GE IC698CRE020-GG Redundant CPU Module (Hot Standby)

Description

The GE IC698CRE020-GG tackles the critical demand for uninterrupted control in high-stakes industrial automation and process control applications where even momentary processor failure can lead to significant safety risks, production halts, or asset damage. In large-scale systems like turbine controls, chemical processing, power generation, or continuous manufacturing lines, engineers need a CPU that delivers fast processing while supporting true hot standby redundancy—meaning seamless failover without process interruption, no cold restarts, and no loss of synchronized state data.

Challenges emerge in mission-critical setups with redundant controllers: synchronization delays, data mismatches during switchover, or single-point failures in the primary CPU can compromise system stability and critical system uptime. The GE IC698CRE020-GG, a high-availability redundant CPU from the PACSystems RX7i series (now under Emerson), provides a 700 MHz Intel Pentium III-based processor paired with built-in redundancy features. It enables hot standby configurations using a pair of these CPUs linked via a Redundancy Memory Xchange (RMX) module, ensuring the backup unit stays fully synchronized in real time. This becomes essential in environments requiring deterministic performance, high scan rates, and zero-downtime tolerance, where legacy or non-redundant CPUs fall short under demanding computational loads or when expanding to handle complex logic, floating-point calculations, and extensive I/O.

The GE IC698CRE020-GG serves as the central processing unit in a PACSystems RX7i rack, occupying the main CPU slot and interfacing directly with the backplane for high-speed communication to I/O modules, Genius or other fieldbus adapters, and expansion racks. It runs user logic at 700 MHz with 10 Mbytes of battery-backed RAM for programs, retentive data, and reference tables, supporting floating-point math for precise control algorithms.

For redundancy, it pairs with an identical unit through the IC698RMX016 RMX module, which handles deterministic data exchange over a dedicated fiber link—keeping the backup CPU’s memory mirror-image of the active one during RUN mode. An embedded Ethernet port (10/100 Mbps) provides TCP/IP connectivity for programming, HMI, SCADA, or peer-to-peer EGD/SRTP communications, while three serial ports support Modbus RTU Slave, SNP, and other protocols for legacy integration or service tools. The module draws power from the RX7i backplane (+5 VDC primary), includes diagnostic LEDs for status/fault indication, and supports Genius I/O for redundant field wiring in hot standby setups. Positioned at the core of the control stack, GE IC698CRE020-GG ensures synchronized execution and bumpless transfer, making it a cornerstone for high-reliability architectures without requiring custom middleware or external failover logic.

Opting for the GE IC698CRE020-GG provides engineers with rock-solid assurance in applications where downtime isn’t an option. Engineered for hot standby redundancy, it delivers bumpless switchover—often in milliseconds—preserving process continuity and avoiding the costly interruptions common with non-redundant or cold-standby designs. The high clock speed and ample memory handle complex logic, large datasets, and fast scan times consistently, reducing bottlenecks in compute-intensive tasks like advanced regulatory control or batch sequencing.

Diagnostics and status reporting simplify troubleshooting: LEDs flag active/backup roles, faults, or sync issues, while Ethernet connectivity enables remote monitoring and firmware updates without halting the process. Over the long term, GE IC698CRE020-GG supports sustained performance in aging RX7i systems, minimizing engineering rework during migrations and extending the value of installed hardware through reliable, low-maintenance redundancy.

The GE IC698CRE020-GG is routinely deployed in power plants for turbine governor control or boiler management, where critical system uptime demands seamless failover during grid disturbances or equipment trips. In oil & gas refineries or petrochemical facilities, it controls continuous processes like cracking units or distillation columns under harsh, vibration-prone conditions with constant operation. Heavy manufacturing sites, such as steel mills or pulp/paper lines, use it for coordinated drive systems or material handling, prioritizing fast execution and redundancy to maintain throughput in 24/7 environments.

Compatible or alternative products in the Emerson PACSystems RX7i family include:

IC698CRE020-GG – 700 MHz redundant CPU with embedded Ethernet (standard high-availability model)

IC698CRE030 – Higher-performance 600 MHz variant (Pentium-M based in some references, for comparison or specific needs)

IC698CPE020 – Non-redundant 700 MHz CPU equivalent for single-CPU applications

IC698CRE040 – Faster 1.8 GHz redundant CPU for more demanding logic or larger programs (upgrade path)

IC698RMX016 – Required Redundancy Memory Xchange module for hot standby pairing

IC698ETM001 – Additional Ethernet module if extra ports or advanced networking needed

IC698CMX106 – Reflective memory module for non-redundant high-speed data sharing

IC695CPU320 – Modern RX3i equivalent CPU (migration path for newer platforms)

Before installing the GE IC698CRE020-GG, ensure the RX7i rack power supply can handle the 4.5 A nominal draw at +5 VDC (plus margin for other modules) and verify backplane compatibility—RX7i racks only. For redundancy, install the RMX module in the designated slot and connect the fiber cables properly between the pair. Confirm firmware versions match between active and backup units to avoid sync failures; use Emerson tools for upgrades if needed. Allow adequate rack ventilation, as the processor generates heat under load—fan kits are often required in dense or high-ambient setups.

Ongoing maintenance focuses on periodic checks: monitor LEDs for active/backup status, fault codes, or sync errors during routine inspections. Test redundancy failover during scheduled shutdowns by forcing a switchover and verifying bumpless transfer. Inspect battery for memory retention (replace every few years per Emerson guidelines) and clean rack filters to prevent overheating. Ethernet and serial connections benefit from annual checks for secure cabling and corrosion in harsh areas—no routine calibration required, but log diagnostics for trend analysis.