DANGER OF DEATH TO YOUR CLASSIC
Contents
1. All DC cables must meet local and national codes Shut off all DC breakers before connecting any wiring Torque all the Charge Controller s wire lugs and ground terminals to the specs found on page 21 Copper wiring must be rated at 75 C or higher Keep cables close together e g using a tie wrap as much as possible to reduce inductance Ensure both cables pass through the same knockout and conduit to allow the inductive currents to cancel DC battery over current protection must be used as part of the installation on the input and output Breakers between the battery and the Classic must meet UL489 standards Breakers between the DC source and the Classic must meet UL1077 or ULA89 standards Design the battery enclosure to prevent accumulation of hydrogen gas at the top of the enclosure Vent the battery compartment from the highest point to the outside A sloped lid can also be used to direct the flow of hydrogen to the vent opening Sealed AGM Gel etc batteries do not normally require ventilation Consult your battery manufacturer for details A WARNING PERSONAL PRECAUTIONS DURING INSTALLATION WARNING BATTERIES PRESENT RISK OF ELECTRICAL SHOCK BURN FROM HIGH SHORT CIRCUIT CURRENT FIRE OR EXPLOSION FROM VENTED GASES FOLLOW PROPER PRECAUTIONS Someone should be within range of your voice to come to your aid if needed Keep plenty of fresh water and soap nearby in2. turc ATTENTION Please Read this cover letter te I BEFORE installing the Classic SL For help with the Classic Classic Lite or Classic SL please see our how to videos and extended documentation Please visit this website www midnitesolar com classic Before calling tech support we recommend visiting this website for some of the most common issues DANGER OF DEATH TO YOUR CLASSIC Warning with Tigo modules Solar Mode must not be used or the Classic will not survive MidNite does not recommend the use of Tigo Module Optimizers with the Classic If Tigo modules must be installed Legacy P amp O MUST be used When the Classic is used with Wind or Hydro a Clipper type device will most likely be needed to protect against over voltage A battery based diversion load WILL NOT keep the Classic safe from over voltage High input voltage is recorded and over voltage is not covered under warranty Never hook a Pump or other load to the Input side of the Classic If a Load must be hooked to the input side of the classic the load and Classic need to have blocking diodes on them Classic SL owner s manual REVB 2056 Never Parallel 2 Classics onto one PV array If 2 Classic s have to be paralleled for wind or hydro NOT SOLAR there must be blocking diodes on each Classic For Larger systems with Large inverters and or multiple inverters like the Radian or XW for example it is important to use appropriate sized cables and bus bars or damage
3. 9ISSE Q0c 3ISSE Q0c YISSe O Q0c 9ISSE QOc YISSE D Q0c ISSE Q0c 9ISSE Q0c 9ISSE Q0c 9ISSE Q0c 9ISSE OG SISSE OG SISSE QG vISSe O OG SISSE OGL 9ISSE OG SISSE OG 9ISSE OG 9ISSe D OG SISSE OG SISSE OS YISSe O OG SISSE OG 9ISSE OG SISSE OG IISSE D BPO Table 7 Classic SL owner s manual REVB 2056 CLASSIC SL MENU MAP MidNite Solar Inc Classic SL Menu Items Status Charge Mode Aux Misc Logs Tweaks and Temps CHARGE MENU Volts EQ Volts Absorb Volts Float Volts ChgTime Absorb Hrs Mins Time 00 00 STATUS MENU Main Status One KWH IN Main Status Two Ahr IN BAT Main Status Three VOC V Amps IN BAT Whizbang Junior Shunt Capacity EQ 00 00 Timer View Min Sec Timer View HrsMin T Comp Comp Mv Deg C Cell Disable Mv EQ Comp D D Lifetime AH Reading Short Term History Power W EQ L Equalization Menu EQ Stopped EQ Started Advanced Ending Amps Rebulk Volts SKP Days Clasc Shunt 00 00 Log Moon Scope Vin V Battery About Classic Software Version Nominal Battery V Classic Version Limits Output Amps Mint Comp Volts Max Volts R Hi Batt Temp C R Symbolizes pushing the Right Soft Key D Symbolizes pushing the Left Soft Key WARNING Tho Classic s USB part is NOT isolated from batter y negative This is typically only an issue on positive grou
4. AC Generator 29 Batteries The Voltage must match the voltage of the inverter Typically 2 3 strings of batteries would be considered the max 30 Optional Battery temperature sensor This is used to compensate for the temperature of the battery If a battery is cold it has to be charged to a slightly higher voltage and when it is hot it will be charged to a slightly lower voltage 3 DC Cables to Inverter 15 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 CLASSIC WIRING FLOW DIAGRAM REVB 10 3 14 dh a AAAAARARM Diagram 1 l6 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 DC Terminal Connector sje 7 i sti L Y l eid ECCE J Tr Ale Pa riii i SRA ot A Utt 3 D E Ld D t s 9 AA F 5 A i ker 0 Se Sr T n m s l m La Figure 7 The Classic s DC terminal connector is located on the circuit board as shown in figure 17 The connector will take up to a 4 AWG 4 AWG THHN when installed in the Classic and MidNite E Panel is rated for over 100 amps and is therefore suitable for the highest power available from the Classic 150 SL After installing the wires for the last time snap in the blue cover that 1s included in the parts bag Maximum and Minimum Wire Size The Classic s Blue DC terminal connector will accept wire from 14 4 AWG The Classic s Aux 1 and 2 te
5. 2123W 73a 1050W 72A 2066W MPPT Input Operating Voltage 74 1065W 160V PV 140V PV o 4 120 PV wm 70 PV 45 Nominal Battery Voltage 14 4 12V Table 2 250V Classic Power Graph 61A 878W 62A 1779W 53A 3095W MPPT Input Operating Voltage 180V PV fn 200V PV Table 3 8 Page 78A 4550W 70A 4080W 55A 3212W sr XX XXX XX 65A 5414W 63A 5247W 5 34 4414W 83 3 72V 3728W 43A 40A 3468W 86 4 72V REV A Classic SL owner s manual REVB 2056 The graphs above represent the max power output for a given input for each Classic Using and understanding these power graphs will help maximize Classic s output power and aid in selecting wire and breaker disconnects Notice that lower battery voltages and lower PV input voltages result in higher continuous output power The PV voltages listed are for reference and are not intended to be the only PV voltages supported The battery voltages listed show the most used battery bank configurations Other voltages are also supported The Classic battery voltage parameters are fully user adjustable For example if you are using a Classic 250 and 48v battery bank the maximum continuous output power based on 25 degree C ambient is 55 amps when using a PV array that yields a Maximum Power Voltage of 180 volts The same set up using a bit higher voltage modules that result
6. OMVTY 9 OMV9 OMV9 OMV9 OMVr OMVTY OMY OMV9 OMVTY OMVrY OMY OMVT MVP OMVY OMVTY OMVTY OMY OMVY OMVTY MVP OMY OMVT OMY OMVTY OMVTY OMVTY OMVTY OMY OMVTY OMVT MVP OMY OMVY 9 0r 9 09 02 09 02 09 9 0G co 09 0 c9 0Z c9 9 09 08707 06 08 06 08 O2 9 08707 06 08 06 08 08707 08707 06 08 06 08 06 08 06 08 06 08 06 08 001 06 001 06 09 001 06 001 06 08 001 001 001 06 001 001 001 06 001 001 Or EG 09 gS cr GG c9 L9 EG G9 eL A 9 G9 CL v G9 07 v Ed 97 97 67 OL 9 6 97 45 6 08 L6 6 c9 v6 96 99 v6 96 Bulzis Jexeelg osse LLG 9LT cc 8 991 Gc GLE GL GI COG eee 99 9 feel v6 6 c cg S 99 LI 99 Gg S OL 9v LO 38 S Gg G OL 62 c 8Gp 9L 6 90 OL P ce 9 281 GLE GL SP 6 C 93 00 002 002 oog 081 081 081 081 091 091 091 091 Orl Ori Orl eu ora ora Ocl Ocl OZ OZ OZ Cra Ocl Ocl OLL OLL OLL 001 001 001 06 06 06 OZ OZ OZ CL SP Vc el CL SP v a CL ov v L CL 9v Vc cl CL ov V cl ov vc c 8p Vc cl ov Vc L 8p V Cl SP Vc cl ov v L v Indul Xe 7L 0L 9zis SIMA OGA091 Puqindino vindinoxej omejjino u OOA 10u A lddW Aa 0S 9ISSE OGC 9ISSE OGE SISSEL OGC 9ISSE OGC 9ISSE OGC 9ISSE OGC YISSB O OGC 9ISSE Q0c ISSE Q0c 9ISSE Q0c YISSe O Q0c 9ISSeE Q0c 9ISSE 00
7. To calculate this take the highest voltage the battery will be at and multiply it by 1 33 if the PV input voltage is lower than that value the Classic will not come out of resting 9 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 Unpacking the Classic SL When you receive your Classic you will want to unpack it and make sure everything is there and in good shape Refer to Figure 1 Included in the Classic package should be Classic charge controller Knock out covers 3 screened Parts bag with stickers Terminal block cover and silicone grease User s manual printed Email customerservice midnitesolar com for more information or if anything is missing or damaged Figure 1 Removing and installing the front cover on the Classic SL Removing the front art deco cover is required to gain access to the wiring compartment Be aware if this is 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 10 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 To remove the front cover of the Classic in preparation for installation remove the 4 Phillips head screws with a 2 Phillips screwdriver Lift the front half of the Classic casting off You will need to unplug the display cable It works the same as any phone cable When installing the cover for the final time squeeze a small amount of Silicone grease Included in the par
8. case battery acid contacts skin clothing or eyes Wear complete eye protection Avoid touching eyes while working near batteries Wash your hands with soap and warm water when done If battery acid contacts skin or clothing wash immediately with soap and water If acid enters an eye flood the eye with running cool water at once for at least 15 minutes and get medical attention immediately following Baking soda neutralizes lead acid battery electrolyte Keep a supply on hand in the area of the batteries NEVER smoke or allow a spark or flame in vicinity of a battery or generator Be cautious to reduce the risk of dropping a metal tool onto batteries It could short the batteries or other electrical parts that can result in fire or explosion Never wear metal items such as rings bracelets necklaces and watches when working with a battery or other electrical circuits A battery can produce a short circuit current high enough to weld a ring or the like to metal causing severe burns 7 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 Classic SL Power Graphs amp Sizing the Solar Array 150V Classic Power Graph 94A 2700W 92A 1325W MPPT Input Operating Voltage Il 120V PV 110V PV 100V PV 28 90V PV Ii TOV PV 2353W 14 4 12V Nominal Battery Voltage 24V Table 1 200V Classic Power Graph 79 A 1137W 77A 1105 TSA 2238W 774A
9. grounding conductor connections The equipment ground terminal inside the Classic must be connected to Earth Ground for the internal DC GFP to work With the exception of certain telecom applications the Charge Controller should never be positive grounded The Charge Controller equipment ground 1s marked with this symbol If damaged or malfunctioning the Charge Controller should only be disassembled and repaired by a qualified service center Please contact your renewable energy dealer installer for assistance Incorrect reassembly risks malfunction electric shock or fire The Charge Controller is designed for indoor installation or installation inside a weatherproof enclosure It must not be exposed to rain and should be installed out of direct sunlight For routine user approved maintenance Turn off all circuit breakers including those to the solar modules batteries and related electrical connections before performing any maintenance Standards and Requirements All installations must comply with national and local electrical codes professional installation is recommended The NEC in the USA requires a DC ground fault interrupter for all residential PV installations The GFP Ground Fault Protection device is built into the Classic 6 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 DC and Battery Related Installation Requirements SCS
10. in a 200V Maximum Power voltage will result in only 53 amps Although 55 to 53 amps is not a significant change it does give you the idea that all things being equal lower voltages are a bit more efficient keeping in mind that an MPPT controller needs to have the open circuit voltage of the array about 30 higher than the highest battery voltage you plan to charge to NOTE You can find the Classic string sizing tool on the web page www midnitesolar com NOTE A typical solar module around 250 watts will be a 60 cell module so it s open circuit voltage will be about 37 volts So for a Classic 150 SL you could put 3 in series A Classic 200 SL you could put 4 5 in series and a Classic 250 SL you could put 5 6 in series PLEASE NOTE this is not intended to be a sizing tool but a general guide Please follow the link above and size your array properly WARNING VOC is a term you will hear a lot it stands for Volts Open Circuit This is what is used to determine how many modules can eo in series VOC will be printed on the actual solar panel as well as on the spec sheet for the solar panel For questions on the values found on the solar panel please consult the panel manufacturer or the distributor NEVER connect any loads or other stuff to the PV input on the Classics Or any charge controller Classics that have exceeded their HyperVOC voltage safe voltage will not be under warranty A Classic needs a MINIMUM Input voltage to turn on
11. lead acid lead antimony lead calcium gel cell or absorbed glass mat type rechargeable batteries Other types of batteries may burst causing personal injury and damage Never charge a frozen battery WARNING RISK OF INJURY To reduce the risk of injury charge only properly rated such as 6 V 12 V and 24 V lead acid GEL AGM Flooded or Nickel Cadmium rechargeable batteries Other battery types may burst causing personal injury and damage WARNING Explosion hazard during equalization the battery generates explosive gases Follow all the battery safety precautions listed in this guide Ventilate the area around the battery using ventilators with brushless motors thoroughly and ensure that there are no sources of flame or sparks in the vicinity An optional Battery temperature sensor 1s available which plugs into the jack beside the DC Terminal connector labeled Batt Temp Route the cable through the E panel into the battery box Pick a battery in the middle of the bank and about half way up the side of the battery thoroughly clean a spot off on the case Then remove the protective tape from the sensor and adhere the temperature sensor to the battery Some manufacturers use a double wall case on the battery For mounting a temp sensor to a double wall battery case please refer to the battery manufacturer s recommended procedure 19 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 COMMON Gh NEGATIVE Insert BTS
12. lets you pick the function of the 6 visible LEDs on a standard Classic 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 MNGP Midnite Graphical interface Panel This is the graphical display included with the standard Classic controller 43 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 Mode This menu lets you turn the charging ability of the controller On Off as well as lets you select the DC input source See page 23 for info on the Mode menu Mod Bus a standard protocol used for communications We have published our protocol to allow users to interface with the Classic See www midnitesolar com for our Mod Bus protocol Pwr Save Allows you to adjust the time the Backlight stays on Resting The Classic is not charging the battery due to low light For certain reasons Resting will appear Please see page 24 T Comp Temperature compensation using a temperature sensor to measure the ambient temperature of the battery bank and will adjust the voltage set points up or down accordingly to ensure a full battery There are 3 parameters to set Minimum and Maximum adjusted voltage as well as volts per degree C per Cell Typica
13. to the inverters or charge controllers can occur Take a single XW E Panel for example it has a positive bus bar for Charge controller battery side connections This bus bar is sufficient for 2 charge controllers so if you needed 3 or more then you need to look at the best way to handle the amperage Or a Dual Radian for example is actually 4 separate inverters Proper size cables become very important as well as large enough battery banks Most manufacturers of Battery based inverters recommend 100AH of battery per KW of solar modules Please consult the inverter manufacture for assistance with cable sizing etc 2 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 This Manual covers models Classic 150 SL 200 SL amp 250 SL 3 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 The MidNite Solar Classic charge controller conforms to UL 1741 Safety for Inverters Converters Controllers and Interconnection System Equipment for Use With Distributed Energy Resources Second Edition May 7 1999 with revisions through January 28 2010 and CAN CSA C22 2 No 107 1 2001 09 01 Ed 3 R2006 MidNite Solar Inc reserves the right to revise this document and to periodically make changes to the content hereof without obligation or organization of such revisions or changes unless required to do so by prior arrangement Disclaimer Unless specifically agreed to in writing MidNite Solar Inc a Makes no warranty as to th
14. 0 DAAVS V0S OMVOLATOE AQ0 OAAVS 40 DAAVS VOS OMVOL VOE AO0 OAAVS 10 DAAVS VOS OMVOL AVOE AQ0 OAAVS JO SAAV9 V0S OMVOL VOC AO0 DAYS 10 DAAVO VOS OMVOL VOE AQOE OAAVS 40 DM V9S vO0S OMVOL VOC AO0 OMVS 40 DAAVS VOS DAAVOL VOE A00 DMV 10 DAAVS VOG AQ0 OAAVS 40 DAAVS VOS OMVOL AVOE AO0 OAAVS 10 DAAVS VOS OMVOL VOE AQ0 OM WS 40 SAAV9 V0S OMVOL AVOC AO0 OM VS 10 DM VO9ATOG AO00 OMVS 10 OMV9 e0S AQOE OAAVS 10 DAAVS VOS OMVOL VOE AO0 DAYS 10 DAAVO VOS DOMVOL AVOE A00 SAAV9 10 DAAV9 e0S AQOE SAAV9 JO DAAVO E0S AO0 DMY 10 DAAVOS VOS OMVOL VOE AQ0 OAAVS 40 DAAVSATOS OMVOL AVOC A00 OMVYr VvOS A00 DAAVS 10 DAAVO VOG AQ0 DAAVS 40 SAAV9 Vv0S OMVOL AVOC AOSL OAAVO AVEO O9N V9 v0S KAOS OMVS9 VED DOMVOL YOE AOSL ONMWS9 VE9 OANVOL YOE AOSI OMVO AVES DAAVS VOS AO0SL OM V9 VED OMVOL YOE KOS OM V9 VES OMVOL YOE AO0SL OMYVO9 AVES DAAVS VOS AO0SL OMVS V 9 DOMVOL WOE AOSL OMVS9 VED OMVOL YOE AOSL VE9 A0SL DMI AVES DAAVS VOS KAOS DAAVO VE9 DAAVOL YOE AOSL DAAVPAVOS AQSL DAVE AVES OMVS VOS KAOS OMV9 VED DAAVOL YOE 4410196 HGZ UMA ell JexeeJq Indu vvv vA cl GL 6rt L 99 vl 9c 8 90T 18 EC cS 6l L8 OL LVS LV ct 92 CC ve cl veg GL 6 9c 9v LI 60 cS 9 9c GS el r Ot v9l 66 SL ee ve sl SL OL 9v BE 28 c vo LI St vv 90 Sc g Le 6S 6L 9v 9 SN AV9 9 OAAVS OMV9 OMV9 OMV9
15. 300 AC Surge protection 14 MNSPD300 DC Surge protection 15 DC breaker for the Inverter Also serves as a disconnect for the Inverter 16 DC breaker for the PV into the Classic Also serves as a disconnect for the Classic 17 DC breaker for the Battery into the Classic Also serves as a disconnect for the Classic 18 ACLI Input Bus Bar This is where the generator L1 input gets wired 19 AC Neutral Bus Bar This is where ALL AC Neutrals get wired 20 AC L1 Output Bus Bar This is where the L1 Output to the Load center for the building would connect 2 Battery Positive Bus Bar This is where we would wire the Battery positive side of the Classic as well as where we would wire up DC loads Do NOT wire the battery cable to this bus bar 22 Earth Ground Bus Bar This is the common Earth Ground bus bar where all the grounds get wired back to and it needs to be connected to the building s ground rod system 23 PV Positive Bus Bar This Is where the Solar Panels positive lead connects 24 Battery negative Bus Bar This is where the solar panel negative lead would go as wellas the Classics negative lead and any negatives from the loads Do NOT connect the battery negative cable to this bus bar 25 DC Shunt The Shunt measures the amperage in or out of the battery You connect the battery to one side and everything else to the other side 26 Earth Ground system of the building 27 Classic Charge controller 28
16. Classic and continue to hold the arrow buttons until the setup screen is displayed Answer the questions on the next few screens to complete the Quick Set Equalization To do a manual Equalization charge go into the Charge menu and highlight EQ and press Enter Now EQ Stopped will be highlighted Scroll up to select Eq Started Press the Status button to return to the home screen To stop a manual EQ in progress simply reverse the steps above A manual EQ when started will last for that day Battery Charge Stages and Meanings Bulk MPPT This stage of the Classic means that the Classic will be putting out as much current as it can to raise the battery voltage to the absorb voltage set point This 1s 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 1s terminated at the end of the Absorb time or the End Amps set point whichever 1s reached first At this stage the Classic 1s not putting out maximum current as that would increase the battery voltage over the Absorb set point This 1s 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 1s considered full at the end of the absorb charge cycle 23 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 Float A Float cycle follows af
17. OC M HyperVOC is a unique feature the Classic has built in HyperVOC refers to when the DC Input Voltage raises above the maximum operating voltage 150V 200V 250V depending on the Classic model HyperVOC gives you the flexibility to go up to the maximum operating voltage PLUS the nominal battery voltage For example the Classic 150 has an input voltage rating of 150 operating volts if the Classic 150 is connected to a 48 volt battery bank the HyperVOC voltage limit will be 150V 48V a total of 198 Volts that the Classic can withstand without damage When the Classic input voltage rises above 150 volts it will switch off stop outputting power As long as the Classic 1s in HyperVOC mode the microprocessor and all other functions like AUX will continue running When the input voltage comes back down below 150v or the rated operating voltage of the Classic depending on model the Classic will wake up and start charging again automatically This could happen in a really cold morning with a system that has a Voltage Open Circuit VOC close to the maximum operating input voltage Note 1 A HyperVOC message will be displayed on the bottom right side of the Status screen Note 2 Max nominal battery voltage to be added 1s 48v 14 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 Diagram 1 Explanations 10 Solar Modules PV 11 DC Combiner Like our MNPV6 or MNPV12 for example 12 MNSPD300 DC Surge protection 13 MNSPD
18. Troubleshooting FAQs How do Ido a software Note this only works on the Classics with Displays not a Classic Lite with the Factory Restore on my MNLP LED Panel Classic or Classic SL Warning this will erase ALL settings Turn the PV breaker and Battery breaker off What you don t have a breaker Get one asap and make sure the display has gone dark Hold the left and right arrow and turn on JUST the battery breaker Continue to hold the arrow buttons until you see the Quick Start pop up Follow the on screen prompts to set up your controller WARNING You must get the battery charging voltages from the battery manufacturer and it is VERY important you do this and do not just leave it as default settings as it 1s likely this will undercharge and slowly destroy your batteries WARNING The Clock is a 24 hr clock Setting it off by 12hrs will cause it to reset to a new day at Noon How do I do a Warning this will erase ALL settings HARDWARE factory Turn the PV breaker and Battery breaker off What you don t have a breaker restore Get one asap and make sure the display has gone dark Do a hardware factory restore There are 4 sets of jumpers directly above the blue terminal block For the purpose of this we will call the left most jumper JP1 and the right most JP4 actually labeled Boot Step 1 Turn the PV and Battery power off to the Classic and remove the front cover Step 2 Locate the 2 jumpers JP1 and BOOT JP4 Take the a
19. ctual jumpers and keep them in your hand Step 3 Turn the Battery power on to the classic Step 4 within 1 minute place jumper JP4 on its two pins and then place jumper JP1 on its two pins at this point the 3 leds on the top of the circuit board should flash back and forth for about 60 seconds Step 5 After the flashing stops power down the classic and remove JP1 and JP4 and stow them back on a single pin like they were Step 6 Put the front cover on and power up the Classic Lite If you have the MNLP set to Custom you will need to go to the local app and reset the battery voltage and setpoints etc What is a VMM It has become industry slang for our factory restore Vulcan Mind Meld from the 2 fingers needed to push the arrows 28 Page XX XXX XX REV A Classic will not power on No Fans or life on power up Classic Display 1s blank but the Classic 1s on Classic says Resting but the sun is out Classic switches between Resting and Bulk MPPT repeatedly but produces 0 watts The Display shows 0 volts 1n or real close but shows battery voltage correctly The Display 1s showing all 0s and or Got Comm The Display 1s showing Mode is OFF Stuck in the Quick Start or VMM The MNGP Display is fuzzy or has odd characters Multiple charge controllers and one or more is showing 0 watts and absorb or float Multiple Classics in Follow Me and they are not all making the same amount of
20. e accuracy sufficiency or suitability of any technical or other information provided in its manuals or other documentation b Assumes no responsibility or liability for loss or damage whether direct indirect consequential or incidental which might arise out of use of such information The use of any such information will be entirely at the user s risk Contact Information Telephone 360 403 7207 Fax 360 691 6862 Email customerservice midnitesolar com Web www midnitesolar com Contents SOUPO iios mdp S SSS SSS S SSS SS E PIDEN S EN M NENNEN MEDIUM GNE 5 Jiliri HI 5 Classic SL Power Graphs amp Sizing the Solar Array esses nennen nennen nennen nnn nnne nnn 8 Unpackins bhe Classe SEE T 10 Removing and installing the front cover on the Classic SL 10 Mounting the Classic SL us 11 YVI HIS Ile CLASSICS uu u ERR 13 DEC Tetinmial C onne u u u uu uu u u u O 17 Maximum and M ininum Wire 126 uuu ll u ua a eura teas uu pie IM eH xv eror VM iau eder 17 Over Current Protection and Wire Size Requirements 17 CODE TIE s L I sss EIE IMEEM EE MEME MM MM MU 18 uos S sco esit MR T m T um 18 on D
21. e real time clock like there 1s on the regular Classics You will need to use the Local App to reset the time after a power cycle The Local App will turn yellow if the time is not in sync with the PC you are viewing it on And the Local app has a time sync button on the Basic Configuration tab We recommend setting the dip switches for normal operation and DHCP Connect to it with the Local App and verify it has connected to the network Now at this point we can go switch the S1 switch 1 and 2 to ON or UP to set the MNLP to custom Do this with the Classic Lite powered on Now you can change the network settings on the Local App if you want Note setting switches to custom first and then powering the Classic Lite can cause issues trying to connect as it assumes you are already connected We anticipate setting to Custom AFTER connecting to the network There was a bug in older firmware that would cause this We recommend updating the firmware and doing a factory restore Warning all settings will be lost The firmware can be found on our website under the software tab Or at the URL below http www midnitesolar com firmware php firmwareProduct ID 1 We advise against this as it is more complicated than most people feel comfortable with We recommend a cheap router for this as it makes it much easier The way to think about this is the Computer and Classic have NO address until the Router addresses them so if we must go direct we have t
22. ection The Classic has internal ground fault protection GFP built in Since 2008 the NEC requires a DC GFP on all PV systems in the USA The built in DC GFP eliminates the need to purchase and install an external DC GFP If the internal grounding jumper is installed in a Classic the battery negative and DC source negative must not be connected to the system grounding conductor anywhere in the system Grounding of these circuits will defeat the GFP function In a network with multiple Classics connected in Follow Me only one Classic should have its internal grounding jumper installed and all should have GFP enabled The factory setting will make a DC negative to System Ground connection in the Classic charge controller The GFP function will need to be disabled for Positive ground or an ungrounded DC system NE E BATTERY COMMON GND PU TURBINE NEGATIVE Y AUX1 RELAY OUT LAS 5 Ka Figure 11 Figure 12 The Ground fault device is simple to understand and use It detects a fault between battery PV negative and earth ground just like the breaker DC GFP system The difference with the Classic 1s that it turns off the charge ability and sounds a loud warning when a ground fault 1s detected The Classic s system consists of a PTC that is between the Negative and Ground internally in the Classic A PTC is basically a self healing fuse that will open when current exceeds its rating and reclose when current is dropped be
23. ed 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 putting all available power into the batteries Float Constant voltage charge stage with a lower voltage than the Absorb charge point The controller is regulating so maximum power will not be seen at this time Float MPPT Maximum current charge stage The Classic is trying to bring the batteries to the Float voltage set point We are basically putting all available power into the batteries FLT Float mode By using the up arrow in Tweaks under FLT you can force the Classic into Float mode GF Ground Fault See page 22 for more info on ground fault protection Got Comm Indicates a lack of communication between the display and the Classic Consult Troubleshooting for information page Error Bookmark not defined 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
24. erating Volts 1n 150VDC 200VDC 250VDC Max Hyper VOC 150 battery 200 battery 250 battery Battery Charge Volts 12 93 volts 12 93 volts 12 93 volts B xx Absolute Current 96a at 12v battery 74a at 12v battery 60a at 12v battery I o 94a at 24v battery 70a at 24v battery 62a at 24v battery Output at 25 C 83a at 48v battery 65a at 48v battery 55a at 48v battery De rate current 40c to 40c Dimensions of Classic 14 87 X 5 95 X 4 00 378mm X 151mm X 102mm 19 00 X 8 50 X 5 70 483mm X 216mm xX145mm Shipping Weight I1 5 b 4 9 kg NOTE Current output ratings were measured with 75 of the PV array s VOC Open Circuit Voltage NOTE Calculated by adding battery voltage to the maximum input operating voltage 48V battery max NOTE Measurement Accuracies 0 12v offset calibration adjustment maybe necessary Table 6 36 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 specifications Mechanical 6 00 3 94 15 53 14 91 01 38 200 20 0 99 0 60 1 3 72 Figure 13 37 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 izing Classic Breaker s JIM pue Jayealq jndul o saldde osje saoge 40128 Ajajes 9G anba jou op pue epo Anp 9500 JO paje je Sue sJexeaiq Jejos JINDII vy euegd 3 lINDIN e episul SIM 2367 Heyo siy uo peseq JeAeAJesuoo si yeya SIU Je aa Ul siojonpuoo Buls JO yeyo aui SI L 0L O3N AO0 DAAVS 10 DAAVS VOS OMVOL AVOE AQ0 OAV 1
25. f the PV array is real low voltage and its max power point is close to the battery voltage disabling LoMax will cause a slight loss in power as the Classic will not be able to track all the way to the battery voltage looking for the MPPT voltage I have a classic that No the Magnum sensor was a different resistance value so those classics came with a grey where modified to use those sensors Call customer service if you need help Magnum Battery temp with a new sensor sensor can I replace it with a Midnite blue one How can I verify that all If you unplug the battery temp sensor and use a flat bladed screw driver to my fans work on My short out all 6 pins inside the jack Carefully so as not to bend the pins the Classic fans should all start spinning How do I find the You won t we removed the wizard as it asked a lot of questions that did Wizard nothing and was confusing We replaced it with the Quick Start that comes up when you first power the classic or do a factor restore My fans run all the time Check to make sure you did not pinch the Fan wire at the top in the casting no matter what the Classic 1s doing I remotely mounted my Check that you made the cable exactly the same as the blue one Note that Pin MNGP display and one on one end becomes Pin 6 at the other end Mirror image now it won t power on Iry a heavier cable We have found that off the shelf phone cables are good or it blinks but won t for abo
26. f you see beeping any voltage here than the system has a fault Call your installer for help finding and rectifying the fault The Classic will automatically stop showing the fault when the issue is fixed 31 Page XX XXX XX REV A My Classic says Set date and time on the display I have a WBjr and the SOC is not showing on the main status screen I don t see a WBjr status screen or I don t see all the settings shown in the manual My State of Charge seems inaccurate Classic says Arc Fault on the display and is making a loud beeping noise My Classic Lite has ALL of its LEDs blinking slowly 32 Page Classic SL owner s manual REVB 2056 Verify you are not setting the date and time with the local app without time sync off in the tweaks menu If not using the local app to set the time then verify that time sync is ON in the tweaks menu Verify the Remove paper was removed out of the coin battery in the display Check coin battery for voltage 1f under 2 5v replace the battery Check the coin battery for glue residue from the remove tag With coin battery removed press in on the 2 tabs to bend them in a little tighter and add more spring pressure to the battery Verify the WBjr is set up properly by looking at the WBjr status screen and verifying the values it is showing look proper The SOC will not show up until the Classic with the WBjr goes to float once so it can calibrate If the
27. i C Vy IUS Duuuwauiwsunaasasasuiquqaamusiaspaqupiykaywasaiyspaaatapswayphayyawpaktskawaysaquyayayaapayaysaaspawpakapassasaussa 18 4 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 Battery Temperature Compensation 19 Battery Temperature Sensor Installation 19 Chassis Co MN oct cs Sarno OU T T UT 21 DC Syster Gro im GIGS yu sence T 21 Positive Ground Systenis o L HERI PHA BERE i ica uu IEEE AERE ees Error Bookmark not defined DC GEP Ground Fault Protection sacs e uum yu sa u u ea Bate au sO a ci ere Pe eS Re dv bubo ed Rea 22 Disabline GEP aus obtestor tuis aqu han ue ere ene ere ee intet unte o uet eon tuu iecit nube a eer ee en ere uu EC 23 Commissioning the Classic SL Quick Start r 23 I ipea Ee M 23 Battery Charge Stages and Meanings 1 5 ordo a Ree AR a Eve Ege ARS ERAN AR UA dodo tou ede AS UNE RAN UL Re UAR aaa s 23 RESIN E tese ka as a a uu i date Maat Oa aut RM ic M m 24 IVO dS OD catenas bunten utes ee tar aces aol es ee esas tu apakunan satis esas tu oh arene tup ut ts onu 24 Adjusti
28. ip Please see the manual for help with that This is indicating the LED panel MNLP is not talking to the Classic Try making sure the blue cable is plugged in well Try plugging the Blue cable into the middle jack If both of the above fail do a HARDWARE factory restore See manual XX XXX xXx REV A My Classic Lite has the left hand 3 LEDs blinking on the LED panel When I make changes to my Classic Lite with the Local App they do not appear to stay My Time gets out of whack on the Local App when the Classic Lite is powered down and back up I am having trouble getting my Classic Lite on the network My Classic or Classic lite keeps going back to address 10 after I readdress it to something else I am having issues connecting my Classic or Classic Lite directly to my PC without a Router 33 Page Classic SL owner s manual REVB 2056 This indicates wrong code If you recently updated code you may have updated with the wrong model code Look at the inductor stickers they will have the model of classic on them also so you can verify and re update with that model code This 1s generally caused by failing to put the MNLP LED panel into Custom mode To put this into custom mode set S1 Switches 1 and 2 to ON or UP this will allow the LED panel to read the classic but not make ANY changes to its programming so you can program the Lite with the Local App Unfortunately on the Lite there 1s no battery to back up th
29. it is backing its current down to prevent overheating Go into the Main Amp Limit menu and the Charge category Look in the Limits sub menu and verify the amp limits for In and Out are set to what you desire My Classic says Hyper This 1s indicating that the input voltage has exceeded the operational voltage VOC on the display of the Classic If this 1s happening now and then on rare occasions when it 1s really cold then this is normal If this 1s happening all the time this indicates the PV array was wired for too high a voltage Please consult your installer for assistance with that My Classic says This is an indication the Classic thinks the battery voltage is to high and has Battery over V on the stopped charging display This can happen with multiple controllers that are not networked together if one of the classics goes to float it can show this and will go away as soon as the other controller goes to float If this is a new install the wrong nominal voltage may be selected and a factory restore will be needed if this is a running system then you may have another charging source that has malfunctioned and over charging the battery bank My Classic says GRND Generally this would be caused by the PV or Battery positive shorting to FLT on the display and ground somewhere in the system The first thing to do is verify it is a real fault is making a loud by carefully measuring between Battery Negative and Earth ground I
30. it works is 1f the charge current falls below the End Amps setting AND the Classic is in Absorb the Classic will go to Float Setting End Amps to 0 will disable it End Amps setting 1s a value the battery manufacturer supplies Make sure you have the Absorb time is set properly Follow Me with my Classic Lites older than serial CL05435 did not work with Follow Me Classic Lite 1s not please call customer service for a new MNLP working Verify you are seeing the short blips of the blue LED internally as talked about above If not please check all your cables My Classic says OCP is This can happen on older Classics that have had the firmware updated This OFF on the display will have no effect on the operation of the classic but to make the message go away do a factory restore to fix this Warning all settings will be lost My Classic says OCP This can be normal if the battery bank 1s small or the inverter cables are too now and then on the small If this shows up just once in a great while that would be ok but if it 1s display happening pretty regularly you may want to look at the size of the battery cables Age of the battery bank or the size of the battery Call customer service for assistance My Classic has an This indicates the Classic 1s current limiting Either because it has reached the orange LED on the current limit you have set in the Charge menu under limits or because it 1s to display lit up and or says hot and
31. lly this is 5 mV but please consult your battery manufacturer See page 19 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 Vpv Input voltage measured at the input terminals of the Classic 44 Page XX XXX XX REV A
32. low its rating The Classic will monitor this PTC and disable the charging when it senses it go open When the fault 1s cleared the Classic will restore charging To disable the internal Ground Fault Protection function the jumper labeled GFP needs to be removed and the GFP function needs to be disabled in the TWEAKS menu See Disabling GFP for instructions To reset the internal GFP function after detection has occurred fix the actual ground fault then turn OFF the Classic and turn it back ON Do this by turning the external battery breaker to OFF position and then to ON position 22 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 Disabling GFP The GFP feature should only be disabled to operate the Classic In an ungrounded power system or in systems where GFP Is not required Press Main Menu Scroll to the right or left until TWEAKS is highlighted and press ENTER In TWEAKS press the right soft key to get to the MORE menu In MORE scroll until GFP 1s highlighted Use the up and down arrow keys to toggle between on and off Press ENTER to save vY v Vv Vv Vv v Commissioning the Classic SL Quick Start The Classic will enter Into the Quick Set screens upon initial power up If the Classic does not enter into the quick set or you want to restore to Factory Default follow these steps to initiate a Quick Set With the power off to the Classic Hold the left and right arrow buttons down Turn the power on to the
33. n menu and selecting the Temps menu The Classic like all other chargers will adjust the actual charge voltage based on the temperature of the battery It uses 2 variables you program in for this 1 Temperature neutral point Typically 25 degrees C and this 1s found in the WBjr set up menus 2 Milli volts per degree C per cell typically 5Mv So verify both of these are set per the battery manufacturers specs So for an example 1f Absorb was set for 58 8 volts and the battery 1s at 35 degrees C and the temp comp is set for 5mv we have a 10 degree C difference 10 x 24 240 x 5 1200Mv or 1 2v so the Classic would actually charge to 57 6v Classic goes to absorb at Verify this is not normal operation do to the battery being cooler than the too high of a voltage Neutral point You can verify the battery temperature by going into the main menu and selecting the Temps menu The Classic like all other chargers will adjust the actual charge voltage based on the temperature of the battery see above calculation s the same works for cold batteries as well you just end up with a negative number so a battery that 1s 15 degrees C would look like 10x24 240x5 1200Mv or 1 2v so the Classic would actually charge to 60v 30 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 Classic goes to Floatto Make sure End Amps Is not set to high causing the Classic to go to Float End early Amps is in the Charge menu and the way
34. n circuit voltage close to 250vdc accounting for the coldest temperature you will encounter This will allow you to run a smaller gauge wire than with a lower voltage charge controller The efficiency of a high voltage Classic 1s less than the lower voltage versions so you need to weigh the benefit If this sounds too complicated use this rule of thumb In selecting the proper Classic PV runs up to 100 feet use the Classic 150 runs up to 180 feet use the Classic 200 or above 180 feet use the Classic 250 If the wire size between the DC source and the Classic 1s larger than the Classic s DC terminal connector you can use a splicer block or similar connector to reduce down to 4 AWG close to the Classic The MidNite E Panels are supplied with a PV input bus bar that accepts up to 2 0 wire 18 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 Battery Temperature Compensation A remote battery temperature sensor BTS can be purchased separately This sensor raises or lowers charge voltage based on temperature Connect BTS to the BATT TEMP jack Refer to Battery Temperature Sensor Installation 20 The Battery temperature menu appears as T Comp in the BATTERY MENU In this menu you can change the voltage compensation as needed If the BTS is disconnected or shorted the Classic will automatically default to 25C on the Battery temperature Battery Temperature Sensor Installation A CAUTION To reduce risk of injury charge only deep cycle
35. nd systerns or systems with a tripped ground fault protection device Care must be taken that a Right Soft Key computer connected to the 10f4 Temp Comp Set Point Volts Classic s USB port is emher Directional Arrow Keys isolated from ground and the Classic s negative or that the computer s USB negative is O CLASSIC KEY PAD common with the Classic s negative and ground www midnitesolar com 17722 67th Ave NE Arlington WA 98223 PH 360 403 7207 Fax 360 691 6862 nig 39 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 CLASSIC SL MENU MAP MidNite Solar Inc AUX MENU Aux 1 Manual Off Manual On SOC Low Lus adl Po SOC High P Tes Tr Off Trip High Vent Fan Low R Volts Vent Fan High 5 Volts Float Low Float High Day Light Nite Light Toggle Test PVV On Low R Low p Dei gt PV V On High Low we R r Delay Lue Waste Not Low To Aux 2 on next page V Low fy High Delay a ipe AUX 1 CONTINUED m 2 of 4 MODE MENU ON OFF ON OFF Function Legacy P amp O R Interval Minutes Depth Watts Solar F Interval Minutes AUX 1 CONTINUED Waste Not High V Low b High T Delay Hold Low Bat Discon R r V Low fy High Hold L Delay Diverson EF V Low fy High T Delay Luna Symbolizes pushing the Right Soft Key D Symbolizes pushing
36. ng Absorb Equalize and Float Voltages 24 hi DL L TEE EUN PD NE M PCR MEN 25 Calibratine Battery and PV VOIUIBE sueco SIE ERO ERN USE M e DU IE e nes RU Ui ues A io Ci Lupe EU asss 25 Contigunme DC Input Source m uy k Dun esi btt bise A enisi atur bise LN d eee hase 25 Selis the Date and DIDI uu eo do ayia toes onu Saca ceed ates eae eae eit IS D La UO D Ut LE LIII MEE DA aqa 26 Uploading New Firmware to the Classic 27 POUND TCS OO GING uuu u lu uu ameet m tatam cem dean Error Bookmark not defined Electrical Specifications u uuu u u Q AR AR u QU AM UDIN IE M LN tU Su Uer cA SSS asss 36 Specifications Mechanical 37 Cos ie Breaker Gi 71 1G n eee mahanap tuse E T O ST 38 Scope This Manual provides safety guidelines and installation Information for the Classic SL charge controller It does not provide brand specific information about photovoltaic panels batteries etc Contact the manufacturer of other components in the system for relevant technical data Introduction The MidNite Classic SL charge controller was designed as a SOLAR only charge controller The Classic 150 SL 200 SL and 250 SL are designed
37. nk that 1s about half a second indicates it did not get any info If the blinks are ALL long then you probably have a bad cable and all cables should be checked immediately The Fans seem way to Tf it is the internal fans make sure no wires or anything have come in contact loud with them inside the wiring compartment If it is the external fan you may want to remove the front half of the Turbo plastic housing and make sure the fan 1s still adhered into the back plastic housing If the fan has come loose a dab of silicone on each side should solve the noise issue Please make sure not to get any silicone on the fan blades Updating the firmware Make sure the MNGP Display 1s actually plugged in using the blue display and the Classic went cable in the top jack of the main circuit board well but the MNGP will Verify you have an MNGP and not an MNLP The MNLP is an LED panel not update that comes with the Classic Lite and does not need to be updated When the black box pops up telling you to power the Classic up Count to 4 before turning the breaker on If you do not have a breaker or disconnect and you are trying to connect a wire to a terminal block or a battery the connection will likely be to dirty for the boot loader Install the proper breakers Classic goes to absorb at Verify this is not normal operation do to the battery being warmer than the too low of a voltage neutral point You can verify the battery temperature by going into the mai
38. o address both of them To do a direct connection we recommend a cross over Ethernet cable Then you need to set the Classic to a static IP say 192 168 1 5 then you need to go into the IPV4 properties on the PC and set it for a static IP also of say 192 168 1 2 Note the important part here is that the first 3 sets of numbers match 192 168 1 xxx for example and that the LAST sets of numbers do NOT match as this is the unique identifier of where each item is You will not need to worry about Gateways or DNS IPs for this connection For more help with this see our video on direct connection to Classic or consult your network guru XX XXX xXx REV A Classic SL owner s manual REVB 2056 I cannot find an Go to the C directory and find the folder labeled midnitesolar and open it In uninstaller for the here you will find an uninstaller simply double left click it to run it After it 1s Midnite firmware complete you can delete the midnitesolar folder to completely remove any files updater left behind What is the All Classics use 142 for the password PASSWORD for the Classic I hear a singing sound This 1s the inductors Singing when the Input voltage is really low This 1s coming from my normal and is no cause for concern however if it bothers you then you can Classic Sort of a high disable it by going to the main menu and entering into tweaks Look for pitched whine that varies LoMax and set it to off and press enter Note I
39. o save the changes The Classic includes a battery CR 1216 in the MNGP portion to keep the time running even when the power is disconnected To replace the battery refer to the Installation Manual 26 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 Uploading New Firmware to the Classic The Classic has the ability to have its firmware updated with a standard USB cable and a Windows based PC The USB cable is Standard to Mini B Please see www midnitesolar com and click on the Software tab for the firmware and instructions Due to the various different Windows configurations we will not go into detail in the Classic Manual The Firmware upgrade is fail safe so if the wrong code is installed the Classic simply says Wrong code prompting you to load the correct code Also if the upload is interrupted for whatever reason simply start over WARNING The Classic s USB port is NOT isolated from battery negative This is typically only an issue on positive ground systems or systems with a tripped ground fault protection device Care must be taken that a computer connected to the Classic s USB port is either isolated from ground and the Classic s negative or that the computer s USB negative is common with the Classic s negative and ground WARNING You cannot turn a Classic 150 into a Classic 200 for example using new software the internal components are also different 27 Page XX XXX XX REV A Classic SL owner s manual REVB 2056
40. oller safe If the orange LED comes on the MNGP it means that the Classic is in current limit mode If you believe the Classic 1s not hot and the orange LED 1s on most likely the current limit set point 1s too low To check this follow steps below e Press Main Menu Highlight the CHARGE menu and press the Enter Button Scroll to LIMITS and press the Enter Button Press the right arrow key to highlight the Out Amps column Use the up and down arrow keys to change the current limit then press the Enter Button to save this data Calibrating Battery and PV Voltage To calibrate the Classic battery and PV voltage reading you will need a Volt meter to check the actual battery bank voltage or input PV voltage Using the volt meter measure the voltage on the DC terminal connector of the Classic refer to Screenshot 1 compare this reading to the reading on the Status screen in the Classic press Status 1f 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 Input voltage Battery voltage 0 lt C ffset offset 13s Displayed HOSTEN Displayed Input battery voltage Sc
41. power 29 Page Classic SL owner s manual REVB 2056 Check for reverse polarity on the Battery positive and negative terminals on the blue terminal block Check for voltage on the Battery positive and negative terminals on the blue terminal block if less than 10v charge the battery or find the bad connection Check that the blue display cable 1s plugged into the top jack on the main circuit board and the display Iry the middle jack on the circuit board Try a different 4 conductor phone cable Resting indicates a lack of power available to the Classic Verify you have voltage on the display under the IN that is at least 130 of the actual battery voltage at that time Verify the charging mode is correct for the source as well as the Mode is on This can be normal under low light conditions Watch the input voltage 1f 1t drops down close to battery voltage and then the Classic goes to Resting this is usually a sign of a bad connection If it is rock solid call customer service Iry doing a factory restore Warning all settings will be lost f this is a new install check for reverse polarity on the PV positive and negative on the blue terminal block inside the Classic If the system has been running all along and this just happened call customer service Make sure you did not put a different display on the Classic Firmware must match on the Classic and MNGP Do a HARDWARE Factory Restore See manual En
42. re are multiple Classics in Follow me we need to make sure the one with the WBjr is the first one to go to float We recommend setting the Classics that do not have WBjrs for about 15 minutes longer on the absorb time this will ensure the Classic with the WBjr goes to float first f you are using End Amps make sure you use the Classic with the WBjr to do the sensing of End Amps If the WBjr status menu is not present or does not match the manual then you most likely have older firmware We recommend updating the firmware and doing a factory restore Warning all settings will be lost The firmware can be found on our website under the software tab Or at the URL below http www midnitesolar com firmware php firmwareProduct ID 1 Verify the neutral temperature for the temp comp is set per the battery manufacturers specs typically 25C Verify the Amp Hours of the battery bank 1s set properly Note batteries in a string do not add in amp hours so if you have a single string of 8 golf cart batteries each having 220AH then you have 220AH of capacity Verify the efficiency of the battery 1s set properly according to the battery manufacturer s specs typically 94 This is generally indicating you have a bad connection somewhere causing arcs This can be anywhere in the system so generally finding it 1s easier if you can turn things off and see what causes the Fault to clear This also can be caused by loads etc and be a nuisance tr
43. reenshot 1 voltage Configuring DC Input Source To select the Mode the Classic will run in follow the steps below Push the Main Menu button Scroll left or right until Mode is highlighted and then push the Enter button 25 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 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 Setthe ON OFF to ON and press Enter oe oe oe The following Modes will appear in this order in the MODE Menu Solar This is the default mode for PV systems and has a very fast sweep 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 1s partial shading at times during the day SOLAR mode is best suited for shaded or un shaded PV arrays that are at least one nominal voltage above the battery voltage For severe partial shading or PV arrays with nominal voltage equal to battery voltage you may also want to try Legacy P amp O Perturb and Observe MPPT mode Legacy P amp O Legacy P amp O Perturb and Observe mode is a slow
44. rminal connector will accept wire up to 218 AWG WARNING Extra fine Stranded wire is actually larger in diameter than standard stranded wire like THHN therefore 4 extra fine strand Welding cable will not fit in the terminal block Over Current Protection and Wire Size Requirements The over current devices wiring and installation methods used must conform to all electrical codes applicable to the location of installation Wiring needs to be protected with proper strain relief clamps and or conduit See page 49 for a breaker and wire size chart 17 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 The USB cable BTS cable and auxiliary input output cables should run in a different conduit to preserve their signal When installing the Classic In a MidNite E Panel it is acceptable to run all wiring through the same knockout hole It is legal to run signal and power wires together as long as all wiring is listed for the highest voltage to be encountered Follow all local code Current Rating The Classic limits the output current based on the model you have The Classic current ratings are Classic 150 SL 96 amps maximum Classic 200 SL 79 amps maximum Classic 250 SL 62 amps maximum Over Current Protection The Classic must have over current protection to protect wiring from over current events A means of disconnect must be installed on the DC In and DC out of the Classic Consult your local codes to determine over c
45. ront cover of the Classic nstall the mounting bracket on the E Panel and start the upper mounting screw into the bracket leaving it about half way out so you can hang the Classic on this screw Install the 1 inch close nipple into the E Panel as shown in the E Panel directions The 1 close nipple 3 locknuts and 2 plastic bushings are included with each E Panel One locknut acts as a spacer Carefully hang the Classic on the screw in the bracket and slide it over the close nipple see figure 4 nstall the lock nut and bushing on the close nipple and tighten the screw in the mounting bracket Don t install the front cover until you complete the wiring of the Classic Figure 3 A Charge controller bracket mounted to the E Panel The bracket comes with every E Panel Figure 3 Classic Mounted to side of E Panel Nipple locknuts and bushings that come with every E Panel Figure 4 Figure 5 Classic mounted to the side of a MidNite Solar E Panel 12 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 Figure 6 Install locknut here to act as a spacer Wiring the Classic SL A WARNING Shock hazard Disconnect the batteries and input power before opening the Classic front cover ALWAYS use proper Over current devices and disconnects on the PV and Battery at the Classic MidNite DC breakers work well for both 13 Page XX XXX XX REV A Classic SL owner
46. s The table below describes the default preset voltages for the different nominal battery voltages This means that 1f you set the Classic from the QUICK START to a different battery voltage the Classic will take the default voltage set points Note If you manually adjust the absorb float or equalize voltage set points and then nominal battery voltage is changed to a different nominal voltage e g from 24v to 12v or to 48v etc manual adjustments may be required Voltage Bulk MPPT Table 4 To adjust these voltage set points follow these steps Absorb Equalize and Float voltages are fully adjustable You will need to get the actual voltages from the 24 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 battery manufacturer To adjust these voltages follow the steps below MA Press Main Menu to enter the Main Menu Scroll right or left until Charge is highlighted and push the Enter button Highlight Volts and press the Enter button Use left and right arrow keys to highlight the set point voltage to adjust Use up and down arrow keys to lower or raise the voltage Press the Enter button to save the new voltages MA e MA e MA Current Limit The Classic has a current limit component which interacts with the temperature of the charge controller If the Classic 1s exposed to extremely hot ambient conditions the output current will be reduced automatically to keep the charge contr
47. s manual REVB 2056 The Classic SL should be wired by a qualified professional and needs to meet all applicable electrical codes Always make sure all source and battery circuits are de energized and wait 5 minutes before working on the wiring in the Classic The Classic has 2 common neutral negative terminals Therefore only one neutral conductor is required to run from the E Panel and terminate on either or both common neutral terminal This negative conductor shoule be sized to match the battery cable The Positive DC source wire goes to the PV Turbine screw The Positive Battery DC wire goes to battery terminal Torque the terminal screws to the specs below To connect the wiring to the Classic Ensure the DC source and Battery are disconnected Connect a grounding conductor between the Classic and system ground Ensure the breaker between the battery and Classic meets UL489 standards Ensure the breaker between the DC source and Classic meets UL1077 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 e SCS e SCS MA SCS SCS SCS The Torque specs on the DC terminal connector big blue terminal connector are Up to 10 AWG torque to 25 35 inch pounds 8 AWG torque to 30 40 inch pounds 6 AWG or above Torque to 40 50 inch pounds HyperV
48. ter Follow PSWD On Off WBRST Yes On D Symbolizes pushing the Right Soft Key D Symbolizes pushing the Left Soft Key www midnitesolar com LOGS MENU History Clear 4 of 4 Daily Logs Hourly Logs Lifetime LW Hours Lifetime Amp Hours WB Jr Net Amp Hours WB Jr Pos Amp Hours WB Jr Neg Amp Hours Hi Fet T Hi Vpv Hi Vbatt kW Hours Float T Hi Power Power V In V Batt Stage Amps Out kW Hours R Graph nig 17722 67th Ave NE Arlington WA 98223 PH 360 403 7207 Fax 360 691 6862 Table 8 42 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 Glossary of Terms Absorb Constant voltage charge stage to fill the batteries The controller is regulating so maximum power will not be seen at this time The Absorb timer is also counting down to the switch to Float Aux Auxiliary relays The Classic has 2 relays Aux 1 can be configured as a 12 volt signal or a dry relay Aux 2 can be used as a PWM signal output Refer to page Error Bookmark not defined for more Aux info BLK Bulk MPPT Mode By using the up arrow in Tweaks under BLK you can force the Classic into Bulk mode Bulk MPPT Maximum current charge stage the Classic is trying to bring the batteries to the Absorb voltage set point We are basically putting all available power into the batteries Comm This menu allows adjustment of things like Mod Bus port USB Mode and MNGP address DvrtCnt When enabl
49. ter the Absorb cycle 1s completed Float 1s displayed on the screen Battery voltage 1s held at the float voltage set point Equalize The Equalization function can be manually initiated or can be set up to Auto Equalize The intent of an Equalization charge 1s 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 1s typically due to low light If the Classic is resting and should not be make sure Aux2 is not set to a logic input that is forcing it into resting Mode is OFF The Classic has a software ON and OFF feature This software Switch basically turns the relay off effectively disconnecting the input source so the Classic will not charge the battery If you see Mode is Off in the bottom right corner of the display then the Mode may have been turned off To turn the mode back ON push the Main Menu button several times until Charge is highlighted Scroll to the right until Mode is highlighted and press Enter On this screen OFF should be 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 Adjusting Absorb Equalize and Float Voltage
50. ter the main menu and select Mode Turn the Mode ON ad press Enter to save this Then press Status to return to the main screen If using the Classic for wind and you cannot turn the mode on this can also indicate the wind curve 1s not linear and the classic cannot work with it Please make sure the wind curve continually goes up hill Check that the blue display cable is plugged In and connections are sound Try unplugging it and plugging it back 1n Check for corrosion also Do a HARDWARE Factory Restore See manual Check to make sure the blue display cable is plugged in well and that it is not running down over the 2 big yellow inductors on the left hand side of the circuit board This 1s normal as the battery is almost full and the extra power is not needed so the controller throttles back to prevent over charging of the battery This is normal as Follow Me simply coordinates the charge stages each Classic still works independently as far as regulating the PV array XX XXX xx REV A Classic SL owner s manual REVB 2056 How do I verify Follow You should first go to the Main menu and then into the Temps menu and Me is working properly verify all controllers are seeing the Battery Temp from the one with the BTS plugged in You should also see a blue LED flashing inside the top vent There are two types of blink A short blink that is about one tenth of a second means it is getting good information A long bli
51. the Left Soft Key www midnitesolar com 17722 67th Ave NE Arlington WA 98223 PH 360 403 7207 Fax 360 691 6862 40 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 CLASSIC SL MENU MAP MidNite Solar Inc Continued from previous page AUX MENU Aux 2 Manual Off Manual On MISC MENU LED Mode Diversion Hi ai bec Diversion Low T d Waste Not Hi Tee ss Waste Not Low T used Toggle Test PV V On High Ts PV V On Low oT Night Light Day Light Float High Float Low Logic Input 1 Logic Input 2 Force Float In Whizbang Junior R Symbolizes pushing the Right Soft Key Time PWRSV Off Rick Mode Blinky LED 1 Comm Test Backlight R Adjust Backlight Contrast R Adjust Contrast Volume P Adjust Volume Play Off Rick Mode Verbose Audio 1 Audio 2 MNGP Address USB Mod MB Port m Phone Jack Routing To enable SMA mode Time 00 00 00 Date 00 00 0000 Off Backlite Short Backlite Long MHE g www midnitesolar com Eg 17722 67th Ave NE Arlington WA 98223 PH 360 403 7207 Fax 360 691 6862 41 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 CLASSIC SL MENU MAP MidNite Solar Inc TEMPS MENU L Remote FETS TWEAKS MENU Offset VBatt Offset Vpv GF On Off LMX 0 On Off Blk hold up arrow to force bulk Fit hold up arrow to force float qm On Off Followme On Off BTS NET Mas
52. to the jack labeled BATTERY TEMP on the control board 20 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 Chassis Grounding In all installations the Classic chassis should be connected to ground For systems with a battery breaker sized 60 amps and smaller 10 AWG 6 mm copper is generally sufficient For systems with a battery breaker sized 100 amps and smaller 8 AWG 10 mm copper is required For grounding conductor requirements on your specific installation please consult your local electrical code The chassis rounding terminal is in the upper right corner of the electrical connection compartment Figure 10 DC System Grounding The Classic charge controller is designed to work with Negative Ground Positive Ground or Ungrounded power systems In grounded systems dc negative may be connected to ground either externally or by using the Classic s internal grounding jumper shown on figure 15 on Page 21 The internal grounding jumper should only be installed when the Classic s GFP is enabled In Positive ground or Ungrounded systems the GFP jumper must be removed See Figure 15 Also note that with Positive ground there will be items still 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 RS232 serial data lines 21 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 DC GFP Ground Fault Prot
53. to work with 12 24 36 48 60 and 72 volt battery banks The Classic SL can be installed stand alone or as a multi unit networked installation Standard features of the Classic SL charge controller include 3 input operating voltage ranges 150 200 and 250 VDC Graphical display Previous 380 days of operational data logged 5 Page XX XXX XX REV A Classic SL owner s manual REVB 2056 This Manual covers Classic 150 SL Classic 200 SL and the Classic 250 SL It covers the installation wiring and use of the Classic charge controller A WARNING Warnings signs identify conditions or practices that could result in personal injury or loss of life A CAUTION cautions identify conditions or practices that could result in damage to the unit or other equipment MIDNITE SOLAR CHARGE CONTROLLER INSTALLATION GUIDELINES AND SAFETY INSTRUCTIONS This product is intended to be installed as part of a permanently grounded electrical system as shown in the system configuration sections The following important restrictions apply unless superseded by local or national codes To use the Classic s built in DC GFP the System s DC Negative conductor must not be bonded to earth ground The Classic does this with its internal Ground Fault Protection circuitry The battery negative and ground are not bonded together directly but are connected together by the Classic s internal GFP device All negative conductor connections must be kept separate from the
54. tracking mode similar to the Micro Hydro mode but with the difference that it 1s slightly faster and will shut off if the power source goes off It has two settings that are user adjustable Sweep Interval 1s the time between mini sweeps in minutes and sweeps around the present 1 e the last found MPP Voltage The range of this sweep is determined by the Sweep Depth user adjustment and 1s 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 Note Mode must be manually turned ON after changing the mode To turn the mode ON highlight the OFF under ON OFF and switch it to ON Press enter to save this change Setting the Date and Time To set the date and time manually on the Classic follow the steps below Push the Main Menu button repeatedly until Charge is highlighted Scroll left or right to highlight MISC and push the Enter button Scroll to Time and push Enter Now scroll left or right to highlight the data you want to manually change Use the up and down buttons to change the data When you have all the data changed push the Enter button t
55. ts bag onto the metal pins of the male Jacks on the Display cable before plugging them in To re install the front cover of the Classic you will need to plug in the display cable and carefully route it around the components on the circuit board as you set the cover in place See Figure 2 Do not force the cover if it does not seat into place easily stop and look for any cables or wires that may be interfering With the cover seated in place install the four Phillips screws with a 2 Phillips screwdriver l Uus i Ll E n i tti Bi Figure 2 Mounting the Classic SL ab i TIX TOTIT FOR A hi DN 3 d d L I PUN g etn Ur H IIRIS The following section covers typical mounting arrangements If you require additional details that are not covered here please contact our technical support team The Classic is designed to be directly mounted onto the MidNite Solar E Panel The Classic can also accommodate other installation methods as well Mount in an upright position out of direct sunlight when possible For your convenience the Classic has four one inch knock outs that are pre cast The Classic has mounting locations and conduit locations that are similar to other brands of charge controllers to facilitate ease of upgrading older technologies 11 Page XX XXX xXx REV A Classic SL owner s manual REVB 2056 Mounting the Classic directly to the E Panel Remove the f
56. urrent ratings The breaker between the battery bank and the Classic must conform to UL489 The breaker between the DC source and the Classic must conform to UL1077 or UL489 The NEC requires 1 56 times short circuit current for PV over current protection This 1s reduced to 1 25 times when using a breaker rated for continuous duty All MidNite Solar breakers are hydraulic magnetic and are rated for continuous duty 100 rating No de rating is required for the output breaker when using MidNite Solar breakers PV in particular will be capable of producing more current than its name plate rating in extreme situations so the safe minimum wire size should be selected for the PV array maximum short circuit current Please consult PV manufacturer for specifications The US National Electrical Code requires 1 56 times the PV short circuit current for wire size on the PV input Output wire size follows the NEC guidelines Typical wire size for output is GAWG for the Classic 250 SL and 4AWG for the Classic 200 SL and 150 SL but check all de ratings for your wire type and installation method Long Distance Wire Runs The Classic offers some unique opportunities 1f you are faced with longer than normal wire runs between the DC source and the Classic The Classic comes in 3 input voltage ranges letting you design a DC source at a higher voltage if it 1s beneficial For example let s say you have a 300 ft run from a PV array to the Classic You could wire for an ope
57. ut 25ft max before the voltage drop is to great We have found that power up cable like Cat3 or Cat5E can go about 100ft no problem How many amps can my The Classic regulates very well so within reason there is no limit on the input Classic handle on the amps or PV wattage We recommend you not exceed 150 of the capacity input side OR Can I put The Classic just like a grid tie inverter can be over driven on the pv side it too much PV on my simply produces the max amount it 1s rated for Classic My Classic is not First it should be noted a solar panel is rated in a lab so in the real world we making the same amount typically see about 8096 of what it 1s labeled So a 100 watt panel becomes an of wattage as I have for 80 watt panel solar Panels Does the Classic say Absorb Float or EQ If so that means the battery 1s nearly full and the Classic 1s throttling back to prevent over charging the battery 34A Page XX XXX XX REV A My Label is gone or I mixed up my covers how do I know what model Classic I have I can t read my serial sticker how can I find my serial How do I know what Nominal voltage my Classic is programmed for I have Aux1 programmed properly but I cannot get 12v out of it when I should I was in the middle of a firmware update and the update got interrupted what do I do Can I use wind and solar on a single Classic Can I have more than one Classic on a single battery Do I ha
58. ve to shut off my Classic if I have a different charger charging Table 5 35 Page Classic SL owner s manual REVB 2056 You can remove the cover and look at the stickers on the big yellow inductors on the left side of the circuit board You can press the status button several times and the Classic will say Connected to Classic xxx on one of them this is your model Press the status button several times and a screen will come up saying Connected to a Classic xxx in the bottom right corner ts the serial number it will start with a CL Press the status button several times and a screen will come up saying Connected to a Classic xxx to the right of this it will say the battery voltage it is programmed to Example 48v Most likely the Jumpers on the bottom left corner of the circuit board are set for a dry relay not for a 12v signal See the Aux portion of the manual for help with that No problem simply start over with the update The Classic has a boot loader that will always look for new firmware on boot up so you can not damage the Classic No they both require drastically different tracking algorithms so you will need two Classics Yes as long as they have separate Solar Arrays No the Classic will work just fine in conjunction with ANY other charger on the same battery XX XXX xXx REV A Classic SL owner s manual REVB 2056 Electrical Specifications Classic150 SL Classic200 SL Classic250 SL l Op
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