Off-Grid Energy Resilience at Springville Foods, PA

A Community Grocery Store Trades Diesel for Clean, Reliable Power with Discover AES 210HV and Sol-Ark

Location: Eastern Lancaster County, Pennsylvania
Client: Springville Foods
Installer: CB Solar, LLC
Distributor and Technical Design Support: Zonna Energy
Storage System: Discover AES 210HV
Inverter Platform: Sol-Ark 60K-3P-480V (x2)
PV Array Size: 75 kW Ground Mount
Commissioned: April 2025

Project Overview

Set against the green farmland of Lancaster County, Springville Foods is now primarily powered by the sun and batteries. This image shows the store, PV array, and surrounding agricultural facilities that rely on resilient power.

Springville Foods is a full-service grocery store nestled in the heart of Pennsylvania Dutch country, serving a loyal base of Amish and rural customers since 2004. Like many businesses in remote or underserved areas, it historically depended on diesel generators to meet its energy needs, operating both a 100 kW primary and a 50 kW secondary generator. These units provided power to essential loads such as commercial coolers, freezers, HVAC, lighting, and point-of-sale systems. While reliable in principle, the diesel solution posed challenges: high fuel costs, regular maintenance requirements, and occasional load management limitations during peak usage.

In pursuit of sustainability, energy independence, and lower operating costs, the owners of Springville Foods partnered with CB Solar and Zonna Energy to transition to a modern hybrid power solution. The result is a clean, quiet, and efficient off-grid system powered primarily by solar and batteries, with diesel used only as a secondary backup.

Project Overview

CB Solar, Zonna, and Discover work on live commissioning of the AES 210HV cabinets and Sol-Ark 60K-3P inverters. Final performance checks on communication and closed-loop performance ensure a smooth transition to energy independence.

Discover’s AES 210HV high-voltage battery storage platform is the backbone of the new system. Two pre-assembled outdoor cabinets were installed, providing a total of 418 kWh of usable energy storage. These cabinets integrate seamlessly with two Sol-Ark 60K-3P commercial hybrid inverters, which deliver a combined 120 kW of continuous power output. A 75 kW photovoltaic array supplies renewable energy directly to the inverters and batteries.
 

The AES 210HV includes advanced thermal management via integrated liquid cooling and heating, built-in fire safety, thermal suppression (aerosol-based), and deflagration ventilation to meet UL9540 safety standards. Communication between the batteries and inverters is managed through the LYNK II Gateway, enabling real-time closed-loop control for optimized charging and discharging.

Key technical features of the system include:

• Storage Capacity: 418 kWh usable (two AES 210HV cabinets)
• Inverter Power: 120 kW continuous (two Sol-Ark 60K-3P inverters)
• Solar Capacity: 75 kW
• Grid Independence: Full off-grid operation with diesel generators now used only as backup
• Load Profile: Commercial refrigeration, HVAC, lighting, registers, and office equipment

Operational Benefits and Lessons for Off-Grid Designers

Two AES 210HV cabinets provide 418 kWh of high-voltage, liquid-cooled lithium storage. Prewired Sol-Ark inverters are wall-mounted next to the store's electrical room, allowing direct AC and DC integration.

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 Today, Springville Foods operates primarily on solar energy and battery power, with diesel backup used sparingly during extended cloudy periods or high-load events. The transition has delivered immediate benefits:

• Fuel savings: Dramatic reduction in diesel consumption and generator runtime
• Maintenance reduction: Fewer mechanical hours and service events for generator upkeep
• Quiet operation: A quieter, cleaner environment for staff and customers
• Load flexibility: Smoother delivery of power to compressors and HVAC systems, especially during peak load transitions
• Future scalability: The system architecture leaves room for adding more PV and storage

This use case highlights how modern hybrid battery solutions can replace legacy diesel generators in rural commercial settings where grid access is undesired, limited, or unreliable. Grocery stores are among the most demanding off-grid applications due to their continuous refrigeration loads and sensitivity to power outages. The combination of Discover’s storage, commercial hybrid inverters, and intelligent communication enables businesses like Springville Foods to operate independently without sacrificing reliability or customer service.

Key Takeaways for Future Projects

• Utility-grade performance at commercial scale: This project showcases how Discover Energy Systems is bridging the gap between industrial BESS solutions and commercial installer needs. By delivering utility-grade reliability, safety, and performance in a cost-effective, scalable package, Discover empowers C&I projects that were previously out of reach due to complexity or cost.
• Simple integration with hybrid inverters: Discover’s AES 210HV platform is purpose-built for compatibility with commercial hybrid inverters like the Sol-Ark 60K. Its plug-and-play DC and communication interfaces significantly reduce installation time, eliminate guesswork, and lower the barrier to entry for commercial solar installers entering energy storage.
• Standards-driven safety and resilience: UL 9540 Listed & UL 9540A Large Scale Fire Tested architecture, integrated aerosol fire suppression, passive deflagration venting, and a liquid thermal management system ensure that even demanding off-grid loads can be handled safely and dependably.
• System design matters: Pairing 418 kWh of usable storage with 120 kW of inverter capacity provided ample headroom for cold storage, air conditioning, and peak-hour loads. The system design ensures reduced generator runtime and flexible growth paths for future loads or PV expansion.
• Collaboration is critical: The success of this deployment is a testament to the alignment between technology providers, local installers, and technical distributors. CB Solar’s field execution, Zonna Energy’s system design expertise, and Discover’s product integration support combined to deliver a solution that exceeded customer expectations.

Installer and Partner Contributions

CB Solar of Gordonville, PA, played a central role in the success of this installation. With deep experience serving agricultural and commercial clients in Pennsylvania, the CB Solar team delivered a turnkey off-grid system that was expertly installed and commissioned to meet the unique needs of Springville Foods. Their familiarity with both rural power infrastructure and high-voltage storage integration allowed them to anticipate and mitigate challenges related to refrigeration loads and seasonal solar variability.

Equally vital was the contribution of Zonna Energy. As a specialized off-grid distributor with a long history of supporting battery-based projects across North America, Zonna provided detailed system design guidance and technical support throughout the planning and commissioning process. Their recommendation of the Discover AES 210HV platform was based not only on cost and performance but also on safety features, inverter compatibility, and long-term serviceability. Zonna’s ability to provide both logistics and hands-on guidance proved instrumental in ensuring this project met its ambitious energy goals without compromising reliability.

Interested in a Similar Solution?

Discover Energy Systems, CB Solar, and Zonna Energy are available to support off-grid and grid-independent projects across North America. If you are a business, farm, or institution exploring energy storage to eliminate or reduce diesel reliance, this project is a strong reference point for what’s possible today. Get in touch with us.