Grape Solar GS-MPPT-ZENITH Series User manual

Rev 2020.04.03 1
Grape Solar
GS-MPPT-ZENITH Series
Charge Controller
User Manual
*Grape Solar reserves the rights to modify these specifications without notice.

Rev 2020.04.03 2
1. Warnings and Tools Icon Chart
Icons
Name
Description
High Voltage
High voltage device.
Installation should be performed by an electrician.
High Temperature
This device will produce heat.
Mount device away from other items.
Environmental
Hazard
Electronic Equipment. Do not put in landfill.
Wire Cutter
A wire cutter is needed for cutting and stripping
wires prior to connection.
Multimeter
A multimeter is needed for testing equipment and
verifying polarity of cables.
Anti-static Glove
Anti-static gloves are recommended to prevent
controller damage caused by static electricity.
Electrical Tape
Electrical tape is recommended to safely insulate
spliced or bare wires.
Screwdriver
A common size screwdriver is needed to attach
wires to the controller.

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2. Safety Tips
Review this manual thoroughly before attempting installation.
Beware of any nearby electrical equipment that may interfere with installing this device.
Solar panels can generate high voltages and currents, make sure your solar panels are
completely covered from sunlight during installation. It is recommended that installation be
performed by an qualified electrician.
Connecting wires to this device can generate sparks, please wear proper insulation gear while
installing this device.
To avoid damage to the battery or controller, use proper fuses in wiring. Please do not hesitate to
contact Grape Solar should you need help with fuse sizing.
Always keep children away from this device.
Be certain to use the correct gauge of wire, see below for a table of recommended wire size for
various current loads.
Solar Input Current
5A
10A
20A
30A
40A
60A
Wire Cross Section Area (mm²)
1.5
2.5
5
8
10
12
Wire AWG
15
13
10
8
7
6

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3. Product Features
Thank you for choosing Grape Solar. This MPPT solar charge controller is a device for solar charge
regulation and direct current output load control. This device is mainly used in small and medium
sized off-grid solar power systems.
The Grape Solar Zenith series MPPT charge controllers have these features:
By continuously checking solar panel power output changes, the Zenith controllers employ
multiple MPPT charge algorithms in combination to boost charging efficiency in different
weather and temperature conditions.
Built-in buffer of 25% exceeding rated current input.
Charging modes available for most common deep-cycle battery types in the market, including
AGM (sealed lead acid batteries), GEL, Flooded, and Lithium. With the Grape Solar blue tooth
controller mobile phone application, additional setting parameters may be adjusted to meet the
needs of any other specialty batteries.
Automatic recognition of 12V/24V battery system by the GS-MPPT-ZENITH-40A model. Automatic
recognition of 12V/24V/36V/48V battery system by the GS-MPPT-ZENITH-60A model.
*Lithium-ion batteries excluded from this feature.
Supports recording of charging data including power generated and power utilized for up to
300 days, compatible with Grape Solar Blue-tooth Monitoring App through IOS and Android.
Provides multiple load control mode options for light based, time based and manually adjusted
scenarios. Low no-load loss.
Industrial grade design with reverse polarity protection for solar panels, battery and load.

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4. Device Diagram
GS-MPPT-ZENITH-40A & 60A
#
Description
#
Description
1
LCD Display Screen
6
DC Load Terminals
2
Function Key ([SET], [UP], [DOWN], [ESC])
7
RS485 Communication Port
3
External Temperature Sensor Terminal
8
LED Indicator (PV, BAT, LOAD, FAULT)
4
Solar Terminals
9
Installation Mounting Holes
5
Battery Terminals
1

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5. Mounting Instruction

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6. Wire Connection Sequences
During installation of your MPPT controller, please follow the order of connection below:
1. Connect the positive battery wire followed by the negative battery wire.
2. Make sure your solar panels are fully covered to prevent electrical shock.
Connect the positive solar array output wire followed by the negative solar array output wire.
3. Connect DC load wires to the DC load output (if applicable).
4. Connect the external temperature sensor to its terminal shown above.
5. Connect the mobile application module to the communication port (if applicable).

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7. LED Light Signal Interpretation Chart
LED Name
LED Display
Signal Indication
PV
Off
Solar Input Not Charging ○!
*PV LED is generally off during nighttime.
Double Flash
Solar Input Charge Detected
Single Flash
Solar Input Reverse Polarity ○!
Steady On
MPPT Charge Mode
Fast Flash
Equalize or Boost Charge Mode
Slow Flash
Float Mode
BATTERY
Single Flash
Battery Input Reverse Polarity ○!
Fast Flash
Battery Over Voltage ○ !
Slow Fast
Battery Over Discharged ○ !
Steady On
Battery On
LOAD
Off
No DC Load Connected/Load Off
Fast Flash
DC Load Short Circuit ○ !
Steady On
DC Load On
FAULT
Off
No Errors
Steady On
System Error – Check Error Code
○!Check the Fault light to spot if a system error may be present.

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8. LED Flash Rhythm Chart
Flash
Status
Indication
Description
Steady
On
On
Off
LED light on.
Off
On
Off
LED light off.
Fast
Flash
On
Off
LED light blinks at frequency of
2Hz (2 times in each 1 second).
Slow
Flash
On
Off
LED light blinks at frequency of
0.5Hz (1 time in each 2 seconds).
Single
Flash
On
Off
LED light blinks for 0.1 second
after every 2 seconds.
Double
Flash
On
Off
LED light blinks for 0.1 second
twice after every 4 seconds.

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9. LCD Display Interface Overview
10.LED Display Interface
Display Section
Display Layout
Charge Status
Charge Mode
&
Parameter
Active Functions

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11.Status Information
Status Icon
Indication
Status
Description
Solar Charge
Indication
Flowing
Solar Power Charging Battery
Off
Solar Power Not Charging Battery
DC Load
Indication
Flowing
DC Load Drawing Power
Off
DC Load Off
Charge Mode
Steady On
MPPT Charge Mode
Boost Charge Mode
Float Charge Mode
Off
Not Charging
Voltage
Setting
On
Setting Charge Voltage
Off
Charge Voltage Has Been Set
Over
Discharge
Volt Settings
On
Setting Discharge Voltage
Off
Discharge Voltage Has Been Set
Solar Icon
Steady On
Daylight Detected
Off
No Daylight Detected
Fast Flash
Solar System Over Voltage
Battery Icon
Steady On
Battery Connected and Functional
Off
No Battery Connection
Fast Flash
Battery Over-Discharged
Load Status
Flash
DC Load Short Circuit or Over-Load
ON
Load ON
OFF
Load Off

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12. Key Functionality Chart
Function Key
System Mode
Input
Input Function
View Mode
Short Press
Enter SET mode
View Mode
Short Press
View Previous Page
View Mode
Short Press
View Next Page
View Mode
Short Press
DC Load On/Off
(Manual Control Program Only)
Function
System Mode
Input
Input Function
Set Mode
Long Press
Save Data & Exit
Short Press
Next Setting
Set Mode
Short Press
Increase Parameter Value
Set Mode
Short Press
Decrease Parameter Value
Set Mode
Short Press
Exit from SET mode

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13. LED Display Rules & Cycles
Pre start-up display cycle when the MPPT controller turns on, this usually last several seconds while
controller detects operating environment.
LED Screen Display Cycle
The battery voltage view will be displayed by default. Use the up and down arrow keys to cycle
through different views. The battery voltage view will resume upon 12 seconds of inactivity.
The error code view will be displayed when an error is detected.

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Setting Battery Mode
Enter SET mode by pressing the Setting key in any view other than Load Mode.
Use the up and down arrow keys to select battery mode, then long press Setting key to save.
Abbreviations
Battery Types
Description
FLD
Flooded Battery
Auto-recognition with default parameters
set for each type of batteries.
SEL
Sealed/AGM Battery
GEL
Gel Battery
LI
Lithium Battery
Some parameters can be customized.
Use
Advanced User Mode
Most parameters can be customized.

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Advanced Battery Settings
In Lithium or User mode, short press the Setting key again to cycle through each parameter view.
Use the up and down arrow key to adjust parameter value, then long press Setting key to save.
For Battery Type: Li
For Battery Type: USER

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Advanced Battery Settings
Enter Load SET Mode by pressing the Setting key in Load Mode view only.
Use the arrow key to cycle through load modes before long pressing SET to save and exit. Short
pressing SET will exit without saving.
Mode
Definition
Description
0
Daylight Auto-Control
DC load turns on when daylight is detected.
1~14
Daylight On/Timer Off
DC load turns on when daylight is detected.
DC load turns off according to timer.
15
Manual Mode
DC load turns on/off by pressing the Return key.
16
Testing Mode
DC load turns on and off in a quick succession.
17
Always On
DC load stays on.

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14. Error Code Chart
Code
Error
Description & Quick Troubleshoot
E00
No error
No action needed.
E01
Battery
Over-discharged
Battery voltage is too low.
DC load will be turned off until battery re-charges to
recovery voltage.
E02
Battery
Over-voltage
Battery voltage has exceeded controller limit.
Check battery bank voltage for compatibility with
controller.
Disconnect controller if battery bank voltage meets
controller requirement, as the controller may be faulty.
E04
Load Short
Circuit
DC load wiring short circuit.
Check load output wire connection for reverse polarity, if
none found, consider possibility of short circuit issues
within the DC load application.
E05
Load Overload
DC load power draw exceeds controller capability.
Reduce load size or upgrade to a higher load capacity
controller.
E06
Overheating
Controller exceeds operating temperature limit.
Ensure the controller is placed in a well-ventilated cool,
dry place.
E08
Solar
Over-amperage
Solar array amperage exceeds controller rated input
amperage.
Decrease the amperage of solar panels connected to the
controller or upgrade to a higher rated controller.
E10
Solar
Over-voltage
Solar array voltage exceeds controller rated input voltage.
Decrease the voltage of solar panels connected to the
controller, this may involve re-wiring your solar panels into
a parallel connection array.
E13
Solar
Reverse Polarity
Solar array input wires connected with reverse polarity.
Disconnect and re-connect with correct wire polarity.
E14
Battery
Reverse Polarity
Battery connection wires connected with reverse polarity.
Disconnect and re-connect with correct wire polarity.
*Contact Grape Solar for live technical support on additional troubleshooting.

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Controller Specification
The variable “n” is adopted as a multiplying factor when calculating parameter voltages, the rule for
“n” is listed as: if battery system voltage is 12V, n=1; 24V, n=2; 36V, n=3; 48V, n=4.
For example, the equalize charge voltage for a 12V FLD (Flooded) battery bank is 14.8V*1=14.8V. The
equalizing charge voltage for a 24V FLD (Flooded) battery bank is 14.8V*2=29.6V.
Parameter
Value
Model No.
GS-MPPT-ZENITH-40BT
GS-MPPT-ZENITH-60BT
Battery System Voltage
12V/24V
Auto (FLD/GEL/SLD)
Manual (Li/User)
12V/24V/36V/48V
Auto (FLD/GEL/SLD)
Manual (Li/User)
No-load Loss
12ma (12V), 10ma (24V)
12ma (12V), 10ma (24V),
8ma (36V), 6ma (48V)
Max Solar Input Voltage
<100V
<150V
Rated Solar Charge Current
40A
60A
Max Solar Input Power
600W/12V
1200W/24V
900W/12V 1800W/24V
2600W/36V 3200W/48V
Light Control Voltage
5V*n
Light Control Delay Time
10s
Max Load Output Current
20A
Operating Temperature
-35ºC ~ +45ºC / -31ºF ~ +113ºF
IP Protection
IP32
IP32
Net Weight
2.0 kg / 4.4 lbs
3.0 kg / 6.6 lbs
Communication Port
RS485
Operating Altitude
≤ 3000 meters/ ≤ 9842 feet
Controller Dimension
245*180*82.5 mm / 9.7*7.1*3.3 inches
280*210*90 mm / 11*8.3*3.5 inches
Parameter
Battery Parameters
Battery Types
FLD
SEL
GEL
USER
LI
Equalize Charge Voltage
14.8V*n
14.6V*n
--
--
Boost Charge Voltage
14.6V*n
14.4V*n
14.2V*n
Default: 14.2V*n
Default: 14.4V*n
Float Charge Voltage
13.8V*n
Default: 14.2V*n
--
Boost Charge Recovery Voltage
13.2V*n
Default: 13.8V*n
--
Over-discharge Recovery Voltage
12.6V*n
Default: 12.6V*n
Default: 6V*n
Over-discharge Voltage
11.1V*n
Default: 11.1V*n
Default: 11.1V*n

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15. Product Dimension
GS-MPPT-ZENITH-40A
GS-MPPT-ZENITH-60A
Product Dimension: 245*180*82.5mm / 9.7*7.1*3.3 inches
Installation Area Dimension: 226*138mm / 8.9*5.4 inches
Installation Hole Size: φ5mm&φ10mm / φ0.2 inch &φ0.4 inch
Connection Socket Size: 7.5*7.5mm / 0.3*0.3 inch
Product Dimension: 280*210*90 mm / 11*8.3*3.5 inches
Installation Area Dimension: 256*154.5mm / 10*6 inches
Installation Hole Size: φ5mm&φ10mm / φ0.2 inch &φ0.4 inch
Connection Socket Size: 7.5*7.5mm / 0.3*0.3 inch