIGH PWM sig above Pv in setpoint TOGGLE TEST Aux2 cycled 1 sec interval OPPORTUNITY LO PWM divert rltv chg state lo OPPORTUNITY HI PWM divert rltv chg state hi DIVERSION LO PWM Divert on Bat voltage lo DIVERSION HI PWM Divert on bat voltage hi To set change threshold voltage as well as time do the following When in the function you wish to use press the right soft button This will take you to the VOLTS menu here is where you set your threshold voltage Use the left and right arrow keys to navigate through the options Use the up and down arrow keys to raise or lower the threshold voltage To change the time press again the right soft button to get to the TIME menu In this menu do the same as you did in the VOLTS menu until desired adjustments are made Press ENTER to save Setting the MNGP features Access the Version of software and Restore factory defaults The Classic comes with an integrated MidNite Graphics Panel MNGP which is the primary interface to the Classic Setting up contrast backlight and volume its simple just follow the steps below Push the Main Menu button Scroll left or right to highlight Misc and push the Enter button
60. Mounting To mount the Classic to a plywood surface use 1 1 2 wood screws in the top key hole slot hole and the holes in the wiring compartment Taking care to make sure the Classic is Plumb and Level Dimensions See page 40 for more details Sealed or Vented The Classic has the ability to be sealed for protection from salt air or dust It comes from the factory Vented If you live in a dusty or salt air environment you may wish to seal the Classic Sealing the Classic does not make the unit water resistant To seal the Classic install the solid 14 Page R0 097 13 535 7 gt 14 905 0 989 plastic knock out covers into any unused knock outs and snap the upper vent cover onto the Classic as seen in the photo below Note that the Classic will be slightly de rated puts out less power by sealing it Refer to the specifications page of the owner s manual for the ratings in the sealed mode To obtain the parts necessary to seal the Classic please contact our Technical Support Team Refer to Figure 1 4 and 1 5 Figure 1 4 Figure 1 5 Nba o gione e Were rci o M n emet ten ten Network Cable Routing and Installation Guidelines The Classic uses a 4 conductor phone cable to communicate with other Classic s or other MidNite products This cable is a standard 4 conductor phone cable and simply plugs into the jack on the Classic labeled sl
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62. Positive Temperature Co efficient PTC fuse protects the AUX internal components from overcurrent or a short circuit gt AUX consists of either RELAY or LOGIC operation depending on the user selection function gt AUX 2 could be set to become an INPUT or OUTPUT One at a time this port could be reading the state of a device connected and takes an action from there AUX 1 AUX 2 OFF RELAY LOGIC INPUT OUTPUT CLASSIC SETUP To configure the Classic s Aux ports Push the Main Menu button Scroll left or right to highlight AUX and push the Enter button Scroll left or right to highlight the relay you wish to change Push the right soft key labeled SETUP Scroll up or down to change the function of the relay Select the right soft key to set the parameters of the function When finished push the ENTER button to save the changes Main Aux Screen shows both Aux1 and Aux2 functions Table 2 0 Off Places output to Low state 0 Volts Auto Selects the assigned function to the Aux output or input On Sets output for Low state 12 Volts or Relay On The Following is a list of the Aux 1 and 2 functions with brief descriptions of their function 31 Page Aux 1 Vent Fan Lo This mode will turn Aux 1 off above the voltage set point you program It allows you to run a vent fan for a battery bank based on battery voltage There is a voltage set point that you set and Aux 1 will turn off when the
63. RVED 10064 84 Page Reserved Address Name units Description 61441 Reserved Reserved 61442 gt LED 7 5 9V power N G p s Q gt L GND power REMOTE oo LED Normally internal MNGP gt gt 9V power TO lt P SLAVE or 9 6 em EXTERNAL MNGP _ TO GND power output SLAVE or 4 1 RX input 43 wocowecr EXTERNAL MNGP no CONNECT Figure 1 Classic RS 232 MODBUS RJ 11 PHONE JACK PINOUTS Top View 85 Page Dealer Information Screen For dealers convenience the Classic has a display screen that can be modified to publicize the dealers business information This is helpful because the customer will know who to contact in case they want to report any problems regarding the product This will also help to promote retailers accessories that are compatible with the Classic This screen is capable of 20 characters per row and four rows for a total of 80 modifiable characters To modify this display screen follow these steps Press main menu Scroll to MISC and select it On the following screen select MNGP and press enter On this screen select LOAD DEFAULTS press enter On the password select 365 and press enter Using the up and down keys will allow you to change the alphabet characters Now scroll left and right to
64. Rs compatibaty with Windows Tell me why Ihis testing is important T thi Continuing your installation of this software may impair or destabilize the correct operation of your system either immediately or in the future Microsoft strongly recommends that you stop this installation now and contact the hardware vendor for software that has passed Windows Logo testing STOP instalation 23 Click Finish to finish driver installation Found New Hardware Wizard Completing the Found New Hardware Wizard The wizard has finished installing the software for 7 USB COC serial emulation Click Finish to close the wizard Changing Classics COM port The Classic charge controller can only be recognized if it is set up for COM 8 on the PC most likely 51 you ll need to change the default COM number of the classic Here is how 24 On your computer go to the Control Panel and click on System E Control Panel Fie Edt Yew Favorites Took Ox 2 gt Folders Address De Control Panel Add Hardware e N a Network Network Setup Connections Wizard system User Accounts 25 Select the tab labeled Hardware and click on Device Manager System Properties The Device Manager lists al the hardware devices installed on you computes Use the Device Manager to change the properties ol arg device
65. Use the left and right arrow keys to select the feature to set and press the Enter button Press the up and down buttons to adjust Press Enter to save 2 Use diagram below for MNGP reference Figure 2 8 36 Page Figure 2 8 Communication indicator USB activity indicator Current limit indicator Speaker Up arrow key Left soft key Left arrow key Status screen Operating the Classic BATTERY CHARGING PARAMETERS lt lt lt gt gt gt 13 Tiphire 215 Enter button Screen name Menu name Menu description Right soft key Right arrow key Main Menu Down arrow key Once the parameters have been set via the set up wizard or from manual set up there are no further requirements to make the Classic function It is all automatic Navigating the Menu s 4 Push MAIN MENU Push right and left buttons to see the different menus To return to the status screen push STATUS button To navigate from one end of the main menus to the other end push the top right and left buttons When the Classic first turns on it will take you through the WIZARD setup After all of these parameters are set and saved you will be placed in the MAIN MENU screen with WIZARD highlighted Below the name of the menu is a description of the menu Pushing the left and right buttons will enable you to see all the main menus provided Inside some of these main
66. Version 1 0 2 BWC EXCEL 1 48 VDC Battery Charging System Owner s Manual EXCEL 1 Wind Turbine Bergey Windpower Co 2200 Industrial Blvd Norman OK 73069 USA Telephone 405 364 4212 Fax 405 364 2078 E mail sales bergey com WINDPOWER Web www bergey com BWC EXCEL 1 Wind Turbine 48V System OWNER S MANUAL Table of Contents 2 2 Cautions and 3 CRM RE 4 4 System Description RM 5 5 SYSTEM OPERA MON Rag ees 7 6 Turbine 9 7 Charge Controller Installation sessessssssssesseeseeeee enne eene entretenir nnns intrent 16 8 Inspections and Maintenance 18 9 Trouble Shooting Problems ssssssssssssssseseeeeennee nennen nren nennen rents 21 PCN D 24 Table of Figures Figure 1 EXCEL 1 with 60 Tilt 2 Figure 2 Major Components of the EXCEL 1 Wind 5 Figure 3 cians 7 Figure 4 Tower Mounting for the EXCEL 1 9 Figure 5 Turbine Mounting sssessssseseessssseses enne enne
67. Y DAMAGE OR DESTROY your Classic and attached equipment like battery banks Please make sure that you understand what you are doing before attempting to change any settings like battery voltage using the raw MODBUS interface MidNite Solar cannot take responsibility for any damage to your Classic in the event of misconfiguration 60 Page Registers and bits marked RESERVED are not necessarily unimplemented Great care must be taken not to overwrite these registers or bits to ensure proper operation of the Classic Wherever possible we have tried to indicate settings that may have an adverse effect on your system if set incorrectly If you need to configure your system please consider using the MNGP s built in configuration wizard which will step you through the process Conventions Register units are expressed using formulas to try to reduce the ambiguity surrounding converting from the raw bus formats and human readable values Due to the nature of the Classic s operation there is not a uniform convention as far as data endianness so you may find some classes of values that follow a Most Significant Byte MSB first convention and others that use the Least Significant Byte LSB first convention Bits are numbered from 0 15 in the little endian or LSB 0 notation That is the least significant bit 1s indexed by 0 For Example the number 43 981 is OXABCD in hex is represented in binary as 1010101111001101 The bit ordering is as show
68. a tions Take no action Do not stand under machine The ice will be shed when there is sufficient sun and wind Repair short circuit Return complete charge controller to BWC for repair Replace rectifier PV is not on even though sun is shining Dump load does not work Dump load comes on during automatic gen erator charge pre venting the batteries from taking a bulk charge 23 Dump load at 97 ca pacity or higher PV hooked up back wards PV fuse blown Fuse blown Voltage below regula tion Dump load set to come on at 28 1 Volts Invert er set to bulk charge batteries at a higher voltage Turn on additional loads to pull down battery voltage See if PV turns on Check polarity Check fuse with VOM Check fuse with VOM Check battery bank voltage with VOM If it is below regulation volt age TEST1 x 10 the dump load should not be coming on During charge battery voltage limited to 28 1 V Extra Load LED lit Normal operation Reverse leads Replace fuse Check resistance of dump load should be no less than 1 2 ohm Replace fuse Normal operation Manually put charge controller in Equalize Mode Contact BWC for help Appendix Installation Planning The location and height of the tower for the BWC EXCEL 1 wind system will be important factors in de termining the overall performance of the system Average wind speed is influenced by many things
69. a check for 125 dollars and we will replace any wearable items like the fans and the capacitors and in general tune the Classic up This will also extend the warranty by 2 additional years as well 91 Page Aux 1 and Aux 2 Graphs Jumpers Figure 3 0 Figure 3 0 shows the two Aux port terminals with their respective polarities These terminals are located at the bottom of the power board below the battery temperature jack Use a mini Aux 2 Aux 1 flat head screw driver to tighten the screws The jumpers are IN OUT RELAY OUT described in the section below In order to select operation of Aux 1 between relay contact or 12v output JP6 and JP8 need to be configured a the instructions provided in this section Wes iS ie 02v SLT de gt When Aux is used to supply 12v JP6 and JP8 have to be in the position shown in Figure 3 1 The basic schematic of how this works is shown in Figure 3 2 The 12v out is more like 14 5v The maximum current from Aux 1 should not exceed 200mA The Aux 1 output can be set to operate at either Active High 12V or Active Low 0V when the Aux 1 function condition is true For more information see Table 2 1 page 31 Tics To configure Aux 1 to use the internal relay JP6 and JP8 have to be in the position shown in Figure 3 4 This configuration is commonly known as dry contact because it does not provide 12v at the Aux1 terminals it acts more like an isola
70. a setting the user can run a cable to the controlling point and see the Classic in a second MNGP The cable is a six wire phone cable Connect one side of the extension cable to the jack in the Classic labeled SLAVE OUT and the other end to the second MNGP Since the Classic transmits power and data signals through the phone cable to the MNGP the length of the cable is limited to 100ft MidNite Solar only offers a 3ft as an optional accessory If you are making your own cable be sure be sure to insert cable end all the way into the phone terminal to get a good contact Use the phone crimping pliers to crimp both ends of the cable We recommend using flat phone cable for extension just because it is easier to work with Use the two pictures above as reference Make sure the color and position of the wires are as shown in the diagram below Use terminal connector tab as reference LES 38 Page Arc Fault The Arc Fault Detector is a unique safety component included in every Classic because safety is not an option the engineers at MidNite take action as the 2011 NEC code requires The Classic is the first charge controller in the world to successfully stop a series arc The Classic can detect an arc in less than 100mSec From low power arcing to devastating high power arcing the Classic will detect and shut down with an audible and visible alert to announce that there is a problem in the PV side of the system When an arc is d
71. a simple and elegant method of providing high wind speed protection The AutoFurl system is based on aerodynamic forces on the rotor gravity and the carefully engineered geometry of the wind turbine As shown in Figure 3 the aerodynamic forces acting on the blades cause a thrust force pushing back on the rotor This force increases with increasing wind speeds NG 7 FURLIN x Figure 3 AutoFurl 7 The thrust force acts through the centerline of the rotor which is offset from the centerline of the tower pivot axis yaw axis Therefore the thrust force on the rotor is always trying to push the rotor over to the side away from the wind But the rotor is kept facing into the wind at speeds up to 12 5 m s 28 mph by the wind turbine s tail assembly The tail in turn is kept straight by its own weight because its pivot at the back of the nacelle is inclined So the weight of the tail holds it against a rubber bumper and the tail holds the rotor into the wind The geometries in the systems are carefully balanced so that at 12 5 m s 28 mph the rotor force acting on the yaw offset is large enough to overcome the preset force holding the tail straight At this point the rotor will start turning away from the wind or furling The tail stays aligned with the wind direction The speed of furling depends on the severity of the wind gusts and whether the wind turbine stays furled de pends on the wind speed As the wind turbin
72. age Technical information Specifications Electrical Classic150 Classic200 Classic250 Classic250KS Operating Volts in 150VDC 200VDC 250VDC 250VDC Max Hyper VOC 150 battery 200 battery 250 battery 250 battery Battery Charge Volts 12 93 volts 12 93 volts 12 93 volts 12 150 volts Absolute Current 96a at 12v battery 74a at 12v battery 60a at 12v battery 5 94a at 24v battery 70a at 24v battery 62a at 24v battery 40a at 120v battery Output at 25 83a at 48v battery 65a at 48v battery 55a at 48v battery De rate current 40 to 40 Dimensions of Classic 14 87 X 5 957 4 00 378mm X 151mm X 102mm 19 00 X 8 507X 5 70 483mm X 216mm xX145mm Shipping Weight 51 4 9kg NOTE Current output ratings were measured with 75 of PV array s 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 88 Page Specifications Mechanical 14 91 89 Page Default Battery charge set points 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 SET Menu see page 25 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 point and then nominal battery voltage i
73. ailing wind direction Try to keep the tower at least two tower heights back from steep slopes DO use thimbles on all guy wires and position the lower malleable clip close to the thimble so that the guy wire captures the thimble securely Not using thimbles or not securing them can lead to guy failure and tower collapse Thimbles are not required on knuckle end an chors such as double eye and triple eye anchors DO follow the recommended wire sizes for your wire run from the wind turbine to the charge controller With the EXCEL 1 oversizing the wire is a bad thing because it will cause ex cessively high currents during high winds Normally over sizing wire is a good thing but not in this case EXCEL 1 SPECIFICATIONS TURBINE e ROTOR DIAMETER 2 5M 8 2 FT e OVERALL LENGTH 2 1M 6 9 FT e TURBINE WEIGHT 34 KG 75 LB e TURBINE THRUST 890 N 200 LB e RATED POWER 1 000 W e RATED WINDSPEED 11 M S 24 6 MPH e RATED ROTOR SPEED 490 RPM e START UP WINDSPEED 3 M S 6 7 MPH e CUT IN WINDSPEED 2 5 M S 5 6 MPH e FURLING WINDSPEED 13 M S 29 MPH e MAX DESIGN WINDSPEED 54 M S 120 MPH e MAX RUNNING CURRENT 60 AMPS e MAX SHORT CIRCUIT CURRENT 120 AMPS WIRE SIZING RECOMMENDATIONS e BATTERY TO CONTROLLER 25 MM 2 4 AWG e DUMP LOAD 16 MM 2 6 AWG e PV PANEL MINIMUM 10 MM 2 8 AWG TURBINE CHARGE CONTROLLER SEE TABLE BELOW DISTANCE FROM TURBINE TO CHARGE CONTROLLER METERS FEET 0 35 0 116 6 AWG 36 56 117
74. ake the form 192 168 0 1 1 or 10 0 0 1 depending on your network configuration and hardware Check your router settings or ask your network administrator which local address to use Also refer to the troubleshooting section for tips DNS 1 amp 2 The DNS is the means by which human readable internet addresses are resolved to actual IP addresses on the network These values can usually be set identically to the gateway address depending on your network hardware If your ISP provides you with specific DNS servers then use those addresses in these fields instead Example 1 Your gateway is a DSL modem with address 192 168 1 1 If your ISP has not given you explicit DNS servers to use then set the D1 field to 192 168 1 1 D2 can be ignored Example 2 Your gateway is a cable modem with address 10 0 0 1 Your ISP has specified primary and 59 Page secondary DNS server addresses of 11 22 33 44 and 11 22 33 55 respectively Set the D1 address to 11 22 33 44 and the D2 address to 11 22 33 55 Web Access MidNite Solar offers a free web service with which you can access your Classic from a web page from anywhere in the world simply by pointing your favorite web browser to http www mymidnite com See the web section further on for instructions on how to create an account and use the web based system All communications between the Classic and MidNite Solar s server are encrypted using a strong session based algorithm To respect your privacy howev
75. and may vary considerably within a relatively small region particularly in complex terrain Site and tower choice however are often limited by such factors as zoning restrictions property size proximity to neigh bors customer preferences and wiring costs All of these factors should be taken into consideration in choosing the best tower site and height A Legal Restrictions and Good Neighbor Relations One of the first steps in planning an installation is to determine the legal status of the proposed wind tur bine installation in the community in which it will be installed In most cities and some counties an instal lation will be subject to zoning laws and building codes Some neighborhoods have protective covenants that limit the types of home improvements In areas requiring permits the installation must be planned weeks to months in advance to allow time for applications to be processed and if necessary hearings to be held The quickest way to determine the local codes and requirements is to call or visit the office of the building inspector Few cities have specific regulations dealing with wind turbines but most will have height re strictions building code requirements and a formal process for obtaining a building permit The most common problem encountered in the United States is a height restriction of 35 particularly in residentially zoned areas The 30 Tilt Tower meets the 35 ft restriction but it does so at some loss
76. at run the full length of the blade The rotor has three blades because three blades will run much smoother than rotors with two blades P h pwernead Alternator 4 Tail Fin A Nacelle Blades A y 2 pinner Tail Boom Tower Mount Figure 2 Major Components of the EXCEL 1 Wind Turbine B Alternator The alternator converts the rotational energy of the rotor into electricity The alternator utilizes permanent magnets and has an inverted configuration in that the outside housing magnet can rotates while the internal windings and central shaft are stationary The alternator was specially designed for the EXCEL 1 and produces power at low speeds eliminating the need for a speed increasing gearbox The output from the alternator is three phase alternating current AC but it is rectified to direct current to charge the battery bank Since it uses permanent magnets the alternator is generating voltage whenever the rotor is turning The output wiring of the BWC EXCEL 1 48 presents a low voltage shock hazard whenever the rotor is turning Caution must be exercised at all times to avoid electrical shock C Nacelle The nacelle is the fiberglass housing around the main body of the machine It contains the main structur al backbone of the turbine called the mainframe the slip ring assembly the yaw bearings and the tower mount The yaw bearings allow the wind turbine to freely pivot
77. ave Plug the other end into the master jack on the second device There is a plastic clamp located on the circuit board for routing the network cables above the USB jack so they stay tied down and out of the way Refer to figure 1 7A and 1 7B 15 Page o un n s O o 4 un 5 Figure 1 7A Master Slave methods of hook up 16 Page Cable Clamp for network cables USB connector 10 foot USB cable is included Ethernet connector I p Figure 1 7B 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 The Classic comes with a Battery temperature sensor which plugs into the jack beside the D
78. aximum ASCII Takes 4213 4210 msp 4210 End place of MODBUS address with 00 if less than 8 in MNGP display if present characters this needs some work 4214 W CTIMEO 4215 lt lt 16 4214 Consolidated Time Registers 4215 possibly atomic op SEE Table 4214 1 4216 W CTIMEI 4217 lt lt 16 4216 Consolidated Time Registers 4217 possibly atomic op SEE Table 4216 1 4218 CTIME2 4218 Consolidated Time Registers SEE Table 4218 1 4219 R W BaudRateStopStartEtc 4219 Baud rate bps MODBUS Serial Baud rate Not implemented as of May Note that writing this register 2011 will immediately change the target unit s serial baud rate which may result in communication problems with other units in the system including the unit s MNGP 4220 R W RemoteMenuMode 4220 Present Remote Menu sent from MNGP 4221 R W RemoteButtons 4221 Remote Buttons pressed from MNGP 4222 R W VbatOvrshootSenstvty 4222 Overshoot Sensitivity not implemented 4223 R W RESERVED 4223 RESERVED Do NOT Write 69 Page 4224 4224 10 Volts PV Terminal V before Relay Address R W Name Conversion Notes 4225 RESERVED Do NOT Write 4226 R W VauxA2Dinput 4226 TBD Aux 2Ato D input TBD 4227 422 RESERVED Do NOT Write 4229 4230 4231 R VocRD 4231
79. b Float and EQ timers to continue to run You will adjust these set points to negative numbers and the numbers are an offset from the voltage set point For examplea 2 would turn Aux 2 on 2 tenths of a volt below your set points This mode will allow you maximum diversion while maintaining your 3 stage charging Diversion Lo This mode is PWM based and is just reverse logic of Diversion Hi It would be comparable to using the NC con tacts of the relay used in Diversion Hi It can be used that way with a solid state relay and NC contacts to do diver sion above a set voltage Diversion Hi This mode is PWM based and will PWM Aux 2 at a set point based on battery voltage V High and stop it at another set point based on battery voltage V Low Aux 1 Function OUTPUT Relay or 12V 0V Signal jumper selectable Aux has the relay so Diversion functions must operate slowly VENT FAN LOW Aux on below setpoint VENT FAN HIGH Aux on above setpoint FLOAT LOW Aux off when in Float FLOAT HIGH Aux on when in Float CLIPPER CONTROL PWM Control for Cipper DAY LIGHT Aux on at dawn off at dusk NITE LIGHT Aux on at dusk off at dawn TOGGLE TEST Aux cycled 1 sec interval Pv VONLOW Aux on below Pv in setpoint Pv V ON HIGH Aux on above Pv in setpoint OPPORTUNITY LO Divrt based on chrg state lo OPPURTUNITY HI Divrt based on chrg state hi LOW BAT DISC Disc load based on bat volt DIVERSION Slow Diversion control 35 Page Aux 2 Function Output
80. casting ie IE 13 Use the provided USB cable to connect the Classic to the PC The smaller terminal connects to the USB port on the Classic The USB port is located on the right side of the Ethernet Jack in the lower part of the Classic 46 Page 14 Connect the other end of the USB cable to an available port of the Install USB Classic driver 47 Page 15 Go back to the electrical panel and turn on the battery breaker to the Classic 16 The LED above the USB port on the Classic will light up and stay on 48 Page 17 The computer will prompt with a Found New Hardware pop up Select Not at this time and press Next Found New Hardware Wizard Welcome to the Found New Hardware Wizard Windows wil search for current and updated soltware by looking on your computer on the hardware mitalshen CD ot on the Windows Update Web site with your permission Bead our privacy policy Can Windows connect to Windows Update to search for tollware Q Yes this time only Yes now and every lime connect a device Click Nest to continue 18 A New Found Hardware Wizard dialog box will appear Select Install from a list or specific lo cation Advanced and click Next Found New Hardware Wizard This wizatd helps you install software foe USB serial poit If your hardware came with an installation CD 2 2 or floppy disk in
81. cription 16385 version Major 16385 15 12 Release version of the application code Minor 16385 11 8 Release 16385 8 4 16386 version Major 16386 15 12 Release version of the communications stack Minor 16386 11 8 Release 16386 8 4 16387 app rev 16388 lt lt 16 Build Revision of the application code 16388 16387 16389 rev 16390 lt lt 16 Build Revision of the communications code 16390 16389 stack 82 Page Communication Statistics are all Read Write registers You may write any value to these registers which will be incremented should the trigger for that counter occur The most useful type of write may be to periodically reset the counters to zero These are all lifetime counters and due to the number of MODBUS transactions may overflow to 0 Communication Statistics Address Name units Description Master In Bus Interface 10001 ok 10002 lt lt 16 Number of correctly received packets 10002 10001 10003 rx crc err 10004 lt lt 16 Number of packets received with crc errors 10004 10003 10005 requested ok 10006 lt lt 16 Number of transactions originating from 10006 10005 this unit that completed successfully 10007 requested err 10008 lt lt 16 Number of transactions originating from 100
82. d tail boom Tail Pivot Pin lt J Y 0 dii 0 Cotter Pin Cotter A Pin o Figure 9 Tail Boom Attachment Step 9 Check the EXCEL 1 wind turbine carefully to make sure that the installation is complete We recommend the following checklist Blade fasteners are secure and properly torqued Blade tips are evenly spaced Spinner is secure Tail fin is secure Tail pivot pin is locked in place with both cotter pins Tower adapter bolts are secure Wiring polarity is tested and marked Step 10 Dynamically brake the EXCEL 1 s alternator by either of two methods 1 using the Stop Mode function of the charge controller if you already have the turbine and battery bank connected to the charge controller 2 connecting the positive and negative output leads together The resulting short circuit will keep the rotor from spinning during tower raising DO NOT raise the wind turbine without first stopping the rotor from turning Step 11 Raise the tower following the procedures outlined by the tower supplier Please make safety your top priority Non tilting Towers On a non tilting tower such as a fixed guyed tower or a self supporting pole type tower there are two general approaches that can be used 1 assemble the tower and turbine to gether on the ground and then use a light duty crane to set the tower in place or 2 erect the tower and then lift the wind turbi
83. d turn it on at another set point based on battery voltage V Low It also allows you to set a delay time in seconds the Classic will wait before turning Aux 1 off after reaching the V High set point It also allows you to set a hold time in seconds the Classic will wait before turning Aux 1 on after reaching the V Low set point This can be used with a NC relay when the battery gets to the set point the Classic will send 12vdc to the relay holding it open and disconnecting the load Diversion This mode will turn Aux 1 on when it reaches a set point based on battery voltage V High and turn it off at another set point based on battery voltage V Low It also allows you to set a delay time in seconds the Classic will wait before turning Aux 1 on after reaching the V High set point It also allows you to set a hold time in seconds the Classic will wait before turning Aux 1 off after reaching the V Low set point 33 Page Aux 2 Float Low This mode will turn Aux 2 off whenever the Classic is in Float Aux 2 will stay off until the Classic falls 3 tenths of a volt below the float voltage set point Float High This mode will turn Aux 2 on whenever the Classic is in Float Aux 2 will stay on until the Classic falls 3 tenths of a volt below the float voltage set point Day Light This mode will turn on Aux 2 at sunrise and turn it off at sunset based on the PV input voltage Nite Light This mode will turn on Aux 2 at sunset and turn it off at
84. dU 93 Aux 2 Voltage Time Relation PWM 93 Breaker 94 ir Mr mr C T H 95 4 Page Scope This Manual provides safety guidelines and installation information for the Classic charge controller It does not provide brand specific information about photovoltaic panels batteries etc Contact the manufacturer of other components in the system for relevant technical data Introduction The MidNite Classic charge controller is unique in its ability to be used for a great variety of DC input sources The Classic is designed to regulate DC input from PV Hydro Wind and other DC sources The Classic 150 200 and 250 are designed to work with 12 24 36 48 60 and 72 volt battery banks The Classic250KS is designed to charge up to a 120V nominal battery bank The Classic can be installed stand alone or as a multi unit networked installation Standard features of the Classic charge controller include 3 input operating voltage ranges 150 200 and 250 VDC Multiple DC input options example Solar Wind or Hydro Wizard driven setup interface including voice and help screens Graphical display Previous 180 days of operational data logged nternet ready This Manual covers Classic 150 Classic 200 Classic 250 and the Classic 250KS It covers the
85. e furls the geometry of the tail pivot causes the tail to lift slightly When the high winds subside the weight of the tail assembly returns the whole turbine to the straight position The AutoFurl system works whether the turbine is loaded or unloaded The AutoFurl system is completely passive so it is very reliable and since there are no wear points like in a mechanical brake system it is very robust AutoFurl was used in the very first wind system produced by Bergey Windpower in 1980 and in every unit produced since AutoFurl is an important element of our Success There is one situation in the field however that we have found can disrupt the operation of AutoFurl If the wind turbine is installed on a sharp hill or next to a cliff so that the wind can come up through the rotor on an incline e g from below as opposed to horizontally we know that this will affect furling and can produce higher peak outputs We strongly recommend avoiding this situation Caution Do not install the EXCEL 1 wind turbine near cliffs or precipices or on sharp hills such that the wind does not travel hori zontally through the rotor 6 Turbine Installation Appendix 1 is an Installation Planning Guide It provides recommendations on tower heights and loca tions electrical components and wiring Please read the Appendix page on How to Avoid the 6 Most Common Mistakes when Installing an EXCEL 1 Tower Mounting The EXCEL 1 wind turbine is attached
86. e required fields and click Submit Name First Last Email Email Verify Email Select Classic Model 150 200 250 250 KS Message 3 email will be sent to you with a link to the firmware Click the link to start the download If the download does not start copy the link paste it in the URL address bar and then press enter 41 Page MidNite Solar Firmware Download midni9 sadar lunarpages com Sent Fr 311 2011 5 57 PM To tob Smidhitesolar com rob Smidritesolar comerFrom info gmidnitesobe comm MidNite Solar Inc Ph 360 403 7207 Fax 360 691 6862 17722 67th Ave NE Arlington WA 98223 Click the link below to start the download http www midnitesolar com firmware MidNiteSolarSetup 3 4 2011 If the download does not start copy the link paste it in the URL address bar and then press enter Thank you MidNite Solar Inc 4 Select Save to save the file on your computer amp www clients midNite firmware Organize New folder S Apps Name Documents LS MidNiteSolarSetup_3 4 2011 exe Music Pictures Videos Homegroup Computer 0s c Network Filename ep Hide Folders 42 Page If your antivirus sees the MidNite Update exe as a threat temporarily disable your antivirus When the install is complete enable your antivirus
87. eaker to the Classic on the electrical panel and open the MidNite Update GUI The MidNite Update GUI can be found by clicking on the Start menu in the lower left portion of the monitor screen and then selecting MidNite Update GUT 22 My Documents 1 Recent Documents My Pictures Do PL Computer gt Control Panel Set Program Access and Defaults come To Printers and Faxes neo and Support yp seh 22 31 Click on the model 150 200 and 250 of the Classic to be updated A black window will appear and close automatically upon completion of the update 54 55 E m Es Solar USB Uploader Update CLASSIC 150 Update CLASSIC 2007 Update CLASSIC 250V Update CLASSIC 250 KS Update MNGP REMOTE Power Down Classic Connect USB cable from Classic to PC Choose COMM function Click Upload Power Up Classic Upload should start 32 Now turn ON the battery breaker to the Classic The update should start automatically Wait until the update goes to 100 then turn the battery breaker to the Classic OFF and then ON 2 C WINDOWS system32 cmd exe of x 1 ic lassic ALL 4 150 3 4 2011 61 C 2007 2011 MidNite UpLoader Plug Classic USB cable in then turn on Classic power Turning the breaker off and on resets the Classic so the new setting
88. election active high or active low This gives a much smoother transition For more information see Configuring Auxiliary Input Output Page 29 WIDTH IN VOLTS VOLTAGE lt d OUTPUT 93 Page Table 6 1 pue jndui oj seidde osje 108 99 anba jou pue epo 9500 101 pae suexeeiq eyNDIIA se JBued 3 297 Heyo SIU uo peseq jeAneAresuoo 5 siu Jie Seu ur sioyonpuoo 10 ey SI 7 L OLEOANy AO0 40 OM VO9 VOS OMVOL VOE AQOE 8 40 OA V9 VOGS OMVOL AVOE AO0 8 40 OM VO9 VOS OMVOL VOE AO00 40 DM VO9 VOS OMVOL VOE AO0 40 DOM VO9 VOS OMVOL VOE AO00 8 40 OM VO VOS OMVOL VOE AO0 40 OM VO9 VOS OMVOL VOE AO0 40 OM VO9 VOS OMVOL VOE 8 10 DAAVOAVOS AO0 40 SAAVO WOS OMVOL VOE AQOE 40 DAAVO VOS OMVOL VOE AQOE SAAS JO DAAVO VOS DAAVOLAVOE 10 OMVS vOS 8 JO 9 806 40 OAAVO9 VOS DAAVOLAVOE AQOE 40 DAAVO VOS DAAVOLAVOE AQOE SAAVS 40 9 806 AO0 SAAS JO DAAV9 E0S AQOE 40 DAAVO VOS DAAVOLAVOE AO0 8 40 DAAWO VOS OMVOL VOE AQOE OMWVY VOS 10 DMVO9 VOS AO0 8 40 DOM VO9 VOS OMVOL VOE AOSL AVEO OMVS VOS
89. er it is required that you manually enable this feature if you d like to use it In order to enable the web access feature e Press Main Menu e Scroll to NET menu and press the Enter button e Using the soft keys navigate to the ADVANCED menu NET NEXT ADVANCED e The Web Access option should be highlighted e Use the up down keys to now enable or disable the feature Note that the Web Access selection indicates the current setting of the feature i e ENABLED means the feature is currently in operation Note also that you will need the values MA and DI handy in order to create an account on the MidNite Solar web site This unique number pair identifies your particular classic to our server and helps to prevent malicious users from trying to access your Classic The DI or Device Id is different than your Unit s Serial Number Local Network Note that your classic identifies itself by name to DHCP enabled routers as Classic There is facility to change the name of a given classic via the local and web based interfaces as well as using third party MODBUS software packages Advanced The Classic advertises its address every 10 seconds using the UDP protocol on port TBD Advanced users and programmers may use this feature to identify Classics on their network MODBUS Preliminary DISCLAIMER There is not a convention on the write ability of registers You may write to any register in the system including registers THAT MA
90. er shown on figure 2 1 The internal grounding jumper should only be installed when the Classic s GFP is enabled In a system with multiple charge controllers the grounding jumper should be installed on every charge controller In Positive ground or Ungrounded systems the GFP jumper must be removed See Figure 2 1 Also note that with Positive ground there will be items still referenced 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 the Ethernet jack Please contact Technical support for assistance on Positive ground systems 19 Page 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 all Classics must have the internal grounding jumper installed and 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 2 1 r The Ground fault device is sim
91. er they should be coated with an anti oxidation compound to prevent galvanic corrosion All loads should be protected by fuses or circuit breakers to avoid hazards from accidental short circuits The wind turbine tower must be well grounded and a good quality lightning surge arrestor connected to a good quality earth ground should be installed on the wiring from the wind turbine We recommend a Del ta LA302DC arrestor installed into the third from the left rear entrance hole of the enclosure This tucks the arrestor neatly behind the enclosure The arrestor leads are connected to the wind turbine terminals The charge controller does not have a built in ground all circuits are floating such that either the positive or the negative can be grounded Some inverter manufacturers recommend grounding and some electri cal codes require it If you do ground the charge controller please conform to local practices for ground ing either the positive or negative bus All negative leads are connected together on the charge controller circuit board so grounding the battery negative lead will ground the turbine negative the PV negative and the dump load negative as well This is the preferred grounding method the enclosure should also be grounded by bolting a box lug to it in a convenient location E Charge Controller Connections We recommend the electrical connections be made in accordance with the charge controller owner s manual which is attac
92. ery voltages listed show the most used battery bank configurations Other voltages are also supported The Classic battery voltage parameters are fully user adjustable For example if you are using a Classic 250 and 48v battery bank the maximum continuous output power based on 25 degree C ambient is 55 amps when using a PV array that yields a Maximum Power Voltage of 180 volts The same set up using a bit higher voltage modules that result in a 200V Maximum Power voltage will result in only 53 amps Although 55 to 53 amps is not a significant change it does give you the idea that all things being equal lower voltages are a bit more efficient Below are the labels present on the Classic MIDNITE SOLAR CLASSIC 250K S MPPT SOLAR WIND HYDRO BUCK BOOST CHARGE CONTROLLER LATING 5 C DE RATED SEE MANUAL MIDNITE SOLAR CLASSIC 200 MPPT SOLAR WIND HYDRO BUCK BOOST CHARGE CONTROLLER NOMINAL OPERATING ENVIRONMENT 25 C 40 C DE RATED SEE MANUAL MAX PV VOLTAGE OPERATING 200V CONFORMS TO UL STANDARD 1741 MAX PV CURRENT OPERATING 79A 2ND EDITION MAY 7 199 MAX PV VOC 200V BATTERY VOLTAGE WITH REVISIONS THROUGH MAX PV SHORT CIRCUIT CURRENT 79A T MAX BATTERY CHARGE CURRENT 79A CERT TO CAN CSA MAX BATTERY CHARGE VOLTAGE 93V 3084883 910 6222 0901 J NOMINAL BAT VOLTAGES 12 72V MAX OUTPUT FAULT CURRENT 436A Designed built the U S A 9 Pas MIDNITE SOLAR CLASSIC 150 MPPT SOLAR WIND HYDRO BUCK BOOST CHARGE
93. et to the BITS menu In BITS press the right soft key to get to ARC ADJ In this menu use the left and right keys to select the feature to adjust Use the up and down arrow keys to change the parameters 060 9 s 39 Ky age In order for the Classic to read the new settings you must power cycle the Classic Do this by turning the DC source PV Wind or hydro etc breaker off Then turn off the external battery breaker Than simply turn the 2 breakers back on starting with the battery breaker View Faults and Warning s The Classic has some helpful safety features including the GFP Ground Fault Protection and AFD Arc Fault Detector When one or more faults are detected the Classic will stop outputting power and display a fault message in the bottom right corner of the home screen STATUS To clear the fault refer to Page 19 and page 33 Arc Fault section View Logged Data The Classic can log the power produced by your system Shown in Total kilo Watt hours KWh you can view daily logged data or accumulated throughout the life time of the Classic Daily logged data is displayed in the bottom left corner of the Status screen the daily logged data will get reset to 0 kWh every 24hrs The total logged data is displayed in a menu screen called LOGS Total logged data is an accumulation of all of the power that has been produced by the system this data cannot be reset back to 0 kWh To view total kWh produced by
94. etected the Classic has to be manually cleared Resetting the Arc Fault Detector after detection has occurred The First thing to do is find and fix the actual arcing wire terminal splice etc The Classic needs to be powered down completely for 15 seconds and then powered back up Do this by turning the DC source PV Wind or hydro etc breaker off Then turn off the external battery breaker Than simply turn the 2 breakers back on starting with the battery breaker The arc fault module has three adjustable parameters consisting of MODE TIME amp SENSITVY MODE Is assigned as a 1 from factory default and it should stay that way unless instructed by MidNite Solar TIME This sets the length of the arc the Classic has to monitor before tripping the Arc fault detection This parameter is set to 4 from the factory SENSITIVITY This parameter determines how sensitive the Arc fault detector will be 1 being the most sensitive and 15 the least This parameter is set to 10 from the factory If you experience nuisance tripping you can raise the sensitivity one digit at a time Follow the instructions below to make adjustments or disable Arc fault As a last resort you may disable Arc fault 1f your system cannot work with the arc fault detector To change the parameters of the Arc Fault follow the steps below 4 Press Main Menu Scroll to the right or left until TWEAKS is highlighted and press ENTER In TWEAKS press the right soft key to g
95. ff the ground to provide room to assemble the EXCEL 1 turbine We recom mend fashioning a temporary support stand to hold the tower up during turbine assembly 10 Step 3 Mount the wind turbine tower adapter to the top of the tower using six M10 1 5 x 20mm bolts and six washers We require applying Loctite 242 Thread Locking Compound to the threads prior to installation to reduce the likelihood of loosening due to vibration Use a torque wrench to achieve the proper fastener torque on the tower mounting bolts The required torque is 45 ft Ibs Nylon Cable Turbine Ties 2 A Mounting re YW Bolts 7 22 1 c Power Cables Figure 5 Turbine Mounting Step 4 Complete the turbine wiring to the charge controller before adding the blades This is recommended so that you can test the DC polarity of the wiring by spinning the alternator by hand It is very important that the polarity positive and negative is correct when the turbine is connected to the charge controller The best way to ensure this is to complete the wiring and then test the polarity with a Volt Ohm Meter or the polarity checker built into the charge controller Do not use the polarity checker on the charge controller circuit board with blades on and the turbine turning under wind power because the voltage will be too high for the polarity check circuitry To connect the battery leads first connect the battery negative wi
96. ffset 4189 10 Battery Voltage Offset Tweak Range Limited Signed 4190 Offset 4190 10 Input Voltage Offset Tweak Range Limited Signed 4191 R VpvTargetRd 4191 10 Volts Input Target V regulation Voltage Usually Vmpp 4192 4193 4194 RESERVED Do NOT Write 4195 4196 4197 R W LgcySweepIntervalSecs 4197 Seconds Legacy P amp O Hydro Solar U Set Sweep Interval Seconds Forcing Sweep resets timer 4198 MinSwpVocPercentage 4198 100 Minimum sweep as a percentage of Voc Unused 4199 R W MaxSwpVocPercentage 4199 100 96 Maximum sweep as a percentage of Voc Unused 4200 R W SweepDepth 4200 Watts Percent of last Mpp Watts 68 Page 4201 RESERVED Do NOT Write Address R W Name Conversion Notes 4202 R W ClipperCmdVolts 4202 10 Volts Variable Voltage command to Clipper or Aux in Clipper mode 4203 WindNumberOfPoles 4203 poles Number of turbine alternator poles for RPM Calc 4204 R W MppPercentVoc 4204 00 to 100 of Voc for U Set mode 4205 WindTableToUse 4205 FUTURE power curve select 4206 WindTableLearn 4206 FUTURE Wind Learn usage 4207 R W LEDmode 4207 See Table 4207 1 4208 4209 RESERVED 4210 R W ID name 4210 msp 142101 Unit Name DHCP and 4211 4210 wss 4210 rsp MODBUS name 8 character 4212 4210 msp 4210 r ss m
97. ght of the readout at eye level if possible so that the system status will be easiest to read The enclosure dimensions and mounting layout for the charge controller are shown in Error Reference source not found The charge controller should be mounted with four M4 0 157 dia screws We rec ommend the following procedure Tools Required Pencil e Carpenters level e Drill with 2 mm or 0 09 dia drill bit 4 4 1 8 or 5 32 screws e Screwdriver Procedure Step 1 Mark the mounting hole locations using the charge controller enclosure as the template Use a carpen ters level to check the levelness of the enclosure before marking the holes Step 2 Drill small 2 5 mm or 0 1 in diameter pilot holes for the mounting screws Step 3 16 Screw the top two mounting fasteners into the wall until 6 mm 1 4 of the shank extends out from the wall Step 4 Remove the charge controller cover and place the charge controller enclosure on the two upper mounting fasteners Slide the enclosure down such that the fasteners are placed at the top of the inverted T slots Step 5 Install the bottom two mounting fasteners and then tighten the top two fasteners D Wiring All wiring should conform to the National Electric Code or other governing local electrical code The use of electrical conduit for wiring between components is highly recommended If you have any connections with dissimilar metals aluminum to copp
98. gisters from its battery backed RTC Name Value Description BITS 11 0 1 to 366 Day of year value in the range of 1 to 365 366 for leap years BITS 31 12 RESERVED RESERVED Do NOT write ones to these bits 79 Page Table 4275 1 Reason For Resting VALUE REASON FOR RESTING 1 Anti Click Not enough power available Wake Up 2 Insane Ibatt Measurement Wake Up 3 Negative Current load on PV input Wake Up i PV Input Voltage lower than Battery V Vreg state 5 Too low of power out and Vbatt below set point for gt 90 seconds 6 FET temperature too high always shows up on boot up Cover is on maybe 7 Ground Fault Detected 8 Arc Fault Detected 9 Too much negative current while operating 10 Battery is less than 8 0 Volts 11 PV input is available but V is rising too slowly Low Light or bad connection 12 Voc has gone down from last Voc or low light Re check 13 Voc has gone from last Voc enough to be suspicious Re check 14 Same as 11 15 Same as 12 16 Mppt MODE is OFF Usually because user turned it off 17 PV input is higher than operation range too high for 150V Classic 18 PV input is higher than operation range too high for 200V Classic 19 PV input is higher than operation range too high for 250V or 250KS 25 Battery Voltage too high of Overshoot small battery or bad cable 80 Page The network reg
99. h switch In some cases you may be able to connect Classic directly to your PC however this is not a recommended topography Wireless Bridge Wireless Router Access Point Figure 5 1 Local network through wireless bridge Wireless enabled com puter Wireless Router Access Point Figure 5 2 Local wireless network S7 Page Wireless Bridge Wireless Router ireless enabled com 2 Access Point puter a Figure 5 3 Local wireless network through wireless bridge There are many different configurations possible when it comes to networking that are beyond the scope of this manual The basic ones in the above figures should help get you going Network Setup Through the MNGP The Classic s Ethernet capabilities may be configured using the Network menu on the MNGP From the main menu select NET There are three screens that configure network settings Table TBD decodes the descriptions from the MNGP s small screen MNGP Long hand Description Mode IP address configuration The Classic supports both static and dynamically DHCP allocated mode DHCP Static IP addresses If you are unsure which to choose try DHCP first If you have trouble move to the troubleshooting section IP IP Address The Network address of the Classic SN Subnet The Subnet or address class specifier GW Gateway Address The address of the network s gateway device D1 Primary DNS Address
100. has a very fast sweep typically1 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 during the day The Classic will show a message of PV SHADE if it thinks the PV array is partially 28 Page shaded if this feature is enabled 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 2 settings that are user adjustable Sweep Interval is the time between mini sweeps in minutes and sweeps around the present 1 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 w
101. he list of pre loaded curves or build your own To access the list of power curves follow the steps below Push the Main Menu button 4 Scroll left or right until Mode is highlighted and push the Enter button Set the status to OFF and then use the right soft key to select Graph Using the left soft key select MEM Now you can scroll up and down through the menu and select from the curve that was designed for your turbine Once you find the correct power curve use the right soft key to select RECALL Now push the Enter button to save this power curve to the Classics memory There are also 9 memory spaces for you to save a custom power curve To build custom power curves select a memory location between 1 and 9 and hit RECALL Use the right and left arrow buttons to scroll through the 16 steps in the custom curve On each step you can set the amperage by using the up and down buttons When you have the power curve the way you want it select Use the up and down buttons to select a location 1 through 9 to save it in and select SAVE Now push the Enter button to save it to the Classic s memory For more information consult the videos contained in this DVD as well as the MidNite Solar web site Classic Wind Graph Editor 1 mpg Setting the Date and Time To set the date and time manually on the Classic follow the steps below Push the Main Menu button Scroll left or right to highlight TIME
102. hed in the Appendix Please ensure that the wires do not pull on or flex the cir cuit board The EXCEL 1 wind turbine system is now ready to operate We recommend that you verify that the EX CEL 1 is producing power by putting the charge controller in Watt Display mode In all but the lightest of winds you should see indication of varying wattage coming from the wind turbine 17 8 Inspections and Maintenance The BWC EXCEL 1 installation should be inspected after 30 days and then again 180 days after installa tion Following these two inspections the installation should be inspected every two years and after any particularly severe weather In corrosive marine environments more frequent inspections are recom mended Inspections should be done on days when the wind is below 7 m s 16 mph Check List for Inspections 1 Inspect each of the anchor points Ensure that all hardware is secure and the guy wires are properly tensioned Check to ensure that no strands are broken 2 Stop the alternator by clicking the mode selector button to place the charge controller into Stop Mode Once the rotor is stopped climb or lower the tower Always use proper safety belts and lanyards when climbing Only qualified personnel with proper safety equipment should climb the tow er Never climb the tower when the ro tor is turning 3 Inspect the blades for A Condition of the leading edge particularly out near the tip B Tip damage
103. hicle traffic fence lines crops gardens septic system lateral lines power poles etc Since the wind turbine installation is semi permanent your future plans for the property should also be taken into consideration When using a Tilt Tower you should consider the extra space needed for the tower when it is tilted down 26 5 Safety The BWC EXCEL 1 should never be installed close to a power line We recommend that the tower be at least 1 1 times the height of the tower from any power line including any overhead service line bringing power to your home The wind turbine towers are typically made of metal which readily conducts electricity If any part of the wind tur bine or tower makes contact with power lines there is a risk of electrocution We also recommend that any guy wire anchors be kept away from roads or paths used by vehicles D Wiring The basic electrical schematic for the BWC EXCEL 1 battery charging system is shown in Error Refer ence source not found The wind turbine alternator produces 3 phase AC which is rectified into DC in the controller A three 3 conductor wire is needed between the wind turbine and the charge controller The charge controller has a fuse for the wind turbine input so a fused disconnect switch is not required at the base of the tower as is recommended for the other BWC wind turbines We recommend that the tower wiring be with SO cord The SO cord s neoprene jacket will provide
104. ic first turns on after the input voltage goes above battery voltage it will sweep from that open circuit voltage down to battery voltage finding the maximum power point voltage MPP V Then return the input to that newly found voltage After the original turn on sweep the Classic will do mini sweeps at user adjustable time intervals If the time interval 1s set to 0 the Classic will not do any mini sweeps but will stay on this first found MPP V until the user goes to the mode menu and turns it off and back on again Micro Hydro mode sweeps slightly slower than Solar mode and has 2 user adjustable settings Sweep Interval is the time between mini sweeps in minutes and sweeps around the present 1 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 Micro Hydro mode the Classic was outputting 1000 Watts and the Sweep Depth percentage was set for 2096 200 Watts the sweep will bring the input voltage DOWN until the output power drops down to 800 Watts then will sweep UP in voltage until the power drops again down to 800 Watts and then go back to the newly found MPP Voltage waiting for the next sweep This mode will NOT go to resting even when the input has been disconnected and will always stay awake so the turbine has the least chance of over spinning Solar This is the default mode for PV systems and
105. idated Time Registers 0 write only to set Classic Time Normally MNGP will set these registers from its battery backed RTC Name Value Description BITS 5 0 0 to 59 Seconds Seconds value in the range of 0 to 59 BITS 5 0 RESERVED RESERVED Do NOT write ones to these bits BITS 13 8 0 to 59 Minutes value in the range of 0 to 59 BITS 15 14 RESERVED RESERVED Do NOT write ones to these bits BITS 20 16 0 to 23 Hours value in the range of 0 to 23 BITS 23 21 RESERVED RESERVED Do NOT write ones to these bits BITS 36 24 0 to 6 Day Of Week Day of week value in the range of 0 to 6 BITS 31 27 RESERVED RESERVED Do NOT write ones to these bits Table 4216 1 Consolidated Time Registers 1 write only to set Classic Time Normally MNGP will set these registers from its battery backed RTC Name Value Description BITS 4 0 1 to 28 29 Day of month value in the range of 1 to 28 29 30 or 3 depending 29 21 the month whether it is a leap year BITS 7 5 RESERVED RESERVED Do NOT write ones to these bits BITS 11 8 1 to 12 Month value in the range of 1 to 12 BITS 15 12 RESERVED RESERVED Do NOT write ones to these bits BITS 27 16 0 to 4095 Year value in the range of 0 to 4095 BITS 31 28 RESERVED RESERVED Do NOT write ones to these bits Table 4218 1 Consolidated Time Register 2 write only to set Classic Time Normally MNGP will set these re
106. ill 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 This mode is also useful for such items as DC generators or rectified ac alternators being driven by a fossil fuel engine An Example would be a Lister diesel with an Other Power 3 phase alternator The AC output would be rectified and run into a Classic set for legacy P amp O NOTE ON HIGH VOLTAGE HIGH POWER INPUT SOURCES When using an unlimited power source it is recommended that the input voltage not be much higher than 4 or 5 times the output battery voltage i e Don t try to charge a 12V battery from an unlimited input power source sitting at say 200 Volts The Classic is able to work with high power high voltage sources but will usually require an input voltage dropping power resistor in series with the input voltage source Please call a MidNite technical representative for advice on what size input resistor to add to the input for these special cases if you are unsure what to place in line and we will try to help Wind Track This mode uses a power curve that is either built by the user or one of the pre installed graphs The power curve consists of 16 set points that consist of output amperage and input voltage allowing the user to custom build a curve for their Wind turbine Please refer to the Wind secti
107. increase more radically with tower height in hilly or wooded areas In flat open areas power produc tion will increase less significantly with tower height The BWC EXCEL 1 wind turbine must be placed on a tower that is tall enough to give the rotor proper exposure to the wind Putting a wind turbine on a tower that is too short is like installing a solar system in the shade As a rule of thumb the BWC EXCEL 1 should be 9 m 30 ft above obstacles within 50 m 160 ft particularly in the prevailing wind direction So the minimum recommended tower height is 9 m 80 ft For most situations a tower of at least 18 m 60 ft is recommended for this unit Table 1 Variation in wind speed and expected relative energy output with tower height Average Tower Wind Relative Height Speed Energy Pro meters m s duction 100 127 5 6 19m 14796 155 185 We do not recommend mounting the BWC EXCEL 1 to a home and we suggest caution if installing one on a larger more substantial building Our concerns are 1 the forces on the turbine and mounting sys 25 tem are substantial and homes are not designed structurally for them 2 the air flow around and over a home or building is complex and can cause considerable turbulence and 3 the wind turbine will cause vibrations that will be amplified through the home s structure BWC offers a guyed tubular tilt up tower the Tilt Tower for the EXCEL 1 in heights form 9 m 30 ft to 32 m
108. isters are all Read Write You may write any values to these registers however this may result in erratic operation in some instances To set A static IP address be sure to clear the DHCP bit in register 20481 before writing the static values to the Network Address Name Units Description 20481 TP Settings 20481 Network Settings Flags See Table 20481 1 20482 IP Address 20483 msp 20483 The IP address of the 20483 20482 20482 Classic 20484 Gateway Address 20485 20485 Network Gateway Address 20485 20484 uss 20484 lt 20486 Subnet 20487 wss 20487 Network Subnet Mask 20487 20486 wss 20486 r 20488 DNS 1 20489 20489 sp Primary DNS Address 20489 20488 msp 20488 isp 20490 DNS 2 20491 20491 rsg Secondary Alternate DNS 20491 20490 20490 lt Address Read Only if the DHCP flag is set To assign a static IP to the Classic first clear the DHCP flag in the IP Settings Register 20481 Table 20481 1 Name Value Description DHCP 0x0001 Set this bit to enable DHCP Web Access 0x0002 Set this bit to enable online access to your Classic through http www mymidnite com 81 Page The Version Registers are all Read Only Writes to any of these registers will have no long term effect Version Address Name units Des
109. l email customerservice midnitesolar com for more information If anything is missing or damaged please refer to Page 2 for details on contacting us Figure 1 1 Removing and installing the front cover on the Classic Removing the front art deco cover is required to gain access to the wiring compartment Be aware there is a cable connecting the cover to the electronics Do not pull hard or fast as damage could occur 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 To re install the front cover of the Classic you will need to plug in the display cable and carefully route it around the components on the circuit board as you set the cover in place See Figure 1 2 Do not force the cover if it does not seat into place easily stop and look for any cables or wires that may be interfering With the cover seated in place install the four Phillips screws with a 2 Phillips screwdriver Figure 1 2 11 Page AAA iun LJ Ms wy AAA e Mounting the Classic 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 S
110. l towers with careful attention given to weld quality Stress risers and brittle materials must be avoided because of the possibility of fatigue and cracking We do not recommend aluminum be used due to the risk of cracking Fasteners should be U S Grade 2 or Grade 5 or equivalent Finish We recommend hot dip galvanizing after fabrication Pipe Tubing Sizes The following standard steel tubing sections have ID and OD dimensions that are compatible with the BWC EXCEL 1 shipped after Sept 2003 4 5 in OD 0 095 in wall thickness 4 in pipe 0 120 in wall thickness 120 mm OD 5 0 mm wall thickness 120 mm OD 2 5 mm wall thickness 32 1 y ams y Qvo y TIYIS ION OG v 0099 E y d3MOL L IX OD A39338 WWS X SJDNVAFIOL ATIVANYW ION OG WW SNOISN3WIQ G31 43NIO OVD 031312345 ISIMSSHIO SSIINN JONVAVIIO 3av1g NI 77 WW 0011 NI SE S WW S8 S3O Vd XIS NI WW LLG S 1 WW S WWILI p 60 51 27 3303 V1 1031333 O1 ONIM VIO 31vOdn NOIIdI42S3G v 83MOL XIS 51108 ONILNNOW l3Ld VOV YSMOL YAMOL 3GISNI SQv31 LAdLNO 3NIgalni 83MOL NI WW 0011 X3ddN YO NI OL WW 552 GO 32
111. left and right keys navigate to the settings to change and use the up and down arrows to adjust the desired fields e Press the COMMIT softkey at any time to commit the settings to the Classic s Flash memory Please note that static settings span two menu screens You may use the soft keys to navigate between the two menus Pressing the ENTER key in either menu saves all settings to Flash memory For convenience when you manually set the device s IP address the Gateway and Primary DNS addresses follow the change See the following sections for details on each of these fields IP Address This is the local network address of your Classic It usually takes the form 192 169 0 1 x or 10 0 0 x depending on your networking equipment You must be careful when selecting this address If it does not match your network subnet then the classic will not be able to communicate with the network If it is the same as another device on the network then collisions will occur causing both devices to act erratically Check your router settings or ask your network administrator which local address to use Also refer to the troubleshooting section for tips Subnet This refers to the class of local network you are using This depends on your network hardware but most users should use 255 255 255 0 for this field Gateway This is the address of your router or modem the device which is connected directly to the Internet proper It will usually t
112. n in the following table 15 14 13 22 21 109 9 8 7 6 5 4 3 2 1 OO 1 0 1 0 1 0 1 1 1 1 0 0 1 1 0 1 So that the binary digit indexed by 0 is 1 1 is 0 6 is 1 and 10 is 0 MODBUS registers are 16 bit 2 octet byte in size When using values from the map to indicate conversion formulas the following convention is used to access different octets Note that when talking about bytes or octets it is more convenient to describe them in hexadecimal base 16 form than in decimal Some values are expressed in bytes as it is a more compact way of dealing with certain classes of numbers IP addresses for example We use the C convention of referring to hexadecimal numbers by prefixing them with So the decimal value 10 is represented by the hexadecimal value 0x0A A note on Read Write The Classic MODBUS does not strictly enforce the Read Write accessibility of some registers It is possible to write to some registers marked Read Only This will usually have no effect on Classic operation but in some cases you may corrupt a register from which you wanted to read data In some cases the registers are reset internally as new values Additionally some counters are accessible directly For example the AbsorbTime 4139 timer is a suggested read only register however if your MODBUS application has reason to reset or adjust this register there is nothing to prevent you from changing it however you please Don t
113. n the Clipper Maximum and Minimum Wire Size The Classic DC terminal connector will accept wire from 14 24 AWG Commissioning the Classic The Classic will enter into the setup wizard upon initial power up If the Classic does not enter into the setup wizard or you want to enter the wizard at any time follow these steps to get into the setup wizard 4 Press the Main Menu button 4 Scroll Left or Right until Wizard is highlighted and press the Enter button Follow the on screen instructions through to the end Using the Classic Setup Screen s The Classic setup wizard will walk you through the set up process Below is a description of the steps DO YOU WANT PASSWORD Sets the password On Classic Settings ENABLED PASWORD WILL BE 142 YES CONNECTED TO Tells you which classic model it is CLASSIC 150 IS THISA This menu will determine how to treat batteries GRID TIED SYSTEM differently sealed batteries lower voltage for BATTERY BACKUP grid tied YES TIME DATE Set time and date this is important because 24 00 00 01 10 2010 Classic will automatically know at what time to wake up and go to sleep mode Sunrise sunset using Astronomical formulas BATTERY CHEMISTRY Sets up battery temp compensation and absolute FLOODED LEAD ACID maximum charge voltages regardless of temp ENTER BATTERY BANK VOLTAGE Selects between different voltage configurations 48 on the system increments of 12 volts 12v 24v 36v
114. nced causing the turbine to move slightly back and forth as it spins Wind is higher than 16 mph but rotor will not turn or turns slowly 22 Blown Turbine fuse Blown output fuse Power transistor failure Turbine rectifier failure possible damaged sta tor winding Blade tips not evenly spaced Ice build up on blades Short in power leads Power transistor or MOV varistor failure Check voltage across fuse with turbine spin ning should be near zero volts DC Reading on charge con troller erratic dump load light stays on check battery fuse with multi meter Turbine voltage is above 10 VDC and Tur bine light is on but no current is being deliv ered Check voltage from the turbine Check tip to tip distanc es with a tape measure They should be within 6 5 mm 4 Visual inspection Se vere icing is very obvi ous Check connections first Isolate power leads Use VOM to check for short circuit Disconnect turbine from charge controller Tur bine should start Disconnect turbine and check with diode meter Should read 1 V in one direction and OL in the other direction Replace fuse Replace 90A battery fuse on charge control ler circuit board Check battery connections Return complete charge controller to BWC for repair Replace rectifier as sembly or stator Loosening one blade at a time adjust the tip spacing to bring dis tances within specific
115. ne to the top with either a light duty crane or a gin pole A gin pole in this case is a tower assembly tool that attaches to the tower and provides an arm with a pulley so that parts can be hoisted above the top of the tower Gin poles are used by professional tower erectors and we do not recommend their use by non professionals We know of at least one homeowner 14 who died approximately fifteen years ago while improperly using a gin pole to install a small wind turbine though not a Bergey turbine Wherever possible we strongly recommend assembling the tower and turbine on the ground In this case please follow the general procedure for turbine assembly provided in the preceding section When raising the tower you must lift the tower not the EXCEL 1 wind turbine The EXCEL 1 cannot support the weight of the tower For customers installing a BWC EXCEL 1 on an existing fixed tower we recommend that you use a crane to lower the tower so that you can attach the turbine on the ground Alternatively we recommend you use a bucket truck like the type used by utility linemen Check with local sign companies because they often offer bucket truck services at reasonable hourly rates If neither of these approaches is possible then we recommend that you engage the services of professional wind turbine or tower erectors to install your wind turbine 15 7 Charge Controller Installation A Electrical System The general electrical configuration f
116. ng Other MidNite Products on the 38 Connecting Classic to Two MNGPs Network cable eese e eere nete ta seen senno 38 iig Pe 39 3 Page View Faults and WAEDIAO S 40 bin gEDNbic E 40 Uploading New Firmware to the Classit scssessssecsssssenssscssssssesssscssssssencsscosssssessssscsestsessssssseesosssesecsessess 40 Updating Classic Firmware Windows gt lt eo Ped ea 40 Connecting th Classic to the 55 ix ird v tke lax EV S6 Networking eneee tenaci enin 56 Network Setup Through th MNGP RARE 58 T 58 Tia 59 re MM CES ME EM MEME 59 SUDNI ae cancers E IM EU 59 59 DNS emp M 59 Rc ACCES RAM C 60 Dor Ty MEM A MEET 60 Adyanc
117. nuts per post before plac ing the new fuse to accommodate the straight tabs on the stock fuse Dump Load Fuse 60 amp or 63 amp Buss P N JJN 60L or JJN 60 or Little Fuse JLLN 60 using 2 x M6 brass nuts per post as described for the Turbine Fuse 20 9 Trouble Shooting Problems The following guide can be used to pinpoint the cause of operational problems with the BWC EXCEL 1 wind turbine and the charge controller For problems or symptoms not found in the following listing please contact the Service Department at Bergey Windpower Co at Tel 405 364 4212 Fax 405 364 2078 e mail service bergey com Battery voltage gets Charge controller regu Excessive battery gas Adjust battery regulation too high lating voltage set too sing Use voltmeter to voltage as on page 9 high check battery cell volt ages or hydrometer to check the specific gravi ty compare to battery manufacturers recom mendations Batteries do not reach Charge controller regu Use hydrometer to Adjust battery regulation full state of charge lating voltage set too check the specific gravi voltage as on page 9 low ty of the battery cells Compare with battery manufacturer s recom mendation Loads are too large Remove largest load If Consult with BWC about battery bank reaches possible remedies higher state of charge then the system is over loaded 21 Rotor turns but the system doesn t charge the batteries Rotor is unbala
118. o adjust Use up and down arrow keys to lower or raise the voltage Press the Enter button to save the new voltages Battery Size and Chemistry The Classic supports a variety of battery chemistries including Flooded lead acid sealed AGM gel cell and Nickel Cadmium These different types of batteries have different charging parameters These parameters are crucial for long time battery life Go through the WIZARD to select the battery type of your system If you replace the batteries for a different type make sure you change the type on the WIZARD That is the only place where the battery type can be changed Battery Temperature Compensation The Classic comes with a battery temperature sensor BTS This sensor raises or lowers charge voltage based on temperature Connect BTS to the BATT TEMP jack Refer to fig 1 7B and 1 9 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 use the default charge voltages non compensated 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 Figure 2 4 com
119. olar 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 12 Page Classic has four one inch knock outs that are pre cast The Classic has mounting locations and conduit locations are similar to other brands of charge controllers to facilitate ease of upgrading older technologies Mounting the Classic directly to the E Panel Remove the front cover of the Classic nstall 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 the 1 inch close nipple into the E Panel as shown in the E Panel directions The 1 close nipple 3 locknuts and 2 plastic bushings are included with each E Panel One locknut acts as a spacer Carefully hang the Classic on the screw in the bracket and slide it over the close nipple see figure 1 3 nstall the lock nut and bushing on the close nipple and tighten the screw in the mounting bracket Don t install the front cover until you complete the wiring of the Classic Figure 1 3A Charge controller bracket mounted to the E Panel The bracket comes with every E Panel Figure 1 3C Nipple locknuts and bushings that come with every E Panel Figure 1 3D Classic mounted to the side of a MidNite Solar E Panel 13 Page Install locknut here to act as a spacer Alternative
120. omplete Float RESERVED 0x04000000 RESERVED EqCountUpf 0x08000000 EQ Timer is counting Up RESERVED 0x10000000 RESERVED RESERVED 0x20000000 RESERVED RESERVED 0x40000000 RESERVED RESERVED 0x80000000 RESERVED 76 Page AUX 1 and 2 modes Extracted and encoded as combined in Aux12Function Table 4165 1 AUX 1 Off Auto On Extracted Encoded as Aux12Function bits 6 7 Name Value Description Aux 1 Off 0 Aux 1 output is OFF 0 Volts Aux Auto 1 Aux 1 operates as defined in Aux2Funtion Aux On 2 Aux output is ON 14 Volts Aux Unimplemented 3 Unassigned at present Aux1OffAutoOn Aux12Function amp 0xc0 gt gt 6 Table 4165 2 AUX 2 Off Auto On Extracted Encoded as Aux12Function bits 14 15 Name Value Description Aux 2 Off 0 Aux 2 output is OFF 0 Volts Aux 2 Auto 1 Aux 2 operates as defined Aux2Funtion Aux 2 On 2 Aux 2 output is ON 14 Volts Aux 2 Unimplemented 3 Unassigned at present Aux2OffAutoOn Aux12FunctionS amp 0xc000 gt gt 14 Table 4165 3 AUX Function Extracted Encoded as Aux12Function bits 0 5 Name Value Description DIVERSION SLW 1 Non PWM On at gt Aux VoltsHiAbs Off at Vbatt lt Aux1VoltsLoAbs Active High DIVERSION SLW 2 Same as DIVERSION SLW but Active Low BAT DIV V REL 3 Non PWM On at gt Aux VoltsHiAbs Off at Vbat
121. on of the manual for full details on programming the curve as well as our video that will help in understanding how to adjust these curves using the wind graph editor Dynamic This is typically used for PV solar input sources and tries to follow on a slow dynamic basis the changing conditions of the input source This mode has one user adjustment which is a forced sweep perturb trigger interval for times when the input condition changes do not trigger a dynamic sweep The interval is in units of minutes U Set VOC This is a fully manual mode based on a percentage of VOC The Classic will sweep based on the user set time in minutes and then park at a user set of the the Classic found on that sweep This mode is 29 Page useful for testing or constant voltage sources The ON OFF has to be set to OFF in order to change the operational mode Scroll to the right to highlight the word ON or OFF and use the up and down keys to change it to OFF Push the Enter button to save this change Now you can scroll to the right and highlight the mode under Function Scrolling up or down changes the modes Once a mode is selected push the Enter button to save this change Then you can use the right soft key to select setup This would be where you will manually set up any parameters specific to the mode you selected Configuring the Classic for Wind Input Source Wind If you selected Wind you will need to select a power curve from t
122. or BWC EXCEL 1 installations will typically involve AC alternating current converting to DC direct current power and they will be used through a connection to the Mid night Classic charge controller to charge 48 volt batteries The charge controller has a limited current carrying capacity so we recommend that you use a DC Source Center whenever you have multiple EXCEL 1 wind turbines DC Source Centers are available from Ber gey Windpower and from other sources Additional Design Guidance 1 If you have multiple EXCEL 1 turbines and charge controllers do not connect more than one wind turbine to one charge controller 2 Connect multiple charge controllers to a DC Source Center via the charge controllers battery terminals 3 Do not connect the charge controller to another controller that could disconnect the charge con troller from the batteries The charge controller should not be disconnected from the battery when there is input from the wind turbine 4 Do not connect the charge controller to the batteries through diodes B Location The charge controller must be installed indoors and should be located relatively close to the battery bank Do not install the charge controller outdoors it is not waterproof C Mounting The charge controller needs to be mounted vertically to a wall or other support structure so that air can pass unobstructed through the passive cooling channel behind the enclosure We recommend setting the hei
123. pare 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 match both of the readings Press the Enter button to save 4 4 4 27 Page Note Use the description below to help complete the calibration of the Classic voltages TWEAKS screen Battery voltage adjust PV in voltage adjust PV in voltage 0 offset Displayed MASTER ical Displayed battery voltage battery voltage Figure 2 7 OFFSET Battery voltage offset 12 6 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 Scroll to the right and highlight the current Mode than use the up and down arrows to set the mode you want 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 2 t tow Oe The following Modes will appear in this order in the MODE Menu Micro Hydro This mode is intended for use with hydro systems but can be used with other sources as well When the Class
124. pical wire size for output is 6GAWG for the Classic250 4AWG for the Classic200 and 150 but check all de ratings for your wire type and installation method Long Distance Wire Runs The Classic offers some unique opportunities 1f 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 15 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 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 busbar that accepts up to 1 0 wire 24 Page Connecting the Classic to the Clipper Not Yet Available Please email customerservice g midnitesolar for status updates o
125. ple to understand and use The Classic DC GFP works a bit different than others 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 simply turns off when a ground fault is detected This 1s different than disconnecting the PV plus circuit This trick of turning off was first pioneered by another charge control company as an alternative to a 100 external circuit breaker assembly The Classic s system consists of a PTC that is between the Negative and Ground internally in the Classic A PTC is basically a type of resistor with a 1 ohm value that when loaded to three quarters of an amp will heat up and go to a very high resistance looking like an open circuit One of the 3 Classic microprocessors watches the PTC and when it sees a high resistance it will disable the Classic The ground fault device will then require a manual reset The PTC is self healing though so there are no fuses to change This method meets the requirement for DC ground fault protection in the National Electric Code To disable the internal Ground Fault Protection function the jumper labeled GFP needs to be removed and the GFP function must be disabled in the TWEAKS menu See section below 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 batter
126. put 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 X X fte X fe X X 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 P Someone should be within range of your voice to come to your aid 1f 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 X X 6 Page 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
127. r be cause the bearing seals have not worn in Battery charging should commence shortly after the rotor spins up to speed Once turning the rotor will continue to turn in lower wind speeds down to approxi mately 2 5 m s 6 mph All operational wind speeds given as sume steady winds sea level altitude and moderate temperatures Hot weather high altitude turbulence and gusting winds will reduce system per formance The rotor speed will increase with increasing wind speed and the system will provide a higher output This output increases rapidly because the energy available in the wind varies as the third power cube of the wind speed For example if the wind speed doubles from 5 m s 11 2 mph to 10 m s 22 4 m s the energy in the wind increases by a factor of eight 2 2 x 2 x 2 8 One result of this relationship is that there is very little energy available in light winds For the average site winds in the range of 5 5 9 m s 12 20 mph will provide most of the system s annual energy production B High Winds AutoFurl During periods of high wind speeds the AutoFurl system will automatically protect the wind turbine When furled the power output of the turbine will be significantly reduced In winds between 13 m s 29 mph and 18 m s 40 mph it is normal for the turbine to repeatedly furl unfurl and then furl again In winds above 18 m s 40 mph the turbine should remain continuously furled AutoFurl is
128. re to the terminal marked BAT With the battery positive wire touch the pad marked POLARITY if red LED D80 lights the connections are backward double check everything to find the cause The green LED D70 should come on if it does leave the wire in contact with the POLARITY CHECK pad for 5 seconds to charge all capacitors and avoid a spark when making the battery connection Quickly connect the battery positive wire to the terminal marked BAT The system will not operate correctly and could be damaged if the polarity is reversed Step 5 Bolt the tail fin to the tail boom using the eight M5 bolts and washers provided as shown in Figure 6 We recommend applying Loctite to the bolt threads prior to assembly 11 Tail Fin Fasteners Figure 6 Tail Fin Attachment Step 6 Place the tail boom on the rear of the turbine powerhead and insert the 12 mm 1 2 tail pivot pin from the top If the parts are aligned properly the pin should insert easily Do not use a hammer to pound the pin in place as this may cause scoring of the bronze bushings Secure the tail pivot pin with two flat washers and cotter pins as shown in Figure 9 Note Failure to properly install and secure both cotter pins will lead to loss of the tail boom Let the tail hang down so the turbine head turns part way up for easier blade assembly Step 7 Turn the EXCEL1 powerhead so that the alternator is facing up Attach the blade
129. 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 86 Page HyperVOC Origins HyperVOC can be useful in overcoming an industry shortcoming in charging 48 volt battery s with standard panels For example let s take a sample system with Solar World 165 s that have a VOC of 44 1vdc The industry has limited us to 2 of these panels in series making it hard to charge a 48vdc battery on hot summer days With the Classic we designed in Hyper VOC to allow you to run 3 of these in series 3 panels at 44 1vdc will give you a total VOC of 132 3vdc When temperature compensated for cold climates to 125 gives you 165vdc This is above the maximum safe limits for most controllers but falls well into the Hyper VOC range of the Classic We do have to use Hyper VOC wisely though if we abuse it the Controller will never wake up in colder weather Troubleshooting 87 P
130. s as shown in Figure 7 using the M10 hardware provided Insert bolts and start all three blade nuts Then partially tighten the nuts in the order shown in Figure 8 We recommend bolting one blade up solidly and leaving the other two somewhat loose while you check the tip to tip blade distance We recommend checking and adjust ing as necessary the blade tip spacing to ensure that the blade tips are equally spaced This step will help make the wind turbine as smooth running as possible which will maximize the operating life of the bearings and reduce vibration related noise The blade tip to tip distances should not differ by more than 1 2 for smooth operation Finally torque the nuts in order shown in Figure 8 to 45 ft lbs each Loctite is not necessary on the blade fasteners because the nylon locking nuts provide adequate locking NOTE For EXCEL 1 s shipped after September 2003 all of the blade bolts are the same length 12 2 Spinner Fasteners Blade Nuts amp 7 2 Washers RS RN Longer bolt goes here a P A n IN SSH 5 Figure 7 Blade and Spinner Fasteners Figure 8 Nut Tightening Order Step 8 Attach the spinner nose cone using the three M5 bolts and washers provided as shown in Figure 7 We recommend applying Loctite to the bolt threads prior to assembly 13 Note Install M12 Flat Washers between cotter pins an
131. s changed to a different nominal voltage e g from 24v to 12v or to 48v etc manually adjustments may be required See page 6 for further infi information Table 6 2 vu 12 24 3 48v 60v 72 Bulk 14 3v 28 6v 42 9v 57 2 71 5v 85 8v Float 13 6v 27 2 40 8v 54 4v 68 0v 81 6v Equalize 14 3 28 6v 42 9v 57 2v 715v 85 8v To adjust these voltage set point see page 25 of this manual Optional accessories Optional accessories for the Classic include Blank display for multiple Classic installations MidNite network cables various Lengths Regulatory Approval 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 CONFORMS TO UL STANDARD 1741 2ND EDITION MAY 7 1999 WITH REVISIONS THROUGH JANUARY 28 2010 CERT TO CAN CSA STD C222 3084883 1071 2001 0901 90 Page Warranty MidNite Solar s Classic comes with a standard 5 year warranty we will repair or replace the Classic at no charge to the consumer during this 5 year period End of Warranty tune up MidNite Solar offers a industry first Tune up Extended Warranty 6 months prior to the end of the warranty period Customers can ship their Classic back to MidNite Solar with
132. s take effect 33 If MNGP MidNite Graphics Panel needs to be updated as well turn OFF the battery breaker to the Classic Click on the MNGP button on the MidNite Update GUI then turn ON the breaker 34 Wait until the uploading percentage reaches 100 and then turn the battery breaker to the classic OFF and then ON Turning the breaker off and on resets the Classic so the new settings to take effect This now completes the firmware installation The battery settings saved graphs and LCD settings on the Classic will remain the same Beware If the Classic has been updated with a different model of Classic firmware than the factory default the charge controller will display a WRONG CODE message on the bottom right corner of the Status screen and it will not turn ON Connecting the Classic to the Internet Networking The Classic supports standard 10 100 base T Ethernet networks For Gigabit networks you will need a common network switch that is capable of mixed mode operation The Classic may also be placed on a b g or n wireless networks by using a wireless network bridge device Depending on your network you may use one of the topographies detailed in Figures 5 5 3 Note that the switch may be self contained or in many cases may already be integrated into your cable or DSL modem Refer to Figure 1 7B for Ethernet connector location in the Classic 56 Page 4 Port Switch Router Figure 5 Local network throug
133. sert it now What do you want the wizard to do O Install the software automatically Recommended Install from a list or specific location Advanced Click Nex to continue 19 Select Search for the best driver in this location Check the Include this location in the search checkbox and then click Browse 49 Page 20 Browse to the MidNite Solar folder located on the C drive and click OK Browse For Folder Select the folder that contains drivers for your hardware Local Disk C To view any subfolders cick plus sign above 21 Click Next Found New Hardware Wizard Please choose your search and installation options Search fot the best driver in these locations Use he check bases below to n or expand the defaut search which includes local paths and removable media The best diver found wil be C Seach removable mada floppy CD ROM v Include this location in the sesch pws Don t search val choose the diver to intall Choose this option to select the device driver from a list Windows does not gusartee that the diver you choose wil be the best match for your hardware Cima Jes Coma 50 Page 22 In the Hardware Installation dialogue box click on Continue Anyway Hardware Installation The software pou installing for this hardware USB serial pod emulation has nol passed Windows Logo testing lo werty
134. ssscorssoessessscssssesoossscscssesssssvessssessssscescseessessoessseecsecssess 17 Ch ssis 19 DC Svstem Grounding asso ocium ion 19 DC GFP Ground Fault Prof cUOD 20 Disabling GEP re 20 Wiring the YS T 21 DC Terminal C OWS CUE EE 23 Over Current Protection and Wire Size Requirements ccsscccsssccsssseccsssccsssessssssssscssessssseseeeees 23 23 Over Current PROTECTION a ossis ze satis Pug ducat a Ev EET dw E O AKERE EE 24 Long Distance Wre RUNS sasarina ea ei Duque I cnt pad 24 Connecting the Classic to the CI ur 25 Maximum and Minimum WATE S126 55 eee ee aoe 25 Commissioning th CUS SIC crc 25 Using th Classi Setup SCREEN 25 Med ir iraAlirr e 26 Battery Charge Stages and MeSIMIBS 1 2nsccacinardeasnsnadeestionssshnlsnindanteyabeahasnensiabnsansensesendesdaendeskennsistntned 26 Bulk MPPP UM SUE 26 PRIS OE 26
135. stalled 60 160 from the owner s house Never choose a site that is closer to a neighbor s home than to your own 2 The local elevation at the tower site Since system performance improves with increased wind turbine elevation it is sometimes best to site the tower on a hill or ridge to gain extra height If as is often the case however the hill or ridge is a consid erable distance more than 330 from the house the additional wiring costs may more than offset the per formance gain to be realized It is often less expensive to avoid the hill and simply chose a taller tower installed closer to the house 3 The length of the wire run While is possible to install wire runs the wiring between the wind turbine and the wind turbine electronics of 650 or more the costs for long wire runs particularly if they are buried can be prohibitive The longer the wire run the larger and more expensive the wire that is required to conduct the electricity with ac ceptable losses As a general rule wire runs over 330 if buried or 650 if installed overhead should be avoided because of their high costs On the BWC EXCEL 1 it is not possible to use transformers to in crease the wire run voltage because the wire run is direct current DC Transformers only work with al ternating current AC 4 General convenience Often the most compelling consideration for locating the wind turbine tower is the space where it will not interfere with ve
136. staller for assistance Incorrect reassembly risks malfunction electric shock or fire The Charge Controller is designed for indoor installation or installation inside a weatherproof enclosure It must not be exposed to rain and should be installed out of direct sunlight For routine user approved maintenance Turn off all circuit breakers including those to the solar modules batteries and related electrical connections before performing any maintenance Standards and Requirements All installations must comply with national and local electrical codes professional installation is recommended The NEC in the USA requires a DC ground fault interrupter for all residential PV installations NEC2011 requires an ARC FAULT detector on all charge controllers and inverters operating above 80VDC Both of these devices are built into the Classic DC and Battery Related Installation Requirements X 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 19 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 out
137. t lt Aux1VoltsLoAbs Active High BAT DIV V REL Non PWM On at Vbatt gt Aux VoltsHiAbs Off at Vbatt lt Aux1VoltsLoAbs Active Low PV V TRIGGER 7 Active High output if Vin exceeds VoltsHiPv PV V TRIGGER 8 Active Low output if Vin exceeds Aux 1 VoltsHiPv MANUAL ON OFF 9 MANUAL On Off allowed using Off Auto On Selection TOGGLE TEST 13 Out Once per second On Off On Off automatic toggle NITE LITE HIGH 14 Active High indicating Night Time Inactive at Wakeup NITE LITE LOW 15 Active Low indicating Night Time Inactive at Wakeup WIND CLIPPER 16 Output goes Active High when V input is above PV input V plus headroom voltage AuxlFunction Aux12Function 77 Page amp Ox3f Table 4165 4 AUX 2 Function Extracted Encoded as Aux12Function bits 8 13 Name Value Description DIVERT DGTL 0 Digital Out PWM Battery Diversion Active High DIVERT DGTL F 1 Digital Out PWM Battery Diversion Active Low BAT DIV V REL 2 Digital Out PWM Relative to Charge Stage Voltage Threshold Diversion Use It Or Lose It Active High BAT DIV V REL 3 Digital Out PWM Relative to Charge Stage Voltage Threshold Diversion Use It Or Lose It Active Low TOGGLE TEST 6 Out Once per second On Off On Off automatic toggle PV IN TRIG 7 Active High output if Vin exceeds Aux2VoltsHiPv PV IN TRIG 8 Active Low output if Vin exceeds Aux2VoltsHiPv MANUAL ON OFF 9 MANUAL On Off allowed using
138. t points to negative numbers and the numbers are an offset from the voltage set point For example 2 would turn Aux 1 off 2 tenths of a volt below your set points This mode will allow you maximum diversion while maintaining your 3 stage charging It also allows you to set a delay time in seconds the Classic will wait before turning Aux 1 off after reaching the V High set point It also allows you to set a hold time in seconds the Classic will wait before turning Aux 1 on after reaching the V Low set point Opportunity Hi This mode will turn Aux 1 on when the Classic gets within a certain range of the voltage set points for each charging stage V High and turn Aux 1 off when it gets to a low set point V Low These set points are user adjustable and will allow the Absorb Float and EQ timers to continue to run You will adjust these set points to negative numbers and the numbers are an offset from the voltage set point For example a 2 would turn Aux 1 on 2 tenths of a volt below your set points This mode will allow you maximum diversion while maintaining your 3 stage charging It also allows you to set a delay time in seconds the Classic will wait before turning Aux 1 on after reaching the V High set point It also allows you to set a hold time in seconds the Classic will wait before turning Aux 1 off after reaching the V Low set point Low bat disc This mode will turn Aux 1 off when it reaches a set point based on battery voltage V High an
139. t voltage until the batteries are charged or it reach Float stage 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 The battery it s considered full at the end of the absorb charge cycle 26 Page Float A Float cycle follows after the Absorb cycle is completed Float is displayed on the screen Battery vol tage is held at the float voltage set point float time can be changed by the user Equalize Equalization function has to be enabled by the user refer to page 25 The intent of an equalization charge is to bring all battery cells to an equal voltage by a deliberate overcharge The goal is to return each bat tery cell to its optimum condition through a series of voltage controlled chemical reactions inside the bat teries Adjusting Absorb Equalize and Float Voltages Setting the Classic up through the wizard will set Absorb Float and EQ to the factory default set voltage to the specified battery type E g Flooded Lead Gel These voltages are fully adjustable just follow the steps below Press Main Menu Scroll to the left until Charge is highlighted and push the Enter button Highlight Volts and press the Enter button Use left and right arrows keys to highlight the set point voltage t
140. ted switch to the ratings of the relay The Aux 1 output can be set to operate at either normally open Active High or normally closed Active Low when the Aux 1 function condition is true For more information see Table 2 1 page 31 This is ideal for an Auto Gen Start 92 Page Aux 1 Voltage Time Relation Relay 12v Aux 1 Function Graph shows the relationship between voltage and time of AUX 1 The axis labeled VOLTAGE could be battery PV wind input voltage etc depending on the function selected by the user VHIGH is the upper voltage limit as soon as the voltage reaches this limit the Delay time will then start as soon as the Delay time expires AUXI will change state and stay there until the voltage drops below VLOW set point then another timer called Hold Time will start and when this expires the out put will go back to the original state VOLTAGE JDELAY TIME HOLD TIME TIME AUX 1 OUTPUT Aux 2 Voltage Time Relation PWM The graph below describes the relation in Aux 2 between voltage and time The difference in Aux 2 1s the use of PWM running at a hundreds of Hz rate and is suitable for use with Solid State Relays SSRs The way this works is user sets a desired threshold and a width voltage this means that at the desired voltage VOLTS the aux will start to PWM and it has to go above or below the width to completely change states from Ov to 12v or from 12v to Ov depending on the user s
141. tp www bergey com from BWC dealers and from BWC directly Figure 1 EXCEL 1 with 60 Tilt Tower 2 Cautions and Warnings This manual contains important information on the installation of your BWC EXCEL 1 wind turbine and charge controller We strongly recommend that you read and follow the instructions contained in this manual At several points in the manual items of special interest or significant impact are highlighted by one of the following notices Warning Hazards or unsafe practices that could cause personal injury or death Caution Hazards or unsafe practices that could cause product damage Significant points of interest 3 Identification Each BWC EXCEL 1 48 wind turbine has a serial number decal located on the tower mount The Serial Number is also written on the box that the turbine came in We recommend writing it here as well BWC EXCEL 1 48 Serial Number 4 System Description EXCEL 1 Wind Turbine Components The major components of the EXCEL 1 wind turbine are shown in Figure 2 A Blades Rotor System The rotor system consists of three fiberglass blades Acting like aircraft wings the blades convert the energy of the wind into rotational forces that can drive a generator The airfoil on the EXCEL 1 is the new SH3045 developed specifically for the EXCEL 1 by Bergey Windpower The fiberglass blades are excep tionally strong because they are densely packed with glass reinforcing fibers th
142. uizis 1exee4g 21558 2 0 09 89 99 29 19 66 S9 e eZ 9 59 cL vL 59 OL vl 22 97 82 62 92 c8 c6 97 v8 6 08 6 c6 68 v6 96 98 v6 96 446 9Vv 99 GLe GL Sl CoS EE E 99 9 61 26 68 99 99 Sc 6 OL LEZ 68 Sc 6 0 62 89 916 80 917 Eeg 81 98 EY Srt 26 68 002 002 004 002 081 081 081 081 09 09 09 091 021 021 01 021 02 OL OL 02 021 02 0 OLL OLL 001 00 001 06 06 06 OL 04 04 cL 8 vc 8 vc 22 8v 22 9v 22 8v ve cb 8v ve gv vc 9v vc 9v vc 8v 8 062 21558 2 052 21558 2 052 21558 2 062 osseo 052 osseo 062 2185812 052 21558 2 062 21858 2 002 2155812 002 218580 002 2188812 002 osseo 002 2185812 002 218580 002 215580 002 2155812 002 2155812 002 osseo 002 215589 002 2155812 002 9ISSe 002 215580 002 9ISSe 091 21558 2 08 2155812 06 osseo 061 21558 2 091 21558 2 091 osseo OS 21888 0 061 2185812 OS 21558 2 08 21558 2 061 21558 2 091 21558 2 08 21558 2 OS osseo OS osseo 94 Page Status Menu Battery Status Home screen Input Status MoonScope About Classic 95 Page Apr 28 2011 CLASSIC MENU MAP MidNite Solar Inc Main Menu Wizard nn Mode Au
143. y breaker to OFF position and then to ON position 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 20 Page Wiring the Classic WARNING Shock hazard Disconnect the batteries and input power before opening the Classic front cover When two or more Classics are paralleled onto one DC Source a blocking diode must be used between each Classic and the input source to isolate each Classic from the other ones The Classic should be wired by a qualified professional and needs to meet all applicable electrical codes Always make sure all source and battery circuits are de energized and wait 5 minutes before working on the wiring in the Classic The Classic has 2 common neutral negative terminals Therefore only one neutral conductor is required to run from the E Panel and terminate on either or both common neutral terminal The Positive DC source wire goes to the PV Turbine screw The Positive Battery DC wire goes to battery terminal Torque the terminal screws to the specs below To connect the wiring to the Classic Ensure
144. y will rub the tower and eventually develop a short circuit Use crimp type ring lugs Use 00 4 Those Y vei ae i These DO use the built in polarity checker when connecting the battery leads to the charge troller Connect either battery lead to the Neg battery terminal on the charge controller and then touch the other lead to the Polarity Test Point A green LED is good a red LED shows that the polarity is reversed Do Not connect your test wire to the Pos terminal Use the same procedure when connecting PV to the charge controller Please note that the Neg Battery terminal is on the LEFT side while the Turb Neg terminal is in the RIGHT side DO NOT install a circuit breaker between the charge controller and the battery bank Using a circuit breaker on the output of the charge controller can allow the charge controller to be open circuited under high output condition which can damage the system If you are using a Trace Power Panel Do Not connect the wind turbine to the PV Array Disconnects in the DC Disconnect Box Do connect the charge controller to the top of one of the Battery Disconnects Pos and the Grounding Block Neg DO NOT install the wind turbine close to a steep slope or cliff If the wind can blow up at an angle as it hits the wind turbine the furling will be hampered and the turbine will experience ex cessive loads and vibration This is most important from the prev

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