Home Bargains Warrington
Project Overview
Genfit recently completed its largest solar installation to date at the TJ Morris (Home Bargains) Regional Distribution Centre at Omega Business Park in Warrington.
The project involved the installation of a 5.12 MWp rooftop solar PV system, designed to generate clean electricity directly on-site to support the significant energy demands of the large-scale logistics and warehouse operation.
With 10,349 solar panels installed across the rooftop, the system transforms previously unused roof space into a major renewable energy asset. The installation will generate over 4.16 GWh of renewable electricity each year, helping to power the distribution centre while reducing reliance on grid electricity.
The system will save approximately 805 tonnes of CO₂ emissions annually, equivalent to planting 36,975 trees, making a significant contribution towards reducing the environmental impact of the facility.
Project Details
System Design & Technology
The installation utilises a SolarEdge commercial PV System, chosen for its advanced monitoring cababilities, enhanced safety features, and ability to maximise energy generation across large commercial rooftops.
30 SolarEdge inverters and 5,186 power optimisers rnsure each section of the array operates efficienctly
Maximum achieved AC power of 3 MW, efficiently converting dolar energy into usable electricity for the building.
Advanced monitoring platform provides real-time performance data and system insights.
Enhanced safety features including module-level monitoring and automatic voltage reduction
DMEGC Magnetic Co. Ltd., DM500M10RT-B60HBB x 10349
- Bifacial Design: Up to 25% higher energy output with dual-sided glass.
- Glass / glass: Class A fire rating
- Excellent Low Light Performance: Generates power even in low light
conditions. - Superior Temperature Coefficient: High efficiency in hot and sunny
environments. - 25-Year Warranty: Peace of mind with a comprehensive 25-year warranty.
- Peak Power Warranty: 30 years linear power output guarantee.
- ISO & TÜV Certified: Industry-leading certifications for quality and reliability.
Module Specifications:
- Max Efficiency: 22.2%
- Weight: 26.8kg
- Dimensions: 1950mm x 1134mm x 30mm
Solaredge SE100K Inverter x 30
- Manufacturer’s Warranty: 12 years standard, can be extended to 20 years
(price for warranty extension available upon request) - Easy 2-person installation with lightweight, modular design (each inverter
consists of 2 or 3 Synergy Units and one Synergy Manager). - Independent operation of each Synergy Unit enables higher uptime and easy
serviceability. - Built-in thermal sensors detect faulty wiring ensuring enhanced protection and
safety. - Built-in arc fault protection and optional rapid shutdown (depending on
Synergy Manager used) - Built-in PID mitigation for maximized system performance.
- Monitored and field-replaceable surge protection devices: integrated RS485
and Type 2 DC SPDs, optional Type 2 AC SPD. - Integrated DC safety switch eliminates the need for external DC isolators.
- DC Fuses (Single Pole) 25A, optional required for more than 3 strings only
Specifications:
- Euro Efficiency: 98%
- Weight: 114kg
- Dimensions (H x W x D): 1168mm x 1008mm x 272mm
Solaredge S1000 x 5186
- Manufacturer’s Warranty: 25 years
- Specifically designed to work with SolarEdge Commercial inverters
- Mitigates all types of module mismatch loss, from manufacturing tolerance to partial shading
- Faster installations with simplified cable management and easy assembly
using a single bolt - Detects abnormal PV connector behavior, preventing potential safety issues
- Module-level voltage shutdown for installer and firefighter safety
- Flexible system design for maximum space utilization
- Compatible with bifacial PV modules
- Superior efficiency (99.5%)
Project Planning & Preparation
Delivering this 5.12 MWp solar installation required extensive planning, design coordination, and safety management while keeping the distribution centre fully operational throughout the 20-week build programme. Genfit acted as both Principal Contractor and Principal Designer under CDM regulations.
Planning & Safety
20-week programme
Principal Contractor & Designer
Full CDM compliance
Safety Management
Permanent edge protection
Skylight fall protection
Detailed risk assessments
Engineering
Structural loading analysis
Kingspan-approved mounting
Grid connection coordination
Delivery
Crane logistics planning
Minimal operational disruption
Full commissioning & testing
Environmental Impact
- 805 Tonnes CO₂ Emissions Avoided
- 36,975 Equivalent Environmental Benefit
Installation & Description of Works
A 5.12 MWp rooftop solar PV system designed, installed and commissioned while the distribution centre remained fully operational. The system integrates with the site’s electrical infrastructure, monitoring platform and grid compliance controls.
Solar PV Array
DMEGC modules installed across the rooftop using Kingspan PowerRail.
Electrical Infrastructure
New DC/AC cabling, LV panel upgrades and custom DC combination boxes.
Monitoring & Safety
Real-time monitoring, export limitation and fire alarm inverter shutdown integration.
Testing & Compliance
Full commissioning to BS 7671, CDM 2015, G99, G100 and DNO requirements.
View Technical Details
System Overview
The project involved the design, supply, installation, and commissioning of a large-scale rooftop solar PV system, integrated into the client’s existing low-voltage electrical infrastructure and site-wide monitoring systems. The installation forms part of the site’s wider energy strategy, enabling renewable electricity generation while maintaining full compliance with UK grid connection and safety regulations.
Solar PV Array Installation
A total of 9,456 Hengdian Group DMEGC DM500M10RT-B60HBB photovoltaic modules were installed across the rooftop. The modules were mounted using the Kingspan PowerRail RW mounting system, specifically designed for installation on Kingspan KS1000RW roof cladding. The system was installed in accordance with manufacturer specifications and structural requirements to ensure long-term reliability while maintaining the integrity of the roof structure. To maximise performance and monitoring capabilities, 4,736 SolarEdge S1000 optimisers were installed in a 2:1 module configuration, providing module-level monitoring and improved overall system performance.
Inverter Installation
The system incorporates 27 SolarEdge SE100K three-phase inverters, which convert the DC electricity generated by the solar panels into usable AC power for the building. The inverters were installed on bespoke Unistrut support frameworks, designed and constructed specifically for the project to safely house the inverter equipment and associated low-voltage infrastructure.
DC & AC Cabling Infrastructure
A comprehensive DC and AC cabling system was installed to connect the solar array to the inverter infrastructure and main electrical distribution points.
Key elements included:
DC cabling installed within stairwells using cable ladder systems with protective lids Pemsa Metatray cable containment installed at roof level to provide UV protection and mechanical support for exposed DC cabling Custom DC combination boxes installed at roof level and at inverter locations These combination boxes allow multiple PV strings to be combined into larger DC circuits for transmission back to the inverter locations, where they are then segregated and terminated safely.
LV Infrastructure & Grid Compliance
The installation required upgrades to the site’s existing low-voltage infrastructure to accommodate the new solar generation capacity. This included the installation of five new LV panels incorporating integrated G99 protection relays, ensuring compliance with UK grid connection regulations. Existing LV panels were also upgraded by specialist contractors, including enhancements to copper busbars to safely accommodate the additional PV circuits.
Monitoring & Export Limitation
The solar PV system has been integrated with the site’s existing Argand monitoring system, which manages system performance and export limitation across the facility. The Argand system interfaces with the client’s existing fibre network infrastructure, enabling real-time monitoring and data reporting. To ensure compliance with G100 export limitation requirements, the monitoring system actively controls the amount of electricity exported to the grid. For additional safety, the Argand system is integrated with the building’s fire alarm system. In the event of a fire alarm activation, a relay signal automatically shuts down all PV inverters. Network cabling to each inverter was installed by specialist contractors to allow full remote monitoring and system management.
Firestopping & Weatherproofing All new building penetrations created during the installation were fire-stopped in accordance with regulatory requirements. Bespoke weather cowls were fabricated using matching cladding materials, ensuring the building envelope remained fully weatherproof while maintaining the appearance and integrity of the roof structure.
Commissioning & Testing
Following installation, the system underwent full inspection, testing, and commissioning in accordance with BS 7671 wiring regulations, DNO requirements, and manufacturer specifications.
Commissioning activities included:
Mechanical and electrical installation inspections DC string polarity and continuity testing Insulation resistance testing of DC circuits Verification of optimiser pairing and communication Inverter configuration and firmware validation Functional testing of G99 protection relays G100 export limitation testing Fire alarm inverter shutdown verification Monitoring system communication checks
All commissioning results and documentation were included within the final project handover pack. Health & Safety & CDM Compliance The project was delivered in full compliance with the Construction (Design and Management) Regulations 2015 (CDM 2015). A detailed Construction Phase Plan (CPP) was developed prior to works commencing, supported by comprehensive risk assessments and method statements (RAMS).
Key safety measures included:
Site inductions and controlled access procedures Work-at-height safety controls and rescue planning Temporary works assessments for bespoke frameworks Crane lifting plans and controlled lifting operations Fire safety planning and emergency procedures All operatives involved in the project were appropriately trained and competent for the tasks undertaken. Quality control inspections were carried out throughout the installation to ensure compliance with design specifications, statutory requirements, and health and safety standards.
Delivering a project of this scale for TJ Morris / Home Bargains is something we’re extremely proud of. A 5MW rooftop solar installation requires careful planning, strong coordination and technical delivery from the whole team. It’s a great example of how large commercial buildings can use their roof space to generate clean energy and make a real impact on carbon emissions.
– Dave Houston
Director, Genfit
