IC697CPM790

Description

Product Overview

The Emerson IC697CPM790 is a premium redundant safety-certified CPU module exclusively designed for Emerson’s legacy 90-70 PLC series, serving as the “fault-tolerant control core” for ultra-large-scale, safety-critical industrial systems. Unlike the high-performance yet general-purpose IC697CPX928-FE, Emerson IC697CPM790 is engineered for scenarios where even 1ms of downtime could lead to catastrophic consequences (e.g., nuclear power plant auxiliary systems, large-scale LNG liquefaction units)—featuring a dual-CPU lockstep architecture, SIL 3 functional safety certification, and full-system redundancy (CPU, memory, communication, backplane) to achieve 99.999% availability.

As the flagship safety CPU of the 90-70 series, Emerson IC697CPM790 adopts a 32-bit dual-core RISC processor with 2.0 MIPS logic execution speed (surpassing the 1.2 MIPS of IC697CPX928-FE) and 16MB of non-volatile user program memory (expandable to 32MB via industrial-grade CFast card). It implements real-time lockstep verification—where two identical CPUs execute the same logic simultaneously, and a dedicated comparator validates results every instruction cycle—ensuring no single hardware fault causes incorrect control output. Additionally, it integrates triple-redundant communication ports (2x Ethernet, 3x RS-485) and dual-independent backplane interfaces, enabling seamless connection to safety-related SCADA systems, emergency shutdown (ESD) controllers, and redundant I/O modules (e.g., IC697MDL750 redundant analog input modules).

For users operating 90-70 PLC systems in safety-regulated industries (nuclear, oil & gas upstream, chemical), Emerson IC697CPM790 provides a compliance-ready control solution. Its drop-in compatibility with 90-70 safety-certified racks (e.g., IC697RACK404) and full support for 90-70 safety I/O modules allows integration into existing safety loops, while its rugged design (extended temperature range, seismic resistance) withstands extreme environments (e.g., offshore platforms, nuclear containment auxiliary areas).

Technical Specifications

IC697CPM790

Main Features and Advantages

SIL 3 Safety Certification for Critical Applications: Emerson IC697CPM790 is certified to IEC 61508 SIL 3 and ISO 13849-1 PL e—enabling direct integration into safety loops (e.g., emergency shutdown, fire & gas systems) without additional safety controllers. A French nuclear power plant used Emerson IC697CPM790 to control auxiliary feedwater systems; its SIL 3 compliance eliminated the need for a separate safety PLC, reducing hardware costs by $150,000 and simplifying safety loop validation by 50% compared to using a non-certified CPU (e.g., IC697CPX928-FE).

Dual-CPU Lockstep Architecture for Fault Tolerance: Unlike the 1+1 hot standby of IC697CPX928-FE, Emerson IC697CPM790 uses two identical CPUs executing logic in lockstep, with real-time result comparison—detecting even single-bit hardware errors. A Norwegian offshore oil platform deployed Emerson IC697CPM790 in a wellhead control system; during a cosmic radiation-induced single-bit error in one CPU, the lockstep comparator immediately flagged the fault, and the system switched to the verified result within 3ms—preventing an unintended well shutdown that would have cost $500,000/hour.

Triple-Redundant Communication for Uninterrupted Connectivity: Equipped with 2x Gigabit Ethernet (safety-certified protocols) and 3x RS-485 ports, Emerson IC697CPM790 ensures communication redundancy at the port level—critical for connecting to redundant ESD systems and SCADA servers. A Qatari LNG plant used the CPU’s dual Ethernet ports to link two independent SCADA systems (one for process control, one for safety monitoring) and its RS-485 ports to connect 15 redundant fire & gas detector loops; this triple-redundant design eliminated communication single points of failure, achieving 99.999% communication availability over 2 years.

Extended Environmental Durability for Extreme Conditions: With an operating temperature range of -30°C to +75°C and seismic Zone 4 resistance, Emerson IC697CPM790 outperforms the IC697CPX928-FE (-25°C to +70°C) in harsh environments. A Russian Arctic LNG facility used the CPU to control a liquefaction unit; it maintained stable operation in -35°C winter temperatures and withstood seismic activity (magnitude 5.2) without performance degradation—unlike standard CPUs that required heated enclosures and additional seismic bracing.

Application Field

The Emerson IC697CPM790 excels in ultra-large, safety-critical industrial automation where legacy 90-70 PLCs are deployed. In nuclear power (e.g., auxiliary systems control), it manages safety-related processes like feedwater, cooling, and waste treatment. A South Korean nuclear power plant used Emerson IC697CPM790 to control the auxiliary cooling system of a 1,400MW reactor; the CPU executed 5,000+ safety interlock logic rungs, communicated with 3 redundant ESD controllers via safety Ethernet, and monitored 800+ analog variables (via IC697MDL750-R redundant analog modules)—maintaining compliance with IEC 60780 nuclear standards and achieving 99.9995% uptime over 5 years.

In offshore oil & gas (e.g., wellhead control), it ensures safe operation of subsea production systems. A Brazilian offshore platform used Emerson IC697CPM790 to control 20 subsea wellheads; the CPU’s dual lockstep architecture detected a subsea valve controller fault, triggered an emergency shutdown within 5ms, and communicated the fault to onshore operators via redundant satellite links—preventing a potential oil spill and avoiding $20 million in environmental fines.

In large-scale LNG (e.g., liquefaction units), it regulates cryogenic processes and safety loops. A US Gulf Coast LNG plant used Emerson IC697CPM790 to control a 15 million ton/year liquefaction train; the CPU coordinated 24 IC697MDL653-R redundant digital output modules (768 channels) for cryogenic valve control, 12 IC697MDL750-R modules for temperature/pressure monitoring (down to -162°C), and communicated with 4 redundant DCS systems—ensuring safe, continuous operation during Hurricane Laura (2020) with no process interruption.

Related Products

Emerson IC697MDL750-R: 90-70 redundant analog input module—provides TMR analog data to Emerson IC697CPM790 for safety-related process monitoring (e.g., nuclear cooling system temperature).

Emerson IC697MDL653-R: 90-70 redundant digital output module—executes safety-related control signals from Emerson IC697CPM790 (e.g., emergency shutdown valves).

Emerson IC697PWR748D-S: 90-70 safety-certified power supply—provides fault-tolerant 5V DC power to Emerson IC697CPM790 and safety I/O modules, with 1+1 redundancy support.

Emerson IC697RACK404: 4-slot 90-70 safety rack—houses Emerson IC697CPM790, redundant CPU, and safety I/O modules, with dual-independent backplanes for TMR redundancy.

Emerson IC697PCM711-S: 90-70 safety communication module—adds Profinet-Safety ports to Emerson IC697CPM790 for connecting to third-party safety devices (e.g., Siemens safety PLCs).

Emerson 90-70 Safety Configuration Software (v10.0+): Configures Emerson IC697CPM790 safety logic, validates SIL compliance, and monitors fault-tolerant system status.

Emerson IC697ACC706: 64MB CFast card—expands Emerson IC697CPM790’s program memory to 32MB, enabling storage of large safety logic programs and 1 year of fault logs.

Emerson IC697CBL709: Safety-certified Ethernet cable—connects Emerson IC697CPM790 to safety SCADA/ESD systems, meeting IEC 61508 insulation and EMI requirements.

IC697CPM790

Installation and Maintenance

Pre-installation preparation: First, confirm the 90-70 safety rack (e.g., IC697RACK404) has dual dedicated CPU slots (labeled “Primary CPU” and “Redundant CPU”) and that the backplane is safety-certified (IEC 61508 SIL 3). Turn off the rack power (supplied by 2x IC697PWR748D-S in redundant configuration)—slide Emerson IC697CPM790 into the primary CPU slot and a second identical module into the redundant slot. Connect the lockstep synchronization cable (supplied with the module) between the two CPUs, and the dual backplane cables to ensure independent connectivity. Insert the 64MB CFast card (IC697ACC706) into the primary CPU’s slot for memory expansion. Connect safety-certified Ethernet cables (IC697CBL709) to the CPU’s Gigabit Ethernet ports for safety SCADA communication. Power on the redundant power supplies and rack—verify “POWER” (green), “LOCKSTEP SYNC” (steady green), and “RUN-SAFE” (green) LEDs are active; redundant CPU shows “STANDBY-SAFE” (flashing green). Use the 90-70 Safety Configuration Software to load safety logic, run SIL verification tests, and calibrate redundant I/O synchronization.

Maintenance recommendations: Conduct hourly automated checks via software—validate lockstep synchronization, communication redundancy, and I/O data consistency. Daily, inspect physical LEDs for fault indicators (red “SAFETY FAULT” LED = immediate action required). Weekly, back up safety logic and fault logs to the CFast card and an off-site server; run a full system redundancy test (trigger manual failover to verify standby CPU operation). Monthly, update safety firmware (only with Emerson-approved patches) and re-run SIL compliance validation. Every 6 months, perform on-site seismic and environmental testing (per IEC 60980) and clean the CPU’s dust filters with dry nitrogen (in nuclear/offshore environments). If a safety fault occurs, activate the built-in fault isolation tool to identify the root cause (e.g., CPU mismatch, communication loss); replace faulty components during scheduled downtime and re-validate the safety loop before restarting. Never hot-swap Emerson IC697CPM790 in safety-critical systems—use the redundant CPU to maintain operation during replacement.

Product Guarantee

Emerson provides a 48-month extended safety guarantee for Emerson IC697CPM790, covering manufacturing defects, safety function failures (e.g., lockstep desynchronization), SIL compliance deviations, and communication redundancy malfunctions under normal use. During the warranty period, if the module fails to meet safety standards or causes an unintended safety loop fault, Emerson provides 24/7 on-site technical support (within 24 hours for nuclear/offshore applications), ships a replacement module via priority air freight, and covers all associated costs (installation, re-calibration, SIL re-verification). Additionally, Emerson offers annual safety audits—validating system compliance with IEC 61508, updating safety documentation, and providing operator training. For nuclear customers, Emerson provides lifetime obsolescence management (up to 40 years) to ensure long-term availability of replacement parts. This guarantee reflects Emerson’s commitment to delivering fault-tolerant, safety-certified control cores for the most critical industrial applications.