Processor unit redundancy is supported for enhanced system reliability. In this configuration, the controller is equipped with two processor units—each integrated with memory for system and application software. One unit functions as the primary, while the other serves as the backup (hot stand-by) to ensure continuous operation. The primary processor unit takes charge of process control, and the backup unit remains on standby to take over immediately if a fault occurs in the primary. The changeover is performed bumplessly and takes less than 10 ms; during this transition, process outputs remain frozen to avoid disruptions.
After a changeover, the system operates in a non-redundant mode with only one processor unit active. The faulty processor unit can be replaced while the system is running; once replacement is completed, the system restores processor unit redundancy. Similarly, if an error occurs in the backup unit, it can also be replaced during system operation without interrupting normal processes.
Notably, errors in the backup unit will never impact the operation of the primary unit, as the primary and backup units are logically isolated from each other. Hardware errors in the primary processor unit—classified as “single errors”—trigger a proper system changeover to the backup unit.
Redundancy has no effect on application programming or communication functions; both remain fully operational and unaffected. It is important to note that the serial port COM3 cannot be used in a redundant CPU configuration.
S800 I/O units connect to the two CPUs via the optical ModuleBus. The built-in electrical ModuleBus on the base plates is not compatible with S800 I/O connections in a redundant CPU setup.
The number of ports and protocols supported by the processor unit can be expanded by adding communication units to the CEX-Bus. Examples of unit types that can be connected to the CEX-Bus include: • FOUNDATION Fieldbus High Speed Ethernet (FF HSE) • PROFIBUS DP • Dual RS-232C ports • S100 I/O • INSUM • IEC 61850 • MasterBus 300 • Modbus TCP • ABB Drives (via DriveBus Interface) • TRIO/Genius • Satt I/O (via ControlNet, including 19” Satt rack I/O, S200 I/O, and S200L I/O) • AF 100 • PROFINET IO • EtherNet/IP
This expansion enables connections to remote I/O, fieldbus instruments, and additional RS-232C ports, enhancing the system’s flexibility.
Power supply units (model: SD83x) are switch-mode power converters that convert AC mains voltage to a regulated 24 V DC output. The input voltage for the mains supply can be either 115 V AC or 230 V AC, selected using a switch mounted on the front panel of the unit.
SD83x power supply units are suitable for both redundant and non-redundant applications. When used in a redundant configuration (connecting multiple units to a common load), a voting device (model: SS823) is required. This device combines the two outputs into a single output via diodes to ensure stable power delivery. Redundant power supply units can be connected to either completely separate mains supplies or the same mains supply, depending on the specific system configuration.
The L- output (0 V) of the power supply units can be used without grounding. If grounding is required, the L- output (0 V) can be grounded directly or through a suitable resistor.
The processor unit does not require an uninterruptible power supply (UPS) for safe shutdown. It is equipped with an internal power reservoir that provides 5 ms of backup power—sufficient for a controlled power-down sequence. Additionally, the power supply units can handle short power interruptions (<20 ms), which are common in industrial environments. However, for certain applications requiring protection against brief voltage failures, installing a UPS is recommended.
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