The single panel and 20 amp should serve you well. #10 and #6 wire would also be fine if the terminals limit the size.
Specs on the 20a says 260w... 30a says 390w max for.... 40 amp 520w....
I would not exceed these specs as it does not state if the power level is self restricted.
Probably stay with single 250w panel and 20a controller. If it proves inadequate just get a second system next summer.
Yes those Costco GC2 are 207s. With conservation you might not even need solar and with solar you will be much more relaxed with power usage.