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BWC EXCEL 1 Owner's Manual

48 vdc battery charging system
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Version 1.0
BWC EXCEL 1
May
2012
48 VDC
Battery Charging System
Owner's Manual
EXCEL 1 Wind Turbine
Bergey Windpower Co.
2200 Industrial Blvd.
Norman, OK 73069 USA
Telephone: (405) 364-4212
Fax: (405) 364-2078
E-mail:
Web:
www.bergey.com
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Summary of Contents for BWC EXCEL 1

  • Page 1 Version 1.0 BWC EXCEL 1 2012 48 VDC Battery Charging System Owner’s Manual EXCEL 1 Wind Turbine Bergey Windpower Co. 2200 Industrial Blvd. Norman, OK 73069 USA Telephone: (405) 364-4212 Fax: (405) 364-2078 E-mail: [email protected] Web: www.bergey.com...

  • Page 2: Table Of Contents

    Table of Figures   Figure 1: EXCEL 1 with 60' Tilt Tower ......................2   Figure 2: Major Components of the EXCEL 1 Wind Turbine ............... 5   Figure 3: AutoFurl ............................7   Figure 4: EXCEL 1 Basic Electrical Schematic ..........Error! Bookmark not defined.

  • Page 3: Overview

    DC-AC inverter and a 48 VDC battery bank the EXCEL 1-48 can also be connected to the power grid. The EXCEL 1-48 turbine consists of an 8.2’, 75 lb wind turbine rated at 1,000 watts, and the Midnite Solar Classic controller.

  • Page 4: Cautions And Warnings

    2. Cautions and Warnings This manual contains important information on the installation of your BWC EXCEL 1 wind turbine and charge controller. We strongly recommend that you read and follow the instructions contained in this manual. At several points in the manual items of special interest or significant impact are highlighted by one of the following notices.

  • Page 5: Identification

    3. Identification Each BWC EXCEL 1-48 wind turbine has a serial number decal located on the tower mount. The Serial Number is also written on the box that the turbine came in. We recommend writing it here as well: BWC EXCEL 1-48 Serial Number :...

  • Page 6: System Description

    The rotor system consists of three fiberglass blades. Acting like aircraft wings, the blades convert the energy of the wind into rotational forces that can drive a generator. The airfoil on the EXCEL 1 is the new SH3045 developed specifically for the EXCEL 1 by Bergey Windpower. The fiberglass blades are excep- tionally strong because they are densely packed with glass reinforcing fibers that run the full length of the blade.
  • Page 7 The slip-ring assembly is the electrical connection between the moving (as it orients with the wind direc- tion) wind turbine and the fixed tower wiring. The slip-rings and yaw bearings are located just above the tower mount. The tower mount attaches the EXCEL 1 turbine to the top of the tower. ...

  • Page 8: System Operation

    A. Normal Operation The rotor of the BWC EXCEL 1 should begin to rotate when the wind speed reaches approximately 3 m/s (7 mph). (For the first several weeks of operation, however, the start-up wind speed will be higher be- cause the bearing seals have not worn-in.) Battery charging should commence shortly after the rotor...
  • Page 9 If the load on the batteries increases, dropping battery voltage, the EXCEL 1 will speed up so that it can deliver more charging current.
  • Page 10 If there is no load at all on the system, then the turbine will be brought to a very slow speed, approximate- ly 20 RPM, and the solar panels will be disconnected completely.

  • Page 11: Turbine Installation

    If you are using the BWC Tilt Tower then the EXCEL 1 will bolt directly in place. If you are mounting the EXCEL 1 to a different type of tower then you will need to ensure that the tower meets the requirements for EXCEL 1 towers (see Appendix) and that it has a proper adapter fitting for attaching the EXCEL 1 tower mount casting (also defined in the Appendix).
  • Page 12 With the tower tilted down, place the powerhead of the wind turbine near the top end of the tower. The tower wiring is connected to the EXCEL 1 wind turbine at the slip-ring using two small screws and ring terminals crimped to the two conductors. BWC does not supply these ring terminals. Cut the outer insulation on the wire back about 60 mm (2.5 in).

  • Page 13: Figure 6: Turbine Mounting

    Step 3: Mount the wind turbine tower adapter to the top of the tower using six M10-1.5 x 20mm bolts and six washers. We require applying Loctite 242 (Thread Locking Compound) to the threads prior to installation to reduce the likelihood of loosening due to vibration. Use a torque wrench to achieve the proper fastener torque on the tower mounting bolts.

  • Page 14: Figure 7: Tail Fin Attachment

    1/2” for smooth operation. Finally, torque the nuts (in order shown in Figure 8) to 45 ft-lbs each. Loctite is not necessary on the blade fasteners because the nylon locking nuts provide adequate locking. NOTE: For EXCEL 1’s shipped after September 2003, all of the blade bolts are the same length.

  • Page 15: Figure 8: Blade And Spinner Fasteners

    Spinner Fasteners Blade Nuts & Washers Longer bolt goes here Blade Bolts Figure 7: Blade and Spinner Fasteners Figure 8: Nut Tightening Order Step 8: Attach the spinner (nose cone) using the three M5 bolts and washers provided, as shown in Figure 7. We recommend applying Loctite to the bolt threads prior to assembly.

  • Page 16: Figure 10: Tail Boom Attachment

    Wiring polarity is tested and marked Step 10: Dynamically brake the EXCEL 1’s alternator by either of two methods: 1) using the Stop Mode function of the charge controller, if you already have the turbine and battery bank connected to the charge controller, or 2) connecting the positive (+) and negative (-) output leads together.
  • Page 17 Wherever possible we strongly recommend assembling the tower and turbine on the ground. In this case please follow the general procedure for turbine assembly provided in the preceding section. When raising the tower you must lift the tower, not the EXCEL 1 wind turbine. The EXCEL 1 cannot support the weight of the tower.

  • Page 18: Powercenter Installation

    Windpower and from other sources. Additional Design Guidance: 1. If you have multiple EXCEL 1 turbines and charge controllers, do not connect more than one wind turbine to one charge controller. 2. Connect multiple charge controllers to a DC Source Center via the charge controllers’ battery terminals.
  • Page 19 Screw the top two mounting fasteners into the wall until ~ 6 mm (1/4”) of the shank extends out from the wall. Step 4: Remove the charge controller cover and place the charge controller enclosure on the two upper mounting fasteners.
  • Page 20 The EXCEL 1 wind turbine system is now ready to operate. We recommend that you verify that the EX- CEL 1 is producing power by putting the charge controller in Watt Display mode. In all but the lightest of...

  • Page 21: Inspections And Maintenance

    8. Inspections and Maintenance The BWC EXCEL 1 installation should be inspected after 30 days and then again 180 days after installa- tion. Following these two inspections the installation should be inspected every two years and after any particularly severe weather. In corrosive marine environments more frequent inspections are recom- mended.
  • Page 22 15. Check condition of all wiring connections into and out of the charge controller. Preventive Maintenance The Bergey EXCEL 1 turbine and tower should be inspected 30 days after installation, and then again 180 days after installation. Following these two inspections the installation should be inspected every two years and after any partic- ularly severe weather.
  • Page 23 The strength of the blades, particularly at the root (inner) end, may degrade over time due to flexure and UV degradation of the fiberglass material. The symptom of degradation is a reduction in blade stiffness fore-and-aft. The blades have to become very flexible in the fore-aft direction before there is any risk of tower strikes during severe weather.

  • Page 24: Trouble-Shooting Problems

    9. Trouble-Shooting Problems The following guide can be used to pinpoint the cause of operational problems with the BWC EXCEL 1 wind turbine and the charge controller. For problems or symptoms not found in the following listing, please contact the Service Department at Bergey Windpower Co. at:...
  • Page 25 Power transistor failure. Turbine voltage is Return complete charge above 10 VDC and Tur- controller to BWC for bine light is on, but no repair. current is being deliv- ered. Turbine rectifier failure, Check voltage from the...
  • Page 26 28.1 Volts, Invert- voltage limited to 28.1 controller in Equalize erator charge, pre- er set to bulk charge V, Extra Load LED lit Mode venting the batteries batteries at a higher Contact BWC for help from taking a bulk voltage charge...

  • Page 27: Appendix

    Appendix Installation Planning The location and height of the tower for the BWC EXCEL 1 wind system will be important factors in de- termining the overall performance of the system. Average wind speed is influenced by many things and may vary considerably within a relatively small region, particularly in complex terrain. Site and tower choice, however, are often limited by such factors as zoning restrictions, property size, proximity to neigh- bors, customer preferences, and wiring costs.

  • Page 28: Table 2: Variation In Wind Speed And Expected Relative Energy Output With Tower Height

    The BWC EXCEL 1 wind turbine must be placed on a tower that is tall enough to give the rotor proper exposure to the wind. Putting a wind turbine on a tower that is too short is like installing a solar system in the shade.
  • Page 29 BWC offers a guyed-tubular tilt-up tower, the Tilt Tower, for the EXCEL 1 in heights form 9 m (30 ft) to 32 m (104 ft). The Tilt Tower is cost-effective and is designed to be installable by non-experts. The installa- tion of these towers is covered in the BWC EXCEL 1 Tilt Tower Installation Manual.
  • Page 30 5. Safety The BWC EXCEL 1 should never be installed close to a power line. We recommend that the tower be at least 1 ½ times the height of the tower from any power line including any overhead service line bringing power to your home.

  • Page 31: Table 3: Recommended Wire Sizes For The Excel 1

    1186 - 1494 Note: These wire sizes have been engineered to provide optimum rotor loading for the BWC EXCEL 1/48 wind turbine. Deviation from these recommendations can result in decreased performance from your machine and / or unnecessary additional wire-run costs.
  • Page 32  Setting the low voltage disconnect (typically part of the inverter) too high so that the battery bank capacity is underutilized...
  • Page 33 6. DO follow the recommended wire sizes for your wire run from the wind turbine to the charge controller. With the EXCEL 1 oversizing the wire is a bad thing because it will cause ex- cessively high currents during high winds. Normally, over sizing wire is a good thing – but not in...
  • Page 34 BASIC TOWER REQUIREMENTS For the BWC EXCEL 1 Wind Turbine Customer supplied towers for the BWC EXCEL 1 Wind Turbine should meet the following mini- mum requirements: Tower Height: 9 m (30 ft) minimum, though we recommend 18 m (60 ft) or higher...
  • Page 35 Finish: We recommend hot-dip galvanizing after fabrication Pipe / Tubing Sizes: The following standard steel tubing sections have ID and OD dimensions that are compatible with the BWC EXCEL 1 (shipped after Sept. 2003): 4.5 in. OD, 0.095 in. wall thickness 4 in.
  • Page 38 MidNite Solar Classic Owner’s Manual This Manual covers models Classic 150, 200, 250 &250KS P a g e...
  • Page 39 The MidNite Solar Classic charge controller conforms to UL 1741, Safety for Inverters, Converters, Controllers and Interconnection System Equipment for Use With Distributed Energy Resources, Second Edition, May 7, 1999 with revisions through January 28, 2010 and CAN/CSA C22.2 No. 107.1: 2001/09/01 Ed: 3 (R2006) Note: The Classic KS has not been evaluated by ETL.
  • Page 40 Scope ................................5 Introduction .............................. 5 Classic Power Curves ..........................8 Unpacking the Classic ..........................10 Removing and installing the front cover on the Classic ..............11 Mounting the Classic ..........................12 Alternative Mounting .......................... 14 Dimensions............................14 Sealed or Vented ..........................14 Network Cable Routing and Installation Guidelines ................
  • Page 41 View Faults and Warning's ........................40 View Logged Data ..........................40 Uploading New Firmware to the Classic ....................40 Updating Classic Firmware (Windows XP) ..................40 Connecting the Classic to the Internet ....................56 Networking............................56 Network Setup Through the MNGP ....................58 DHCP ..............................

  • Page 42: Scope

    Scope This Manual provides safety guidelines and installation information for the Classic charge controller. It does not provide brand specific information about photovoltaic panels, batteries etc. Contact the manufacturer of other components in the system for relevant technical data. Introduction The MidNite Classic charge controller is unique in its ability to be used for a great variety of DC input sources.
  • Page 43 • 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.
  • Page 44 ™ 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. ™...

  • Page 45: Classic Power Curves

    Classic Power Curves P a g e...
  • Page 46 Figure 2.1 The graphs above represent the max power output for a given input for each Classic. Using and understanding these power graphs will help maximize Classic’s output power and aid in selecting wire and breaker/disconnects. The built in set up wizard also helps select breakers and wire sizes. Notice that lower battery voltages and lower PV input voltages result in higher continuous output power.

  • Page 47: Unpacking The Classic

    Unpacking the Classic When you receive your Classic you will want to unpack it and make sure everything is there and in good shape. Refer to Figure 1.1. Included in the Classic package should be: *Classic charge controller *Battery temperature sensor **Snap on upper vent cover *Knock out covers 4 screened **Knock out covers 4 solid...

  • Page 48: Removing And Installing The Front Cover On The Classic

    *1 ten foot custom USB cable **Note. These items are optional email [email protected] for more information If anything is missing or damaged please refer to Page 2 for details on contacting us. Figure 1.1 Removing and installing the front cover on the Classic Removing the front art deco cover is required to gain access to the wiring compartment.

  • Page 49: Mounting The Classic

    Mounting the Classic The following section covers typical mounting arrangements. If you require additional details that are not covered here please contact our technical support team. The Classic is designed to be directly mounted onto the MidNite Solar E-Panel. The Classic can also accommodate other installation methods as well.
  • Page 50 Classic has four one inch knock outs that are pre cast. The Classic has mounting locations and conduit locations are similar to other brands of charge controllers to facilitate ease of upgrading older technologies. Mounting the Classic directly to the E Panel: *Remove the front cover of the Classic.

  • Page 51: Alternative Mounting

    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 is Plumb and Level. Dimensions See page 40 for more details.

  • Page 52: Network Cable Routing And Installation Guidelines

    plastic knock out covers into any unused knock outs and snap the upper vent cover onto the Classic as seen in the photo below. Note that the Classic will be slightly de-rated (puts out less power) by sealing it. Refer to the specifications page of the owner’s manual for the ratings in the sealed mode. To obtain the parts necessary to seal the Classic please contact our Technical Support Team.
  • Page 53 Master Classic Slave Classic Figure 1.7A Master / Slave methods of hook up P a g e 16 |...

  • Page 54: Battery Temperature Sensor Installation

    Cable Clamp for network cables Battery Temp Sensor USB connector 10 foot USB cable is included Ethernet connector Figure 1.7B Battery Temperature Sensor Installation 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.
  • Page 55 Figure 1.8 Insert BTS to the jack labeled BATTERY TEMP on the control board. Figure 1.9 18 | P a g e...

  • Page 56: Chassis Grounding

    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.

  • Page 57: Dc Gfp (Ground Fault Protection)

    DC GFP (Ground Fault Protection) The Classic has internal ground fault protection (GFP) built in. Since 2008 the NEC requires a DC-GFP on all PV systems in the USA. The built in DC-GFP eliminates the need to purchase and install an external DC-GFP.

  • Page 58: Wiring The Classic

    Wiring the Classic Shock hazard. Disconnect the batteries and input power before opening the Classic WARNING front cover When two or more Classics are paralleled onto one DC Source a blocking diode must be used between each Classic and the input source to isolate each Classic from the other ones. The Classic should be wired by a qualified professional and needs to meet all applicable electrical codes.
  • Page 59 Figure 2.2 22 | P a g e...

  • Page 60: Dc Terminal Connector

    DC Terminal Connector 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. #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.

  • Page 61: Over Current Protection

    Temperature Current Limit The Classic has a current limit component which interacts with the temperature of the charge controller. If the Classic is exposed to extremely hot ambient conditions the output current will be reduced automatically to keep the charge controller safe, if the orange LED comes on, on the MNGP it means that the Classic is in current limit mode.

  • Page 62: Connecting The Classic To The Clipper

    Connecting the Classic to the Clipper Not Yet Available Please email customerservice@midnitesolar for status updates on the Clipper. Maximum and Minimum Wire Size The Classic DC terminal connector will accept wire from #14-#4 AWG Commissioning the Classic The Classic will enter into the setup wizard upon initial power up. If the Classic does not enter into the setup wizard or you want to enter the wizard at any time follow these steps to get into the setup wizard.

  • Page 63: Setting Nominal Battery Voltage

    DO YOU KNOW THE BATTERY BANK AMP HR Helps set Absorption time and EQ defaults CAPACITY WHAT IS THE VOLTAGE This is necessary for the set up software to help OF AN INDIVIDUAL figure out battery capacity BATTERY SET CURRENT LIMIT Sets classic’s max output current ENTER TO CONTINUE CONTROLLER MODE...

  • Page 64: Float

    Float A Float cycle follows after the Absorb cycle is completed; Float is displayed on the screen. Battery vol- tage is held at the float voltage set point, float time can be changed by the user. Equalize Equalization function has to be enabled by the user, refer to page 25. The intent of an equalization charge is to bring all battery cells to an equal voltage by a deliberate overcharge.

  • Page 65: Configuring Dc Input Source

    Note. Use the description below to help complete the calibration of the Classic voltages. TWEAKS screen Battery voltage adjust PV in voltage adjust PV in voltage Battery voltage offset offset Displayed Displayed battery voltage battery voltage Figure 2.7 Configuring DC Input Source To select the Mode the Classic will run in, follow the steps below.
  • Page 66 shaded (if this feature is enabled). SOLAR mode is best suited for shaded or un-shaded PV arrays that are at least one nominal voltage above the battery voltage. For severe partial shading or PV arrays with nominal voltage equal to battery voltage, you may also want to try Legacy P&O (Perturb and Observe) MPPT mode.

  • Page 67: Configuring The Classic For Wind Input Source

    useful for testing or constant voltage sources. The ON/OFF has to be set to OFF in order to change the operational mode. Scroll to the right to highlight the word ON or OFF and use the up and down keys to change it to OFF. Push the Enter button to save this change.

  • Page 68: Configuring Auxiliary Input/Output

    helps determine when the Classic wakes up and when it goes to sleep. This setting tells the Classic when sunrise and sunset are to happen. The Classic will use this information on future features also. To set longitude and latitude coordinates you need to go thought the WIZARD that is the only way to gain access of this feature Configuring Auxiliary Input/Output The Classic includes two auxiliary ports which can be configured to become inputs or outputs.
  • Page 69 Aux 1 Vent Fan Lo This mode will turn Aux 1 off above the voltage set point you program. It allows you to run a vent fan for a battery bank based on battery voltage. There is a voltage set point that you set and Aux 1 will turn off when the battery reaches that set point.
  • Page 70 Pv V on High This Mode will turn Aux 1 on above a user set voltage based on the input voltage to the Classic ( V High) and turn Aux 1 off when it hits a low voltage set point (V Low). It also allows you to set a delay time in seconds the Classic will wait before turning Aux 1 on after reaching the V High set point.
  • Page 71 Aux 2 Float Low This mode will turn Aux 2 off whenever the Classic is in Float. Aux 2 will stay off until the Classic falls 3 tenths of a volt below the float voltage set point. Float High This mode will turn Aux 2 on whenever the Classic is in Float. Aux 2 will stay on until the Classic falls 3 tenths of a volt below the float voltage set point.

  • Page 72: Aux 1 Function

    Opportunity Hi This mode is PWM based and will PWM Aux 2 when the Classic gets within a certain range of the voltage set points for each charging stage (V High) and stop when it gets to a low set point (V Low). These set points are user adjustable and will allow the Absorb, Float and EQ timers to continue to run.

  • Page 73: Aux 2 Function. Output/Input

    Aux 2 Function. Output/Input OUTPUT = 12V/0V Signal FLOAT LOW Aux2 off when in Float FLOAT HIGH Aux2 on when in Float DAY LIGHT Aux2 on at dawn off at dusk NITE LIGHT Aux2 on at dusk off at dawn CLIPPER CONTROL PWM Control for Clipper Pv V ON LOW...

  • Page 74: Operating The Classic

    Figure 2.8 Screen name Communication indicator Menu name USB activity Menu indicator description Current limit indicator Right soft key Speaker Up arrow key Right arrow key Left soft key Left arrow key Main Menu Status screen Down arrow key Enter button 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.

  • Page 75: Viewing Other Midnite Products On The Display

    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.

  • Page 76: Arc Fault

    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.

  • Page 77: View Faults And Warning's

    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).
  • Page 78 2. Fill out the registration form with the required fields and click Submit. 3. An email will be sent to you with a link to the firmware. Click the link to start the download. If the download does not start, copy the link, paste it in the URL address bar and then press enter.
  • Page 79 4. Select “Save” to save the file on your computer. P a g e 42 |...
  • Page 80 If your antivirus sees the MidNite Update.exe as a threat, temporarily disable your antivirus. When the install is complete enable your antivirus. 5. After saving the MidNiteSolarSetup_3-4-2011.exe file double click on it to start the installation. 6. The Software License Agreement dialog box will appear. Click “Yes” to except the terms. 7.
  • Page 81 8. The “Start Copying Files” dialog box will appear, click “Next”. Files will begin to install on your computer. 9. In the Setup Complete dialog box click “Finished”. A new MidNite Solar folder will be placed in your C:\ drive. We will refer to this folder in step 20. By default the “View Readme” check box is checked. If you don’t want to read the Readme file, uncheck this box before clicking the “Finish”...
  • Page 82 Prepare Classic charge controller for update. 10. Now go to your electrical panel and identify the input and output breakers for the Classic. Turn them off. Wait 3 minutes for the Classic to de-energize. 11. Remove the four screws holding the front cover of the Classic charge controller. Do not let the front cover hang by the cable.
  • Page 83 12. Holding the front cover with one hand, place a screw in the top left hole of the front cover and screw it into the top right hole of the back casting. 13. Use the provided USB cable to connect the Classic to the PC. The smaller terminal connects to the USB port on the Classic.
  • Page 84 14. Connect the other end of the USB cable to an available port of the PC. Install USB Classic driver P a g e 47 |...
  • Page 85 15. Go back to the electrical panel and turn on the battery breaker to the Classic. The LED above the USB port on the Classic will light up and stay on. P a g e 48 |...
  • Page 86 17. The computer will prompt with a “Found New Hardware” pop-up. Select “Not at this time” and press “Next”. A “New Found Hardware Wizard” dialog box will appear. Select “Install from a list or specific lo- cation (Advanced)” and click “Next”. Select “Search for the best driver in this location”.
  • Page 87 Browse to the MidNite Solar folder located on the C:\\ drive and click OK. Click “Next”. P a g e 50 |...
  • Page 88 In the Hardware Installation dialogue box click on “Continue Anyway”. 23. Click Finish to finish driver installation. Changing Classics’ COM port The Classic charge controller can only be recognized if it is set up for COM 8 on the PC; most likely P a g e 51 |...
  • Page 89 you’ll need to change the default COM number of the classic. Here is how: 24. On your computer go to the Control Panel and click on System. Select the tab labeled “Hardware” and click on “Device Manager”. P a g e 52 |...
  • Page 90 In the Device Manager, expand the tree branch labeled “Ports (COM & LPT1)”. Right click on “USB CDC serial port emulation (COMxx)” and select “Properties”. 27. Select the tab labeled “Port Settings” and click on “Advanced”. P a g e 53 |...
  • Page 91 28. In the “COM Port” number drop down selection box, select “COM8” and press “OK” to exit that window. 29. Click “OK” on the “USB CDC serial port emulation (COM8) Properties” to save changes. Now close the “Device Manager”, click “OK” on “System Properties” and then close the “Control Pan- el”.
  • Page 92 32. Now turn ON the battery breaker to the Classic. The update should start automatically. Wait until the “update” goes to 100% then turn the battery breaker to the Classic OFF and then ON. Turning the breaker off and on resets the Classic so the new settings take effect. P a g e 55 |...

  • Page 93: Connecting The Classic To The Internet

    33. If MNGP (MidNite Graphics Panel) needs to be updated as well, turn OFF the battery breaker to the Classic. Click on the “MNGP” button on the “MidNite Update GUI” then turn ON the breaker. 34. Wait until the uploading percentage reaches 100% and then turn the battery breaker to the classic OFF and then ON.
  • Page 94 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 Wireless Router/ Bridge Access Point Figure 5.1 Local network through wireless bridge. Wireless enabled com- puter Wireless Router/...

  • Page 95: Network Setup Through The Mngp

    Wireless enabled com- Wireless Wireless Router/ puter Bridge Access Point 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.

  • Page 96: Static Ip

    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.

  • Page 97: Web Access

    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.

  • Page 98: Conventions

    Registers and bits marked RESERVED are not necessarily unimplemented. Great care must be taken not to overwrite these registers or bits to ensure proper operation of the Classic. Wherever possible we have tried to indicate settings that may have an adverse effect on your system if set incorrectly.
  • Page 99 ex: [4116] indicates the value of the register at address 4116. Square brackets followed by an means to use the most-significant byte of the register. ex: if the value at register 4116 is 0x04B1 (decimal 1201): [4116] = 0x04B1, then [4116] = 0x04 Square brackets followed by an...
  • Page 100 [4116] = 0x0002 Then [4116] >> 1 = 0x0001. OR two numbers together (aligned to LSB) & AND two numbers together (aligned to LSB) XOR two numbers together (aligned to LSB) String Concatenate. [4116] = 0x4142. [4116] || [4116] => 0x41 || 0x42 => ‘A’ ||‘B’ => “AB” Examples: Using the example of the Average PV Voltage register: dispavgVpv @ 4116 Suppose using a MODBUS scanner you retrieve the following (integer) value from the dispavgVpv...
  • Page 101 Base Registers Address R/W Name Conversion Notes 4101 UNIT_ID PCB revision = [4101] The PCB revision is a value Unit Type = [4101] between 0 and 255 indicating the hardware revision of the PC board. The Unit Type is an integer value indicating the voltage category of the Classic See Table 4101-1.
  • Page 102 Address R/W Name Conversion Notes 4123 RESERVED 4124 MatchPointShadow [4124] Instantaneous value of Wind curve being used. Values [1…16] 4125 AmpHours ([4125] / 10) Amp Hour Daily Amp Hours reset once per 4126 TotalkWhours (([4127] << 16) + [4126]) Lifetime Energy Generation 4127 4128 TotalAmpHours...
  • Page 103 Address R/W Name Conversion Notes 4147 NoDoubleClickTimer [4142] Seconds Forced time space between manual MPPT sweeps. 4148 R/W Battery output Current Limit [4148] / 10) Amps Battery Current Limit Amps (example: 23.4 A = 234) 4149 R/W Absorb Set Point Voltage ([4149] / 10) Volts Battery Absorb Stage Set point Voltage...
  • Page 104 Address R/W Name Conversion Notes 4162 R/W Equalize Time [4162] Seconds Initialize Time for Batteries to remain in Equalize Stage. 4163 R/W Equalize Interval Days [4163] Days Number of days between Equalize Stages (Auto EQ) 4164 R/W Mppt Mode (Solar, Wind, [4164] (bit 0 = On/Off) Maximum Power Point ……………...
  • Page 105 Address R/W Name Conversion Notes 4179 R/W Aux1VoltsHiPv (absolute) ([4179] /10) Volts Aux 1 High PV Voltage Threshold 4180 RESERVED (Do NOT Write) 4181 R/W Aux2VoltsHiPv (absolute) ([4181] /10) Volts Aux 2 High PV Voltage Threshold 4182 RESERVED (Do NOT Write) 4183 R/W ArcFaultSenstvty Time = [4183]...
  • Page 106 4201 RESERVED (Do NOT Write) Address R/W Name Conversion Notes 4202 R/W ClipperCmdVolts ([4202] /10) Volts Variable Voltage command to Clipper or Aux in Clipper mode 4203 R/W WindNumberOfPoles [4203] poles Number of turbine alternator poles (for RPM Calc) 4204 R/W MppPercentVoc [4204] 00 to 100 % % of Voc for U-Set mode...
  • Page 107 4224 R/W PreVoc ([4224] /10) Volts PV Terminal V before Relay Address R/W Name Conversion Notes 4225 RESERVED (Do NOT Write) 4226 R/W VauxA2Dinput [4226] TBD Aux 2 A to D input (TBD) 4227 4228 RESERVED (Do NOT Write) 4229 4230 4231 VocRD...
  • Page 108 4250 BattMonVolts Address R/W Name Conversion Notes 4251 BattMonSOC 4252 BattMonAmps 4253 BattMonAHefficiency 4254 RESERVED (Do NOT Write) 4255 4256 4257 R/W RebulkTimerSec [4257] seconds Rebulk interval timer. Cleared if Vbatt >= Rebulk 4258 4259 4260 RESERVED (Do NOT Write) 4261 4262 4263...
  • Page 109 4278 Input Vpv ([4377] / 10) Volts PV Voltage Unfiltered 4279 Address R/W Name Conversion Notes 4280 Typeint ([4279] << 16) + [4278] 4281 4282 RESERVED (Do NOT Write) 4283 Table 4101-1 Device Type Name Value Description Classic150 Classic 150 Classic200 Classic 200 Classic250...
  • Page 110 Table 4130-1 Info Flag Bits: READ ONLY Flag Value Description Classic Over Temperature 0x00000001 Classic Over Temperature if set EEPROM error 0x00000002 Classic EEprom read/write found an error if set RESERVED 0x00000004 RESERVED Equalize In Progress 0x00000008 Equalize Charge stage Active if set RESERVED 0x00000010 RESERVED...
  • Page 111 Table 4158-1 Battery Type (not used yet as of May 2011) Name Value Description Flooded Lead Acid (Flooded) Lead Acid (Gel) Lead Acid (AGM) AGM2 Lead Acid (AGM2) Lithium LiIon Nicad Nickel Cadmium VRLA AGM or AGM or AGM2 actually AbsolyteIIP User1 Table 4160-1 ForceFlagsBits (can write to low or high 16 bits independently if wanted)
  • Page 112 Table 4164-1 MPPT MODE† Value Description PV_Uset 0x0001 U-SET MPPT MODE (includes MPPT ENABLED (On) FLAG i.e. if 0x0000 MPPT mode is OFF) Slow Dynamic Solar Tracking (old Solar 1 O & P ) DYNAMIC 0x0003 Legacy P&O 0x0009 Legacy P & O sweep mode SOLAR 0x000B Fast SOLAR track (old PV Learn mode)
  • Page 113 Table 4240-1 Internal Flags bits (Read Only) (flagsRD) Name Value Description 0x00000001 RESERVED RESERVED 0x00000002 RESERVED RESERVED 0x00000004 RESERVED RESERVED 0x00000008 RESERVED RESERVED 0x00000010 RESERVED RESERVED 0x00000020 RESERVED RESERVED 0x00000040 RESERVED RESERVED AbsorbTimeRunf 0x00000080 Bulk/Absorb Timer Counting is Enabled EqTimeRunf 0x00000100 EQualize Timer Run flag FloatTimeRunf...
  • Page 114 AUX 1 and 2 modes Extracted and encoded as combined in Aux12Function Table 4165-1 AUX 1 Off – Auto – On (Extracted/Encoded as Aux12Function bits 6,7) Name Value Description Aux 1 Off Aux 1 output is OFF (0 Volts) Aux 1 Auto Aux 1 operates as defined in Aux2Funtion Aux 1 On Aux 1 output is ON (~14 Volts)
  • Page 115 Table 4165-4 AUX 2 Function (Extracted/Encoded as Aux12Function bits 8-13) Name Value Description DIVERT DGTL F+ Digital Out PWM Battery Diversion (Active High) DIVERT DGTL F- Digital Out PWM Battery Diversion (Active Low) BAT DIV V REL+ Digital Out PWM Relative to Charge Stage Voltage Threshold Diversion (Use It Or Lose It) (Active High) BAT DIV V REL- Digital Out PWM Relative to Charge Stage Voltage...
  • Page 116 Consolidated Time Registers 0 Table 4214-1 (write only to set Classic Time -- Normally, MNGP will set these registers from its battery backed RTC) Name Value Description BITS 5:0 0 to 59 Seconds Seconds value in the range of 0 to 59 BITS 5:0 RESERVED RESERVED (Do NOT write ones to these bits)
  • Page 117 Table 4275-1 Reason For Resting VALUE REASON FOR RESTING Anti-Click. Not enough power available (Wake Up) Insane Ibatt Measurement (Wake Up) Negative Current (load on PV input ?) (Wake Up) PV Input Voltage lower than Battery V (Vreg state) Too low of power out and Vbatt below set point for > 90 seconds FET temperature too high (always shows up on boot up) (Cover is on maybe ?) Ground Fault Detected Arc Fault Detected...
  • Page 118 The network registers are all Read/Write. You may write any values to these registers, however this may result in erratic operation in some instances. To set A static IP address, be sure to clear the DHCP bit in register 20481 before writing the static values to the Network Address...
  • Page 119 The Version Registers are all Read Only. Writes to any of these registers will have no long-term effect. Version Address Name units Description 16385 app_version Major: [16385](15…12) Release version of the application code Minor: [16385](11…8) Release: [16385](8..4) 16386 net_version, Major: [16386](15…12) Release version of the communications stack Minor: [16386](11…8) Release: [16386](8…4)
  • Page 120 Communication Statistics are all Read/Write registers. You may write any value to these registers which will be incremented should the trigger for that counter occur. The most useful type of write may be to periodically reset the counters to zero. These are all lifetime counters and due to the number of MODBUS transactions may overflow to 0.
  • Page 121 Communication Statistics Remote bus interface 10033 rx_ok ([10034] << 16) + Number of correctly received packets 10034 [10033] 10035 rx_crc_err ([10036] << 16) + Number of packets received with crc errors 10036 [10035] 10037 requested_ok ([10038] << 16) + Number of transactions originating from 10038 [10037] this unit that completed successfully...
  • Page 122 Reserved Address Name units Description 61441- Reserved Reserved 61442 Figure 1. Classic RS-232 MODBUS RJ-11 PHONE JACK PINOUTS (Top View) P a g e 85 |...

  • Page 123: Dealer Information Screen

    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.

  • Page 124: Hypervoc ™ Origins

    HyperVOC ™ Origins HyperVOC can be useful in overcoming an industry shortcoming in charging 48 volt battery’s with standard panels. For example let’s take a sample system with Solar World 165’s that have a VOC of 44.1vdc. The industry has limited us to 2 of these panels in series making it hard to charge a 48vdc battery on hot summer days.

  • Page 125: Technical Information

    Technical information Table 6.1 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 *Battery Charge Volts 12-93 volts 12-93 volts 12-93 volts 12-150 volts 96a at 12v battery 74a at 12v battery 60a at 12v battery **Absolute Current...

  • Page 126: Specifications Mechanical

    Specifications Mechanical P a g e 89 |...

  • Page 127: Default Battery Charge Set Points

    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.

  • Page 128: Warranty

    Warranty MidNite Solar's Classic comes with a standard 5 year warranty we will repair or replace the Classic at no charge to the consumer during this 5 year period End of Warranty tune up MidNite Solar offers a industry first Tune up / Extended Warranty. 6 months prior to the end of the warranty period Customers can ship their Classic back to MidNite Solar with a check for $125 dollars and we will replace any wearable items like the fans and the capacitors and in general tune the Classic up.

  • Page 129: Aux 1 And Aux 2 Graphs/Jumpers

    Figure 3.0 Aux 1 and Aux 2 Graphs/Jumpers Figure 3.0 shows the two Aux port terminals, with their respective polarities. These terminals are located at the bottom of the power board below the battery temperature jack. Use a mini Aux 2 Aux 1 flat head screw driver to tighten the screws.

  • Page 130: Aux 1 Voltage-Time Relation (Relay/12V)

    Aux 1 Voltage-Time Relation (Relay/12v) Aux 1 Function Graph shows the relationship between voltage and time of AUX 1. (The axis labeled VOLTAGE could be battery, PV, wind input voltage, etc. depending on the function selected by the user) VHIGH is the upper voltage limit, as soon as the voltage reaches this limit the Delay time will then start, as soon as the Delay time expires AUX1 will change state and stay there until the voltage drops below VLOW set point, then another timer called Hold Time will start and when this expires the out put will go back to the original state.

  • Page 131: Classic Breaker Sizing

    Table 6.1 Classic Breaker sizing P a g e 94 |...

  • Page 132: Classic Menu Map

    Classic Menu Map P a g e 95 |...

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