// projects / hmi
HMI SystemThe PLC monitors maximum demand in real time and automatically engages the right-sized generator — no manual intervention required.
HMI SCREEN — DUAL GENSET CHANGEOVER WITH MAX DEMAND CONTROL
// the_challenge
Facilities that operate two diesel generators of different capacities — a smaller unit for low-load periods and a larger one for peak hours — face a recurring operational challenge: someone must constantly watch the load and manually decide when to switch between gensets. Running the large generator at light load wastes fuel and increases wear. Switching too aggressively causes unnecessary start/stop cycles. Manual decisions introduce delays and human error.
Our Dual Genset Changeover Panel automates this decision completely. Current transformers continuously feed the facility's load current to the PLC, which calculates real-time maximum demand and compares it against configurable thresholds. When demand crosses the upper threshold, the PLC smoothly transfers load to the large genset; when it falls below the lower threshold with a user-defined time delay, it transfers back. All parameters — thresholds, delays, preferences — are configurable from the HMI without any PLC reprogramming.
// capabilities
Current transformers on each phase feed live current data to the PLC, which calculates kVA demand continuously and displays it on the HMI with a trend bar.
The PLC evaluates demand against the configured thresholds and initiates changeover with proper time delays — ensuring the incoming generator is stable before the outgoing one is released.
Upper and lower demand setpoints, changeover time delays and minimum run-time parameters are all adjustable from the HMI. No engineer or PLC programmer required for routine adjustments.
Operators can force either genset into service via the HMI at any time. The system acknowledges the override, holds the manual state and resumes automatic control when the operator releases it.
Every changeover event — automatic or manual — is logged with a timestamp, the demand reading at the time of changeover and the operator's name (if manual). Logs are viewable on the HMI and exportable.
The system is designed for expansion. A third generator or a mains-priority mode can be added by updating the PLC program and HMI screens — the panel wiring and control hardware are pre-planned for this.
// technology
Have a dual-source or genset changeover requirement?We'll size, build and commission the panel — fully turnkey.
