Hybrid system DG + inverter + battery: how to save up to 85% of fuel and ensure uninterruptible power supply during outages
In the context of regular scheduled and emergency power outages in Ukraine, owners of private houses, medical facilities, and enterprises face the need to use diesel generators to ensure uninterruptible power supply. However, operating a generator in a classic mode leads to significant fuel costs, accelerated wear of the motor resource, and high maintenance costs
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Why is traditional DG use inefficient?
Diesel generators have a nominal power that often significantly exceeds the average load of the facility. For example, a 48 kW generator installed to cover a peak consumption of 40 kW, with an average load of 15 kW, operates with low efficiency. This leads to:
- Irrational fuel use: the generator consumes fuel in proportion to its nominal power, not the actual load
- Accelerated motor resource wear: operating in an underload mode shortens engine life
- High maintenance costs: scheduled maintenance of diesel generators must be performed every 150-250 motor hours depending on the model, which under continuous operation leads to significant costs
- Increased number of refuelings: more frequent refuelings require additional labor and costs
Solution from Total-Energo: hybrid system DG + Quattro + LiFePO4
We offer an integrated system
The solution from Total-Energo LLC — a hybrid system based on a diesel generator, Victron Quattro inverters, and modern Sacred Sun LiFePO4 batteries allows you to reduce fuel consumption by up to 85%, extend the life of the generator, and ensure a stable power supply even during prolonged outages.
- Diesel generator of appropriate power
- Victron Quattro hybrid inverter with two AC inputs and unique PowerControl and PowerAssist functions
- Sacred Sun LiFePO4 batteries with a resource of over 6000 cycles at 80% depth of discharge
- Optional: solar panels for additional generation and even greater savings
Unique advantages of Victron Quattro inverters
Quattro is equipped with two AC inputs (AC-in-1 and AC-in-2), allowing you to connect:
- The grid and a diesel generator
- Two different generators
- The grid and an alternative power source
The inverter automatically selects the active power source without delays or interruptions. Switching between sources occurs in less than 20 milliseconds, allowing computers, servers, and medical equipment to operate without failures.
Intelligent power management: allows you to set the maximum current that can be consumed from the grid or generator. Quattro automatically accounts for the current load and uses the remaining power to charge the batteries, without overloading the generator.
Practical example: if the limit is set at 75% of the generator's power (the optimal operating mode for a diesel engine), the inverter will maintain this load level, directing excess power to charge the batteries during low consumption or adding energy from the battery during peak load – PowerAssist.
Additional power without overload: automatically adds power from the batteries when consumption exceeds the generator's capabilities or the set limit. This allows you to:
- Use a lower power generator to cover peak loads
- Prevent generator overload and emergency shutdown
- Ensure stable operation of technological equipment without voltage drops
Application example: With a peak consumption of 40 kW and a 48 kW generator running at 75% power (36 kW), an additional 4 kW is automatically provided from the batteries, which eliminates overload and preserves the optimal operating mode of the engine.
Modern LiFePO4 batteries: reliability and durability
Sacred Sun batteries based on lithium iron phosphate technology have unique characteristics:
- Resource: over 6000 cycles at 80% depth of discharge (DOD)
- Service life: 15-20 years with proper operation
- High safety: excellent thermal stability, no risk of ignition
- Low self-discharge rate: batteries retain their charge for a long time
- Eco-friendliness: do not contain toxic metals
Compared to traditional lead-acid batteries (300-700 cycles) and conventional lithium-ion batteries (500-1500 cycles), LiFePO4 provide a 4-20 times longer service life.
Real savings: specific examples
Based on real calculations for Ukrainian operating conditions, we have prepared two examples for different types of facilities.
Example 1: A facility with an average load of 15 kW (refrigeration units and refrigerated vehicles)
- Average consumption: 15-20 kW
- Peak consumption: 40 kW
- Generator: Cummins C66D5E, 48 kW
- Fuel consumption: 12 l/h at 75% load
- Hybrid system: Quattro 36 kW + 75 kWh batteries
- Outages: 720 scheduled hours + 80 emergency hours annually
| Indicator | DG only | DG + Quattro + Battery | Savings |
|---|---|---|---|
| Generator operating time per year, hours | 800 | 118.6 | 85.2% |
| Fuel consumption, liters | 9,600 | 1,423 | 8,177 L (85.2%) |
| Fuel cost, UAH | 566,400 | 83,949 | 482,451 UAH |
| Generator motor resource, hours | 800 | 118.6 | −681 hrs (85.2%) |
| Maintenance cost, UAH | 120,000 | 17,786 | 102,214 UAH |
| Number of refuelings | 64 | 10 | −54 times (84.4%) |
| Refueling cost (excluding fuel), UAH | 32,000 | 5,000 | 27,000 UAH |
| Total expenses, UAH | 718,400 | 106,734 | 611,666 UAH |
| Maximum autonomy on one tank, hours | 12.5 | 33.5 | +21 hours |
Electricity costs for charging the battery from the grid (when available): 77,314 UAH
depending on equipment cost
Example 2: A small facility with an average load of 5 kW (private house, small dental clinic)
- Average consumption: 5 kW
- Peak consumption: 10 kW
- Generator: 13 kW
- Fuel consumption: 3.6 l/h at 75% load
- Hybrid system: Quattro 12 kW + 20 kWh batteries
- Outages: 720 scheduled hours + 80 emergency hours annually
| Indicator | DG only | DG + Quattro + Battery | Savings |
|---|---|---|---|
| Generator operating time per year, hours | 800 | 176 | 78% |
| Fuel consumption, liters | 2,880 | 634 | 2,246 L (78%) |
| Fuel cost, UAH | 169,920 | 37,382 | 132,538 UAH |
| Generator motor resource, hours | 800 | 176 | −624 hrs (78%) |
| Maintenance cost, UAH | 53,333 | 11,733 | 41,600 UAH |
| Number of refuelings | 116 | 26 | −90 times (77.6%) |
| Refueling cost (excluding fuel), UAH | 34,800 | 7,800 | 27,000 UAH |
| Total expenses, UAH | 258,053 | 56,916 | 201,138 UAH |
| Maximum autonomy on one tank, hours | 6.9 | 16.3 | +9.4 hours |
Electricity costs for charging the battery: 13,928 UAH
Motor resource preservation and reduced maintenance costs
Generator motor resource
One of the most important advantages of a hybrid system is a drastic reduction in generator operating hours.
- Air-cooled backup units: 2,500-5,000 motor hours
- High-quality liquid-cooled diesel generators: 10,000-40,000 motor hours
By reducing the operating time by 78-85%, the time before overhaul increases by 4.5-6.8 times.
Savings on Maintenance
Scheduled maintenance of diesel generators is performed every 150-250 motor hours (oil and filter changes, tuning, and diagnostics).
The cost of one maintenance service for a medium-power generator: 10,000-30,000 UAH.
With an operating time reduction of 78-85%, the number of maintenance services is reduced by 4.5-6.8 times, which provides savings of 41,600-102,214 UAH annually.
Operating principle of the hybrid system
Scenario 1: Scheduled outages (4 hours)
- Outage start: Quattro instantly (< 20 ms) switches to battery power
- Autonomous operation: At an average load of 15 kW and a reserve of 75 kWh, the system runs for 3.5 hours on the battery
- Generator startup: When reaching 30% battery charge, the generator starts automatically
- Optimal mode: The generator runs at a stable 75% power — the most efficient mode for a diesel engine
- Simultaneous power and charging: Quattro directs part of the power to the load, and the excess — to charge the battery
- Generator shutdown: When reaching 80% charge, the generator turns off, and the load is again powered by the batteries
Result: Instead of 4 hours of generator operation — only 0.5 hours, fuel savings of 87.5%.
Scenario 2: Emergency outages (10 hours)
During prolonged outages, the system automatically alternates battery operation and periodic generator startup for recharging, ensuring:
- Fuel savings of 64-71% even during prolonged outages
- Uninterruptible power supply for critical equipment
- Maximum autonomy duration up to 24 hours (battery + generator combination). This period of autonomous uninterruptible operation can be extended to 72-96 hours due to the increased capacity of the fuel tank. It is important to remember that this happens not solely due to generator operation, but thanks to the calculated cycle "DG operation + battery charge + battery operation until the next DG start".
Scenario 3: Hybrid system with solar panels
Adding solar panels to the system provides additional advantages:
- Charging the battery from the sun during the daytime reduces dependence on the generator and the grid
- Reducing generator operating time by another 10-30% depending on the SPP power
- Ability to operate in Net Metering mode — selling surplus electricity to the state (when the grid is stable)
- Complete energy independence on sunny days with proper sizing of panel power
Solar panels installed after the Quattro hybrid inverters provide an additional flow of energy that can be used to: directly power the load, charge the batteries, reduce the load on the generator.
Example: When installing 10 kW solar panels in regions with average insolation of 4 hours a day, the additional savings is 40 kWh per day, which is equivalent to 3.5 hours of generator operation.
Additional and indirect advantages of the hybrid system
- Reduction of CO₂ emissions by 78-85%
- Reduction of noise pollution
- Eco-friendly LiFePO4 batteries
- No delay when switching (< 20 ms)
- Redundancy at the IT systems level
- Suitable for single- and three-phase systems (from 3 to 270kVA)
- Less time spent on refueling (saving 54-90 refuelings per year)
- Reduced downtime risks
- Less wear on fuel system components
- Ability to increase battery capacity
- Parallel connection of up to 6 Quattro inverters
- Integration with existing generators
Remote monitoring via VRM Portal and mobile app:
- Automatic generator start and stop + notifications
- Programmable relays for automatic starting
- Setting priorities for power sources (first priority consumers are always powered, second priority — can be automated to turn off)
- Ability to configure charging schedules according to a two-zone tariff
For enterprises and production facilities, reducing electricity costs by 534,000-611,000 UAH annually directly affects the cost of production, increasing competitiveness.
- Quieter operation: noise level is reduced
- Safety: modern battery BMS systems
- Stable quality: pure sine wave from the inverter
For whom the system implementation is most effective
Medical facilities
Hospitals, clinics, and dental offices require absolute power reliability for life-supporting equipment. The hybrid system guarantees:
- Uninterruptible power supply without breaks
- Savings of budget funds on fuel and maintenance
- Opportunity to direct savings toward medical development
Private houses
Homeowners with a consumption power of over 5-8 kW (electric heating, boilers, home appliances) receive:
- Reduction of electricity costs by 5-7 times compared to a generator
- Comfort and quiet — the generator runs minimally
- Energy independence when adding solar panels
Enterprises and production facilities
Facilities with constant consumption ≥ 20 kW requiring stable operation of technological equipment:
- Elimination of failures due to instant switching
- Reduction in production costs through savings on energy sources
- Increased reliability of production processes
Commercial facilities
Shops, restaurants, service stations, offices with a limited grid connection limit:
- PowerAssist helps avoid the expensive increase in connection limits
- Covering peak loads without overloading the input
- Backup power during outages
Implementation: step-by-step instructions
Specialists of Total-Energo LLC analyze the facility's load profile — daily and weekly cycles.
We calculate the optimal configuration of Quattro, battery capacity, the necessity and power of the SPP.
Creation of a connection diagram, drawings, and a technical estimate with a justification for each element.
Only original Victron Energy and Sacred Sun equipment with an official warranty.
Installation and programming of the system by qualified engineers with the transfer of documentation.
Personnel training, verification of all operating modes, handover of documentation and access passwords.
Periodic verification and remote support via VRM Portal. You are not left alone with this system.
Why choose Total-Energo LLC?
Reliability and experience
Total-Energo LLC — is an official partner of Victron Energy in Ukraine with many years of experience in implementing energy solutions:
Contact us for a free consultation and calculation of economic efficiency for your facility!
Briefly — why a DG is better with an inverter and batteries
In the context of the energy crisis in Ukraine, the hybrid system DG + Quattro inverter + LiFePO4 batteries is not just a technological solution, but an economically justified investment that pays off in 1.5-2.5 years and provides:
- Savings of up to 85% of fuel and a corresponding reduction in costs
- Generator motor resource preservation by 4.5-6.8 times
- Reduction of maintenance costs by 78-85%
- Extension of autonomy by 168-300%
- Covering the peak load utilizing the inverter and battery
- Absolute power reliability without interruptions
- Eco-friendliness and reduction of noise pollution
When adding solar panels, the system becomes even more efficient, bringing the facility closer to complete energy independence.
Total-Energo LLC is ready to calculate and implement the optimal solution for your facility.
Ready to save up to 85% on fuel?
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