Commercial Battery Storage Installation in Cornwall

100kW / 215kWh Dyness System for Chapman Machinery near Bude

We have recently completed a large-scale commercial battery storage installation for Chapman Machinery, a manufacturing facility near Bude in Cornwall.

Following a successful competitive tender process, we were appointed to design and install a 100kW / 215kWh zero export battery storage system to integrate with the site’s existing 100kWp solar PV system.

The Project Overview

Client: Chapman Machinery
Location: Near Bude, Cornwall
Sector: Manufacturing
Existing Solar PV: 100kWp
Battery System Installed: Dyness DH200F 100kW / 215kWh All-in-One
Export Limitation: 70kW (G100 compliant)
Operation Mode: Zero export, solar self-use + off-peak grid charging

The facility already had a 100kWp solar array installed. However, without battery storage, excess solar generation was either exported at low rates or curtailed.

Our solution was to install a commercial energy storage system (BESS) that would:

• Store surplus solar generation during the day
• Charge overnight on cheaper off-peak tariffs
• Discharge during peak operating hours
• Operate within DNO export limitations
• Deliver zero export functionality

The result? Lower electricity bills, improved energy resilience, and maximum return from their existing solar investment.

The Battery System: Dyness DH200F 100kW / 215kWh

For this project, we selected the Dyness DH200F 100kW / 215kWh All-in-One commercial battery system.

This is a containerised, outdoor-rated commercial battery solution designed specifically for industrial and commercial applications.

Key System Specifications:

• 100kW three-phase inverter capacity
• 215kWh lithium battery storage
• Outdoor IP-rated cabinet
• Integrated cooling and fire protection
• G99 compliant
• Compatible with G100 export limitation schemes
• Suitable for peak shaving and time-of-use optimisation

The system integrates with the site’s existing SolarEdge 100kW inverter, with export limited to 70kW as per DNO requirements

Zero Export Commercial Battery Design

This installation required a carefully engineered zero export control strategy.

The site has:

• 100kW existing solar inverter
• 100kW battery inverter
• Aggregate generation capacity of 170kW
• Export limited to 70kW

As confirmed within the connection documentation, the system operates under G100 control to ensure export never exceeds the agreed threshold.

This type of configuration is becoming increasingly common across Cornwall and Devon, where grid capacity constraints limit export capability.

By implementing a properly designed commercial battery storage system, we allow:

• Solar energy to be captured rather than curtailed
• Manufacturing loads to be supported during peak hours
• Export compliance without expensive network upgrades

Installation & Engineering Team

The installation was delivered by our in-house commercial electrical team:

• Ben B – Electrical Manager
• Adam O – Lead Electrician
• Ben M – Electrical Apprentice

The project included:

• Three-phase cable installation
• CT positioning for export limitation
• Integration with existing distribution board
• Commissioning and compliance testing
• DNO coordination and documentation

How Commercial Battery Storage Benefits Manufacturers

For manufacturing businesses like Chapman Machinery, electricity usage often peaks during operational hours — exactly when energy tariffs are highest.

A properly designed commercial BESS system can:

1. Reduce Peak Demand Charges

Battery discharge during peak load periods reduces maximum demand.

2. Maximise Solar Self-Consumption

Rather than exporting at low SEG rates, solar is stored and reused.

3. Charge on Cheaper Tariffs

Off-peak charging enables energy arbitrage.

4. Improve Energy Resilience

Future-proofing against rising grid costs.

5. Support Net Zero Goals

Reduce carbon footprint without increasing infrastructure spend.

Commercial Battery Storage in Cornwall & Devon

Grid capacity across the South West is increasingly constrained.

Many commercial solar installations are now:

• Export limited
• Curtailed during peak generation
• Unable to expand without reinforcement costs

Battery storage solves this problem.

At GreenGenUK, we design and install:

• Commercial battery storage systems (50kW–1MW+)
• Zero export battery systems
• Solar + battery retrofits
• Peak shaving solutions
• Grid compliance (G99 / G100)
• Fully containerised BESS systems

We manage:

• DNO applications
• Connection agreements
• Protection studies
• Export limitation control
• Commissioning & monitoring

Is Commercial Battery Storage Right for Your Business?

If your business:

• Already has solar PV
• Is export limited
• Pays high peak electricity rates
• Has 3-phase supply
• Has consistent daily load

Then a commercial battery system could significantly reduce your operating costs.

We offer:

• Site surveys
• Load profile analysis
• Financial modelling
• ROI projections
• Tender submissions

Looking to Install Commercial Battery Storage in Cornwall or Devon?

GreenGenUK specialises in commercial solar and battery storage installations across Cornwall, Devon and the South West.

If you’re a manufacturer, industrial operator, farm, school, hotel or commercial premises looking to:

• Reduce energy bills
• Improve energy independence
• Install a zero export battery system
• Retrofit storage to existing solar

Get in touch with our sales team.

📞 01326 564513
🌐 www.greengenuk.com
📧 [email protected]