DG Synchronization Panel Manufacturer in Coimbatore, Tamil Nadu
Akshayam Controls & Automation manufactures DG synchronization panels for installations running more than one diesel generator. The same sync panel goes by several names: generator synchronization panel, generator sync panel, DG sync panel or load sharing panel.
Each generator sync panel is built to the DG sets it serves. Paralleling is through motorised air circuit breakers sized to the individual set rating, with a synchronizing controller — Deep Sea Electronics (DSE), Woodward EasyGen or ComAp — governing speed and excitation to bring the incoming machine into step. Protection covers reverse power, over and under voltage, over and under frequency and overcurrent, with breaker interlocking that prevents an out-of-sync closure.
Panels leave our Peelamedu works for sites in Coimbatore, Tiruppur, Erode, Salem, Karur, Madurai and Trichy, and for installations in Bengaluru, Kochi and elsewhere in South India. DG synchronization is rarely bought alone — most systems are supplied with AMF / ATS panels for the grid changeover and PCC panels for downstream distribution.
What is a DG Synchronization Panel?
A DG synchronization panel is a control switchboard that lets two or more diesel generator sets run in parallel on a common busbar and share the site load between them.
DG Paralleling & Synchronization Process Flow
- Voltage Matching: generator output voltage must match the busbar voltage.
- Frequency Matching: the running speed of the incoming engine must match system frequency.
- Phase Sequence: the rotational sequence of the three phases must be identical.
- Phase Angle: the phase angle difference must be minimal before the breaker closes.
Only when the controller confirms all four does the incoming generator's breaker close. Getting this wrong is not a nuisance fault — closing out of step can wreck an alternator and its coupling in a fraction of a second.
How Does a DG Synchronization System Work?
DG Start
Standby sets are started on demand, or on a load threshold set in the controller.
Tracking
The system monitors incoming generator voltage, frequency and phase against the live bus.
Match
The controller trims governor speed and AVR excitation until all four conditions are met.
Close Breaker
The breaker closes within the permitted phase window, bringing the set onto the bus.
Load Share
Running sets take load in proportion to their capacity, and hold that balance as demand moves.
Key Features of Our DG Synchronization Panels
Automatic Synchronization
The controller adjusts governor speed and AVR excitation to bring each incoming set into step without operator intervention.
Proportional Load Sharing
Active (kW) and reactive (kVAR) load distributed in proportion to each set's capacity, so no machine carries more than its share.
Load-Dependent Start / Stop
Sets brought on as demand rises and shut down as it falls, avoiding long periods of inefficient low-load running.
Generator Sequencing
Priority and duty rotation configurable, so running hours stay balanced across the fleet.
Breaker Interlocking
Motorised ACBs interlocked so no breaker can close outside the synchronizing window.
Full Parameter Metering
kW, power factor, voltage, frequency, current and sync-scope readings live on the panel front.
DG Synchronization Panel Applications
Multi-generator systems turn up wherever a single set would be either too small or too wasteful:
Textile Industries
Continuous backup for weaving, looms and processing lines where a stop costs a shift.
Engineering Industries
Parallel capacity to absorb the starting currents of large machines without dipping the bus.
Manufacturing Plants
Generation matched to how many lines are actually running that day.
Commercial Infrastructure
Malls, software parks and office towers with large, variable standby demand.
Water Treatment Plants
High-HP pump stations kept in service through extended grid outages.
Data Centres
Coordinated standby generation supporting continuous uptime.
Industrial Applications of DG Synchronization Systems
Four situations account for most of the DG set synchronization work we do:
Multiple Generator Systems
Any installation where two or more sets have to run as one coordinated supply.
Industrial Plants
Generation planned around production and utility load profiles rather than peak demand alone.
Textile Industries
Paralleling systems sized for the sustained standby demand of a spinning or processing mill.
Variable Load Applications
Running capacity matched to a load that moves through the day, instead of one large set at part load.
Benefits of Generator Synchronization Systems
- Two or more DG sets operating as one coordinated supply
- Automatic load sharing keeps any single set from being overloaded
- Capacity matched to demand rather than sized for the peak
- Sequencing balances running hours across the fleet
- Flexible response to a load profile that changes through the day
- Less low-load running, which is where engines wear and waste fuel
- Centralised monitoring and fault tracking for all sets
- Automatic synchronizing removes the risk of a manual mis-close
- Capacity can be scaled later by adding a set to the bus
- Protection relays cover reverse power and out-of-limit conditions
Our DG Synchronization Panel Engineering & Manufacturing Process
DG & Load Study
Generator ratings, number of sets, governor and AVR types, load profile, operating strategy and system architecture.
Sync Strategy
Synchronizing method, load sharing scheme, start and stop thresholds, sequencing priority and control philosophy.
Electrical Design
Panel architecture, busbar, breaker control, protection, metering, controller selection and interlocking, drawn for approval.
Panel Manufacturing
Enclosure, busbar, ACB mounting and wiring built to the approved drawing, with control and power wiring segregated.
Inspection & Testing
Wiring checks, interlock verification, controller configuration, protection settings and simulated sync testing before dispatch.
Delivery & Support
Dispatched with drawings, controller settings and documentation, plus on-site commissioning alongside your generator engineers.
DG Synchronization & Automatic Power Management
On most sites the sync panel is one layer of a larger backup system, and the layers have to be designed together:
Integrated Power System Layout
Automatic Generator Load Sharing
Load sharing works through the same two controls used to synchronize: governor speed sets how much active power (kW) a machine takes, and AVR excitation sets its share of the reactive power (kVAR). The controller trims both continuously across every running set.
Done properly this prevents the three failures that follow bad load sharing — one set carrying the plant while another idles, reverse power trips when a machine is pushed below zero load, and over-excitation on the set carrying all the reactive demand. Each generator instead takes load in proportion to its own capacity.
Why Choose Akshayam Controls for DG Synchronization Panels?
Built Around Your Generators
Configuration set by DG ratings, governor and AVR types and the operating strategy you want, not by a standard template.
Coimbatore-Based Manufacturer
Built at our Peelamedu works, with design reviews you can attend and support across Tamil Nadu.
Controllers We Actually Commission
Deep Sea Electronics (DSE), Woodward EasyGen and ComAp — configured and tested here, not just bought in and wired up.
Protection and Interlocking Taken Seriously
Reverse power, over and under voltage and frequency, and breaker interlocking sized and set properly. This is the part of a sync panel that has to be right.
Integration With the Wider System
Sync panels tied into AMF / ATS changeover, PCC distribution, and PLC or SCADA monitoring where required.
Support Through Commissioning
From load study and sync strategy to manufacturing, testing, delivery and on-site commissioning with your generator supplier.
DG Synchronization Panel Specifications
| Parameter | Specification Details |
|---|---|
| Panel Type | DG Synchronization Panel / Generator Load Sharing Panel |
| Application | Generator synchronization and automatic load sharing |
| Number of DG Sets | 2 to 8 sets on a common bus |
| Generator Rating | 15 kVA to 3000 kVA (As per project requirement) |
| Bus Voltage | 415 V ± 10%, 3-phase, 4-wire, 50 Hz |
| Synchronization | Automatic, with manual synchronizing facility |
| Load Sharing | Active (kW) and reactive (kVAR), proportional to set capacity |
| Synchronizing Controller | Deep Sea Electronics (DSE), Woodward EasyGen or ComAp |
| Breaker Control | Motorised air circuit breakers (ACBs), or MCCBs on smaller sets |
| Monitoring | Voltage, frequency, phase angle, current and sync-scope |
| Protection | Reverse power, over / under voltage, over / under frequency, overcurrent |
| AMF Integration | Available, for automatic grid failure start and changeover |
| Metering | Digital multi-function meters |
| Communication | Modbus RTU / Modbus TCP / Profinet / Ethernet |
| Control Voltage | 12 V DC / 24 V DC (generator battery), 230 V AC panel supply |
| Cable Entry | Top or bottom |
| Testing | FAT, insulation resistance test, interlock verification and simulated synchronization testing |
DG Synchronization Panel Manufacturer Serving Coimbatore & Tamil Nadu
Generator paralleling work comes to us from mills, commercial complexes, treatment plants and data facilities — anywhere a single set would be too small or would spend its life at part load. Coimbatore, Tiruppur, Erode, Salem, Karur, Madurai and Trichy make up most of it, with further installations in Bengaluru and Karnataka, Kochi and Kerala, and across South India. Send your DG ratings, governor and AVR details and we will propose a sync strategy before quoting.
Frequently Asked Questions About DG Synchronization Panels
What is a DG synchronization panel?
A DG synchronization panel is a control switchboard that parallels two or more diesel generator sets onto a common busbar so they share the site load. It is also called a generator synchronization panel, a generator sync panel or a load sharing panel.
Why are diesel generators synchronized?
Because one large set running at 30% load burns fuel inefficiently and wears badly, while two smaller sets can run at sensible loading and give you redundancy. DG set synchronization also lets capacity be added later without replacing what you have.
Which synchronizing controllers do you use?
Deep Sea Electronics (DSE), Woodward EasyGen and ComAp. If your existing sets already run one of these, we build to match so your engineers keep working with a familiar interface.
Can two or more DG sets operate in parallel?
Yes, provided voltage rating, phase sequence, governor characteristics and AVR type are compatible. Send us the make, model, governor and AVR details of each set and we will confirm before quoting.
What parameters are checked during generator synchronization?
Four: voltage level, frequency, phase sequence and phase angle. All four must match the running bus within the controller's window before the breaker is allowed to close.
What is generator load sharing?
Load sharing trims governor speed and AVR excitation so active (kW) and reactive (kVAR) demand is split between running sets in proportion to their capacity, rather than one machine taking most of it.
Can DG synchronization panels be customised?
Yes. Number of sets, breaker ratings, controller type, protection settings, sequencing strategy, metering and communication are all built to your system.
Can DG synchronization be integrated with AMF / ATS systems?
Yes, and most installations need it. The AMF logic starts the sets on grid failure, the sync controller parallels them, and the changeover transfers the load. We build both, so the two are designed together rather than bolted on.
Can generators start and stop automatically with load demand?
Yes. Load-dependent start and stop is configurable — when running sets pass a set threshold, say 80% of capacity, the next set starts, synchronizes and parallels. As load falls, the surplus set is unloaded, opened and run through its cool-down.
Can solar be synchronized with a DG set?
Yes, and it is an increasingly common requirement in Tamil Nadu. Strictly it is parallel operation rather than synchronization in the classic sense: the solar inverters run alongside the generator, and the controller has to hold the DG above its minimum loading — usually around 30 to 40 percent — so the engine is never pushed towards reverse power by solar output. That calls for reverse power protection, export limiting and PV ramp-rate control, all coordinated between the sync panel and the inverter. Send us your PV capacity, inverter make and DG ratings and we will confirm what the site needs.
Do you manufacture DG synchronization panels in Coimbatore?
Yes. Design, assembly, wiring, controller configuration and simulated sync testing are all carried out at our works in Gandhi Maa Nagar, Peelamedu, Coimbatore, Tamil Nadu.
How can I request a DG synchronization panel quotation?
Send generator ratings, governor details, AVR models, the number of sets and a single-line diagram to sales@akshayamcontrols.co.in, use the enquiry form on this page, or call our engineers on +91 89403 32552.
Need a DG Synchronization Panel for Your Generator System?
Tell us how many sets you run, their ratings and their governor and AVR types. Our engineers will propose the synchronizing and load sharing strategy, size the breakers, and quote a panel built for your installation.
Phone: +91 89403 32552
Email: sales@akshayamcontrols.co.in