Grape Solar GS-540-KIT Assembly instructions

www.GrapeSolar.com
Tel. [phone] (toll free), 1-541-349-9000 Document Version 20190316
©Copyright 2019, Grape Solar, Inc. All Rights Reserved
540 Watt Off-Grid Charging Kit
(GS-540-KIT)
Quick Connect Guide
IMPORTANT: Please read GS-PWM-COMET-40 charge
controller owner’s manual and GS-STAR-180W Connection
Guide (included with products) before assembling kit.
For additional information about Grape Solar products:
email [e-mail], or
call 1-877-264-1014 for live telephone support.
GS-540-KIT PHOTOVOLTAIC
POWER GENERATION SYSTEM
QUICK CONNECT GUIDE REV. 190316
1Check your order to make sure that all parts are included:
 GS-PWM-Comet40 Charge Controller
 3x 10-Amp MC4 In-Line Fuse
 2x MC4 Branch Connector Set
 3x GS- STAR-180W Solar Panel
 5-ft. Red/Black 10 AWG Cable Pair
 2x 15-ft. MC4 Cable
 6-in. Red/Black MC4-to-Bare Wire Pair
Additional tools and equipment you will need:
◦Screwdriver– Philips Head
◦12-Volt Deep-Cycle Battery Bank ◦Voltmeter (for Troubleshooting)

x3

x2
x2


x3

To estimate how much average monthly
power this system should produce in your
area, please use the PV Watts Calculator
found at:
https://pvwatts.nrel.gov/
This System Size= 0.54 kW DC
(only applicable for zip codes in the U.S.A.) [The Quick Connect Guide
diagrams are not to scale.]


www.GrapeSolar.com
Tel. [phone] (toll free), 1-541-349-9000
Document Version 20190316
©Copyright 2019, Grape Solar, Inc. All Rights Reserved
GS-540-KIT PHOTOVOLTAIC
POWER GENERATION SYSTEM
QUICK CONNECT GUIDE Rev. 190316
4Branch connector sets  are typically clipped
together when shipped. Unclip the branch
connectors until there are 4 separate units.
Connect one branch connector  with the
“female” output to the “male” end of a 15-ft.
MC4 cable . Connect an additional “female”
output branch connector  to the attached
branch connector.
With the other 15-ft MC4 cable , connect one
branch connector  with the “male” output to the
“female” end of the cable. Connect an additional
“male” output branch connector  to the attached
branch connector.
Now, attach an in-line fuse  to each of the “female”
inputs.
5
Mount the 180-watt solar panels  so that they are facing due South at approximately the same angle as your
latitude. The ideal area has full sun and no shading. If the following connections are made during daylight, cover
the panels with cardboard, cloth, or a similar opaque material so that the panel does not output power.
Connect the bare wire end of the 10 AWG (thinner) red
battery cable  to the (+) battery terminal on the bottom
of the Comet40 charge controller . Connect the bare
wire end of the 10 AWG (thinner) black cable  to the
(-) battery terminal. A Phillips head screwdriver can be
used to loosen and tighten the screw clamps onto the
wires.
Attach the ring lug end of the red cable  to the positive
terminal of a 12V deep cycle battery. Attach the ring lug
end of the black cables  to the negative terminal of the
battery.
The charge controller  display screen will be visible if
the battery has sufficient charge. If the display screen is
not visible, the battery must be charged from an another
source before processing solar power. The charge con-
troller, which regulates solar power flow to the battery, is
powered by the battery.
2
3
 

*12V deep cycle battery
is not included with kit
 




input side
output side
 


6
GS-540-KIT PHOTOVOLTAIC
POWER GENERATION SYSTEM
QUICK CONNECT GUIDE Rev. 190316
www.GrapeSolar.com
Tel. [phone] (toll free), 1-541-349-9000
Document Version 20190316
©Copyright 2019, Grape Solar, Inc. All Rights Reserved
Connect each positive solar panel  cable to
one of the “female” fuse  ends from the
previous connections.
Connect the negative panel cables to the
“male” branch  connector ends .
Attach the bare-wire ends of the MC4-to-Bare
Wire pair  to the charge controller . The red
wire connects to the (+) input and the black wire
connects to the (-) input.
Remove the panel covering. In good sunlight, the
charge controller’s  ”BAT %” should increase to
100%. When the controller is set to “LOAD ON,”
the system will provide power through the load
control output or through the USB port.
7
9



Connect the 15-ft MC4 cables  to the compatible
charge controller MC4 cables .
8








DISCLAIMER:
Installations of this kit could be subject to national and local building and electrical codes. Installers should have adequate knowledge of
national and local code to ensure the installation passes inspection by the local electric authority.
Proper fuses or breakers should be used to comply with all local and national codes. Contact Grape Solar for specific recommendations.
All batteries used for this system should be identical. Do not mix battery types or sizes. Do not mix old batteries with new batteries.
Performance and charging anomalies can occur if types, sizes, or age of batteries are not identical.
Grape Solar does not warrant the accuracy, sufficiency, or suitability to all customers of any technical or other information provided in
product manuals. Grape Solar does not claim any responsibility or liability for losses, damages, costs or other expenses whether special,
indirect, consequential or incidental, which might arise out of the use of such information.
DISCLAIMER:
Installations of this kit could be subject to national and local building and electrical codes. Installers should have adequate knowledge of
national and local code to ensure the installation passes inspection by the local electric authority.
Proper fuses or breakers should be used to comply with all local and national codes. Contact Grape Solar for specific recommendations.
All batteries used for this system should be identical. Do not mix battery types or sizes. Do not mix old batteries with new batteries.
Performance and charging anomalies can occur if types, sizes, or age of batteries are not identical.
Grape Solar does not warrant the accuracy, sufficiency, or suitability to all customers of any technical or other information provided in
product manuals. Grape Solar does not claim any responsibility or liability for losses, damages, costs or other expenses whether special,
indirect, consequential or incidental, which might arise out of the use of such information.
www.GrapeSolar.com
Tel. [phone] (toll free), 1-541-349-9000
Document Version 20190316
©Copyright 2019, Grape Solar, Inc. All Rights Reserved
GS-540-KIT PHOTOVOLTAIC
POWER GENERATION SYSTEM
QUICK CONNECT GUIDE Rev. 190316
