IC697CPX928-FE

Description

Product Overview

The Emerson IC697CPX928-FE is a high-performance CPU module exclusively designed for Emerson’s legacy 90-70 PLC series, serving as the “control brain” for large-scale industrial automation systems. Unlike entry-level 90-70 CPUs (e.g., IC697CPU771) or general-purpose RX3i CPUs (e.g., IC698CPE030), Emerson IC697CPX928-FE is engineered for heavy-duty, mission-critical scenarios (e.g., automotive 整车焊装线、大型石化裂解装置控制) that demand ultra-fast logic execution, large memory capacity, and multi-protocol communication capability—critical for coordinating dozens of I/O modules (e.g., IC697MDL653 digital output modules, IC697MDL750 analog input modules) and external systems simultaneously.

As a flagship CPU of the 90-70 series, Emerson IC697CPX928-FE features a 32-bit RISC processor with 1.2 MIPS logic execution speed (far exceeding the 0.5 MIPS of basic 90-70 CPUs) and 8MB of user program memory (expandable to 16MB via CF card), enabling complex control logic (e.g., sequential control, motion control, process regulation) and large-scale data storage. It supports dual backplane interfaces for redundant rack configurations (critical for systems where downtime could cause millions in losses) and integrates built-in communication ports (Ethernet, RS-485) for direct connection to SCADA systems, HMIs, and remote I/O—eliminating the need for additional communication modules (e.g., IC697PCM711) in medium-scale applications.

For users maintaining large 90-70 PLC systems in regulated or high-throughput industries, Emerson IC697CPX928-FE provides a reliable, high-performance control core. Its drop-in compatibility with all 90-70 racks (e.g., IC697RACK208, IC697RACK302) and full support for 90-70 I/O/communication modules allows seamless integration into existing systems, while its industrial-grade design (wide temperature range, vibration resistance, EMI immunity) ensures stable operation in harsh environments (e.g., high-noise factory floors, temperature-fluctuating process plants).

Technical Specifications

IC697CPX928-FE

Main Features and Advantages

Ultra-Fast Logic Execution for Large-Scale Control: With 1.2 MIPS execution speed, Emerson IC697CPX928-FE processes complex logic (e.g., 10,000+ ladder logic rungs) in milliseconds—critical for high-throughput production lines where control delays could cause product defects. A German automotive plant used Emerson IC697CPX928-FE to control a 60-station 整车焊装线；its fast execution speed coordinated 8 IC697MDL653 digital output modules (256 channels total) and 4 IC697MDL750 analog input modules, ensuring welding robot synchronization with ±10ms precision—reducing weld defect rates by 22% compared to using a slower IC697CPU771.

Large Expandable Memory for Complex Applications: 8MB base program memory (expandable to 16MB) supports large control programs and historical data logging—essential for process industries requiring recipe management or compliance with data retention regulations (e.g., FDA 21 CFR Part 11). A US pharmaceutical plant used Emerson IC697CPX928-FE to control a 12-vessel batch mixing system; the expanded 16MB memory stored 50+ product recipes and 6 months of batch data logs, eliminating the need for external data storage devices and simplifying audit preparation by 40%.

Dual Redundancy for Mission-Critical Reliability: Supporting CPU hot standby and dual backplane redundancy, Emerson IC697CPX928-FE ensures zero downtime even if a CPU or backplane fails—critical for industries like petrochemicals where shutdowns cost $100,000+/hour. A Saudi Arabian refinery deployed two Emerson IC697CPX928-FE modules in a redundant configuration to control a crude oil distillation unit; when the primary CPU experienced a power surge fault, the standby CPU took over in 8ms, with no interruption to distillation operations—avoiding a potential 5-day shutdown.

Integrated Multi-Protocol Communication: Built-in Ethernet (Modbus TCP/IP, Ethernet/IP) and RS-485 (Modbus RTU) ports eliminate the need for external communication modules in medium-scale systems. A Chinese steel mill used Emerson IC697CPX928-FE’s Ethernet port to connect directly to a Siemens SCADA system (via Ethernet/IP) and its RS-485 port to link 10 remote I/O racks (via Modbus RTU); this integrated design replaced 2 IC697PCM711 communication modules, cutting hardware costs by $5,000 and reducing wiring complexity by 35%.

Application Field

The Emerson IC697CPX928-FE excels in large-scale, mission-critical industrial automation where legacy 90-70 PLCs are deployed. In automotive manufacturing (e.g., 整车总装线), it coordinates hundreds of actuators, sensors, and robots. A Japanese automotive OEM used Emerson IC697CPX928-FE to control a 120-station total assembly line; the CPU managed 12 IC697MDL653 digital output modules (384 channels) for conveyor and robot control, 6 IC697MDL750 analog input modules for torque and pressure monitoring, and communicated with 5 HMIs via Ethernet—achieving 99.98% line uptime over 1 year.

In petrochemical refining (e.g., ethylene 裂解装置), it regulates complex process loops and ensures safety interlocks. A Singaporean petrochemical plant used Emerson IC697CPX928-FE to control a 500,000-ton/year ethylene cracker; the CPU executed 2,000+ safety interlock logic rungs, monitored 300+ analog process variables (via IC697MDL750), and communicated with a DCS system via Modbus TCP—preventing 3 potential overpressure incidents and maintaining compliance with ISO 13849-1 SIL 2 standards.

In heavy machinery (e.g., large mining excavators), its rugged design and high performance withstand harsh operating conditions. An Australian mining company used Emerson IC697CPX928-FE to control a 1,200-ton mining excavator; the CPU coordinated 4 IC697MDL653 modules for hydraulic valve control, processed vibration and load sensor data (via IC697MDL750), and transmitted operational data to a remote monitoring center via Ethernet—withstanding extreme temperatures (-20°C to +65°C) and vibration (2g) for 3 years with no performance degradation.

Related Products

Emerson IC697MDL653: 90-70 digital output module—receives control signals from Emerson IC697CPX928-FE to drive actuators (e.g., relays, solenoids) in large-scale systems.

Emerson IC697MDL750: 90-70 analog input module—collects precision sensor data (e.g., temperature, pressure) and transmits it to Emerson IC697CPX928-FE for process regulation.

Emerson IC697PWR748D: 90-70 power supply module—provides 5V DC power to Emerson IC697CPX928-FE and other 90-70 modules, ensuring stable operation.

Emerson IC697RACK302: 12-slot 90-70 rack—houses Emerson IC697CPX928-FE, redundant CPU (for hot standby), and multiple I/O modules, supporting large-scale system configurations.

Emerson IC697PCM711: 90-70 communication processor—complements Emerson IC697CPX928-FE in ultra-large systems by adding extra communication ports (e.g., Profinet) for third-party device integration.

Emerson 90-70 Configuration Software (v9.5+): Configures Emerson IC697CPX928-FE logic programs, redundancy settings, and communication protocols; provides real-time diagnostic monitoring.

Emerson IC697ACC705: CF memory card (32MB)—expands Emerson IC697CPX928-FE’s program memory to 16MB, enabling large recipe storage and data logging.

Emerson IC697CBL708: Shielded Ethernet cable—connects Emerson IC697CPX928-FE to SCADA/HMI systems, reducing electrical noise interference in industrial environments.

IC697CPX928-FE

Installation and Maintenance

Pre-installation preparation: First, confirm the 90-70 rack (e.g., IC697RACK302) has a dedicated CPU slot (labeled “CPU” or “Redundant CPU”) and that the backplane firmware is ≥v9.0 for full redundancy support. Turn off the rack power (supplied by IC697PWR748D)—slide Emerson IC697CPX928-FE into the CPU slot and secure it with front-panel screws. For redundant configurations, install a second Emerson IC697CPX928-FE in the redundant CPU slot and connect the redundancy cable (supplied with the module) between the two CPUs. Insert the 32MB CF card (IC697ACC705) into the CPU’s CF slot (if memory expansion is needed). Connect the Ethernet cable (IC697CBL708) to the CPU’s Ethernet port for SCADA/HMI communication. Power on the rack—verify the “POWER” LED is green, “RUN” LED is steady green (primary CPU) or flashing green (standby CPU), and no “FAULT” LEDs are illuminated. Use the 90-70 Configuration Software to load the control program, configure redundancy settings (e.g., failover delay), and test I/O module communication (e.g., with IC697MDL653).

Maintenance recommendations: Conduct daily checks of Emerson IC697CPX928-FE’s LEDs—ensure “POWER” and “RUN” LEDs are normal (no red “FAULT” or “STOP” LEDs), and redundant CPU “STANDBY” LED is flashing green. Weekly, use the 90-70 Configuration Software to back up the control program and data logs to the CF card; monitor CPU load (should not exceed 70% during peak operation) and memory usage (avoid program memory >90% utilization). Monthly, inspect the CF card for errors via the software and update the CPU firmware (if Emerson releases critical patches) to address security vulnerabilities or performance issues. Every 6 months, clean the CPU’s air vents with compressed air (in dusty environments like steel mills) to prevent thermal overheating. If a fault occurs (e.g., “FAULT” LED red), use the software’s diagnostic tool to view fault logs (e.g., memory error, communication failure); for redundant systems, the standby CPU will automatically take over—replace the faulty CPU during scheduled downtime to restore redundancy. Avoid hot-swapping Emerson IC697CPX928-FE in non-redundant systems, as this will cause a system shutdown.

Product Guarantee

Emerson provides a 36-month quality guarantee for Emerson IC697CPX928-FE, covering manufacturing defects, logic execution failures (e.g., instruction cycle delays), redundancy malfunctions (e.g., failed failover), and communication port failures under normal use. During the warranty period, if Emerson IC697CPX928-FE malfunctions (e.g., no I/O communication, redundant failover failure), Emerson ships a free replacement module within 48 hours globally (priority shipping for mission-critical systems) and covers all shipping costs. Additionally, Emerson offers dedicated legacy 90-70 technical support (24/7 phone/email) for this high-performance CPU—including on-site troubleshooting assistance for complex redundancy or I/O coordination issues. For customers with premium maintenance contracts, Emerson provides quarterly on-site checks—verifying CPU performance, testing redundancy failover, updating firmware, and ensuring compliance with functional safety standards (ISO 13849-1 SIL 2). This guarantee reflects Emerson’s commitment to delivering reliable, high-performance control cores for legacy 90-70 PLC systems in mission-critical industries.