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Bachmann Redundancy ControlMaximum availability through redundancy

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Malfunctions and failures in important operating components reduce the uptimes for machines and plants. In addition to this, they often lead to consequential damage and lengthy repairs. This involves considerable costs, and the production downtime leads to fi nancial losses.

Safety net in case of an incident

Redundant systems maximize availability and

secure productivity

Bachmann’s redundancy solutions enable you to increase the availability of your plant effectively and sustainably: With implementation variants that are tailored to meet your particular requirements, you can reduce downtimes and optimize productivity. The seamless embedding in hardware, engineering and programming concept, together with the robustness of proven Bachmann components, guarantee the highest level of operational reliability, thus maximizing yield.

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Certifi ed worldwide

Internationally accredited test institutes verify conformity with the most important standards and thus provide approval for the most demanding applications.

Easy retrofi tting and upgrading

Three expansion levels ● Network redundancy secures

communication in harsh environments with redundant transmission paths

● Warm standby redundancy Alarm and monitoring systems benefi t from genuine CPU redundancy

● Hot standby redundancy The bumpless switchover enables use in process control and in closed-loop control applications

Seamless integration in the SolutionCenter engineering environment(commissioning, confi guration, programming, monitoring)

Robust and reliablecoldclimate modules for use also in extreme conditions

Integrated and scalable

Automation solutions based on the M1 controller can be created as redundant systems with little effort – even as a retrofi t. Together with its optimized design for cost-sensitive requirements, the Bachmann redundancy concept is enabling implementations in new application fi elds. Starting from simple communication and media

redundancy, the concept can be implemented in levels up to meeting the requirements of the most demanding systems, such as those of a distributed hot standby redundancy system. For this only standard Bachmann devices are used, and the controller does not have to be exchanged.

Bachmann redundancy concept

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Flexible redundancy concept

Seamless embedded in the automation system

Automation solutions from Bachmann stand out on account of their outstanding robustness and availability. Nevertheless, no single system can guarantee failsafe operation on its own. Using the redundancy system enables the risk of unplanned machine and plant downtimes to be considerably further reduced.

Minimum switchover timesThe switchover time is a quality feature of a network redundant system. Typical systems often operate using a ring topology, in which the network devices reroute the data packets in the event of a failure. However, the detection of a fault and the subsequent rerouting takes time. The redundancy solutions from Bachmann directly integrate the detection and switchover operation into the communication end points. In this way, switchover times can be considerably improved. Due to the comprehensive Ethernet conformity, any topology can be selected.

Fault detection integrated in the end pointsAnother benefi t of the integration is the voting mechanism used by all Bachmann terminal devices. After being confi gured once in the application program, redundant process variables

here can be used and processed as a single variable without having to manually read or write the values twice. Management and fault detection are fully handled by the system, thus reducing the workload for the user.

Scalable and cost effi cientWith Bachmann systems, redundancy can be tailored to meet the requirements at hand. The use of standard components offers a wide choice of CPUs with different processing speeds, which can communicate with the substations either via copper or fi ber optic connections. Combined with the product variants, this results in the most economical solutions – from simple network redundancy for protection from communication failures, right through to the virtually fully available system.

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Warm standby redundancy

By adding a second master CPU, this topology also protects from any possible failure of the primary CPU, as well as from failures in the transmission path. A selection algorithm (voter) decides autonomously which of the redundantly calculated and transferred data packets are used. This therefore eliminates the need to manually manage redundant signals when the program is created. This simplifi es programming and shortens the time required for the implementation, whilst reducing susceptibility to errors at the same time. The switchover time can be confi gured as required (0, 1, 2, ... PLC cycles).

Hot standby redundancy

Hot standby operation is an extension of warm standby redundancy. The two redundant master CPUs are synchronized in real-time. If the primary device fails, the secondary device is activated seamlessly. Confi guration and monitoring in the SolutionCenter are also provided with specifi c support for creating and monitoring redundant applications in the IEC61131-3 compliant programming environment. Switching between the two devices is bumpless and is thus also suitable for critical monitoring and closed-loop control tasks.

Network redundancy

To create network redundancy (media and communication redundancy) the data transfer between master CPU and connected substations is implemented via a second transmission medium. Different cabling routes provide additional protection from total failure by a single event. The confi guration is simple: Diagnostic tools, programming interfaces and libraries integrated in the development environment ensure the effi cient creation of applications. The switchover to the redundant path takes place within the same PLC cycle.

Master CPU

Slave Station

Operator Terminal

Master A

Operator Terminal

Operator Terminal

Slave Station

Master A Master B

Master B

Slave Station

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The Bachmann SolutionCenter covers all phases of the engineering process – from planning and confi guration, to system installation and programming, mounting and commissioning, right through to regular operation and service. The redundancy solutions are fully embedded in the SolutionCenter environment. Tools for monitoring, diagnostics and programming, with additional free function libraries, simplify commissioning and troubleshooting, thus helping to save time and costs.

During ongoing operation, detailed error messages and diagnostic tools enable faults to be examined and repair measures to be completed, such as the replacement of a CPU. This information is

used for the preventative and ongoing adaption of maintenance schedules, and thus to further reduce the probability of malfunctions. All this information is fully available both for the IEC61131 programming environment and for teleservice tasks.

The user confi gures and programs the redundant system in the SolutionCenter. All relevant status information for the entire system, details on the master CPUs and information about the redundancy, error, and synchronization status of the application is shown clearly.

Seamless engineering

Configuration and monitoring the

redundancy solution in the SolutionCenter

At a glance: Confi guring, programming and monitoring redundancy in the SolutionCenter

Engineering with the SolutionCenter

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Seamless integration of redundancy in hardware, software and engineering

Optimum performance (switchover times, execution speed)

Use of standard components coldclimate components enable

use in extreme environmental conditions with transient extreme temperatures as low as -40°C and when condensation is present.

Full compatibility to bus systems such as Profi net, Profi bus, CANopen, NMEA or J1939.

Implementation of distributed solutions via copper or fi ber-optic connections.

Access to the complete network from any station.

Maintenance or control terminals can be connected directly to the I/O stations or the redundant network.

Maintenance terminals(e.g. notebooks) for troubleshooting, process visualization or control of each node can be connected during operation at any network point.

Alarm and monitoring systems, as well as the connection to stations for process control, operate with TCP/IP using standard protocols such as OPC, Modbus, Java and C/C++.

Redundant systems have a reputation of being complex, expensive and extraordinarily labor-intensive for programming and operating. Not so with Bachmann redundant solutions: They offer full real-time capability, are easy to program and are fully integrated into the engineering environment.

Robust, efficient – and easy to retrofit

The new form of redundancy

The facts of the Bachmann redundancy solution are impressive

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Germany

Bachmann electronic GmbHHeadquarters GermanyEgermannstraße 753359 Rheinbach / Bonn, GermanyP +49 (0) 22 26 / 1 57 46-0offi ce.bonn@bachmann.info

Bachmann Monitoring GmbHWeimarische Straße 1007407 Rudolstadt, GermanyP +49 (0) 36 72 / 31 86-0monitoring@bachmann.info

Bachmann Offi ce BochumKonrad-Zuse-Straße 3, 44801 Bochum, GermanyP +49 (0) 234 / 93 25 98-0offi ce.bochum@bachmann.info

Bachmann Offi ce MeinerzhagenVolmestraße 158540 Meinerzhagen, GermanyP +49 (0) 23 54 / 7 08 69-0offi ce.meinerzhagen@bachmann.info

Denmark

Bachmann Offi ce SilkeborgBachmann electronic DanmarkVejlsøvej 518600 Silkeborg, DenmarkP +45 70 20 28 34offi ce.silkeborg@bachmann.info

Benelux

Bachmann Offi ce VeenendaalBachmann electronic NederlandVendelier 653905 PD Veenendaal, NetherlandsP +31 (0) 85 / 210 05 50offi ce.veenendaal@bachmann.info

USA

Bachmann Offi ce ChicagoBachmann electronic Corp.34121 North Route 45, Suite 203 Grayslake, IL 60030, USA P +1 847 / 249 30 03offi ce.chicago@bachmann.info

China

Headquarters ChinaBachmann electronic TechnicalServices Co., Ltd.

East Ocean CenterRoom 14C, Phase 2618 Yan‘an East Road200001 Huangpu District, Shanghai,PR ChinaP +86 (0) 21 23 13 51 88offi ce.shanghai@bachmann.info

Bachmann Offi ce BeijingAnlian Building, Buildung 3, Room 1208No.38 North Road Dongsan Huan100026 Beijing, Caoyang DistrictPR ChinaP +86 (0) 10 85 87 06 07offi ce.beijing@bachmann.info

India

Bachmann Offi ce PuneBachmann electronic IndustrialAutomation Private Limited, Pune1/E, Classic Building, North AvenueKalyani NagarPune 411006, IndiaP +91 (0) 20 40 04 61 92offi ce.pune@bachmann.info

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Austria

Corporate HeadquartersBachmann electronic GmbHKreuzäckerweg 336800 Feldkirch, AustriaP +43 (0) 55 22 / 34 97-0info@bachmann.infowww.bachmann.info