ONAN Repair Services India
ONAN, a Cummins company, is a global leader in power generation and backup power systems for industrial, marine, and residential applications. Known for dependable diesel and petrol generators with integrated electronic controls, ONAN equipment is widely deployed across Indian manufacturing plants, data centres, hospitals, and construction sites requiring uninterrupted power supply and load management.
ONAN, a Cummins company, is a global leader in power generation and backup power systems for industrial, marine, and residential applications. Known for dependable diesel and petrol generators with integrated electronic controls, ONAN equipment is widely deployed across Indian manufacturing plants, data centres, hospitals, and construction sites requiring uninterrupted power supply and load management.
Synchronics specializes in repairing ONAN power generation controllers, automatic transfer switches, genset control boards, and electronic governor systems. Our 180+ engineers have repaired 4+ ONAN product lines including controller modules, voltage regulators, and load-sharing systems for critical Indian industries. We deliver fast turnaround diagnostics and component-level repairs with warranty, trusted by plant managers across Gujarat, Maharashtra, and pan-India.
ONAN genset controller and ATS repairs — 30+ years' experience, PAN India support.
ONAN Equipment We Repair — By Category
ONAN Product Lines We Repair
Our engineers are trained on the full ONAN product range. Below are the major product families we service.
ONAN ATS (Automatic Transfer Switch) Controllers
Solid-state and microprocessor-based automatic transfer switches managing seamless power transition between grid and generator. Common issues include relay chatter, logic board failures, voltage sensing faults, and contactor coil burnout affecting switching reliability.
ONAN Genset Control Boards
Integrated control and monitoring modules for ONAN generator sets handling load regulation, frequency control, and system diagnostics. Frequent failures include capacitor degradation, microprocessor resets, sensor interface loss, and metering circuit faults impacting real-time power monitoring.
ONAN Electronic Governor Systems
Closed-loop speed and load-sharing governors maintaining stable frequency output and balanced parallel operation of multiple gensets. Typical defects include actuator malfunction, feedback sensor degradation, droop compensation failure, and calibration drift under heavy load.
ONAN Voltage Regulation & Excitation Boards
AVR and excitation control circuits maintaining stable output voltage across load variation and grid synchronization. Common faults include rectifier bridge failure, thyristor malfunction, reference circuit instability, and harmonic distortion compensation module failure.
Why Choose Synchronics for ONAN Repairs?
PCB-Level Expertise
We repair down to the component level — not just swap boards. Our engineers identify root causes, replace failed IGBTs, capacitors, processors, and gate drivers on ONAN equipment.
Fast Turnaround
Standard 7–10 working days. Express 3–5 days available for critical breakdowns. Emergency same-day/next-day service for unplanned downtime.
6-Month Warranty
Every repaired unit ships with a 6-month comprehensive warranty on parts and labour. Our repair success rate is over 94% across all brands.
All-India Service
Couriered repairs accepted from any city in India. Doorstep pickup available in Vadodara, Mumbai, Pune, Ahmedabad, Surat, Chennai, and more.
Common ONAN Equipment Faults We Fix
Based on 30+ years of repair data, these are the most frequent failure modes we see in ONAN equipment arriving at our workshop.
- ✓ONAN genset fails to start or cranks but no ignition — Control board microprocessor lockup, fuel solenoid driver circuit failure, or sensor input loss (speed/oil pressure sensor disconnection). Thermal shutdown triggered by over-temperature detection during previous run cycle.
- ✓ATS controller stuck in generator mode, grid transfer fails — Contactor logic stuck due to relay weld, voltage sensing circuit malfunction reading false grid voltage, or microprocessor firmware corruption. Loss of grid synchronization signal prevents automatic switch-back.
- ✓Load-sharing control unbalanced — gensets do not parallel correctly — Droop compensation network degradation, CT (current transformer) secondary winding open circuit, or load-share module communication fault between parallel genset controllers. Differential current feedback failure causes load shedding to one unit.
- ✓Erratic frequency and voltage fluctuation under load pickup — Governor response lag due to actuator arm friction or dead-band adjustment loss; AVR excitation delay from rectifier diode forward voltage drift or thyristor gate drive timing skew. Fuel servo feedback potentiometer wear causes hunting.
- ✓ONAN controller displays fault code 12 or alarm lockout — Engine speed sensor (PMG or magnetic pickup) intermittent signal loss, wiring harness corrosion, or control board speed detection comparator failure. Noise coupling into low-voltage signal lines triggers false over-speed or under-speed detection.
- ✓Genset runs but metering displays blank or incorrect kW/kVAR readings — Metering IC communication bus failure, CT secondary winding short or open, VT (voltage transformer) fuse blown, or digital display segment driver IC malfunction. Power supply to metering circuit drops due to capacitor degradation.
How We Repair Your ONAN Unit
Receive & Log
Your unit is logged into our tracking system with a unique job number. You receive WhatsApp / email updates at every stage.
Fault Diagnosis
Board-level diagnosis using oscilloscopes, LCR meters, and thermal cameras. Root cause identified before any repair begins.
Component Repair
Faulty ICs, capacitors, MOSFETs, IGBTs, and gate drivers replaced with genuine or equivalent-spec components.
Full-Load Test
Unit tested under rated load with original or equivalent motor. All parameters verified. 6-month warranty issued.
Industries Using ONAN Equipment
We serve plant maintenance teams across all major industries where ONAN automation is deployed.
Frequently Asked Questions — ONAN Repairs
Do you repair ONAN equipment anywhere in India?+
Yes. Synchronics repairs the full ONAN product range — genset controllers, ATS modules, electronic governors, and voltage regulators. We offer PAN India door pickup from Mumbai, Delhi, Pune, Chennai, Hyderabad, Ahmedabad, Bangalore, Kolkata, and all other cities. All equipment is serviced at our advanced facility in Vadodara, Gujarat, with same-day diagnostic reporting and typical 5-7 day turnaround.
What is the typical turnaround time for ONAN ATS or genset controller repair?+
Synchronics delivers diagnostic report within 24 hours of receipt. Most ONAN control board repairs — including component replacement, microprocessor reprogramming, and functional testing — are completed within 5-7 working days. Critical repairs for running plant emergency backup systems are expedited with priority handling and same-day component availability.
Can Synchronics repair ONAN genset controller boards with corrupted firmware or locked microprocessor?+
Yes. Our engineers perform firmware extraction, corruption diagnosis, and EPROM/Flash reprogramming for ONAN ECM and control modules. We maintain archived ONAN firmware libraries covering genset models from 2005 onwards. Microprocessor unlock, parameter reload, and full functional burn-in testing are included. Reprogrammed boards retain original calibration data and load-sharing parameters.
Do you provide warranty on ONAN repair work?+
Synchronics provides 12 months comprehensive warranty on all component replacements and repair work for ONAN equipment. Warranty covers parts failure and defective repairs; labor and shipping for repeat issues are complimentary within warranty period. We also offer extended warranty options for mission-critical genset control systems in data centres and industrial plants.
Why do ONAN load-share controllers fail when paralleling multiple gensets in Indian manufacturing plants?+
Harmonics and voltage distortion from non-linear loads (VFDs, welders, furnaces) degrade CT (current transformer) accuracy and confuse droop compensation networks. Inadequate neutral bonding and earthing practices in older Indian plants cause circulating ground currents that corrupt load-share signal integrity. Synchronics upgrades CT wiring with Faraday shielding, verifies earthing continuity, and recalibrates compensation networks to handle 20-30% THD common in Indian industrial sites.
How do I send my ONAN unit for repair?+
Pack the unit securely and courier it to our Vadodara workshop. Include a note with the fault description and your contact details. We will log it into our system and WhatsApp you a job number within 24 hours of receipt. Doorstep pickup is available in Vadodara, Ahmedabad, Surat, Mumbai, and Pune.
What is the cost of repairing a ONAN drive or PLC?+
Repair cost depends on the model and the fault. We offer a free diagnosis — once we identify the fault, we provide a fixed quotation before proceeding. Typical repairs cost 20–40% of the new unit price. We will never repair without your approval.
What warranty do you provide on ONAN repairs?+
All repaired units carry a 6-month comprehensive warranty covering the same fault and related issues. If the fault recurs within the warranty period, we repair it free of cost.
Do you provide a no-fix, no-fee guarantee?+
Yes. If we cannot repair your ONAN unit after diagnosis, you pay only the diagnosis fee (₹500–₹1,500 depending on the product). The unit is returned to you at no additional charge.
ONAN Repair Catalog
Showing 1–4 of 4 ONAN products
Other Brands We Repair in the Same Categories
Get Your Equipment
Back in Action — Fast
Send us your faulty industrial electronics. Our engineers will diagnose it and provide a detailed quote within 24 hours — with no obligation to proceed.
Free Evaluation
No obligation
48hr Turnaround
Fastest in India
6-Month Warranty
Every repair
No Fix, No Charge
Zero risk policy
Pan-India Pickup
Doorstep service