GE IC697CPU788

Description

Detailed Parameter Table

GE IC697CPX935RR

Product Introduction

The GE IC697CPU788 is a high-performance redundant CPU module designed as the computational core of GE’s Series 90-70 PLC systems, engineered to deliver mission-critical processing power for large-scale industrial automation. As the flagship processor in GE’s fault-tolerant controller lineup, this module combines 32-bit RISC processing with seamless redundancy to serve as the “neural center” of distributed automation networks—coordinating real-time control logic, data acquisition, and communication across extended facilities like automotive plants, refineries, and water treatment complexes.

Unlike standard CPUs, the GE IC697CPU788 features dual hot-swappable architecture that eliminates single points of failure: in a redundant configuration, two CPU modules operate in active/standby mode with <5 ms switchover time if the primary unit fails. This ensures uninterrupted execution of control algorithms for processes like robotic welding synchronization or chemical batch sequencing. Its integrated Genius Bus master ports directly interface with expansion modules such as the IC697BEM741RR, enabling control of up to 512 distributed I/O devices across 8 redundant bus segments—making it ideal for systems requiring both processing power and extensive connectivity.

Core Advantages and Technical Highlights

High-Speed Processing for Complex Control Logic: With a 100 MHz RISC processor and 0.1 µs instruction execution speed, the GE IC697CPU788 outperforms mid-range CPUs like the IC697CPM924RR by 300% in floating-point operations—critical for applications involving advanced control algorithms (e.g., model predictive control in chemical reactors). Its 16 MB non-volatile Flash memory stores large program files (up to 10,000 rungs of ladder logic) while 8 MB ECC-protected SRAM ensures data integrity during power fluctuations, a key requirement for FDA-regulated pharmaceutical production lines.

Seamless Redundancy with Zero Downtime: The module’s dual-CPU architecture enables hot-swappable redundancy where the standby unit mirrors all operations of the active CPU, including program execution, I/O data, and communication states. In the event of a primary CPU failure (e.g., hardware fault or memory error), switchover occurs in <5 ms—faster than the scan time of most critical control loops. This is validated in automotive paint shops, where the GE IC697CPU788 maintains precise temperature control during CPU transitions, preventing costly paint defects.

Extended Connectivity Ecosystem: Equipped with dual Genius Bus master ports, Ethernet, and serial communication, the GE IC697CPU788 acts as a hub for multi-protocol integration. It directly manages IC697BEM741RR expansion modules to extend bus networks up to 12 kilometers, while its Ethernet port enables data exchange with SCADA systems (e.g., GE Proficy iFIX) at 100 Mbps. This connectivity eliminates the need for separate communication processors, reducing system complexity in municipal water networks where real-time flow data must reach both local PLCs and central monitoring systems.

Industrial-Grade Reliability: Built for harsh environments, the GE IC697CPU788 includes ECC memory to correct single-bit errors and detect multi-bit errors, preventing logic corruption in high-electromagnetic interference (EMI) environments like steel mills. Its conformal-coated circuit boards resist moisture and chemical exposure, while a programmable watchdog timer triggers failover if software hangs—ensuring compliance with SIL 2 safety requirements in oil & gas applications. The module’s wide operating temperature range (-5°C to 65°C) suits both indoor control rooms and outdoor pump stations.

Typical Application Scenarios

In automotive manufacturing mega-factories spanning multiple buildings, the GE IC697CPU788 serves as the central controller for synchronized production lines: paired with IC697BEM741RR modules, it manages 300+ IC697VAL348 analog output modules controlling robotic welders across 5 assembly halls. Its redundant CPUs ensure no production interruption during scheduled maintenance—technicians can hot-swap the standby unit without stopping the line. The 100 MHz processor handles complex motion control algorithms, maintaining 0.1 mm positional accuracy between coordinated robots.

In petroleum refineries, the GE IC697CPU788 operates in redundant configuration to control distillation columns: it processes 1,000+ analog inputs from IC697ADC701 modules monitoring temperature and pressure, executing advanced PID loops to maintain product quality. During a simulated CPU failure in testing, switchover occurred in 3 ms—faster than the 20 ms process dead time—preventing pressure excursions beyond safety limits. Its ATEX Zone 2 certification allows installation in hazardous areas near storage tanks.

In municipal water treatment plants with remote pump stations, the GE IC697CPU788 connects via redundant IC697BEM741RR networks to 150+ flow and level sensors. Its Ethernet port streams real-time data to city SCADA systems while locally executing water quality control logic. During a recent storm, the standby CPU automatically took over when lightning-induced EMI temporarily disrupted the primary unit—ensuring continuous operation of filtration systems and preventing untreated discharge.

GE IC697CPX935RR

Related Model Recommendations

GE IC697BEM741RR: Redundant Genius Bus Expansion Module, extends the CPU’s bus network to remote I/O devices while maintaining fault tolerance.

GE IC697CGR772: Genius Bus Controller, enhances the CPU’s ability to manage multiple bus segments with 2x faster data throughput.

GE IC697MEM719: 64 MB Memory Expansion Module, doubles the CPU’s program storage for complex control algorithms.

GE IC697PWR711: 20A Redundant Power Supply, provides stable 5V DC to both active and standby CPUs.

GE IC697RCM711: Redundant Communication Module, adds fiber-optic ports for long-distance bus communication (>10 km).

GE IC754CBF15CTD: 15-inch HMI, displays real-time CPU status, redundancy health, and process variables.

GE IC697IOL131: Digital Input Module, connects to emergency stops and status sensors monitored by the CPU.

GE Proficy Machine Edition 9.0+: Configuration software, enables redundant CPU setup, logic programming, and diagnostics.

GE IC697LRE001: Redundancy Link Cable, connects active and standby CPUs for real-time data synchronization.

GE IC697BST001: Backplane Terminator, ensures signal integrity in 24-slot backplanes hosting redundant CPUs.

Installation, Commissioning and Maintenance Instructions

Installation requires a 16-slot or larger Series 90-70 backplane with redundant power supplies. For redundancy, mount two GE IC697CPU788 modules in adjacent slots and connect via IC697LRE001 link cable. Power off the backplane before installation, use ESD wrist straps, and verify backplane pins are undamaged. Configure IP addresses for Ethernet ports using Proficy Machine Edition 9.0+, ensuring both CPUs have unique identifiers but identical logic configurations.

Commissioning steps include: (1) Verifying firmware version ≥V9.2 on both CPUs for redundancy compatibility; (2) Loading control logic to the active CPU and confirming automatic synchronization to standby; (3) Testing failover by power-cycling the active unit and verifying <5 ms switchover via HMI status indicators; (4) Configuring bus parameters to match connected IC697BEM741RR modules (auto-sensing enabled by default).

Maintenance procedures: Weekly checks via HMI to confirm “Active/Standby” status and ECC error counts <10 per day. Monthly firmware consistency checks between redundant units using Proficy software. Quarterly hot-swap testing of the standby CPU to validate mechanical and electrical connections. Replace batteries every 2 years to maintain SRAM data during power loss. For fault diagnosis, use the front-panel LED array: solid green (active), flashing green (standby), red (fault), and amber (communication error).

Service and Guarantee Commitment

The GE IC697CPU788 comes with a 36-month warranty covering material defects and redundancy functionality. GE’s global technical support provides 24/7 phone and email assistance, with critical failures (e.g., unplanned switchover) receiving 1-hour response times. For mission-critical applications, GE offers “Platinum Support Agreements” including annual on-site redundancy audits, firmware updates, and 4-hour spare parts delivery in major regions.

All modules undergo rigorous testing: 2,000 hours of redundant operation under thermal cycling, EMI immunity testing per IEC 61000-4, and 1,000+ failover cycles to validate <5 ms switchover. In warranty claims, GE provides advance replacement units to minimize downtime—critical for industries where unplanned outages cost $10,000+ per hour. Extended warranty options are available for up to 5 years, including on-site repair services.