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Classic 150 Manual

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1. Battery Absorb Float Equalize Absorb Absorb Equalize Time Equalize Type Voltage Voltage Voltage Minimum Maximum minutes Interval Time Time days minutes minutes 12 Volt battery Gel 14 0 13 7 30 90 Sealed 1 14 2 13 7 14 4 30 90 60 28 Sealed 2 14 3 13 7 14 6 30 90 60 28 AGM 144 13 7 15 1 30 120 120 28 Flooded 1 14 6 13 5 15 3 30 120 120 28 Flooded 2 14 7 13 5 15 4 30 120 120 28 Flooded 3 154 13 4 16 0 30 180 180 14 Custom 24 Volt battery Gel 28 27 4 30 90 Sealed 1 28 4 27 4 28 8 30 90 60 28 Sealed 2 28 6 27 4 29 2 30 90 60 28 AGM 28 8 27 4 30 2 30 120 120 28 Flooded 1 29 2 27 30 6 30 120 120 28 Flooded 2 29 4 27 30 8 30 120 120 28 Flooded 3 30 8 26 8 32 30 180 180 14 Custom 48 Volt battery Gel 56 54 8 30 90 Sealed 56 8 54 8 57 6 30 90 60 28 Sealed 2 57 2 54 8 58 4 30 90 60 28 AGM 57 6 54 8 60 4 30 120 120 28 Flooded 1 58 4 54 61 2 30 120 120 28 Flooded 2 58 8 54 61 2 30 120 120 28 Flooded 3 61 6 53 6 64 30 180 180 14 Custom Tf Auto Eq is set to Auto then the Equalize interval is in effect If Auto Eg is set to Manual the Equalization stage will not occur unless started manually Table 9 60 Page 10 001 1 REV Classic owner s manual continued Using MNGP Remote to program a Classic Lite The Classic Lite can be programmed using an MNGP remote This is an easy way to get into and program not only the basic functions but the
2. OMY OMY OMY OMY OMY OMY OMY OMY OMY OMY OMY ESOP Or 909 es 04 09 09 07 08 es 909 eb 809 0 9 z9 01 88 i9 909 es 08 04 58 06 08 e 06 08 el 0 9 9 08 07 58 06 08 e 06 08 bl 08 02 lt 9 0801 ol 06 08 be 06 08 dL 06 08 94 06 08 8 06 08 6L 06 08 9 001 06 28 6 06 08 9 001 06 ve ook 6 06 08 08 ook 16 00 6 001 06 8 v6 ool 96 001 06 98 v6 00 96 Bulzis Jayeelg oisse 3 LEZ Oy tee 8394 ez SLE SL GL ccc E 999 geek tel 6 ees et 991 sz El OL 9v vec 585 sz S OL 622 89v 916 80 91 tee 28 g2 GL Sr cec 585 ooz ooz ooz ooz Osh 084 08 08L 09 09 09 09 orl Otk Obl Ork OzL Ozl ozi Oz OZ 0 Oz Oct Oz OzL OL OL OLL 00 ool 06 06 06 OL 7 0 91e Sjoxeelq JejoS eL 8r vz zi ZL 8r vz e c 8r yz e eu 87 yz zl El sy vz e er ve e sy vz zi sy ve a sy ve e 8v ve 2 er vE e 086 osseo 065 osseo osz 91558 0 066 91558 0 096 osseo 007 91558 0 OGz 2 sse 5 086 9ISSRIO ooz 51558 0 006 9ISSRIO 005 osseo 006 91558 0 007 51558 0 006 9ISSe o 005 osseo 006 51558 0 006 55 005 asse 007 51558 0 006 91558 0 006 9 556 ooz 51558 0 006 91558 0 OG osseo OSL 91558 0 OSL osseo OG osseo 091 91558 0 OSL 51558 0 OSL 9 586 OG osseo OSL 91
3. Equalization with the Classic Lite Commissioning the Classic Quick Start Battery Charge Stages and Meanings Page 10 001 1 REV C Classic owner s manual continued Adjusting Absorb Equalize and Float Voltages Current Limit LED Modes and the Blinking Red LED Calibrating Battery and PV Voltage Configuring DC Input Source Configuring the Classic for Wind Input Source Setting the Date and Time Setting Longitude and Latitude jiciicccscsittsccssdssccecssinssscccsscssscecocssisocsccsssbesteastsnsncosidacassesesstaoessotetsastsedtoasobsdistersbeatessto 36 Aux 1 Voltage Time Relation Relay 12v Aux 2 Voltage Time Relation PWM Setting he MNGP features 44 Navigating the Menu s Viewing Other MidNite Products on the Display Connecting Classic to Two MNGPs Network cable cdsi rasaire inaen i arisi Shas Eaa NESSE oor ois 46 Arc Fault View Faults and Warning s View Logged Data Graphical Logging Display modes Dealer Information Screen assic Lite Program LED explanations Programming 54 Dip Switches Section 1 Switch settingsexplained ensar 56 Section 2 Switchsettingsexplained nsan 57 Battery voltage
4. 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 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 Table 5 The Following is a list of the Aux 1 and 2 functions with brief descriptions of their function Aux 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 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
5. se 14 4 28 7 58 4 12v Nominal Battery Voltage 24V 48V Table 1 as 200V Classic Power Graph so 79A 1137W 78A 2238W IA 11081 78A 4550W 75 e 74 2123W 73A 10500 fee m g 74A 1065W 2066W 65A 5414W 2 65 65A 37 T MPPT Input Operating Voltage 63A 5247W 160V PV 140V PV 55 4 120 Pv mMm 70 PV 50 53A 4414W vd 14 4 28 7 58 4 83 3 Nominal Batt Vonage 12V 24V 45V Table 2 10 Page 10 001 1 REV C Classic owner s manual continued 250V Classic Power Graph 65 61A 878W 62A 1779W 4 60 x a A 60A 55 58A 1722W 554 3212W 835W B 5 H 3095W 3728W Ba 43A MPPT Input Operating Voltage SS 29 180v PV Pp Ar 200V PV 3468W 14 4 28 8 43 2 57 6 72 86 4 Nominal Battery 45v 24V 48V am Voltage Table 3 250VKS Classic Power Graph A 564 800W 58A 1660W ASS 180 2900 50 a 56A 53A 1600W 40 750W BE 30 Operating Voltage 20 35A 4 180v Pv 5000w h 200V PV 10 gt 14 4 28 7 58 4 143 3 pr Battery 12V 24V 48V 120V Table 4 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 selec
6. Classic can be set up to automatically equalize your batteries periodically programmed as days between Equalization and the number of days the Classic will try to finish the programmed equalization charge cycle To set up Auto EQ go into the CHARGE menu and highlight EQ and press Enter Now press the SOFT RIGHT key labeled AUTO EQ Pressing the AUTO EQ soft key enters the Auto EQ setup menu screen The left side of the EQ setup menu will show and select the number of days or interval between auto EQ charge cycles If set to zero 0 it will display MANUAL which is the same thing as DISABLED Mir e Figure 18 On the right side of the Auto EQ setup menu is the number of DAYS that the Auto EQ will retry if it does not finish the number of Hours and Minutes the Classic has been programmed to EQ for during the first day For instance you set the Auto EQ for an interval of every 30 days and the RE TRY for 3 days Then the first day it attempts an EQ the Classic only accumulates 1 hour of a 2 hour EQ cycle the next day the Classic will re attempt the EQ cycle If the Classic still didn t finish the EQ cycle on the 2nd day of its 3 allotted re try days it will have one more day to try to finish the Equalize cycle A fter this if it did not complete the 2 hours of EQ time it will not continue another day The Classic will show EQ DONE on the status screen until either the start of the next day or until the user presses a butt
7. MidNite Solar have been designing renewable energy disconnect boss for tweety years The majority of the existing disconnect bores wero detigned by us We Bink we have finally get eight People in the industry have spent years teaching us what is important to tham Our E Panels take care of the over curront and disconnect requirements This allows you to devote more of your hard samed money lo he performance components such as PV panels power electronics and batteries Bahia Figure 26 Prepare Classic charge controller for update 1 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 Figure 27 63 Page 10 001 1 REV Classic owner s manual continued 2 Remove the four screws holding the front cover of the Classic charge controller Do not let the front cover hang by the cable Figure 28 3 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 casting Figure 29 64 P age 10 001 1 REV C Classic owner s manual continued 4 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 Figure 30 Figure 31 Connecting the Cl
8. NC Milo Be Milos Milo He Ms G AUX OUTPUT 1 13VDC 200mA RECONFIGURABLE AS 3 JC 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 S WITH 75 C MINIMUM RATED COPPER CONDUCTOF 78 Page 10 001 1 REV C Classic owner s manual continued RS232 Jack Pin Out o X KSV power M NGP Fe Ys un 4 GND power REMOTE S 0 gt LED Normally internal MNGP TT or x SLAVE or 3 GND power z o3 eno poe EXTERNAL MNGP E 4 o CONNECT TO E Mum SLAVEOr I7 5 Mew EXTERNAL MNGP eO NO CONNECT Figure 1 Classic RS 232 MODBUS RJ 11 PHONE JACK PINOUTS 79 P age 10 001 1 REV
9. 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 41 Page 10 001 1 REV C Classic owner s manual continued 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 VVVVVVV Figure 3 0 Aux and Aux 2 Graphs Jumpers 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 flat head screw driver to tighten the screws The jumpers are described in the section below Aux 2 Aux 1 IN OUT RELAY OUT In order to select operation of Aux 1 between relay contact or 12v output JP6 and JP8 need to be configured accordingly following the instructions provided in this section 442v Aux1 PTC Contac
10. 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 MEM 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 repeatedly until Wizard is highlighted Scroll left or right to highlight MISC and push the Enter button Scroll to Time and push Enter Now scroll left or right to highlight the data you want to manually change Use the up and down buttons to change the data When you have all the data changed push the Enter button to save the changes The Classic includes a battery 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
11. and 48 volt systems are included in this menu 36 and 72 volt battery set up can be accomplished using the Custom set up method 84 96 108 and 120 volt batteries for KS model Battery Type Switches 5 6 7 Section 1 Switches 5 6 and 7 allow you to select from 7 different battery types and charging profiles These profiles can be found in the 2 charts on the following pages These should cover most common applications If slightly different voltages are desired this can be done using Custom Mode and programming methods 2 3 or 4 Auto Equalize Switch 8 Section 1 Switch 8 is used to select Automatic equalization In the OFF position a manual equalization cycle if desired is selected by pressing the Equalize button on the MNLP for 3 seconds To Cancel Equalize Press Equalize button for 3 seconds With Switch 8 in the ON position the Lite will attempt to equalize the batteries automatically The equalize interval is dependent upon the battery type selected Please refer to Dip switch battery settings for 12 24 or 48 volt batteries for specific information on this function 56 Page 10 001 1 REV C Classic owner s manual continued Section 2 Switch settings explained DHCP or Static IP address Switch 1 Section 2 On Section 2 Switch 1 when on will enable DHCP This will allow the Router on the network to assign the Classic Lite an IP address When off it sets the Classic to a static IP address that will be det
12. and time settings Using MNGP Remote to program a Classic Lite Programming the Lite with a Networked Standard Classic essent 61 Programming the Lite with the Local App ies Clearing Fault Notes on the Lite 4 Page 10 001 1 REV C Classic owner s manual continued Explanations of Solar and Legac Uploading New Firmware to the Clas Connecting the Classic to the Interne Networking Network Setup Through the MNGP Web Access Local Network Positive Ground systems aia tend aksam n DLE ee e 69 iro blesh dting 71 Specifications Eli Na 72 Specifications Mechanical Default Battery charge set points E A E A EE 74 Regulatory Approval onanan aa a anlaman 74 Warranty E A ero verte tee e t ep e ge RA 75 Appendix Classic Breaker sizing Label Set from Classic RS232 Jack Pin Out 5 Page 10 001 1 REV C Classic owner s manual continued Absorb Constant voltage charge stage to fill the batteries The controller is regulating so maximum power will not be seen at this time The Absorb timer is also counting down to the switch to Float A EQ R This will reload the Auto Equalize counters basically it will start the counters from day 1 AF Arc Fault See page 46 for more i
13. can manually enter the longitude and latitude coordinates geographic location is important because it 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 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 36 Page 10 001 1 REV C Classic owner s manual continued AUX 1 AUX2 RELAYILOGIC INPUT OUTPUT CLASSIC SETUP Screenshot 2 To configure the Classic s Aux ports
14. 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 secondary DNS server addresses of 11 22 33 44 and 11 22 33 55 respectively Set the D1 address to 68 Page 10 001 1 REV C Classic owner s manual continued 11 22 33 44 and the D2 address to 11 22 33 55 Web Access MidNite Solar will be offering a free web service with which you can access your Classic from a web age 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 however 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 fea
15. number from 1 to 380 This number shows the index or position of the data in the 380 data log time slots The most recently stored data has an index of 1 Two data points ago shows an index of 2 etc This index goes for either Daily History or Recent History text log viewing screen Graphical Logging Display modes Both DAILY and HOURLY logging can also be viewed in a graphical manner While in the text viewing log screen pressing the Soft Right key labeled GRAPH will bring up this view screen The HOURLY view is also available in the main status cycle of screens changed by repeatedly pressing the STATUS key just after STATUS TWO screen This is labeled as SHORT TERM HISTORY in the STATUS screens 50 Page 10 001 1 REV C Classic owner s manual continued A summary of the next Status screen will be shown while holding the status button before releasing it and entering that next status screen This also goes for the Recent History graph screen in Status Each data point shown in the graphical view screen is shown as a dot There are a maximum of 96 dots appearing horizontally per screen with some information about each dot shown on the left side of the screen An individual data point can be selected for investigation by moving a small flashing once per second vertical cursor horizontally across the graphed data by using the Left and Right arrow keys The most recent data is shown on the right most side of the first screen The cursor fir
16. 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 2 Page 10 001 1 REV C 6 Classic owner s manual continued ontents Scope Introduction C U lassic Power Curves npacking the Clas R Mounting the Classic emoving and installing the front cover on the Classic Alternative Mounting Sealed or Vented Battery Temperature Compensation uico ettet ios 16 Follow ME Charging coordination eee 17 Battery Temperature Sensor Installation csssvscssiscsscasctasscissedsctbascsnscasasaseasesipedsssesspaassoustesgaaietesstadeckestidsaaeohssdaeles 19 Chassis Grounding DC System Grounding DC GFP Ground Fault Protection cscs 22 IDisabling nen uenti e ri 22 A 23 O DC Terminal Connector ver Current Protection and Wire Size Requirements A 27 Over Current PROS CUO sxicic aradi 27 Long Distance Wire RUNS qc 27 Connecting the Classic to the Clipper Maximum and Minimum Wire Size m Ke e e LE TURN
17. putting all available power into the batteries Float Constant voltage charge stage with a lower voltage than the Absorb charge point The controller is regulating so maximum power will not be seen at this time Float MPPT Maximum current charge stage the Classic is trying to bring the batteries to the Float voltage set point We are basically putting all available power into the batteries FLT Float mode By using the up arrow in Tweaks under FLT you can force the Classic into Float mode GF Ground Fault See more info on ground fault protection Got Comm Indicates a lack of communication between the display and the Classic Consult Troubleshooting for information pass Insomnia This when enabled will keep the Classic from going to Resting This is intended for hydro mode only where you may need time to open water valves and do not want to wait for the Classic to wake up LED MODE This selection lets you pick the function of the 6 visible LED s on a standard Classic 6 Page 10 001 1 REV C Classic owner s manual continued LMX LoMax This enables the Classic to track the input voltage all the way down to Battery voltage When disabled the Classic will stop tracking the input around 5 volts above the battery voltage When the input voltage is within a couple volts of the battery voltage the inductors can Sing this is usually not very loud and will do no harm Local App Monitoring software
18. 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 Classics 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 t MNGP s small screen e 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 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 10 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
19. 558 0 OSL 9 55 061 558 5 OG 91558 0 OSL 9 558 0 OSL osseo OG 9 55 Table 14 Classic owner s manual continued CLASSIC MENU MAP Apr 28 2011 MidNite Solar Inc Status Menu Main Menu Wizard Solar Wind Hydro Charge Volts Quickset Right Soft Key ChgTime Battery Status Home screen View Right Soft Key TComp L View Right Soft Key EQ EndAmps Limits I Mode Solar L Setup Right Soft Key Wind Track L Graph Right Soft Key Input Status Hydro Slow Track U Setup Right Soft Key U Set VOC 96 n 96 Right Soft Key Aux L Aud Aux 2 PA Misc Led Mode Time Audio MoonScope Volume Play Display Version Backlight Contrast Comm Dflts L Password L Dealer Message FP Logs Tweaks LL More L Arc Adj Temps Net About Classic Next ve tedi Table 15 77 Page 10 001 1 REV Classic owner s manual continued Label Set from Classic MIDNITE SOLAR CLASSIC 200 MPPT SOLAR WIND uvVERO oues BOOST CHARGE CONTROLLER 5 RATED SEE MANUA MAX BATTERY CHA RGE CUR MAX BATTERY TAGE Designed and built in the U S A 3084883 MIDNITE SOLAR CLASSIC 250 MPPT SOLAR WIND HYDRO BUCK BOOST CHARGE CONTROLLER i EE MIDNITE SOLAR CLASSIC 250KS MPPT SOLAR WIND HYDRO BUCK BOOST CHARGE CONTROLLER MIDNITE SOLAR
20. Aux 1 will turn off 37 Page 10 001 1 REV C Classic owner s manual continued 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 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 Class
21. Classic owner s manual continued 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 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 Classic 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 is 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 i e the last fo
22. Follow ME and BTSNET on it Here you need to highlight Follow ME and turn it on using the up arrow You will also need to highlight BTSNET and turn it on if you want to share battery temperature data After enabling these press Enter to save this data Ground Fault sharing To share Ground fault you need to install the GFP Jumper on one classic only You then need to make sure Ground Fault is Enabled in the tweaks menu for any of the networked Classics you want to shut down on detection of ground fault For example say you have 3 solar Classics and one Wind Classic and you do not want the wind Classic to shut down for GFP make sure in the tweaks menu of that Classic GFP is Disabled Naming the Classic The included Local Application software allows you to issue a name to the Classic with upper and lower case letters as well as numbers This name can be up to 8 characters This name will show up on the Display of the Classic instead of the word CLASSIC It will be shown in all upper case on the Classics display The Naming process can be helpful for networked Classics that use one MNGP Display to view multiple Classics Addressing the Classic s You can assign unique addresses to each networked Classic This is not necessary for Follow Me to work but it is necessary if you want to view multiple Classics from a single MNGP To address a Classic simply use the MNGP that is plugged into that Classic or plug the MNGP into that classic and hol
23. 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 Press Main Menu e Scroll to NET menu and press the Enter button e Highlight and select DCHP 67 Page 10 001 1 REV Classic owner s manual continued 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 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 d
24. MidNite Solar Classic Owner s Manual 1 7 13 Standard Classic Classic Lite This Manual covers models Classic 150 200 250 amp 250KS as well as the Classic 150 200 250 amp 250KS LITE Este manual tambi n est disponible en Espa ol La versi n en Espa ol puede encontrarse en nuestra pagina web en la ficha Documentos y haga clic en Manuales Classic owner s manual continued The MidNite Solar Classic charge controller conforms to UL 1741 Safety for Inverters Converters Controllers and Interconnection System Equipment for Use With Distributed Energy Resources Second Edition May 7 1999 with revisions through January 28 2010 and CAN CSA C22 2 No 107 1 2001 09 01 Ed 3 R2006 Notice of Copyright MidNite Solar s Classic charge controller User s Manual Copyright C 2010 all rights reserved MidNite Solar Inc reserves the right to revise this document and to periodically make changes to the content hereof without obligation or organization of such revisions or changes unless required to do so by prior arrangement Disclaimer Unless specifically agreed to in writing MidNite Solar Inc a Makes no warranty as to the accuracy sufficiency or suitability of any technical or other information provided in its manuals or other documentation b Assumes no responsibility or liability for loss or damage whether direct indirect consequential or incidental which might arise out of use of such information The use
25. S DANVOL N OE AO0 9MVS 10 OMVO9IVOG DMWOL VOE AO0 DMV8 10 AO0 OMS 10 03 AO0 9MVS 10 OMV9 VOG DANWOL VOS AO0 OMVS 10 OMVSIVOG DANVOLATOE AO0 OMVrATOS 00 DMV8 10 OMV9 VOG DMVE 10 OMVS VOG DANVOL TOE AOSI 9MV9 DMV9 VOS A061 OMV9 VEO DMVOL YOE AOS OMVS WES YOE AOSL 9MV9 WE DMVS vOS NOS DMY VES DMVOL YOS AOGL OMVO9 VE9 OMVOL WOE AOSL OMY9 AVES DMVE VOS AOS OMV9 VEO DMVOL WOE AOS OMYY VE9 WOE WED AOSL DAYI AES DMVS VOS AOS OMVO VES YOS NOS OMVYATOS AOSL 9MV9 VE9 DMVE VOS AOSL VE9 DMVOL VOS 4410108 96061 UnA 14 indu vr vb vl TL 6 eL 991 972 907 28 ZS 6L t8 or 2e pras Sec vezl veo SIGE 86 ev L S0 eG g oz Sel roe vo 76 BL ze veel SOL 99 32 4816 SE bp 90 92 ez Le 65 6b ZE 9v 9r vandu xe 521 046 9215 eJ M OGAOSL bug Indino y andino xeW ope MOUI 50A 100 A LddN AWE de osje a4oge 40126 jajes 9G al nbal jou op pue 9249 Ainp 94001 104 paje Jeueq 3 e episul a 257 HEYD SIU uo peseq AjeAjeAJesuoo SI eu siu 8 eau ul siojonpuoo ejBuis Jo PEYI Buy SI L 0L693N OMV9 8 OMV9 OMV9 OMVH 9 OMV9 OMY OMY OMY OMY OMY OMAY OMYy OMY
26. V C Classic owner s manual continued other positive normally battery but not both otherwise the Classic input and output will be shorted HyperVOC TM Hyper VOC 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 Hyper VOC 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 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 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 Hyper VOC can be useful in overcoming an industry shortcom
27. a ay bat v batter Output at 25 C aay bati De rate current gi 40c to 40c Dimensions of Classic 14 87 X 5 95 X 4 00 378mm X 151mm X 102mm Shipping Weight NOTE Current output ratings were measured with 75 of the PV array s VOC Open Circuit Voltage NOTE Calculated by adding battery voltage to the maximum input operating voltage 48V battery max NOTE Measurement Accuracies 0 12v offset calibration adjustment maybe necessary Table 12 72 Page 10 001 1 REV C Classic owner s manual continued Specifications Mechanical Figure 32 73 P age 10 001 1 REV Classic owner s manual continued 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 START see page Error Bookmark not defined 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 is 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 information Battery 12v 24v 36v 48v 60v TN Voltage Bulk MPPT 14 3v 28 6v 42 9v 57 2v 71 5v 85 8v Float 13 6v 272v 40 8v 54 4v 68 0v 81 6v Equalize 14 3 28 6v 42 9v 572v 71 5v 85 8v Table 13 To adjust t
28. acy 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 i e the last found MPP Voltage The range of this sweep is determined by the Sweep Depth user adjustment and is expressed as a percentage of Watts that the sweep started from For example if in Legacy P amp O mode the Classic was outputting 500 Watts and the Sweep Depth percentage was set for 10 50 Watts the sweep will bring the input voltage DOWN until the output power drops down to 450 Watts then will sweep UP in voltage until the power drops again down to 450 Watts and then go back to the newly found MPP Voltage waiting for the next sweep 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 section 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
29. advanced features as well In Dip Switch Section 1set DIP Switches 1 2 3 and 4 to ON This will tell the Classic Lite s MNLP display to allow custom programming Next remove the plug from the back of the MNLP and plug it into the MNGP Now you basically have a Standard Classic The programming for this is found in the Standard Classic Manual Included on the DVD you got with your Lite Once programmed in this way the MNGP can be removed and the MNLP replaced All functions and voltages programed into the Classic will now be retained in permanent memory Programming the Lite with a Networked Standard Classic The third method of programming is to use a Standard Classic in the system to program the Lite in a simple Follow Me network In Dip Switch Section 1set DIP Switches 1 2 3 and 4 to ON This will tell the Lite s MNLP display to allow custom programming You will need to use the MNGP from the standard Classic to set the Address and Follow Me parameters See the Follow Me section for full details Programming the Lite with the Local App You can use the Local Application software that was included with the Lite to program it as well You will need the serial number of the Classic to unlock the 2 way functionality of the Local App Please see the Local App instructions for more details Clearing Faults If either the Ground Fault or Current Limit fault light is lit then the equalize button can be tapped to clear these faults If th
30. ased on our Classic charge controller It has all of the same features Power and versatility minus only the Graphic Display and arc fault detection It still has all of the other advanced features found in the Classic and can be used in all of the same applications For the advanced features to be accessed and programmed you will need to use the included Local Application software and a PC or a MidNite Solar MNGP Graphics Panel or the Graphics panel of another Standard Classic in the system If desired the Classic Lite can be used with an MNGP instead of the supplied MNLP controller LED explanations The Lite control panel MNLP has 6 status LEDs to indicate various modes of operation as well as faults There are 3 behind the small window on the upper left The top Orange status LED will light solid to indicate that the controller is in Bulk Charge mode The center Yellow status LED will light solid to indicate that the controller is in the absorption stage The lower Green LED will light solid to indicate that the controller is in Float and blink slowly to indicate the controller is Resting due to low light All 3 of these status LED s will blink slowly to indicate Wrong Code please see trouble shooting on page 71 for help with this There are also LED indicators for Current limit Ground Fault and Equalize All LEDs blinking slowly indicate a loss of communication with the Classic Check that the cable is plugged in to the top Jac
31. assic 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 65 Page 10 001 1 REV C Classic owner s manual continued 4 Port Switch meis m Example 1 Local network through switch In some cases you may be able to connect Classic directly to your PC however this is not a recommended topography Wireless 2 Bridge Wireless Router Access Point Example 2 Local network through wireless bridge Wireless enabled Wireless Router computer Access Point e E N Example 3 Local wireless network 66 Page 10 001 1 REV Wireless Bridge Classic owner s manual continued FY Wireless enabled computer Wireless Router Access Point GAN Qe Example 4 Local wireless network through wireless bridge There are many different configurations possible when it comes
32. ay then the Mode may have got turned off To turn the mode back ON push the Main Menu button several times until Wizard is highlighted Scroll to the right until Mode is highlighted and press Enter On this screen OFF should be highlighted use the up or down arrow to change it to ON and press Enter Press the Status button once to return to the main status screen Note This is the same menu you would use to change between Charging algorithms Solar Hydro etc Adjusting Absorb Equalize and Float Voltages Absorb Equalize and Float voltages are fully adjustable You will need to get the actual voltages from the battery manufacturer To adjust these voltages follow the steps below Press Main Menu to enter the Main Menu Scroll right or left until Charge is highlighted and push the Enter button Highlight Volts and press the Enter button Use left and right arrows keys to highlight the set point voltage to adjust Use up and down arrow keys to lower or raise the voltage Press the Enter button to save the new voltages fo e de K de e gt k 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 limi
33. 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 VOC the Classic found on that sweep This mode is useful for testing or constant voltage sources Note Mode must be manually turned ON after changing the mode To turn the Mode on highlight the OFF under ON OFF and switch it to ON Press enter to save this change Configuring the Classic for Wind Input Source Wind If you selected Wind you will need to select a power curve from the 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 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 35 Page 10 001 1 REV C Classic owner s manual continued to select RECALL Now push the Enter button to save this power curve to the Classics memory There are
34. cts a fault between battery PV negative and earth ground just like the breaker DC GFP system The difference with the Classic is that it turns off the charge ability and sounds a loud warning when a ground fault is detected This is 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 battery breaker to OFF position and then to ON position Disablin
35. customerservice midnitesolar com for more information or if anything is missing or damaged Figure 1 12 Page 10 001 1 REV Classic owner s manual continued 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 if this is not the first removal of this cover there is a cable connecting the cover to the electronics Do not pull hard or fast as damage could occur 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 2 13 Page 10 001 1 REV C Classic owner s manual continued 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 d
36. d the Left arrow button down and tap the up or down button The normal default address is 10 so going up will take you to 11 and down to 9 When you get to the unused address you want for that Classic hold the left and right arrows for a second until Data sent and saved shows up Now this Classic has been re addressed to the new address Do this for all the Classics or Classic lites on the network 17 Page 10 001 1 REV C Classic owner s manual continued To view other Classics on the network use the same button strokes Hold the left arrow down and tap the up or down arrow depending on which number you are looking for We suggest going from 10 up for clarity So if you had 4 Classics they would be 10 11 12 and 13 You would scroll up from the normal position to find the other 3 To Display To Display To Display To Display Classic 1 Classic 2 Classic 3 Classic 4 You can Network as many Classic s as needed The Last Classic has to connects to the first Classic as shown by the orange Line You need to go from Out on Classic 1 to In on Classic 2 and so on Midnite Solar offers 3ft Network cables If you need custom lengths and want to make your own the Network Cables need to be 4 conductor with RJ11 jacks the blue and white wires in the picture below are not needed Pin 1 on one end becomes pin 6 on the other Most off the shelf 4 conductor phone cables can be used 5 YELLOW PHONE Pind GREEN CABLE Pin 1 Fig
37. e fault condition has not been removed however then the light will re illuminate indicating that a fault condition is still present Notes on the Lite If anything is set to Custom then the MNGP lite will not send any programming data to the Classic So a Custom setting effectively disables MNGP Lite Control over the Classic requiring the user to use a PC or MNGP to configure the Classic Note The Custom setting still allows full function of the LED s and the EQ button 61 Page 10 001 1 REV C Classic owner s manual continued Explanations of Solar and Legacy Solar This is the default mode for PV systems and has a very fast sweep typically 1 2 second or less that will re sweep at user adjustable sweep intervals unless the Classic finds that it needs to do a sweep on its own because of changing conditions The timed sweep interval is user adjustable and is in units of minutes SOLAR mode is typically best for PV systems especially if there is partial shading at times during the day The Classic will show a message of PV SHADE if it thinks the PV array is partially 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 Obser
38. e 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 76 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 26 Page 10 001 1 REV C Classic owner s manual continued Current Rating The Classic limits the output current based on the model you have The Classic current ratings are Classic 150 150 Lite 96 amps maximum Classic 200 200 Lite 79 amps maximum Classic 250 250 Lite 62 amps maximum Classic 250ks 250ks Lite 58 amps maximum Over Current Protection The Classic must have over current protection to protect wiring from over current events A means of disconnect must be installed on the DC in and DC out of the Classic Consult your local codes to determine over current ratings The breaker between the battery bank and the Classic must conform to ULA89 The breaker between the DC source and the Class
39. eded Keep plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eyes 9 Page 10 001 1 REV C Classic owner s manual continued Wear complete eye protection Avoid touching eyes while working near batteries Wash your hands with soap and warm water when done If battery acid contacts skin or clothing wash immediately with soap and water If acid enters an eye flood the eye with running cool water at once for at least 15 minutes and get medical attention immediately following Baking soda neutralizes lead acid battery electrolyte Keep a supply on hand in the area of the batteries NEVER smoke or allow a spark or flame in vicinity of a battery or generator Be cautious to reduce the risk of dropping a metal tool onto batteries It could short the batteries or other electrical parts that can result in fire or explosion Never wear metal items such as rings bracelets necklaces and watches when working with a battery or other electrical circuits A battery can produce a short circuit current high enough to weld a ring or the like to metal causing severe burns Classic Power Curves 100 150V Classic Power Graph 96A 1380W os x 94A 2700W 93A 13 90 92A MA 1325W 2611W e 86A 5022W 85 H 83A 4847W E so MPPT Input Operating Voltage 82A e 80444672W 2353W 75 120V PV 110v PV 76A S 100v PV 90V PV 4438W 70 70V PV
40. ermined by Switches 2 3 and 4 IP Address Switches 2 3 and 4 Section 2 On Section 2 Switches 2 3 and 4 will set the Static IP Address of the Classic Lite to the address shown in the table below if Switch 1 is set to Off for Static IP ModBus Port Switches 5 6 and 7 Section 2 On Section 2 Switches 5 6 and 7 set the ModBus port of the Classic Lite The values that correspond to the switches are found in the table below The actual Labels that are on the inside of the MNLP 1 SLIDE SWITCH UP TO TURN ON 4 LLL DEFAULT 10 194 1 REV DCA 4 06 12 Table 6 57 Page 10 001 1 REV C Classic owner s manual continued Section 1 Switches Ithrough 8 Section 1 Section 2 On On 12 3 4 5 6 8 1 2 3 4 5 6 7 8 Mode System Battery EQ DHCP IP Address MODBUS Voltage Type port Section 1 Mode Mode Switch 1 Switch 2 Solar Off Off Legacy Off On Reserved On Off Custom On On System Voltage System Voltage Switch 3 Switch 4 12V Off Off 24V Off On 48V On Off Custom On On Battery Type Switch 5 Switch 6 Switch 7 Gel Off Off Off Sealed 1 Off Off On Sealed 2 Off On Off AGM Flooded Off On On Flooded 1 On Off Off F
41. ery 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 de 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 4 The Torque specs on the DC terminal connector big blue terminal connector are Up to 10 AWG torque to 25 35 inch pounds 4 8 AWG torque to 30 40 inch pounds 6 AWG or above Torque to 40 50 inch pounds 23 Page 10 001 1 REV C Classic owner s manual continued GROUND CORSO ar O GROUND ROD PV INPUT PV DISCONNECT PODA on eon in BATTERY DISCONNECT BATTERY BUS BAR MIDNITE E PANEL Diagram 1 24 Page 10 001 1 REV C Classic owner s manual continued GENERATOR WITH BRANCH 19 CIRCUIT BRERS BASIC HOOK UP DIAGRAM 18 BATTERY BANK MIDNITE E PANEL REV 10 001 1 25 Page Classic owner s manual continued DC Terminal Connector The Classic s DC terminal connector is located on 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 suitable for the highest power availabl
42. etails 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 take 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
43. g 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 22 Page 10 001 1 REV C Classic owner s manual continued gt Press Main Menu gt Scroll to the right or left until TWEAKS is highlighted and press ENTER gt In TWEAKS press the right soft key to get to the MORE menu gt In MORE scroll until GFP is highlighted gt Use the up and down arrow keys to toggle between on and off gt Press ENTER to save Wiring the Classic A 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 the DC source and Batt
44. ge charge controller The efficiency of a high voltage Classic is less than the lower voltage versions so you need to weigh the benefit If this sounds too complicated use this rule of thumb in selecting the proper Classic PV runs up to 100 feet use the Classic 150 Runs up to 180 feet use the Classic 200 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 2 0 wire Connecting the Classic to the Clipper The connections between the Clipper and Classic are fairly basic There is the DC and conductors from the Clipper to the PV input on the Classic There is also a smaller set of and conductors connecting Auxiliary 2 to the PWM input on the Clipper To program the Classic to work with the Clipper 27 Page 10 001 1 REV C Classic owner s manual continued the Aux 2 needs to be programmed Follow the steps below to program this Note see our instructional Enter the Main menu and scroll to Aux and press Enter Scroll to the right to highlight the text under Aux 2 and press the upper right soft key Scroll up or down to find Clipper control and press the right soft key again On this screen we need to select AC or DC for the Clipper you have DC is default Press
45. goes on and new data is acquired those unused data points will start to appear and be valid Of course the Daily history will take many days to fill in where the Recent hourly minutes really data will fill in after a few hours or maybe a day or two depending on how long the Classic is on and running for that day Remember the Classic does not normally log data while it is in Resting mode 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 go to the next character block Do this until your desired message is complete Press enter to save on the classic memory 52 Page 10 001 1 REV C Classic owner s manual continued Classic Lite Programming The Classic Lite is b
46. hese 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 7A Page 10 001 1 REV C Classic owner s manual continued 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 Appendix 75 Page 10 001 1 REV C Classic owner s manual continued izing Classic Breaker s asm pue Jexeeiq ndul S AO0 DMV8 10 OMWOL VOE AO0 9MV8 JO OMVO9 VOS OMVOL VOE AO0 OMV8 10 DMVI VOS OMVOL VOE AOQE 9MV8 10 OMVS VOS DMWOL VOE AO0 DIMVE 10 OMVO9 VOS OMVOL VOE AQOE 9MV8 10 OMVOIVOS OMVOL VOE 00 9MV8 10 DAAVI VOS OMVOL VOE AO0 OMVS 10 DAAV9 VOS DMWVOL VOE A00 DMVE 1 OMV9 VOG ADOE 10 OMVS VOS DAAVOL VOE ADE OMW8 10 OMV9 VOS DAMWOL VOE AO0 9MVS 10 OMVS VOG DANVOLAOE AO0 DMV8 10 OMVINOS AO0 OMV8 10 OMV9 e0G 00 9MVS 10 OMV9 VO
47. ic must conform to UL1077 or UL489 The NEC requires 1 56 times short circuit current for PV over current protection This is reduced to 1 25 times when using a breaker rated for continuous duty All MidNite Solar breakers are hydraulic magnetic and are rated for continuous duty No de rating is required for the output breaker when using MidNite Solar breakers PV in particular will be capable of producing more current than its name plate rating in extreme situations so the safe minimum wire size should be selected for the PV array maximum short circuit current Please consult PV manufacturer for specifications The US National Electrical Code requires 1 56 times the PV short circuit current for wire size on the PV input Output wire size follows the NEC guidelines Typical wire size for output is GAWG for the Classic250 and 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 if you are faced with longer than normal wire runs between the DC source and the Classic The Classic comes in 3 input voltage ranges letting you design a DC source at a higher voltage if it is beneficial For example let s say you have a 300 ft run from a PV array to the Classic you could wire for an open circuit voltage close to 250vdc accounting for the coldest temperature you will encounter This will allow you to run a smaller gauge wire than with a lower volta
48. ic 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 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 set points to negative numbers and the numbers are an offset from the voltage set point For example 38 Page 10 001 1 REV C Classic owner s manual continued a 2 would turn Aux 1 off2 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
49. ighlighted 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 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 Coming Soon 45 Page 10 001 1 REV C Classic owner s manual continued 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 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 plier
50. included with the Classic for monitoring over the Local Network or Internet MNGP Midnite Graphical interface Panel This is the graphical display included with the standard Classic controller MNLP MidNite LED interface Panel This is the LED display that comes standard with the Classic Lite Mode This menu lets you turn the charging ability of the controller On Off as well as lets you select the DC 1 for info on the Mode menu input source See page Mod Bus a standard protocol used for communications We have published our protocol to allow users to interface with the Classic See page Error Bookmark not defined for our Mod Bus protocol My MidNite Web based monitoring for the Classic Not available yet Nite Log When enabled allows the Classic to log data in the evening when the Classic is Resting PV Shading This indicates the Maximum power point voltage is less than half the open circuit voltage Pwr Save Allows you to adjust the time the Backlight stays on Resting The Classic is not charging the battery due to low light For reasons Resting will appear please see page 31 Shade When enabled the Classic will show PV Shading on the display when the Maximum power point voltage is ess than half the open circuit voltage T Comp Temperature compensation using a temperature sensor to measure the ambient temperature of the attery bank and will adjust the voltage set points u
51. ing 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 70 Page 10 001 1 REV C Troubleshooting Classic owner s manual continued Classic will not power on No self test on power up Check for voltage between the Battery and the common on the blue terminal block inside the Classic If voltage is present and above 10vde contact customer service If no voltage is present back step through the and to find the fault Classic Display is blank but Classic is on Check that the blue cable is plugged in between the display and the top most jack on the circuit board Try another cable A standard short 4 conductor phone cable will work Classic says Resting but the sun is out Resting indicates a lack of power available to the Classic Verify there is voltage on the dis
52. irectly mounted onto the MidNite Solar E Panel The Classic can also accommodate other installation methods as well Mount in an upright position out of direct sunlight when possible For your convenience the Classic has four one inch knock outs that are pre cast The Classic has mounting locations and conduit locations 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 Install the mounting bracket on the E Panel and start the upper mounting screw into the bracket leaving it about half way out so you can hang the Classic on this screw Install the 1 inch close nipple into the E Panel as shown in the E Panel directions The 1 close nipple 3 locknuts and 2 plastic bushings are included with each E Panel One locknut acts as a spacer Carefully hang the Classic on the screw in the bracket and slide it over the close nipple see figure 1 3 Install the lock nut and bushing on the close nipple and tighten the screw in the mounting bracket Don t install the front cover until you complete the wiring of the Classic A Charge controller bracket mounted to the E Panel The bracket comes with every E Panel Figure 3 Classic Mounted to side of E Panel Nipple locknuts and bushings that come with every E Panel Figure 4 Figure 5 14 Page 10 001 1 REV C Classic o
53. ite if your manufacturer does not recommend Equalizing your AGM batteries Equlize Button The Equalize button serves two purposes the first is to begin an Equalize stage the second is to clear faults Equalization An Equalize stage can be scheduled or started at any time by holding the Equalize button down for 2 3 seconds Holding the the EQ button down for 2 3 seconds at any point once equalization is activated will cancel the equalization stage and return back to the most appropriate battery stage When the equalize button is pressed the EQ light will come on solid Once Equalize proper starts the light will flash If Equalization cannot begin immediately then the MNGP Lite will try to engage equalization for 18 hours and then stop if it can t See page 60 for the Voltage and Time parameters of EQ 29 Page 10 001 1 REV Classic owner s manual continued Equalization with the standard Classic Manual EQ To do a manual Equalization charge Go into the Charge menu and highlight EQ and press Enter Now EQ Stopped will be highlighted Scroll up to select Eq Started Press the Status button to return to the home screen To stop a manual EQ in progress simply reverse the steps above A manual EQ when started will last for that day unless the Classic is on say Hydro or Wind and the controller never goes to Resting that night in this case it will stay in EQ until it completes or the controller goes to Resting Auto EQ The
54. justable parameters consi MODE Is assigned as a 1 from factory default and it shou TIME This sets tl This parameter is e length of the arc the Classic has to moi set to 4 from the factory sting of MODE TIME amp SENSITVY d stay that way unless instructed by MidNite Solar nitor before tripping the Arc fault detection SENSITIVITY TI Figure 22 is parameter determines how sensitive t e 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 if your system cannot work with the arc fault detector Ze 4 Press Main Menu Scroll to the right or left until TWEAKS is highlig d 5 Ze 4 d 4 In this menu use the left and right keys to select th 5 To change the parameters of the Arc Fault follow the steps below hted and press ENTER In TWEAKS press the right soft key to get to the BITS menu In BITS press the right soft key to get to ARC ADJ e feature to adjust Use the up and down arrow keys to change the parameters 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 exte
55. k on the Classic If error persists try another cable or call Tech support for assistance Status LED s Status LED definitions Equalize button MI Ma CURRENT ped GROUND FAULT Figure 23 53 Page 10 001 1 REV C Classic owner s manual continued Programming There are four separate ways to program a Classic Lite 1 The programming is done using Dip Switches under the front cover of the MNLP 2 The Classic Lite can be programmed with an independent MNGP 3 The Lite can be Networked with a standard Classic and programmed using the standard Classic s MNGP 4 The Classic Lite can be programmed using the Local App Through the Ethernet connection software included on the DVD or available at www midnitesolar com Dip Switches Below you will find an Explanation of the Dip switches and the values associated with their settings Up is on and down is off on the switches To access the Dip switches you need to remove the front cover on the Lite display panel Firmly grasp the left and right side of the cover and slide it off Figure 24 54 Page 10 001 1 REV C Classic owner s manual continued Now you will need to use the supplied tool Toothpick to place all 15 switches in the correct position All the information on the switches can be found on the labels on the MNLP as well as in the tables below Keep in mind if any of the switches are set to Custom the Lite display becomes a LED display only and you wi
56. lay 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 output will go back to the original state da ep b lt d 1112011 I DELAY TIME HOLD TIME TIME AUX 1 OUTPUT Diagram 6 43 Page 10 001 1 REV C Classic owner s manual continued Aux 2 Voltage Time Relation PWM The graph below describes the relation in Aux 2 between voltage and time The difference in Aux 2 is 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 selection active high or active low This gives a much smoother transition For more information see Configuring Auxiliary Input Output Page 29 WIDTH IN VOLIS VOLTAGE Diagram 7 Setting the MNGP features 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
57. ll need to use the included PC software or a MNGP to program the Classic Please see page in the Appendix for info on using the Local App software in conjunction with a PC 2 SLIDE SWITCH UP TO TURN ON UTD once 521 IPADOR als STATICN OFF o nce Figure 25 55 Page 10 001 1 REV C Classic owner s manual continued Section 1 Switch settings explained Mode Switches 1 and 2 Section 1 On Section 1 the first 2 Switches are used to select which Solar Mode will be used For Solar Mode set switches and 2 to OFF This is the optimum setting for virtually all solar installations For Legacy Mode Set Switch 1 to OFF and Switch 2 to On Legacy Mode can be used in cases where the Open Circuit Voltage is close to the battery voltage For example a 22 volt open circuit array and a 12 volt battery Or where there are mixed sizes of panels in an array Solar Salad When switch 1 2 3 and 4 are set to ON the Lite is in Custom Programming mode and can be programmed using any of the other 3 methods Custom set up will be required for Wind Hydro Fuel Cell applications as well as setting up the Aux output controls and for Battery voltages of 36 60 and 72 84 96 108 and 120 volt batteries for KS model System Voltage Switches 3 and 4 Section 1 On Section 1 set Switches 3 and 4 to the appropriate positions Found in the Chart corresponding to your system s battery voltage 12 24
58. looded 2 On Off On Flooded 3 On On Off Custom On On On Auto Equalize Switch 8 Manual Off Auto On Table 7 58 Page 10 001 1 REV Classic owner s manual continued Section 2 Switches 1 through 7 Section 1 Section 2 On On 32 4 5 6 8 12 3 45 6 7 8 Mode System Battery EQ DHCP IP Address MODBUS Voltage Type part Section 2 or Static IP address Switch 1 Static IP Off DHCP On IP Address only if DHCP is set to Static IP Switch 2 Switch 3 Switch 4 192 168 0 223 Off Off Off 192 168 1 223 Off Off On 192 168 1 224 Off On Off 192 168 2 223 Off On On 10 0 0 223 On Off Off 10 0 1 223 On Off On 10 0 1 224 On On Off 10 1 1 223 On On On MODBUS Port Switch 5 Switch 6 Switch 7 502 default Off Off Off 3900 Off Off On 3901 Off On Off 3902 Off On On 3903 On Off Off 3904 On Off On 3905 On On Off 3906 On On On Setting any value to custom effectively disables the MNGP Lite as a controller LED s and Equalize button still work and requires you to configure the Classic using a PC or MNGP Table 8 59 Page 10 001 1 Classic owner s manual continued Battery voltage and time settings
59. nfo on arc fault protection Arc Adjust This menu is where you adjust the Arc Fault sensitivity For info on Arc Fault see page 46 A RST Auto reset of the Classic controller The Classic will reboot around Midnight every night when this is enabled This is useful for very remote sites where a loss of internet capability for example would be a hard ship Aux Auxiliary relays The Classic has 2 relays Aux 1 can be configured as a 12 volt signal or a dry relay Aux 2 can be used as a PWM signal output Refer to pag or more Aux info BLK Bulk MPPT Mode By using the up arrow in Tweaks under BLK you can force the Classic into Bulk mode Bulk MPPT Maximum current charge stage the Classic is trying to bring the batteries to the Absorb voltage set point We are basically putting all available power into the batteries Comm This Menu allows adjustment of things like Mod Bus port USB Mode and MNGP address DvrtCnt When enabled allows the charge stage timers to continue to run when the diversion modes are holding the battery voltage just below the actual set point Equalize Constant voltage charge stage to equalize the batteries The controller is regulating so maximum power will not be seen at this time The Equalize timer is also counting down to the switch to Float EQ MPPT Maximum current charge stage the Classic is trying to bring the batteries to the Equalize voltage set point We are basically
60. o 40 Page 10 001 1 REV C Classic owner s manual continued This mode is PWM based and is just reverse logic of Diversion Hi It would be comparable to using the NC contacts of the relay used in Diversion Hi It can be used that way with a solid state relay and NC contacts to do diversion 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 1 has the relay so Diversion functions must operate slowly VENT FAN LOW Aux on below setpoint VENT FAN HIGH Aux on above setpoint FLOATLOW 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 PvV ON LOW 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 Aux 2 Function Output Input OUTPUT 12V OV 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 PvVONLOW PWM sig below Pv in setpoint Pv V ON HIGH PWM sig
61. on on the MNGP to stop it earlier At the bottom of the AUTO EQ screen shows the time in hours and minutes that the EQ is set for Pressing the Soft Right key labeled VIEW takes you to a screen where you can view the interval and re try counters timers 30 Page 10 001 1 REV C Classic owner s manual continued Standard Classic programming Commissioning the Classic Quick Start The Classic will enter into the Quick Set screens upon initial power up If the Classic does not enter into the quick set or you want to restore to Factory Default follow these steps to get initiate a Quick Set With the power off to the Classic Hold the left and right arrow buttons down Turn the power on to the Classic and continue to hold the arrow buttons until the setup screen is displayed Answer the questions on the next few screens to complete the Quick Set Battery Charge Stages and Meanings Bulk MPPT This stage of the Classic means that the Classic will be putting out as much current as it can to raise the battery voltage to the absorb voltage set point This is also known as constant current mode Absorb This stage means that the Classic will maintain the absorb set point voltage until the batteries are charged This stage is terminated at the end of the Absorb time or the End Amps set point whichever is reached first At this stage the classic is not putting out maximum current as that would increase the battery voltage over
62. p or down accordingly to ensure a full battery There are 3 parameters to set Minimum and Maximum adjusted voltage as well as volts per degree C per Cell Typically this is 05 mV but please consult your battery manufacturer See page 16 for Temperature compensation info Tweaks This menu has all the advanced adjustments for the Classic For example Voltage off set adjustments etc VBatt Battery voltage measured at the battery terminals of the Classic VOC Open Circuit Voltage unloaded voltage measurement V pv Input voltage measured at the input terminals of the Classic Web Access When enabled allows the Classic to send data over the internet to My MidNite s Server for you to view when wanted 7 Page 10 001 1 REV C Classic owner s manual continued 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 and Approved Hydro and Wind turbines for other DC sources please contact MidNite Solar tech support The Classic 150 200 and 250 are designed to work with 12 24 36 48 60 and 72 volt bat
63. play under IN that is greater than battery voltage Verify the Charging mode is correct for the source as well as the Mode is ON Classic switches between Resting and Bulk MPPT repeatedly but produces 0 watts This can be normal during low light conditions Watch the IN voltage and see if it is setting stable and does not change when the Classic goes from Resting to Bulk MPPT if so call customer service Watch the IN voltage and see if it slowly drops to battery voltage Or Close when the Classic goes to Bulk MPPT if so this is usually a sign of a High resistance connection Loose Connection between the Classic and DC source The Display shows 0 volts in or real close but the battery voltage looks correct If this is a new install or recently altered install check for reverse polarity on the DC input of the Classic f this just happened out of the blue or reverse polarity has been eliminated call customer service The Display is showing Mode is Off Enter into the main menu and select Mode Turn the Mode ON and press Enter to save Table 11 71 Page 10 001 1 REV Classic owner s manual continued Specifications Electrical moa Classic150 Classic200 Classic250 Classic250KS Operating Volts in 150VDC 200VDC 250VDC 250VDC Max Hyper VOC 150 battery 200 battery 250 battery Battery Charge Volts 12 93 volts 12 93 volts 12 93 volts 96a a atte Absolute Current
64. 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 and 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 batter
65. pot 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 19 Page 10 001 1 REV C Classic owner s manual continued Insert BTS to the jack labeled BATTERY TEMP on the control board CRM 20 Page 10 001 1 REV Classic owner s manual continued Chassis Grounding In all installations the Classic chassis should be connected to ground For systems with a battery breaker sized 60 amps and smaller 10 AWG 6 mm copper is generally sufficient For systems with a battery breaker sized 100 amps and smaller 8 AWG 10 mm copper is required For grounding conductor requirements on your specific installation please consult your local electrical code The chassis grounding terminal is in the upper right corner of the electrical connection compartment see Figure 14 DC System Grounding The Classic charge controller is designed to work with Negative Ground Positive Ground or Ungrounded power systems In grounded systems dc negative may be connected to ground either externally or by using the Classic s internal grounding jumper shown on figure 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 jumpe
66. push the Enter button 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 de e de 9 7 de e Use diagram below for MNGP reference 44 Page 10 001 1 REV C Classic owner s manual continued Figure 19 Screen name Communication indicator n Menu name USB activity indicator MODE Menu BATTERY CHARGING PARAMETERS description Current limit lt lt lt gt gt gt 18 indicator Right soft key Sener MI re Up arrow key gt x Left soft key Va Left arrow key Cw STATUS Status screen MENU Main Menu Enter button Down arrow key Navigating the Menu s Push MAIN MENU Push right and left buttons to see the different menus To return to the status screen push STATUS button te To navigate from one end of the main menus to the other end push the top right and left buttons 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 menus will be sub menus to adjust the parameters of the selected feature Here is an overview of these menus lt lt 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 h
67. r format that the data was captured that day The category of data captured is of course more suited for minute by minute capture rather than the maximum data statistics captured on a day by day basis in the DAILY log screen The left side of the recent history text log screen can be individually viewed by selecting the left side and pressing the UP DOWN arrow keys to show the power voltages charge stage etc and various information captured at the time shown on the right side time selection 49 Page 10 001 1 REV C Classic owner s manual continued Screenshot 5 At the bottom of the DAILY text log screen the TIME the maximum statistics were stored is shown whereas at the bottom of the HOURLY text log screen the DATE ofthe capture is shown Again if for some reason the year of the time stamp was less than 2011 the time date will alternate between INVALID and the time date stamped along with that data and does not necessarily mean the data itself is not correct If the data is all zeros and the year is shown as 2000 the data IS most likely invalid and not correct or the logging memory has not been filled yet This is why the Classic powers up with the year 05 04 2003 It means that data was actually logged but the date was not set whereas if it is showing 00 00 2000 it will normally mean that the data is just zero and therefore invalid data as well as invalid time and date The upper right corner of the text log screens displays a
68. r 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 21 Page 10 001 1 REV C Classic owner s manual continued DC GFP Ground Fault Protection The Classic has internal ground fault protection GFP built in Since 2008 the NEC requires a DC GFP on all PV systems in the USA The built in DC GFP eliminates the need to purchase and install an external DC GFP If the internal grounding jumper is installed in a Classic the battery negative and DC source negative must not be connected to the system grounding conductor anywhere in the system Grounding of these circuits will defeat the GFP function In a network with multiple Classics 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 15 Figure 16 The Ground fault device is simple to understand and use The Classic DC GFP works a bit different than others It dete
69. rnal 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 Detector When one or more faults are detected the Classi in the bottom right corner of the home screen STATUS 47 Page GFP Ground Fault Protection and AFD Arc Fault ic will stop outputting power and display a fault message 10 001 1 REV C Classic owner s manual continued View Logged Data The Classic logs 380 days worth of data in its memory The data logging in the Classic has two modes and frequency of data capture DAILY HISTORY Is captured once each day and is saved at night after 2 hours of no activity when the PV input voltage is below battery voltage for solar or in modes that do not necessarily rest at night like wind or hydro the capture will happen once every 24 hours Data logged each day is kilo watt hours Float time in hours and minutes the maximum power output for the day maximum FET temperature inside the unit maximum PV or input voltage and maximum battery voltage for the day HOURLY HISTORY Also referred to as Short term History is captured once every five 5 minutes anytime the Classic is not resting when it is charging Data logged every 5 minutes is power input voltage battery voltage Charging Stage amps out and kW Hours A time and date stamp is associated with each data entry in both Daily and Hourly hi
70. s to crimp both ends of the cable Figure 21 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 Diagram 8 below Use terminal connector tab as reference 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 46 Page 10 001 1 REV C Classic owner s manual continued world to successfully stop a series arc The Classic can det to devastating high power arcing the Classic will detect an ect an arc in less than 100mSec From low power arcing 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 detected the Classic has to be manually cleared Resetting the Arc Fault Detector after detection has occurre wire terminal splice etc The Classic needs to be powered The First thing to do is find and fix the actual arcing own 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 ad
71. st appears around 20 dots or data points from the right side of the first screen About 20 data points ago in history To scroll the data viewed one third of a screen to the left hold the Shift key the Soft Left button down and tap the Left arrow key Each press of this combination of buttons will scroll the graphical view horizontally another 1 3 screen Holding the Shift key and Right arrow key on the most recent data screen will push the cursor up against the right side and onto data point one Pressing the Up arrow button will change the data viewed to the next category For instance in the Recent history graph screen the displayed data will change from Power to input voltage battery voltage and kW Hours Pressing the Down arrow key will bring the category of data back down again A very brief 5 or 6 character annunciator displayed in the upper left corner tells us what category of data the graph is showing us The number just below this 5 or 6 character descriptions is the actual number in volts or watts or applicable unit of data displayed at that cursor position centered on the dot of the graph The third line down on the left side of the recent data screen shows the time stamp of that data where the cursor is positioned on the graph Finally the bottom left of the graph screen alternates between two indicators One is the charge stage at the cursor position and the other is the scaling of the vertical axis of the graph Power for in
72. stance can show a very wide range of values and power lends itself better to using a logarithmic vertical scale shown as LOG Voltage and other data shows up fine using a LINEAR vertical axis scale and is spelled out on the lower left of the graphic screen d DEL LITER Screenshot 6 51 Page 10 001 1 REV C Classic owner s manual continued The Date of the particular selected cursor positioned data point is shown on the bottom middle of the graphic screen Moving the cursor left or right using the Left and Right arrow keys selects the next data points to the left or to the right of the present cursor position The flashing cursor is short and may be hard to detect at first so you may have to look for it The cursor aligns and centers itself right on the dot itself that is selected The bottom date or time displayed may tend to obscure the data line graphed behind it The time date and the graph data will be mixed together about a second after the date time is drawn on the bottom of that graph log screen If for some reason the graphic log screen display shows bogus data or dots that look like they should not be shown simply press the Enter button and the screen will be quickly erased and re drawn without the extra lines or dots There may or may not be any valid data past a certain point to the left if the unit is fairly new The data shown in unused spots may be zero or it may be off the screen and not viewable As time
73. story logs The main time date stamp for each data logging mode is Date for daily history and Time for recent history although both time and date are stored and displayed for each logging mode Screenshot 3 48 Page 10 001 1 REV C Classic owner s manual continued When entering the LOGS menu you will see two items displayed there The top line is lifetime kW Hours for the Classic and below that is time spent in float today Note Float Absorb Bulk and EQ time is also viewable in the TIMER VU sub menu of the ChgTime menu in the main CHARGE menu Pressing the SOFT LEFT key enters the DAILY history data viewing menu Similarly pressing the SOFT RIGHT key enters the HOURLY recent history data viewing menu In the DAILY menu the LEFT side category of information displayed can be changed by pressing the UP or DOWN arrow keys Switching over to the RIGHT side of the screen by pressing the RIGHT arrow key highlights the DAY change key Pressing the UP key decrements the date goes back 1 day and displays that capture date above the word DAY There are 380 days of information stored in the Classic After 380 days are captured and stored the oldest data stored will be overwritten as new daily data fills in as the most recent data Screenshot 4 The HOURLY log menu actually captured every 5 minutes works very similar to the DAILY log menu except that the time stamp above the word TIME is the time shown in 24 hou
74. t lt GND Aux1 Diagram 4 When Aux 1 is used to supply 12v out 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 Configuring Auxiliar y Input Output lon page 36 42 Page 10 001 1 REV C Classic owner s manual continued 12v Diagram 5 To configure Aux 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 Aux terminals it acts more like an isolated 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 Configuring Auxiliary Input Output lon page 36 Aux Voltage Time Relation Relay 12v Aux 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 De
75. t breakers and wire sizes Notice that lower battery voltages and lower PV input voltages result in higher continuous output power The PV voltages listed are for reference and are not intended to be the only PV voltages supported The battery voltages listed show the most used battery bank configurations Other voltages are also supported The Classic battery voltage parameters are fully user adjustable For example if you are using a Classic 250 and 48v battery bank the maximum continuous output power based on 25 degree C ambient is 55 amps when using a PV array that yields a Maximum Power Voltage of 180 volts The same set up using a bit higher voltage modules that result in a 200V Maximum Power voltage will result in only 53 amps Although 55 to 53 amps is not a significant change it does give you the idea that all things being equal lower voltages are a bit more efficient 11 Page 10 001 1 REV Classic owner s manual continued 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 Knock out covers 4 screened User s manual DVD printed installation instructions USB cable for upgrading Firmware Snap on upper vent cover Knock out covers 4 solid Note These items are optional and do not ship as standard equipment Email
76. t mode If you believe the Classic is not hot and the orange LED is on most likely the current limit set point is too low To check this follow steps bellow e Press Main Menu e Highlight the CHARGE menu and press the Enter Button e Scroll to LIMITS and press the Enter Button Press the right arrow key to highlight Out Amps or In Amps column Use the up and down arrow keys to change the current limit then press the Enter Button to save this data 32 Page 10 001 1 REV C Classic owner s manual continued LED Modes and the Blinking Red LED The Classic may have a Red Blinking LED on its display This has no effect on the Classic and simply shows it is communicating with the Display New Classics ship with this disabled Below we will explain the different LED Modes To change the LED Mode press the Main Menu button repeatedly until Wizard is highlighted Scroll to the right until Misc is highlighted and press Enter Now scroll to LED Mode and press Enter Here you can use the up and down arrows to select the mode you prefer After selecting the appropriate LED Mode press Enter to save this data to the Classic Pressing Status will now bring you back to the home screen OFF No LED activity no matter what Rick Mode LED Activity for Errors and Warnings only Over current Arc Fault Etc Blinky basically cycles all the LEDs in a Disco fashion Useful for Partys LED 1 LED acti
77. tallation 7 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 16 Page 10 001 1 REV C Classic owner s manual continued Follow ME Charging coordination Follow Me will allow the Classics to share charge stages as well as Battery temperature info and Ground fault coordination Follow Me also allows you to program a single Classic for Equalize charging and it will instruct all the others to Equalize as well You do need to set the Equalize parameters in each classic For the Battery Temp sensor you will need one BTS only and it can be on any of the Classics The Follow Me function basically is just what it is called The Classic will simply ask the Classic to its right What do I do now and this propagates around the loop continually Whoever goes to Float first for instance will simply tell everyone else it is time to go to float To enable Follow Me you need to wire the classics network cables as shown below You also need to enable Follow ME To do this go to the Tweaks Menu To do this press the Main Menu button repeatedly until Charge is highlighted Scroll to the Right until Tweaks is highlighted and press Enter Now press the right soft key Upper right button 4 times until you see the screen with
78. tery 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 Internet ready This Manual covers Classic 150 Classic 200 Classic 250 and the Classic 250KS It covers the installation wiring and use of the Classic charge controller A WARNING Warnings signs identify conditions or practices that could result in personal injury or loss of life A CAUTION Cautions identify conditions or practices that could result in damage to the unit or other equipment MIDNITE SOLAR CHARGE CONTROLLER INSTALLATION GUIDELINES AND SAFETY INSTRUCTIONS This product is intended to be installed as part of a permanently grounded electrical system as shown in the system configuration sections The following important restrictions apply 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 de
79. 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 Float A Float cycle follows after the Absorb cycle is completed F oat is displayed on the screen Battery voltage is held at the float voltage set point Equalize Equalization function can be manually initiated or can be set up to Auto Equalize refer to page Error Bookmark not defined for details on setting up EQ The intent of an equalization charge is to bring all battery cells to an equal voltage by a controller deliberate overcharge The goal is to return each battery cell to its optimum condition through a series of voltage controlled chemical reactions inside the batteries Resting Resting will show on the display when the Classic is not charging the batteries this is typically due to low light 31 Page 10 001 1 REV C Classic owner s manual continued Mode is OFF The Classic is unique it has multiple charging algorithms for just about any DC input Because we support such a wide variety of DC inputs we have also added a software ON and OFF feature This software Switch basically turns the relay off effectively disconnecting the input source so the Classic will not charge the battery If you see Mode is Off in the bottom right corner of the displ
80. the right soft key again and here we need to set the absolute voltage we want the clipper to allow Press Enter to save this data and press Main Menu until you get back to the Aux 1 and Aux 2 screen Set the Text under Aux 2 to say Clipper Control and press Enter Press Status to return to the home screen Aux PWM Signal to Clipper from Classic AUX2 DC to Classic Earth Ground Drawn by Ruan 1 262012 Diagram 3 28 Page 10 001 1 REV Classic owner s manual continued Maximum and Minimum Wire Size The Classics Blue DC terminal connector will accept wire from 14 44 AWG The Classics Aux 1 and 2 terminal connector will accept wire up to 18 AWG Equalization Manual and Auto Equalization with the Classic Lite 51 52 On On 1 2 3 4 5 6 7 8 1 8 4 5 6 7 8 Mode system Battery EQ DHCP IP Address MODBUS Voltage Type port Auto Equalize Switch 8 Equalize Manual Off Auto On By setting Auto Equalize to Manual the Equalize intervals in the Battery Settings table are effectively disabled and Equalization stages will have to be started manually Please note that not all manufacturers recommend Equalizing AGM batteries Check with your manufacturer and make sure to DISABLE auto Eq on the L
81. 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 contacts of the relay used in Opportunity Hi It can be used that way with a solid state relay and NC contacts to do diversion above a set voltage 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 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 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 L
82. ture 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 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 Disabling GFPlon page 22 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 on Pagel 76 IMPORTANT Do not connect both positive battery and positive PV input to ground One or the 69 Page 10 001 1 RE
83. und 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 20 200 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 Solar This is the default mode for PV systems and 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 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 34 Page 10 001 1 REV C Classic owner s manual continued Leg
84. ure 10 Follow Me diagram 18 Page 10 001 1 REV Classic owner s manual continued Cable Clamp for network cables Battery Temp Sensor included USB connector USB cable is included Ethernet connector Figure 11 Battery Temperature Sensor Installation AN 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 DC 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 s
85. ve mode is a slow tracking mode similar to the Micro Hydro mode but with the difference that it is slightly faster and optimized for Solar Legacy mode can be very usefull for arrays that experience heavy shading issues as well as PV arrays that have a low voltage If the array has a VOC Open Circuit Voltage of less than 125 of the battery voltage Solar mode will not work as well so Legacy will be a better choice Uploading New Firmware to the Classic The Classic has the ability to have its firmware updated with the included USB cable and a Windows based PC Please Se me click on the Firmware tab for the firmware and instructions Do to the various different Windows configurations we will not go into detail in the Classic Manual The Firmware upgrade is fail safe so ifthe wrong code is installed the Classic simply says Wrong code prompting you to load the correct code Also if the upload is interrupted for whatever reason simply start over WARNING The Classic s USB port is NOT isolated from battery negative This is typically only an issue on positive ground systems or systems with a tripped ground fault protection device Care must be taken that a computer connected 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 62 Page 10 001 1 REV C Classic owner s manual continued Robin s Corner The engineers at
86. vice 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 8 Page 10 001 1 REV C Classic owner s manual continued With the exception of certain telecom applications the Charge Controller should never be positive grounded The Charge Controller equipment ground is marked with this symbol e If damaged or malfunctioning the Charge Controller should only be disassembled and repaired by a qualified service center Please contact your renewable energy dealer installer for assistance Incorrect reassembly risks malfunction electric shock or fire The Charge Controller is designed for indoor installation or installation inside a weatherproof enclosure It must not be exposed to rain and should be installed out of direct sunlight For routine user approved maintenance Turn off all circuit breakers including those to the solar modules batteries and related electrical connections before performing any maintenance Standards and Requirements All installations must comply with national and local electrical codes professional installation is recommended The NEC in the USA requires a DC ground fault interrupter for all residential PV installations NEC2011 requires an ARC FAULT detector on all charge controllers and inverters operating above 80VDC Both of these de
87. vices are built into the Classic DC and Battery Related Installation Requirements All DC cables must meet local and national codes Shut off all DC breakers before connecting any wiring Torque all the Charge Controller s wire lugs and ground terminals to the specs found on page 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 output Breakers between the battery and the Classic must meet UL489 standards Breakers between the DC source and the Classic must meet UL1077 or UL489 standards 44 dee 4 e e Ls 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 A WARNING PERSONAL PRECAUTIONS DURING INSTALLATION WARNING BATTERIES PRESENT RISK OF ELECTRICAL SHOCK BURN FROM HIGH SHORT CIRCUIT CURRENT FIRE OR EXPLOSION FROM VENTED GASES FOLLOW PROPER PRECAUTIONS Someone should be within range of your voice to come to your aid if ne
88. vity for Warnings and Errors as well as info A green LED on the display indicates the Classic is in Float A yellow LED on the display indicates a warning Over Temp over current etc A red LED on the Display indicates an Error Arc Fault etc There is also 3 LEDS inside the Classic that can be viewed through the upper vents The red LED indicates Auxiliary 1 is active The blue LED is not used at this time and the yellow LED indicates Auxiliary 2 is active 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 compare this reading to the reading on the Status screen in the Classic press Status if not in this screen to adjust the reading of the Classic to the one in the volt meter follow these steps Press Main Menu scroll to TWEAKS and press Enter Highlight VBatt and use the up and down arrow keys to match both of the readings Press the Enter button to save Note Use the description below to help complete the calibration of the Classic voltages TWEAKS screen Battery voltage adjust Input voltage adjust pv Input voltage 0 offset FFSET VOLTS 0 0 E Displayed MASTER ias Displayed Input battery voltage Screenshot 1 voltage Battery voltage offset 33 Page 10 001 1 REV C
89. wner s manual continued Classic mounted to the side of a MidNite Solar E Panel Figure 6 Alternative Mounting To mount the Classic to a plywood surface use 1 1 2 wood screws in the top key hole slot hole and the holes in the wiring compartment Taking care to make sure the Classic is Plumb and Level Dimensions See page 73 for more details 15 Page 14 905 Figure 7 10 001 1 Classic owner s manual continued 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 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 and 1 5 Figure 9 Figure 8 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 Battery Temperature Sensor Ins
90. y 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 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 39 Page 10 001 1 REV C Classic owner s manual continued 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 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 is preprogrammed with the best parameters

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