DG Synchronisation
Automatic synchronisation and load sharing for multiple diesel generator sets
A DG synchronisation system that automatically parallels multiple diesel generator sets onto a common busbar, shares load between them and monitors every set for data centres, utilities and industrial sites.
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What the system does
When several DG sets supply one site, they must match voltage, frequency and phase angle before closing onto a common busbar, and then share the load evenly. Done manually or poorly, synchronisation causes trips at the worst possible moment.
We design and build synchronising panels with one controller per DG set, individual ACBs, a main ACB, emergency stop and a common busbar. A documented example configuration is 4 × 500 kVA DG sets with isolator panels and a synchronising panel.
The system synchronises automatically on dead bus or live bus, shares kW and kVA load, and logs events and data for review.
- 01
Automatic synchronisation
Matches voltage, frequency and phase angle before closing each DG set onto the common busbar.
- 02
Dead bus and live bus synchronisation
Handles both the first set closing onto a dead bus and subsequent sets synchronising to a live bus.
- 03
Load sharing
Automatic sharing of kW, kVA and power factor between running sets so no set is overloaded.
- 04
Manual and auto modes
Operators can run the system automatically or take manual control for testing and maintenance.
- 05
HMI, alarms and logging
HMI with status and trending, real-time alarms, and event and data logging for every DG set.
- 06
Communication
Modbus and Ethernet communication to BMS, EPMS or centralised monitoring.
Across the automation layers
What the solution does at each layer of your facility.
L1 · Field
Connects DG sets, ACBs, isolators and busbar metering through control and power cabling.
L2 · Control
Provides the synchronising panel with one controller per DG set, individual ACBs, main ACB and emergency stop.
L3 · Supervision
Shows DG status, load sharing, alarms and trends on the panel HMI and on SCADA.
L4 · Enterprise
Feeds event logs and running data into EPMS and fuel consumption reports.
Scope and specification
| Item | Detail |
|---|---|
| Example configuration | 4 × 500 kVA DG sets with isolator panels and a synchronising panel |
| Controllers | One synchronising controller per DG set |
| Switchgear | Individual ACB per DG set, main ACB, common busbar, emergency stop |
| Synchronising parameters | Voltage, frequency, phase angle |
| Load sharing | kW, kVA and power factor |
| Synchronisation modes | Dead bus and live bus |
| Operation | Auto and manual modes |
| Monitoring | HMI status and trending, real-time alarms, event and data logging |
| Communication | Modbus, Ethernet |
What it means for operations
Sectors served
- Smooth power transitionSets close onto the busbar in a controlled sequence, avoiding trips during an outage.
- Balanced loading and fuel useAutomatic load sharing keeps sets in their efficient range and optimises fuel consumption.
- Redundancy built inParallel operation means the loss of one set does not mean the loss of supply when capacity allows.
- ScalableAdditional DG sets can be added to the common busbar as the site grows.
Frequently asked questions
How many DG sets can be synchronised?
The design is scalable, with one controller per DG set. A documented example is 4 × 500 kVA sets; the number and rating for your site are set during design based on load and redundancy requirements.
Can you synchronise DG sets from different manufacturers or ratings?
This is assessed case by case during design, based on the governor and AVR interfaces of each set. We confirm compatibility in the requirement study before committing to a configuration.
Is the panel tested before delivery?
Yes. Panels are built and tested in our manufacturing units and offered for factory acceptance testing before dispatch, then commissioned on site with the DG sets.
Does it link to our fuel and power monitoring?
Yes. The synchronising panel communicates over Modbus and Ethernet with EPMS, HSD automation and centralised monitoring, so DG status, load and fuel are seen together.
Let’s start by understanding your facility
Send us a short description of the site and its current systems, and an engineer will come back with clear next steps.