1. Introduction
The MakeSkyBlue 40A MPPT Solar Charge Controller (Model 40A-V119) is an advanced device designed to efficiently manage power flow from your solar panels to your battery bank. Utilizing Intelligent Maximum Power Point Tracking (MPPT) technology, it optimizes solar energy harvesting, ensuring your batteries are charged effectively and safely. This controller features a built-in DSP controller for high performance and supports three-stage charging to prolong battery life.
Equipped with a multi-function LCD display, the V119 model provides real-time system information. It is suitable for various battery types, including 12V, 24V, 36V, and 48V systems. The V119 also includes Wi-Fi connectivity for monitoring via an Android application, facilitating convenient system management. Please note that the Wi-Fi function is for direct connection between the controller and an Android phone only, not for internet or cloud services.
Figure 1: Front view of the MakeSkyBlue 40A MPPT Solar Charge Controller, showing the LCD display and control buttons.
2. Safety Information
Please read all instructions and warnings carefully before installation and operation. Failure to follow these instructions may result in electric shock, fire, or severe injury.
- Ensure all wiring is performed by qualified personnel and complies with local electrical codes.
- Always disconnect power from solar panels and batteries before installing or servicing the controller.
- Use appropriate circuit breakers for both solar panel input and battery output to prevent overcurrent.
- Do not expose the controller to water, excessive humidity, or corrosive environments.
- Ensure adequate ventilation around the controller to prevent overheating.
- Batteries can produce explosive gases; ensure proper ventilation when working with batteries.
- Wear appropriate personal protective equipment, including eye protection, when working with batteries and electrical systems.
3. Setup and Installation
Proper installation is crucial for the optimal performance and longevity of your MPPT charge controller. Follow these steps carefully.
3.1 Mounting the Controller
Mount the controller vertically on a non-flammable surface, ensuring sufficient clearance (at least 6 inches) around the unit for proper airflow and heat dissipation. Avoid direct sunlight exposure to the controller.
Figure 2: Side view of the controller, highlighting the cooling fan and ventilation slots.
3.2 Wiring Connections
Connect the components in the following order: Battery > Solar Panel > DC Load. Always ensure circuit breakers are open (off) before making connections.
- Battery Connection: Connect the battery cables to the 'BT+' and 'BT-' terminals on the controller. Ensure correct polarity. It is recommended to install a circuit breaker (e.g., 63A for 40A controller) between the battery and the controller.
- Solar Panel Connection: Connect the solar panel cables to the 'PV+' and 'PV-' terminals. Ensure correct polarity. Install a circuit breaker (e.g., 15A) between the solar panels and the controller.
- DC Load Connection (Optional): If using, connect your DC load to the 'OU+' and 'OU-' terminals. Ensure the load current does not exceed 5 Amps.
Use appropriate wire gauge (e.g., 10 AWG) for all connections, ensuring all wires from breakers are of the same length and size for optimal performance.
Figure 3: Detailed wiring diagram showing connections for solar panels, battery, and DC load with recommended circuit breakers.
3.3 Initial Power-Up
Once all connections are secure and verified for correct polarity, close the battery circuit breaker first, then the solar panel circuit breaker. The LCD display should illuminate, indicating the controller is powered on.
4. Operating Instructions
The controller features an LCD display and four buttons for navigation and settings adjustment.
Figure 4: Close-up of the controller's LCD display and control buttons (PRG/ESC, Up, Down, ENTER).
4.1 LCD Display Functions
The LCD cycles through various parameters, including battery voltage, charging current, solar panel voltage, and power output. Refer to the on-screen indicators for specific data.
4.2 Button Navigation
- PRG/ESC: Enters programming mode or exits current menu/setting.
- Up/Down Arrows: Navigate through menu options or adjust values.
- ENTER: Confirms selection or saves changes.
4.3 Battery Type and Voltage Settings
The controller supports various battery types. The default charging mode is for lead-acid batteries. You can set the charging voltage range:
- For 12V Battery Systems: Set voltage from 12V-17V.
- For 24V Battery Systems: Set voltage from 24V-34V.
- For 48V Battery Systems: Set voltage from 48V-68V.
It is important to calibrate the battery voltage reading in the device for accurate measurements, especially for lithium battery configurations.
4.4 Wi-Fi Connectivity (V119 Model)
The V119 model includes a Wi-Fi module for monitoring via a dedicated Android application. To connect:
- Download the MakeSkyBlue application from the Android app store.
- Enable Wi-Fi on your Android phone and search for the controller's Wi-Fi network.
- Connect to the network. The default password is typically '88888888'.
- Open the application to view real-time data and adjust settings.
Note: This Wi-Fi connection is a direct link between the controller and your phone and does not provide internet access or cloud connectivity.
5. Maintenance
Regular maintenance ensures the longevity and efficient operation of your charge controller.
- Cleaning: Periodically clean the exterior of the controller with a dry, soft cloth. Ensure ventilation openings and the cooling fan are free from dust and debris.
- Fan Operation: The internal cooling fan activates when the internal temperature exceeds 45℃ and turns off when it drops below 40℃. Ensure the fan is not obstructed.
- Connection Checks: Annually inspect all wiring connections for tightness and corrosion. Re-tighten if necessary.
- System Monitoring: Regularly monitor the LCD display and the mobile application for any unusual readings or error messages.
6. Troubleshooting
This section addresses common issues you might encounter with your MPPT charge controller.
| Problem | Possible Cause | Solution |
|---|---|---|
| Controller not powering on | No battery connection or reversed polarity; Battery voltage too low. | Check battery connections and polarity. Ensure battery voltage is within operating range. |
| No charging current | No solar input; Reversed solar polarity; Solar panel voltage too low/high; Overcast weather. | Check solar panel connections and polarity. Verify solar panel Voc is within specified range (20V-80V for 12V, 37V-105V for 24V, 72V-160V for 48V). |
| Inaccurate battery voltage reading | Calibration required; Loose battery connections. | Perform battery voltage calibration through the controller's menu. Check and tighten battery terminal connections. |
| Wi-Fi connection issues | Incorrect password; App issues; Interference. | Ensure correct Wi-Fi password ('88888888'). Restart the app and controller. Try connecting with another Android device. |
| Overheating / Fan constantly running | Insufficient ventilation; Excessive load; High ambient temperature. | Ensure proper airflow around the unit. Reduce load if possible. Check ambient temperature. |
6.1 Protection Features
The controller is equipped with several protection mechanisms:
- Limited Current Protection: Limits output current to 42A.
- Temperature Protection: Shuts down if internal temperature exceeds 75℃.
- Overcharging Protection Voltage: Prevents overcharging at 15V (12V battery), 30V (24V battery), and 60V (48V battery).
7. Specifications
| Feature | Specification |
|---|---|
| Model Number | 40A-V119 |
| Brand | MakeSkyBlue |
| Maximum PV Array Power (12V Battery) | ≤ 480W |
| Maximum PV Array Power (24V Battery) | ≤ 960W |
| Maximum PV Array Power (48V Battery) | ≤ 1700W |
| PV Array Open Circuit Voltage (12V Battery) | 20V-80V |
| PV Array Open Circuit Voltage (24V Battery) | 37V-105V |
| PV Array Open Circuit Voltage (48V Battery) | 72V-160V |
| Limited Current Protection | 42A |
| Temperature Protection | >75℃ |
| Fan-on Temperature | >45℃ |
| Fan-off Temperature | <40℃ |
| Overcharging Protection Voltage (12V) | 15V |
| Overcharging Protection Voltage (24V) | 30V |
| Overcharging Protection Voltage (48V) | 60V |
| Product Dimensions | 8.46 x 1.97 x 4.53 inches |
| Item Weight | 2.52 pounds |
| Display Type | LCD |
| Operating Temperature | Up to 55 Degrees Celsius |
8. Warranty Information
MakeSkyBlue products are manufactured to high-quality standards. For specific warranty terms and conditions, please refer to the warranty card included with your product or contact MakeSkyBlue customer support. Keep your purchase receipt as proof of purchase for any warranty claims.
9. Support
For further assistance, technical support, or inquiries, please contact MakeSkyBlue customer service. You may also find additional resources and FAQs on the official MakeSkyBlue website.
A digital version of this user manual is available for download: User Manual (PDF)
