In critical power generation systems, redundancy in genset controllers ensures reliability and minimizes downtime in case of a controller failure. Depending on the level of importance and the tolerance for downtime, redundancy can be implemented as cold, warm, or hot redundancy. Below, we explain these three types with a focus on genset controllers and provide examples for each.
The easYgen3000XT empowers hot redundancy starting with software version 2.17 (released in April 2025).
Find more details in the product specifications and manuals.
[webinar link to be added in May 2025]
Redundancy Type | Back-up System Status | Switch-Over Speed | Description | Key Features | Application Example |
Cold Redundancy | Inactive, requires start | Slow | Cold redundancy is used in systems where downtime is acceptable and response time to a failure is not critical. In the event of a failure, manual intervention is required to switch to the backup system. | - Backup genset controller is not active during normal operation. - Manual operator intervention is required to activate the backup. - Minimal cost and complexity. | Example: A backup genset is available for a non-critical industrial facility. If the primary genset controller fails, an operator manually activates the backup genset and its controller. |
Warm Redundancy | Standby mode, faster switch-over | Moderate | Warm redundancy is used when downtime must be minimized, but a brief interruption is acceptable. The backup controller is pre-configured and partially synchronized, allowing it to take over operations with minimal delay. | - Backup controller is on standby, monitoring the primary controller. - Minimal downtime during switchover. - Requires pre-configuration for seamless transition. | Example: In a manufacturing plant, the backup genset controller is pre-configured and ready to take over if the primary controller fails. A brief outage may occur during the transition, but operations resume quickly. |
Hot Redundancy | Runs in parallel, immediate | Fast | Hot redundancy is used for critical systems where even a brief interruption is unacceptable. Both the primary and backup controllers operate in parallel, ensuring instantaneous switchover without any downtime. | - Both controllers are active and synchronized. - Instantaneous switchover in case of failure. - Higher cost and complexity. | Example: A hospital's critical power system requires uninterrupted power. The primary and backup genset controllers run in parallel, ensuring seamless transition in the event of a failure. |
Key Takeaways:
Cold Redundancy: Cost-effective, but suitable only for non-critical systems where downtime is acceptable.
Warm Redundancy: Balances cost and performance, suitable for systems where minimal downtime is tolerable.
Hot Redundancy: Ideal for mission-critical applications, but comes with higher costs and complexity.
Selecting the right redundancy type for your genset controllers depends on the criticality of the application and the tolerance for controller downtime. Critical systems, such as hospitals, data centers, and chemical plants, may require hot redundancy to ensure uninterrupted operations, while less critical systems may rely on cold or warm redundancy to balance cost and reliability.