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Midnite-Solar-Classic-Users-Manual

1. MINIMUM INTERRUPT RATING 4000 AMPS DC FOR OVERCURRENT PROTECTION DEVICE TORQUE TERMINAL BLOCK AND GND TERMINAL TO 35 IN LBS 4Nm SUITABLE FOR USE WITH 75 C MINIMUM RATED COPPER CONDUCTORS THIS DEVICE IS PROVIDED WITH AN INTEGRAL PV DC GROUND FAULT INTERRUPTER IF THE PV GROUND FAULT PROTECTION IS TRIPPED THE NEGATIVE CONDUCTOR MAY BE ENERGIZED DANGER ELECTRICAL SHOCK AND BURN HAZARD SOLAR PANELS WILL CONTINUE TO PRODUCE VOLTAGE EVEN WHEN DISCONNECTED ENSURE THAT PV MODULES ARE COVERED TURN OFF PV ARRAY AND CHARGE CONTROLLER OUTPUT PRIOR TO SERVICE RISK OF ELECTRIC SHOCK DO NOT REMOVE COVER NO USER CAUTION SERVICEABLE PARTS INSIDE REFER SERVICING TO QUALIFIED SERVICE PERSONNEL DANGER DE CHOC ELECTRIQUE ET DE RISQUE DE BRULURE LES PANNEAUX SOLAIRES CONTINUERONT DE PRODUIRE LELECTRICITE MEME SILS SONT ATTENTION DEBRANCHES S ASSURER QUE LES PANNEAUX SOLAIRES SONT COUVERTS PENDANT L ENTRETIEN POUR TOUTE ACTION DENTRETIEN LA SORTIE DES PANNEAUX SOLAIRES ET DU CONTR LEUR DE CHARGE DOIVENT ETRE DECONNECTEES RIEN A D PANNER A LINTERIEURE DU E PANNEAU NE PAS OUVRIR CAUTION LE COUVER POUR TOUTE R PARATION OU SERVICE D ENTRETIEN CONSULTER UN AGENT SP CIALIS 100261 MIDNITE SOLAR INC drac cas A coses III an SURFACES CHAUDES HOT SURFACES ARLINGTON WA 98223 USA WWW MIDNITESOLAR COM 91Page Unpacking the Classic When you receive your Classic you will want to unpack it and make sure everything is there and in good shap
2. 50 Page 3JIM pue Jeyeauq Indu o saldde osje saoge 0g Ajejes 9G anba jou op pue 3149 Anp 00L JO pae je aJe S18Y291q ejoS JINDIN za JINDIN 9G Peyo siy uo paseq J ABBA1 SU02 SI yeya SIU Je u SIOJONPUOD apus JO yeya SU SI L OLEOIN A008 SAAV9 10 ORAV9 VOS OMVOL VOE 7006 SAAV9 10 OMAV9 VOS OMVOL VO AOO SAAV9 JO SAAV9 V0S OAAVOL VOE AOO SAAV9 10 SAAV9 V0S OAMVOL VOE AOO OAAVYS JO ORAV9 VOS OMVOL VO 7006 DAYS 10 ORAV9 VOS DAAVOLAVOE 7006 DAYS JO ORAV9 VOS OAMVOL VOE 7006 ORAV8 10 ORAV9 VOS SVV0L v0 7006 DAAYS JO ORAV9 VOS AQOE OMYS 10 ORAV9 VOS OMVOL VOE AOO SAAV9 JO SAAV9 V0S DAAVOLAVOE AOO OAAVYS JO ORAV9 VOS DAAVOLAVOE A00 DAAVS JO ORAV9 VOS A00 DAAVS JO ORAV9 L0S 7006 DAAVS 10 ORAV9 VOS OMVOL VOE 7006 SNAV9 10 ORAV9 VOS OMVOL VOE 7006 DAAVS JO ORAV9 00S 7006 SAAV9 JO ORAV9 00S KOGE SAAV9 10 SAAV9 V0S DAAVOLAVOE AQOE DAAVS JO ORAV9 VOS 2270 706 7006 DMY AOS 7006 SAAV9 JO ORAV9 VOS AOO DMYS JO ORAV9 VOS DAAVOLAVOE A0SL DMY9 AVEO DAAVS VOS AOSL SAAV9 VE9 OMVOL YOE A0SL ORAV9 VEJ ORMAVOL YOE AOSI SAAV9 AVES DAAVSAVOG AOSI DAAY9 VE9 DAAVOL YOE AOSI SAAV9 VE9 OM VOL YOE AOGL SAAV9 AVES SAAV9 v0S KOS SAAV9 VE9 OMVOL YOE A0SL SAAV9 YE9 OMVOL YOE AOSI Vc9 A0SL ORAV9 VE9 DAAVSAVOG AOSI SAAV9 VES OMVOL YOE AQSL DAAWPAVOS A0SL ORAV9 AVEO DAAVS VOS A0S
3. Aux has the relay so Diversion functions must operate slowly Output toggle once per second Aux2 Function Output Input DIVERT DGTL F Battery diversion controlled by PWM Active high Output DIVERT DGTL F Battery diversion controlled by PWM Active high Output Battery diversion relative to charge stage voltage controlled by PWM BAT DIV V REL Active high Output BAT DIV V REL Battery diversion relative to charge stage voltage controlled by PWM Active low Output Output toggle once per second Output 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 v v v v v v v 311Page Setting the MNG P features Access the Version of software and Restore factory defaults The Classic comes with an Integrated MidNite Graphics Panel MNGP which is the primary interface to the Classic Setting up contrast backlight and volume its simple just follow the steps below Push the Main Menu button Scroll left or right to highlight MN
4. DHCP in which all networking settings are derived from a DHCP enabled router This 1s the simplest configuration method and recommended unless you explicitly need a statically allocated IP address for your Classic n this mode all other settings are automatically configured and are read only informational with the exception of the Web Access feature e Press Main Menu e Scroll to NET menu and press the Enter button 421Page e Highlight and select DCHP 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 Rey in either menu saves all settings to Flash memory For convenience vvhe
5. 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 Below are the labels present on the Classic MIDNITE SOLAR CLASSIC 250KS MPPT SOLAR WIND HYDRO BUCK BOOST CHARGE CONTROLLER NORMAL OPERATING ENVIRONMENT 25 C 446 C DE RATED SEE MANUAL MAR PY VOLTAGE OPERATING 250 MAS PV CURRENT OPERAT ING 55A MAX PY YOC 2504 BATTERY VOLTAGE WAX PY SHORT CIRCUIT CURRENT 554 WAX BATTERY CHARGE CURRENT 554 MAX BATTERY CHARGE VOLTAGE 150 MOMIMAL BAT WOLT AGES 12 4120 MAX OUTPUT FAULT CURRENT 4364 SlPage MIDNITE SOLAR CLASSIC 200 MPPT SOLAR WIND HYDRO BUCK BOOST CHARGE CONTROLLER NOMINAL OPERATING ENVIRONMENT 25 C 40 C DE RATED SEE MANUAL MAX PV VOLTAGE OPERATING 200V CONFORMS TO UL STANDARD 1741 MAX PV CURRENT OPERATING 79A 2ND EDITION MAY 7 1999 MAX PV VOC 200V BATTERY VOLTAGE Ell MMMREVSIONS THROUGH MAX PV SH
6. change to COM8 Flow control 39 Page Advanced Settings for COMS Use FIFO butters requires 16550 compatible UART Select lower settings to correct connection problems Select higher settings for faster performance Defaults Receive Bufer Low i J Hha 14 Transmit Buffer Low 1 J High 16 COM Port Number COMB e Click OK and close all open Dialogs Finished with this part Note After running MidNite Update exe first time only Windows will remember every time a Classic is connected to the PC it will be set for COM Port 8 4 NOW you can power down the Classic and proceed to update its software using the MidNite Up date program e Go to Start Programs and open MidNite Update The Classic must be UN powered at first when updating its software even before opening the MidNite Update program The MidNite Update exe program will give the basic directions on the bottom of the screen e Under COMM FUNCTION you must select the correct Classic model or section you are updating And click Upload e Follow the instructions in the window e After the upload status has reached 100 the window will automatically close the Classic firmware has been successfully updated e One last step turn battery power off from the Classic and then turn it back on The first screen in the Classic should have a different date If you are updating the whole Classic including Networking and MNGP repeat step 4 for each
7. into the jack labeled MASTER IN Clipper and the other end into the jack labeled SLAVE OUT on the Classic The DC output of the Clipper will go to The DC input terminals on the Classic Refer to the figures below me v Teel Classic network To Classic Figure 2 5 23lPage NPUT OUTPUT MIDNITE CLIPPER OR CLIPPER JR COMM LOAD DIVERSION CLASSIC MPPT CONTROLLER BATTERY BANK CONTROLLER Figure 2 6 Commissioning the Classic The Classic will enter into the setup wizard upon initial power up If the Classic does not enter into the setup wizard or you want to enter the vvizard at any time follow these steps to get into the setup vvizard Press the Main Menu button Scroll Left or Right until Wizard is highlighted and press the Enter button Follow the on screen instructions through to the end Using the Classic Setup Screen s The Classic setup vvizard will walk you through the set up process Below is a description of the steps DO YOU WANT PASSWORD Sets the password On Classic Settings ENABLED PASWORD WILL BE 142 YES NO CONNECTED TO Tells you which classic model it is CLASSIC 150 IS THIS A This menu will determine how to treat batteries GRID TIED SYSTEM differently sealed batteries lovver voltage for BATTERY BACKUP orid tied YES NO TIME DATE Set time and date this 1s important because 24 00 00 01 10 2010 Classic will automatically know at what t
8. AMidMiteSolar a Don t search will choose the driver to install Choose this option to select the device driver from list Windows does not guarantee that the driver you choose will be the best match for your hardware You will now get the warning dialog shown below because the driver for the USB chip has not undergone Windows Logo testing Just select Continue anyway ho proceed Found New Hardware Wizard Please wait while the wizard installs the software Hardware Installation The software vou are installing for this hardware USB COC serial port emulation has not passed Windows Logo testing to very its compatibility with Windows SF T ell me why this testing is important Continuing your installation of this software may impair or destabilize the correct operation of pour system either immediately or in the future Microsoft strongly recommends that you stop this installation now and contact the hardware vendor for software that has passed Windows Logo testing STOP Installation The driver files have now been installed and your installation 1s complete Select L Finish to close the dialog 37 Page Found New Hardware Wizard Completing the Found New Hardware Wizard The wizard has finished installing the software for 3 USE COC serial port emulation Click Finish to close the wizard lt Back Cancel e Nowa New hardware has successfully been installed
9. EQ You most likely will want to adjust it slightly below the set point voltage For example 0 3 Volts There is also a voltage width adjustment the voltage width being the range where the PWM goes from a short pulse beginning right at the charge set point voltage and full on at the diversion set point voltage plus the width voltage For example if the Controller is presently Absorbing voltage regulating at 14 5 Volts and the Aux 2 Relative threshold voltage 1s set for 0 3 Volts the Aux 2 diversion PVVM pulsing or buzzing will start to become ACTIVE when the battery reaches 0 3 Volts below 14 5 volts 14 2 Volts and if the Width adjustment is at 1 0 Volts The Aux 2 diversion output would be fully Active not pulsing anymore at 14 3 V PLUS 1 0 Volt or 15 3 Volts This voltage width gives the PWM diversion function some room for the SSR and loads to work How much of that voltage width 1s actually used depends on the value of the load resistance and the amount of power available from the source PV or turbine etc If the diversion load resistance is not low enough it will not be able to load down the battery enough and will more likely approach the full voltage width The higher the diversion load is lower resistance the less width will be used This leaves some room for more available power to be diverted However the diversion load resistance doesn t want to be TOO low or the diversion Operation won t work quite as sm
10. Main Menu Scroll to LOGS and Press the Enter button Uploading New Firmware to the Classic There is also an Ethernet method for updating software in the Classic itself Ethernet for MNGP Remote coming soon Up to this point the Classic cannot be updated using Windows 7 There are 4 main things that need to happen to be able to update the Classic 1 Run and install MidNite Update exe 2 Successfully install driver 3 Both com port settings in Classic and in PC have to correspond 4 Have the Classic power off before opening the installed MidNite Update program Updating the Classic is relatively complicated this is because the user has to be able to directly interact with the computer up to a technical level 1 To install the driver in your PC first you need to run and install the MidNite Update exe either from the DVD or download from www midnitesolar com When prompted on the step in where 35 Page you specify where to install the folder we strongly recommend installing in the default location this will make next steps easier C WidNiteSolar USB Installation for Windows XP e With the Classic battery power on plug the USB device into the computer and Windows will au tomatically detect the connected device This will begin the Found New Hardware Wizard e The Wizard will give the option to connect to Windows Update to search for software compo nents select No not at this time Note On XP ope
11. UL489 standards a 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 VVARNING 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 6lPage Someone should be within range of your voice to come to your aid if needed Keep plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eyes Wear complete eye protection Avoid touching eyes while working near batteries Wash your hands with soap and warm water when done If battery acid contacts skin or clothing wash immediately with soap and water If acid enters an eye flood the eye with running cool water at once for at least 15 minutes and get medical attention immediately following Baking soda neutralizes lead acid battery electrolyte Keep a supply on hand in the area of the batteries NEVER smoke or allow a spark or flame in vicinity of a battery or generator Be cautious to reduce the risk of dropping a metal tool onto batteries It could
12. VS ii 7 Unpacking the ii IA 10 Removing and installing the front cover on the Classic 10 Mountins the Classic AA Ka Ka tn 12 ANUSA VA Nlouniilipi AA 13 DIMBA SONS ee as E 13 Seale FOr Ve ME 0 Toa map ugamayhauspuqhuatuamaya qatananta ania aiesieh te a 13 Network Cable Routing and Installation Guidelines 14 Battery Temperature Sensor Installation 16 GORE Qu uhu Qu Dia Sbi s us 18 DC GFP Ground Fault Protection 18 I bi AA ne h mahu uleanum ee rete met 19 Wirin the CLASSIC AI 19 DCMA AA a rimes 21 Over Current Protection and Wire Size Requirements 21 CUTTING FR ANE Shyla cot acetat tec teta ca etat seis mat Sau uma usb aba mone 22 Temp rature Current mit nissan nent 22 Over Curent wa OCS CU OM En ccs AAA AAA WAA AAA WAUA 22 Dons Dis ance Wire RUSSE A SKETE EEN 22 M mun and Viana iis VV e126 23 Connechns the Cl ssic fo the CMD PEP ai 23 COMMISSIONING the ClASSIC nine stimule 24 Usinge the Classic Setup SCOR ii 24 Setting Nominal Battery VOA AAA 25 Battery Charge Stages and Me
13. bubble message will appear in the bot tom right corner of the screen 3 Change the COM Port Settings e To change the Port Number of the USB COM Port open Device Manager by clicking Start gt Control Panel gt System or hold down the Windows key and press Pause Break se lect the Hardware Tab and click the Device Manager button Or Click Start gt Run and enter devmgmt msc e The USB CDC serial port emulation COMA is in the Ports section To change the Port num ber right click the USB Serial Device and select Properties e Change the Bits per second to 19200 38lPage El A DVD CD ROM drives Es Human Interface Devices IDE ATA ATAPT controllers HS IEEE 1394 Bus host contrallers El Es Keyboards El Mice and other pointing devices FH ls Modems El Monitors Network adapters o L 1394 Net Adapter 2 FE Broadcom 570x Gigabit Integrated Controller BBB Dell TrueMobile 1300 WLAN Mini PCI Card 83 Dell TrueMobile 1300 WLAN Mini PCI Card 2 l El PCMCIA adapters Fl Ports COM amp LPT YF Communications Port COM1 ed ECP Printer Port LPT1 yf USB CDC serial port emulation oms MR Processors Update Driver S Smart card readers Disable ED Sound video and game controllers Uninstall Opens property sheet for the current selection Scan for hardware changes Bits per second 19200 e Select the Port Settings Tab and Data bits click Advanced e Select COM Port Number and Party
14. one of the items being updated just select the corresponding function under COMM FUNCTION to be updated For further information consult the Read me document contained in the MidNite Update exe installation Or contact MidNite Solar Note Check and compare the Classic about screen date to the date in the MidNite Update exe see Menu Map for screen location to check you are actually UPGRADING firmware we don t have a system yet that checks that you could be upgrading to an older version 40 Page Connecting the Classic to the Internet Networking The Classic supports standard 10 100 base T Ethernet networks For Gigabit networks you will need a common network switch that is capable of mixed mode operation The Classic may also be placed on a b g or n wireless networks by using a wireless network bridge device Depending on your network you may use one of the topographies detailed in Figures 5 5 3 Note that the switch may be self contained or in many cases may already be integrated into your cable or DSL modem Refer to Figure 1 7B for Ethernet connector location in the Classic 4 Port Switch Router Figure 5 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 Bridge Wireless Router Access Point Figure 5 1 Local network through wireless bridge Wireless enabled computer Wire
15. 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 Hke to metal causing severe burns 2 2 AOC Classic Power Curves Figure 2 1 150V Classic Power Graph 120V PV 100V PV e 70V PV 65 Nominal Voltage Battery Voltage Figure 2 2 200V Classic Power Graph 14 4 Nominal Voltage 12V Battery Voltage Figure 2 3 250 Classic Power Graph 65 61 Amps 878 watts _ B2AMPS 4779 watts 60 ia 2 mps 55 7 Fer Tl watts 53 Amps 50 lt S 3095 watt g 3728 watts 45 Am lt 180V PV 40 2 200V PV FREE 3468 watts 39 s tts 30 Nominal Voltage NY SP pou Yona 43 2 ER 2 Ao The graphs above represent the max power output for a given input for each Classic Using and understanding these power graphs will help maximize Classic s output power and aid in selecting wire and breaker disconnects The built in set up wizard also helps select breakers and wire sizes Notice that lower battery voltages and lower PV input voltages result in higher continuous output power The PV voltages listed are for reference and are not intended to be the only PV voltages supported
16. 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 Classic and turn it back ON Do this by turning the external battery breaker to OFF position and then to ON position Disabling GFP 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 BITS menu In BITS scroll until GFP is highlighted Use the up and down arrow keys to toggle between on and off Press ENTER to save vy v Vv V v v Wiring the Classic A WARNING Shock hazard Disconnect the batteries and input power before opening the Classic front cover The Classic should be vvired 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 4 terminal Torque the terminal screws to the specs below To connect the vviring to the Classic Ensure the DC source and Battery are disconnected Connect a grounding conductor betvveen the Classic and system ground Ens
17. the controlling point and see the Classic in a second MNGP The cable 15 a six wire phone cable Connect one side of the extension cable to the jack in the Classic labeled SLAVE OUT and the other end to the second MNGP Since the Classic transmits power and data signals through the phone cable to the MNGP the length of the cable is limited to 100ft MidNite Solar only offers a 3ft as an optional accessory If you are making your own cable be sure be sure to insert cable end all the way into the phone terminal to get a good contact Use the phone crimping pliers to crimp both ends of the cable We recommend using flat phone cable for extension just 33 Page because it is easier to work with Use the two pictures above as reference Make sure the color and position of the wires are as shown in the diagram below Use terminal connector tab as reference Arc Fault The Arc Fault Detector is a unique safety component included in every Classic because safety is not an option the engineers at MidNite take action as the 2011 NEC code requires The Classic is the first charge controller in the world to successfully stop a series arc The Classic can detect an arc in less than 100mSec From low power arcing to devastating high power arcing the Classic will detect and shut down with an audible and visible alert to announce that there is a problem In the PV side of the system When an arc Is detected the Classic has to be manually clea
18. 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 bracRet Don t Install the front cover until you complete the wiring of the Classic N Figure 1 3A Charge controller bracket mounted to the E Panel The bracket comes with every E Panel Figure 1 3C Nipple locknuts and bushings that come with every E Panel COMMON Gi NEGATIVE Install locknut here to act as a spacer 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 1s Plumb and Level R0 097 Dimensions See page 40 for more details Sealed or Vented The Classic ships with all parts needed to convert to a sealed unit 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 14 905 0000000 00 201 00 201 13 Page si seen in the photo below Note that the Classic will be slightly de rated put
19. GL Sv vc L GL 8p 76 L CL Sv vc L 8p vc L 8p PZ L Sp vc L Sv PZ cl Sp vc cl Sv vc L v yndul XeW LOLE 8ZIS SAM OCAOSI DUG ndinO v indno xew ongi1no ul OOA JOU A LddIN Ag OGC ISSE OGC 2354 OGC SISSEJD OGC 2354 OGC SISSEJD OGC 2356 OGC 2554 OGC SISSEJD 00 7354 00 9 SSE O OOZ ISSE 00 YISSE D 00 2 3566 00 2556 00 7356 00 2ISSEN 00 215519 00 SISSEJD 00 7554 00 3554 00 2356 00 2354 00 3554 OG 2354 OGL 3352 05 2556 OG 2354 OSL 255 OG 2354 OG 255 2 OGL 2356 OG 2554 OG 3735 05 2554 OGL 215519 OSL 2352 OG 2554 OGL 3554 9007 S1lPage CLASSIC MENU MAP Jan 5 2010 Status Menu Main Menu Wizard Solar Wind Hydro Charge Volts Battery Status Output Quickset Soft Key Chalime L Timer VW Soft Rey T Comp View Soft Key Master EQGO EndA SOC L Bat 5OC Soft Key Type Limits Soft Key Mode U Set VOC Input Status colar TO lt MPPV Soft Key Setup Soft Key Wind Track Graph Soft Key Wind Learn Legacy P amp O Ls Interval Soft Key PV Learn L Setup Soft Key AUX MNGP Led Mode r a Version Backlight Contrast Load DFLTs L Password L Dealer Message Audio Volume Play Comm Time EFGH Logs Tweaks Lo Bits Soft Key L Are Adj Soft Key About Classic Temps Net L Next Soft Key L Advanced Soft Key 52 Page
20. GP and 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 SCS e yA Use diagram below for MNGP reference Figure 2 8 Figure 2 8 Screen name Communication indicator Menu name USB activity a CHAT OL Menu lor BATTERY CHARGING PARAMETERS Current limit lt lt lt gt gt gt 13 indicator mm Right soft key Speaker Miphire Up arrow key Right arrow key Left soft key KEJ Left arrow key Main Menu Status screen Enter button Down arrow key Operating the Classic Once the parameters have been set via the set up wizard or from manual set up there are no further requirements to make the Classic function It is all automatic Navigating the Menu s Push MAIN MENU Push right and left buttons to see the different menus To return to the status screen push STATUS button 32 Page To navigate from one end of the main menus to the other end push the top right and left buttons When the Classic first turns on 1t will take you through the WIZARD setup After all of these parameters are set and saved you will be placed in the MAIN MENU screen with WIZARD highlighted Below the name of the menu is a description of the menu Pushing the left and right buttons will enable you to see all the main menus provided Inside some of these main menus wi
21. L SAAV9 VEJ DAAVOL YOE 10198 SZ L UNA ellM 184881q Indu rr vl 72 CL GL 6V amp L 99 TL 96 8 90 t 28 etc CS 6L LS OL LVS Y CE 96 cc ve cl veg GL 6 86 Sti LE GO CS 8 96 GS l OC r 9L 6 BLEE ve sl GL OL 9y 86 28 L lt 70 LL S rtr 90 SC 8 2 LE 6S 6L ce 97 91 SAAN9 9 ORV9 SAAV9 DM YI SAAV9 DAAYY 9 DAAYO SAAV9 DAM YI OMY OMAP DAAVY OMA gt DMY OMY OMVYY ODAAVY OMVY OAAVE DMV gt OMY OMAP NAVY OMY DM Yp OMVY OMY OMVY OM VP c9 0r 9 09 02 09 02 09 c9 0S 8 09 0 7 9 09 9 09 08 07 06 08 06 08 0 7 9 08 02 06 08 06 08 086 08 07 06 08 06 08 06 03 06 08 06 08 06 08 001 06 004 06 08 00106 004 06 08 00 00 00L 06 004 004 00106 004 00 OV EG 09 8S cr SS 9 L9 ES G9 GL cL 69 G9 CL 72 G9 OZ r zi 9 82 62 92 9 6 9 78 66 08 L6 6 c9 6 96 98 76 96 BUIZIS seyeoug 91SS219 LEG 9 cc 8 991 GC GLE GL GL COG tee 999 cc El 76 66 lt cg S 99 LL 99 OL 9y L LEZ ee G GC G OL GEC 89 t 9L 6 802 OLY cc 8 28 1 GLE G Sr L 6 co S 006 006 006 006 084 08L 084 081 09 034 09 09 Or Ovl Ovl Orl 06 0 OL 02 0 0 OZ ora 04 va OLL OLL OLL 00 004 00 06 06 06 0 0 0 CL SP vc L c 87 vc cl
22. MidNite Solar Classic Owner s Manual Tk gt This Manual covers models Classic 150 200 250 amp 250KS 1 Page The MidNite Solar Classic charge controller conforms to UL 1741 Safety for Inverters Converters Controllers and Interconnection System Equipment for Use With Distributed Energy Resources Second Edition May 7 1999 with revisions through January 28 2010 and CAN CSA C22 2 No 107 1 2001 09 01 Ed 3 R2006 Notice of Copyright MidNite Solars Classic charge controller User s Manual Copyright 2010 all rights reserved MidNite Solar Inc reserves the right to revise this document and to periodically make changes to the content hereof without obligation or organization of such revisions or changes unless required to do so by prior arrangement Disclaimer Unless specifically agreed to in writing MidNite Solar Inc a Makes no warranty as to the accuracy sufficiency or suitability of any technical or other information provided in its manuals or other documentation b Assumes no responsibility or liability for loss or damage whether direct indirect consequential or incidental which might arise out of use of such information The use of any such information will be entirely at the user s risk Contact Information Telephone 360 403 7207 Fax 360 691 6862 Email customerservice midnitesolar com Web www midnitesolar com 2 Page Contents SCO Ia IA AA 5 UA WA AA EA 5 Classic Power Cur
23. ORT CIRCUIT CURRENT 79A SS MAX BATTERY CHARGE CURRENT 79A Intertek D ID MAK BATTERY CHARGE VOLTAGE 93V 3084883 No 107 1 2001 09 01 NOMINAL BAT VOLTAGES 12 72V MAX OUTPUT FAULT CURRENT 436A MIDNITE SOLAR CLASSIC 150 MPPT SOLAR WIND HYDRO BUCK BOOST CHARGE CONTROLLER NOMINAL OPERATING ENVIRONMENT 25 C 40 C DE RATED SEE MANUAL MAX PV VOLTAGE OPERATING 150V CONFORMS TO UL STANDARD 1741 MAX PV CURRENT OPERATING 96A Designed and built in CD amy aa NI the U S A wakak de PV RRENT 96 OUT Aaa ee 09 MAX BATTERY CHARGE CURRENT 96A kia a Intertek CERT TO CANICSA MAX BATTERY CHARGE VOLTAGE 93V 3084883 10 e222 a J NOMINAL BAT VOLTAGES 12 72V MAX OUTPUT FAULT CURRENT 436A MIDNITE SOLAR CLASSIC 250 MPPT SOLAR WIND HYDRO BUCK BOOST CHARGE CONTROLLER NOMINAL OPERATING ENVIRONMENT 25 C 40 C DE RATED SEE MANUAL _ MAX PV VOLTAGE OPERATING 15 250V WITH REVISIONS THROUGH MAX PV SHORT CIRCUIT CURRENT 62A ae RTS MAX BATTERY CHARGE CURRENT 62A Intertek CERT TO CAN CSA MAX BATTERY CHARGE VOLTAGE 93V 3084883 910 0222 ng J NOMINAL BAT VOLTAGES 12 72V MAX OUTPUT FAULT CURRENT 436A CONFORMS TO UL STANDARD 1741 MAX PV CURRENT OPERATING 62A 2ND EDITION MAY 7 1989 MAX PV VOC 250V BATTERY VOLTAGE MC lo erza YA flee AA ee AA AUX OUTPUT 1 13VDC 200mA RECONFIGURABLE AS 3 3VDC AUX INPUT AUX OUTPUT 2 500mA RELAY DRY CONTACT RECONFIGURABLE AS 13VDC 200mA OUTPUT
24. age 25 of this manual Optional accessories Optional accessories for the Classic include Blank display for multiple Classic installations MidNite network cables various Lengths Regulatory Approval The MidNite Solar Classic charge controller conforms to UL 1741 Safety for Inverters Converters Controllers and Interconnection System Equipment for Use With Distributed Energy Resources Second Edition May 7 1999 with revisions through January 28 2010 and CAN CSA C22 2 No 107 1 2001 09 01 Ed 3 R2006 CONFORMS TO UL STANDARD 1741 2ND EDITION MAY 7 1999 WITH REVISIONS THROUGH JANUARY 28 2010 CERT TO CAN CSA a STD C222 3084883 No 107 1 2001 0901 48 Page Warranty MidNite Solars Classic comes with a standard 5 year warranty we will repair or replace the Classic at no charge to the consumer during this 5 year period End of Warranty tune up MidNite Solar offers a industry first Tune up Extended Warranty 6 months prior to the end of the warranty period Customers can ship there Classic back to MidNite Solar with a check for 125 dollars and we will replace any vvearable items like the fans and the capacitors and in general tune the Classic up This vvill also extend the vvarranty by 2 additional years as vvell 49 Page Aux 1 and Aux 2 Graphs Aux 1 Voltage Time Relation VOLTAGE JDELAYI TIME TIME AUX 1 OUTPUT Aux 2 Voltage Time Relation WIDTH IN VOLTS VOLTAGE
25. alibrating 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 ee Highlight VBatt and use the up and down arrow keys to match both of the readings 2 Press the Enter button to save 26lPage Note Use the description below to help complete the calibration of the Classic voltages TWEAKS screen Battery voltage adjust PV in voltage adjust yul pv PV in voltage 4 offset 12 6 VOLTS 0 0 HF Displayed MASTEN s Displayed battery voltage battery voltage Figure 2 7 VBatt OFFSET Battery voltage offset 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 The ON OFF has to be set to OFF in order to change the operational mode Scroll to the right to highlight the word ON or OFF and use the up and down keys to change it to OFF Push the Enter button to save this change Now you can
26. ation 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 e Turn off all circuit breakers including those to the solar modules batteries and related electrical connections before performing any maintenance Standards and Requirements All installations must comply with national and local electrical codes professional installation is recommended The NEC in the USA requires a DC ground fault interrupter for all residential PV installations NEC2011 requires an ARC FAULT detector on all charge controllers and inverters operating above 80VDC Both of these devices are built into the Classic DC and Battery Related Installation Requirements 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
27. beled BATTERY TEMP on the control board Figure 1 9 Wi I no I SULFURIC T XPLOSIVE SPARKS CAN MEDICAL 1 SUL ASES CAN I CAUSE KEN G GAME Plas oa t AI NO F SUOK i AC ae ING SEVERE BURNS H SPARKS g CA cal OUT OF REACH OF CHLOREN DO NOT TIP KEEP CAPS TIGHT AND LEVEL SS OR INJURY Des qe DE IMM DIATELY i J WITH WATER rr l Before placing the Battery Temperature Sensor make sure battery surface is clean from any dust or acids Placement is not very critical 17 Page Grounding The Classic charge controller is designed to work with negatively grounded or ungrounded systems For grounding conductor reguirements on your specific installation please consult your local electrical code The chassis grounding terminal 1s in the upper right corner of the electrical connection compartment see figure 2 0 lt Figure 2 0 DC GFP Ground Fault Protection The Classic has internal ground fault protection GFP built in NEC 2008 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 GFP is enabled 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 Only one Classic is to have the GFP function enabled If more than one GFP device 1s enabled the featur
28. e Refer to Figure 1 1 Included in the Classic package should be Classic charge controller Battery temperature sensor Snap on upper vent cover Knock out covers 4 screened and 4 solid User s manual DVD printed installation instructions ten foot custom USB cable If anything is missing or damaged please refer to Page 2 for details on contacting us Figure 1 1 Removing and installing the front cover on the Classic Removing the front art deco cover 1s required to gain access to the wiring compartment Be aware there is a cable connecting the cover to the electronics Do not pull hard or fast Damage will result 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 10 long 6 conductor phone cable To re install the front cover of the Classic you will need to plug in the display cable and carefully route 101Page it around the components on the circuit board as you set the cover in place See Figure 1 2 Do not force the cover 1 1t does not seat into place easily stop and look for any cables or vvires that may be interfering With the cover seated in place install the four Phillips screws with a 2 Phillips screwdriver Figure 1 2 IllPage zs K 2009 HI lar Inc hi ight 0 o Z U E C
29. e Stages and Meanings Bulk MPPT This stage of the Classic means that the Classic will be putting out as much current as it can trying to charge the batteries to the absorb voltage set point This is also known as constant current mode Absorb This stage means that the Classic will maintain the absorb set point voltage until the batteries are charged or it reach Float stage At this stage the classic is not putting out maximum current as that would increase the battery voltage over the Absorb set point This is also referred to as constant voltage mode The absorb time is proportional to the bulk time 1 e the time bulk takes to reach the absorb voltage The battery it s considered full at the end of the absorb charge cycle 25 Page Float A Float cycle follows after the Absorb cycle is completed Float is displayed on the screen Battery volt age is held at the float voltage set point float time can be changed by the user Egualize Egualization function has to be enabled by the user refer to page 25 The intent of an equalization charge is to bring all battery cells to an equal voltage by a deliberate overcharge The goal is to return each bat tery cell to its optimum condition through a series of voltage controlled chemical reactions inside the bat terles Adjusting Absorb Egualize and Float Voltages Setting the Classic though the wizard will set Absorb Float and EQ to the factory default set voltage to the spec
30. e following screen select LCD and press enter On this screen select LOAD DEFAULTS press enter On the password select 360 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 Troubleshooting 45 Page Technical information Specifications Electrical Model Classic150 Classic200 Classic250 Classic250KS Operating Volts in 150VDC 200VDC 250VDC 250VDC Max Hyper VOC 150 battery 200 battery 250 battery 250 battery Bat charge volts 12 93 volts 12 93 volts 12 93 volts 12 150 volts es 20 t9 406 Shipping weight 46lPage Specifications Mechanical 13 53 14 91 1 38 47 Page Default Battery charge set points The table below describes the default preset voltages for the different nominal battery voltages This means that if you set the Classic from the QUICK SET Menu see page 25 to a different battery voltage the Classic will take the default voltage set points Note If you manually adjust the absorb float or egualize 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 s 12v 24v 36v 60v 72v Voltage Bulk MPPT To adjust these voltage set point see p
31. e may not work as designed 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 an ungrounded DC system Figure 2 1 The Ground fault device is simple to understand and use The Classic DC GFP works a bit different than others It detects a fault between battery PV negative and earth ground just like the breaker DC GFP system The difference with the Classic 1s that it simply turns off 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 100 external circuit breaker assemblies The Classic s system consists of a PTC that is between the 18 Page 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 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 jumper labeled GFP needs to be removed or it can be disabled in
32. e protects the AUX internal components from overcurrent or a short circuit gt AUX 1 consists of either RELAY or LOGIC operation depending on the user selection function gt AUX 2 could be set to become an INPUT or OUTPUT One at a time this port could be reading the state of a device connected and takes an action from there AUX 1 AUX 2 6 OFF RELAYILOGIC INPUT OUTPUT CLASSIC SETUP To configure the Classic s Aux ports Push the Main Menu button Scroll left or right to highlight AUX and push the Enter button Scroll left or right to highlight the relay you wish to change Push the right soft key labeled SETUP Scroll up or down to change the function of the relay Select the right soft key to set the parameters of the function When finished push the ENTER button to save the changes Main Aux Screen shows both Auxl and Aux2 functions Places output to Low state 0 Volts Selects the assigned function to the Aux output or input Sets output for Low state 12 Volts or Relay On Aux 2 Used with a SSR relay a FET type of SSR for the DC side should be perfect here You can set the 29 Page diversion threshold V to either be absolute pick a voltage or a voltage relative to the particular charge stage the system is In at the moment Absorb EQ Float This diversion mode can be adjusted to start diverting Pulsing or Buzzing at 0 0V or above below the present battery set point voltage absorb float
33. es 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 spot off on the case Then remove the protective tape from the sensor and adhere the temperature sensor to the battery Some manufacturers use a double wall case on the battery For mounting a temp sensor to them please refer to the battery manufacturer s recommended procedure 16lPage Figure 1 8 b SLAM SEE w os i ot mm s P om COMMON GNU NEGATIVE a cret Ya WA a VAA Cos ku mika lt La Insert BTS to the jack la
34. ess the right soft Rey to get to ARC ADJ In this menu use the left and right keys to select the feature to adjust Use the up and down arrow keys to change the parameters a Le a a Le a Le a Le a Le In order for the Classic to read the new settings you must power cycle the Classic Do this by turning the DC source PV Wind or hydro etc breaker off Then turn off the external battery breaker Than simply turn the 2 breakers back on starting with the battery breaker View Faults and Warning s The Classic has some helpful safety features including the GFP Ground Fault Protection and AFD Arc Fault Detector When one or more faults are detected the Classic will stop outputting power and display a fault message in the bottom right corner of the home screen STATUS To clear the fault refer to Page 19 and page 33 Arc Fault section View Logged Data The Classic can log the power produced by your system Shown in Total kilo Watt hours kWh you can view daily logged data or accumulated throughout the life time of the Classic Daily logged data 1s displayed in the bottom left corner of the Status screen the daily logged data will get reset to 0 RVVh every 24hrs The total logged data 1s displayed in a menu screen called LOGS Total logged data is an accumulation of all of the power that has been produced by the system this data cannot be reset back to 0 kWh To view total kWh produced by you system se Press
35. he current setting of the feature 1 e ENABLED means the feature is currently in operation Note also that you will need the values MA and DI handy in order to create an account on the MidNite Solar web site This unique number pair identifies your particular classic to our server and helps to prevent malicious users from trying to access your Classic The DI or Device Id is different than your Unit s Serial Number Local Network Note that your classic identifies itself by name to DHCP enabled routers as Classic There is facility to change the name of a given classic via the local and web based interfaces as well as using third party MODBUS software packages Advanced The Classic advertises its address every 10 seconds using the UDP protocol on port TBD Advanced users and programmers may use this feature to identify Classics on their network 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 441Page Scroll to MNGP and select it On th
36. hlight TIME and push the Enter button Now scroll left or right to highlight the data you want to manually change Use the up and down buttons 28 Page to change the data When you have all the data changed push the Enter button to save the changes The Classic Includes a battery in the MNGP portion to keep the time running even when the power is disconnected To replace the battery refer to the Installation Manual Setting Longitude and Latitude With the built in virtual map you are able to select where you are in the world For a more precise setting you can manually enter the longitude and latitude coordinates geographic location is important because it 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 tvvo auxiliary ports vvhich 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 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 fus
37. iaiehJRoelaliotu u uuu AA aa 50 AUX Volliseshink KUO ucun nn de Acier 50 Classic Breaker SIZING Aa 51 Classic Menu Ma pi ner PS 52 4 Page Scope This Manual provides safety guidelines and installation information for the Classic charge controller It does not provide brand specific information about photovoltaic panels batteries etc Contact the manufacturer of other components in the system for relevant technical data Introduction The MidNite Classic charge controller is unigue in its ability to be used for a great variety of DC input sources The Classic is designed to regulate DC input from PV Hydro Wind and other DC sources The Classic 150 200 and 250 are designed to work with 12 24 36 48 60 and 72 volt battery banks The Classic250KS is designed to charge up to a 120V nominal battery bank The Classic can be installed stand alone or as a multi unit networked installation Standard features of the Classic charge controller include 3 input operating voltage ranges 150 200 and 250 VDC Multiple DC input options example Solar Wind or Hydro Wizard driven setup interface including voice and help screens Graphical display Previous 180 days of operational data logged 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 VVARNING Warnings signs identify conditions or practices that could resu
38. ified battery type E g Flooded Lead Gel These voltages are fully adjustable just follow the steps below Press Main Menu Scroll to the left until Charge is highlighted and push the Enter button Highlight Volts and press the Enter button Use left and right arrows keys to highlight the set point voltage to adjust Use up and down arrow keys to lower or ratse the voltage Press the Enter button to save the new voltages a Le a a a a a Battery Size and Chemistry The Classic supports a variety of battery chemistries including Flooded lead acid sealed AGM gel cell and Nickel Cadmium These different types of batteries have different charging parameters These parameters are crucial for long time battery life Go through the WIZARD to select the battery type of your system If you replace the batteries for a different type make sure you change the type on the WIZARD That is the only place where the battery type can be changed Battery Temperature Compensation The Classic comes with a battery temperature sensor BTS This sensor raises or lowers charge voltage based on temperature Connect BTS to the BATT TEMP jack Refer to fig 1 7B and 1 9 Battery temperature menu appears as T Comp in the BATTERY MENU In this menu you can change the voltage compensation as needed If the BTS is disconnected or shorted the Classic will automatically use the default charge voltages non compensated C
39. ime to wake up and go to sleep mode Sunrise sunset using Astronomical formulas BATTERY CHEMISTRY Sets up battery temp compensation and absolute FLOODED LEAD ACID maximum charge voltages regardless of temp ENTER BATTERY BANK VOLTAGE Selects between different voltage configurations 48 on the system increments of 12 volts 12v 24v 36v 48v 60v 72V 24lPage DO YOU KNOW THE BATTERY BANK AMP HR Helps set Absorption time and EO defaults CAPACITY YES NO WHAT IS THE VOLTAGE This is necessary for the set up software to help OF AN INDIVIDUAL figure out battery capacity BATTERY 6 SET CURRENT LIMIT Sets classic s maz output current 80 ENTER TO CONTINUE CONTROLLER MODE Selects classic s mode This can be changed in SOLAR WIND HYDRO the mode menu SCROLL lt gt TO SELECT THEN PUSH ENTER STC Photovoltaic module power rating MODULE POWER 210 WATTS STC Photovoltaic module voltage rating VOC RATING 44 31 VOLTS STC Photovoltaic module current rating ISC RATING Setting Nominal Battery voltage Upon initialization the Classic will display battery To set up the Classic to a preset battery voltages e g 12v 24v 48v follow the steps below Press Main Menu Scroll to the left until Charge is highlighted and push the Enter button Highlight Volts and press the Enter button Press the Right soft key Scroll up and down to select the desirable battery voltage yA yA Battery Charg
40. less Router Access Point wasa Figure 5 2 Local wireless network 41 Page Wireless Router Wireless enabled Access Point computer Wireless Bridge Figure 5 3 Local wireless network through wireless bridge There are many different configurations possible when it comes to networking that are beyond the scope of this manual The basic ones in the above figures should help get you going Network Setup Through the MNGP The Classic s Ethernet capabilities may be configured using the Network menu on the MNGP From the main menu select NET There are three screens that configure network settings Table TBD decodes the descriptions from the MNGP s small screen MNGP Long hand IP address configura The Classic supports both static and dynamically DHCP al tion mode located IP addresses If you are unsure which to choose try DHCP Static DHCP first If you have trouble move to the troubleshooting section IP IP Address The Network address of the Classic _____ O o Primary DNS Address Primary Address lookup device Secondary DNS Ad Secondary Address lookup device optional dress Web Enables or disables the Classic s online web service feature Access MAC Address The hardware or Ethernet address of the Classic DI Device ID The unique MidNite Solar address of the Classic Table 5 1 Net Menu Details DHCP The Classic supports Dynamic Host Configuration Protocol
41. ll be sub menus to adjust the parameters of the selected feature Here is an overview of these menus lt lt WIZARD CHARGE MODE AUX MNGP LOGS TWEAKS TEMPS NET gt gt Below each of the menu names is a row with a description of the menu inside To enter a menu the name of the menu has to be highlighted Pushing ENTER will show the submenus The up and down arrow keys are enabled for easier navigation Highlighting a sub menu and pushing ENTER will take you inside the submenu where you will be able to change the parameters of the unit To get out of the submenus push MAIN MENU this will take you out of the submenus one at a time every time you push it See page 44 for entire Menu Map Viewing Other MidNite Products on the Display The Classic is able to view other products or Classics connected to the network For example the MidNite Solar Clipper To view other products or Classics connected to the Classic network go to the Status screen and press the UP and DOWN arrows to scroll between the addresses of the different items The Classic is address 10 and labeled CLASSIC Connecting Classic to Two MNGPs 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
42. lt 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 5 Page are connected together by the Classic s internal GFP device All negative conductor connections must be kept separate from the grounding conductor connections The eguipment ground terminal inside the Classic must be connected to Earth Ground for the internal DC GFP to work Continue With the exception of certain telecom applications the Charge Controller should never be positive grounded e The Charge Controller equipment ground is marked with this symbol If damaged or malfunctioning the Charge Controller should only be disassembled and repaired by a qualified service center Please contact your renewable energy dealer installer for assistance Incorrect reassembly risks malfunction electric shock or fire e The Charge Controller is designed for indoor install
43. n you manually set the device s IP address the Gatevvay and Primary DNS addresses follow the change See the following sections for details on each of these fields IP Address This is the local network address of your Classic It usually takes the form 192 169 0 1 x or 10 0 0 x depending on your networking equipment You must be careful when selecting this address If it does not match your network subnet then the classic will not be able to communicate with the network If it is the same as another device on the network then collisions will occur causing both devices to act erratically Check your router settings or ask your network administrator which local address to use Also refer to the troubleshooting section for tips Subnet This refers to the class of local network you are using This depends on your network hardware but most users should use 255 255 255 0 for this field Gateway This is the address of your router or modem the device which is connected directly to the Internet proper It will usually 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 ga
44. oothly as it would if it has SOME room to move about Aux I diversion mode is similar to Aux 2 diversion mode except that it does not PWM Pulse or buzz at hundreds of Hz rate Instead Aux 1 diversion goes Active at or above the High voltage setting after a programmable Delay time and goes Inactive when the voltage drops below the Low voltage setting after a programmable Hold time These Delay or Attack and Hold times are adjustable in 0 1 Volt increments The Aux Relative Voltage adjustments are referenced to the temperature compensated Absorb Float or EQ voltage In the Classic the EQ regulation voltage can be chosen to be either battery temperature compensated or not This choice is picked in the Charge Temp Comp menu In battery relative diversion mode when either Aux outputs go active either solidly for Aux 1 or pulsed for Aux 2 you can choose to keep the charge timers and counters running or not for the Absorb and EQ stages so that the controller will go to Float when that charge stage is finished its timer has expired This could be important because the diversion might be holding the battery voltage below the desired set point voltage for that charge stage As long as the Relative diversion threshold voltage and absolute Absorb Float and EQ voltages charge menu are chosen with some degree of thought using the diversion in concert with the normal raising the input power source voltage method to regulate battery vol
45. opyr dize WA pa HT q ra 22 h ea lt lt om ne og VR 4 R ba ti cet L gv Q s 111188 Be 4 EN FR ef a WASA Bad 1 j HA 34 dha dle 2 ue e hd gt u j titii tiili i et h 132414444454 124 s SO s d LEN gt Mounting the Classic The following section covers typical mounting arrangements If you require additional details that are not covered here please contact us at technical support The Classic is designed to be directly mounted onto the MidNite Solar E Panel as well as other Installation methods Mount in an upright position out of direct sunlight when possible The Classic has four one inch knock outs for your convenience they are pre cast The Classic has mounting and conduit location similar to other brands to facilitate ease of upgrading older technologies to features available only on the Classic 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
46. ower 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 to select RECALL Now push the Enter button to save this power curve to the Classics memory There are also 9 memory spaces for you to save a custom power curve To build custom power curves select a memory location between 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 Vind Graph Editor l mpe Setting the Date and Time To set the date and time manually on the Classic follow the steps below Push the Main Menu button Scroll left or right to hig
47. r shadows of a tree branch U SET voc U SET Lets the user pick the VOC 90 meaning that for any specific reason the VOC should stay constant it will only while in BULK MPPT charging state after going to absorb or float VOC will change to 27 Page maintain the batteries at their absorb voltage set point See pg 31 This mode will not automatically find Maximum Power Point U SET will also let you do an interval But it is utilized differently To set Interval time or to set VOC do the following Press main menu and scroll to MODE press Enter Highlight ON OFF and select OFF Scroll to the right and press the up and dovvn arrovv Reys to select from the list of input modes Highlight the mode you wish to use and press the right soft Rey to enter the setup window Use the left and right arrow Rey to select the parameter to change Press the up and down arrow keys to adjust Press Enter to save ya a a Le a Le a a Le a SOLAR 1 O amp P Same as PV LEARN this mode will automatically do a sweep down to just a couple of volts above battery voltage to find the MPP but in variation will take longer to do this sweep This mode makes use of a much different method to obtain the MPP In the Setup menu you can select how often it does a sweep Interval can also be set in this mode Configuring the Classic for Wind Input Source Wind Track If you selected Wind Track you will need to select a p
48. rating systems you should see a systray balloon popup showing that the device was connected as shown here 1 Found New Hardware BootLoader Version 1 03 After a few seconds you should see the Found New Hardware Wizard appear as shown below Select the option titled Install from a list or specific location Advanced and click the Next button Found Mew Hardware Wizard This wizard helps you install software for USE COC serial port emulation G If your hardware came with an installation CD or floppy disk insert it now What do vou want the wizard to do Install the software automatically Recommended 83 Install from a list or specific location Advanced Click Hest to continue You should now see the dialog shown below Insure that the Include this location in the search checkbox is selected and hit the Browse button to navigate to the directory where the software was in stalled Note Your directory path will look like the dialog shown below if you did not change the default installa tion directory 36 Page Found Hew Hardware Wizard Please choose your search and installation options SS Ce Search for the best driver in these locations Use the check boxes below to limit or expand the default search which includes local paths and removable media The best driver found will be installed L Search removable media floppy CD ROM J Include this location in the search C
49. re factory defaults 32 Operatine the CSE AAA 32 NASA Be BE MONU 32 Viewing Other MidNite Products on the Display 33 Connectins Classic to 33 AC Tal WA AA IA 34 View Faults and Wana ia 35 View lossc Daln uuu u S aS ee uQ tanta esta 35 Uploading New Firmware to the Classic 35 Connectine the Classic 10 l u uma 41 NW Aa 41 Network Setup Throws ii the WING P SSSR AA WAA KA emma 42 DIC TR unumanta aka mi 42 SA WAA AA AA AA emeten 43 UA 43 43 EN A ie 43 DAS 43 MICDUACCES AAA 44 44 UU ii tt dt et ni nets nn tre aaa dent eee tte a nest 44 Dealer Information Se r ee u uy AA 44 Troubleshoo Hno uy y EA 45 Technical MOLA uu 2 au usu tn haha Gua 46 Sp ecilications Eleeirical u IA 46 Specifications Niechaniql uuu Aa 47 Default Battery charge set PA uuu a l a ua cedent tam a uw s emet 48 Optional ACCESS OFIES escasses a w a S Qa 0 umasa w awa 48 Resulato oryApDprovali u i Gais a a SSS w ao a sss 48 VV ALAIN ua Q Q Q Q an u a unqu 49 EO Lara UNED tenacitat CEO CIC Rae 49 AUX Land Auk 2 Graphs ceramista si dec nue etats tele tonne emet mesi 50 Aux L VollaesesT
50. red Resetting the Arc Fault Detector after detection has occurred The First thing to do 1s find and fix the actual arcing wire terminal splice etc The Classic needs to be powered down completely for 15 seconds and then powered back up Do this by turning the DC source PV Wind or hydro etc breaker off Then turn off the external battery breaker Than simply turn the 2 breakers back on starting with the battery breaker The arc fault module has three adjustable parameters consisting of MODE TIME amp SENSITV Y MODE Is assigned as a 1 from factory default and 1t should stay that way unless instructed by MidNite Solar TIME This sets the length of the arc the Classic has to monitor before tripping the Arc fault detection This parameter is set to 4 from the factory SENSITIVITY This parameter determines how sensitive the Arc fault detector will be 1 being the most sensitive and 15 the least This parameter 1s 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 34 Page To change the parameters of the Arc Fault follow the steps below Press Main Menu Scroll to the right or left until TWEAKS is highlighted and press ENTER In TVVEARS press the right soft key to get to the BITS menu In BITS pr
51. row Rey to highlight Out Amps column Use the up and down arrow keys to change the current limit 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 breaRer 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 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 1s 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 6AWG 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 oppor
52. s out less power by sealing 1t Refer to the owner s manual for the specifications page for ratings in the sealed mode Refer to Figure 1 4 and 1 5 Figure 1 4 Figure 1 5 eg AAA ns 4 TLE KA AAA Figure 1 6 Power wire hook up between the Classic and E Panel Network Cable Routing and Installation Guidelines The Classic uses a network cable to communicate with other Classic s or other MidNite products This cable is a standard 6 conductor phone cable and simply plugs into the jack on the Classic labeled slave Plug the other end into the master jack on the second device There is a plastic clamp located on the circuit board for routing the network cables above the USB jack so they stay tied down out of the way Refer to figure 1 7A and 1 7B 14 Page Figure 1 7A Master Slave methods of hook up ar P Hd n Ahamia mu z Sie En em k A a ste Bi Re i SN Re S ma aana MA m GE 1 Bene i Dp bs Skr 9 E ay RE Cr i i hi hee een l SU wD LU ey IR gt Thay le A P Juta Ki a i Lo 15lPage Cable Clamp for network cables USB connector 10 foot USB cable is included Ethernet connector 2 i FE Figure 1 7B Battery Temperature Sensor Installation A CAUTION To reduce risk of injury charge only deep cycle lead acid lead antimony lead calcium gel cell or absorbed glass mat type rechargeable batteries Other typ
53. s used must conform to all electrical codes applicable to the location of installation Wiring needs to be protected with proper strain relief clamps and or conduit See page 49 for a breaker and wire size chart The network cables USB cable BTS cable and auxiliary input output cables should run in a different conduit to preserve their signal When installing the Classic in a MidNite E Panel it is acceptable to run all wiring through the same knockout hole It is legal to run signal and power wires together as long 21 Page as all wiring 1s listed for the highest voltage to be encountered Current Rating The Classic limits the output current to the maximum for the model you have The Classic current ratings are Classic 150v 96 amps mazimum Classic 200v 79 amps mazimum Classic 250v 62 amps maximum Temperature Current Limit The Classic has a current limit component which interacts with the temperature of the charge controller If the Classic is exposed to extremely hot ambient conditions the out put current will be reduced automatically to keep the charge controller safe if the orange LED comes on on the MNGP it means that the Classic is in current limit mode If you believe the Classic is not hot and the orange LED is on most likely the current limit set point is too low To check this follow steps bellow e Press Main Menu Highlight CHARGE menu and press the Enter Button Press the upper right soft button Press the right ar
54. scroll to the right and highlight the mode under Function Scrolling up or down changes the modes Once a mode 1s selected push the Enter button to save this change Then you can use the right soft key to select setup This would be where you will manually set up any parameters specific to the mode you selected Configuring the Classic for Photovoltaic Input Source The Classic has more than one mode to be used for Photovoltaic arrays USET O amp P Solar PV LEARN and Solar 1 PV LEARN This is the ultra fast Maximum Power Point tracking mode It finds MPP in less than half a second with a precision of 5 watts this 1s the default solar mode Use this mode except in special cases To select this mode just select PV LEARN from the list in the MODE Menu There is one parameter of this mode which can be configured Interval In minutes Is the maximum amount of time in between sweeps We recommend to set the time to 15 min let the Classic figure out if the input power has changed in which case the Classic will automatically sweep for a new MPP 1 Note Setting Interval to 0 will set the Classic to only do an initial sweep down to battery voltage when turned ON However it will still do automatic sweeps 2 Note The Classic does automatic sweeps thought out the day to optimize maximum output power Every time there is a change in the input power of more than 10 the Classic will do a sweep this could be caused by a cloud passing by o
55. ses AAA 25 BOL NIPP Tu ae a en da done such lo ERE RE 25 PX DS ORD AA WA WAA AA KAA aaa AA S AA AA ati 25 NG A ted E a te IE A au CE un ta DE dalt anem et pap cut 26 EE CU Coia umaman kamayka lianes Dante m Aa Shanaya te Shu aysa pacte tem ase 26 Adjusting Absorb Equalize and Float Voltages 26 Battery Size ande Aa 26 Battery Temp rature COMP NSATONE uuu upaku eink esmaltat Us ns nes detente 26 Calibrating Battery and PV Voltagee 26 Confisurms DC Input SO uu Sn t u uit 27 Configuring the Classic for Photovoltaic Input Source 27 PV OPAR en UAE 27 SE AOC gest Gen tetes ee at a ac tn oi 27 SOLAR TOS P re kasaq aaa kaykaa aka a massa laYak aaah aq dsdominden aules 28 Configuring the Classic for Wind Input Source 28 NW Hi illik uysal ac site DES ec em re E 28 Setting the Date and Ime Q uu a Saqi Sa ua shua 28 Setin Lonaitiideand i m i S S Su Wa me es 29 Contisurins Vuxirary Input Output simis a u Qua S u u sa see 29 ADUN A PUNCH ON ESS nas ds sn ads ee sn AAA 31 3lPage AUX PUN Chon QUE DU aa au WA AA a uhu eae 31 Setting the MNG P features Access the Version of software and Resto
56. tage can work very well for battery charging cycles You might want to set the absolute a few tenths of a volt higher than usual so that the diversion mode can be used to greater benefit This will help to ensure that if the diversion loads go away the battery voltage won t go TOO much higher than desired and battery over gassing would be minimal Using diversion in this way is what we call Use It Or Lose It mode U1 Lo1 Just think of the song Louie Louie For Relative diversion using Aux or Aux 2 the default to keep the charge timers running will be enabled Aux and Aux 2 outputs can also be chosen to be Active High or Active Low Active High is the normal mode of operation and means that the Aux output will be at 0 Volts ground when Off and 12 Volts when On Low being O volts and High being 12 volts Active High is shown in the Aux menus 30 Page with a sign following the mode name and Active LOW mode with a following the name The output voltage for a High is actually more like 14 or 15 Volts DC and can supply up to 200 milli Amps of current Aux I also has a small relay that can be jumpered into the circuit if an isolated switch is needed This might be used to start or stop a generator Remember though that this is a very small relay with 1 Amp rating and a series 1 2 Amp re settable fuse in series with it to help protect its contacts Aux 1 Function OUTPUT Relay or 12V OV Signal jumper selectable
57. teway address depending on your network hardware If your ISP provides you with specific DNS servers then use those addresses in these fields instead Example 1 Your gateway is a DSL modem with address 192 168 1 1 If your ISP has not given you 4d3lPage explicit DNS servers to use then set the D1 field to 192 168 1 1 D2 can be ignored Example 2 Your gatevvay is a cable modem vvith 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 11 22 33 44 and the D2 address to 11 22 33 55 Web Access MidNite Solar offers a free web service with which you can access your Classic from a web page from anywhere in the world simply by pointing your favorite web browser to http www mymidnite com See the web section further on for instructions on how to create an account and use the web based system All communications between the Classic and MidNite Solar s server are encrypted using a strong session based algorithm To respect your privacy however it is required that you manually enable this feature 1f you d like to use it In order to enable the web access feature e Press Main Menu Scroll to NET menu and press the Enter button using the soft keys navigate to the ADVANCED menu NET NEKT ADVANCED The Web Access option should be highlighted Use the up down keys to now enable or disable the feature Note that the Web Access selection indicates t
58. tunities 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 than with a lower 22 Page voltage charge controller The efficiency of a high voltage Classic is less than the lower voltage versions so you need to weigh the benefit If this sounds too complicated use this rule of thumb in selecting the proper Classic PV runs up to 100 feet use the Classic 150 Runs up to 180 feet use the Classic 200 Above 180 feet use the Classic 250 or 250KS If the wire size between the DC source and the Classic is larger than the Classic s DC terminal connector you can use a splicer block or similar connector to reduce down to 4 AWG close to the Classic The MidNite E Panels are supplied with a PV input busbar that accepts up to 1 0 wire Maximum and Minimum Wire Size The Classic DC terminal connector will accept wire from 14 4 AWG Connecting the Classic to the Clipper The Classic will work in conjunction with either of the MidNite Solar Clipper s when available To connect the Classic to a Clipper you need to plug a MidNite network cable standard 6 conductor phone cable
59. ure 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 vvire to the Classic Connect any communications cable or auxiliary input output wires Torque terminal connector screws to the following specs a Le a a a a a a Le The Torque specs on the DC terminal connector big blue terminal connector are Up to 10 AWG torque to 25 35 inch pounds 19l Page 8 AVVG torque to 30 40 inch pounds 6 AWG or above Torque to 40 50 Inch pounds Xe Figure 2 2 BASIC HOOK UP DIAGRAM CLASSIC 16 mm ul GENERATOR WITH BRANCH TT Oo a LE LLI of 20lPage GROUND FEEC IE IL El INPUT Ng GROUND ROD Figure 2 2 PV DISCONNECT BATTERY DISCONNECT PDA 4 W BATTERY BUS BAR DC Terminal Connector 4 P pp es pz 3VA0Z1 VI CE ue 72 1 2S1 J30 Figure 2 4 The Classic s DC terminal connector is located on the circuit board as shown in The connector will take up to a 4 AWG 4AWG THHN wire when installed in the Classic The MidNite E Panel is rated for over 100 amps and is therefore suitable for the highest power Classic 150 Over Current Protection and Wire Size Requirements The over current devices wiring and installation method

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