GE Automation & Controls IC698CRE020 PLC Redundancy Module

Product Details

IC698CRE020 Product Description

The GE IC698CRE020 is a dedicated Redundancy Control Module engineered for the PACSystems RX7i platform, delivering seamless hot-standby redundancy across the full IC698 control architecture. Designed to operate within GE's high-availability automation framework, the IC698CRE020 coordinates primary and secondary CPU synchronization, manages redundancy state transitions, and ensures uninterrupted process control across mission-critical industrial environments. Its role within the control hierarchy spans the control layer, communication layer, power layer, and diagnostic layer, making it a foundational component for any engineer specifying fault-tolerant PLC architectures in manufacturing, energy, petrochemical, water treatment, or heavy process industries.

The IC698CRE020 integrates directly with the IC698CPE030 and IC698CPE040 CPU modules, synchronizing scan-cycle data and I/O state tables across the primary and secondary racks. This synchronization is managed over a dedicated fiber-optic redundancy link, ensuring that switchover times remain within the sub-100ms range required for continuous process control. When paired with the IC698PSA100 or IC698PSA350 power supply modules, the redundancy architecture achieves full power-layer isolation, eliminating single points of failure at the rack level. The module's compatibility with the IC698CHS009 and IC698CHS017 nine-slot and seventeen-slot backplanes allows engineers to configure scalable redundancy architectures without compromising I/O density or communication throughput.

Within the communication layer, the IC698CRE020 supports integration with IC695ETM001 Ethernet interface modules and IC695PBM300 PROFIBUS master modules, enabling the redundant controller pair to maintain consistent fieldbus communication during switchover events. This is particularly critical in distributed control architectures where PROFIBUS DP slaves, remote I/O racks, and intelligent field devices must continue operating without interruption. The module also supports coordination with IC695CMM002 serial communication modules for legacy serial device integration, ensuring backward compatibility across mixed-generation control architectures.

For I/O layer integrity, the IC698CRE020 works in conjunction with IC698MDL740 discrete output modules and IC698ALG728 analog I/O modules, maintaining synchronized I/O state tables across both controller racks. This ensures that field signals — whether discrete 24VDC inputs, analog 4–20mA process variables, or thermocouple inputs — are accurately reflected in both the primary and secondary CPU scan cycles. The result is a control architecture where I/O data integrity is preserved even during planned maintenance switchovers or unplanned fault events.

At the HMI and SCADA layer, the IC698CRE020-equipped redundant system interfaces seamlessly with GE iFIX and Proficy HMI/SCADA platforms via OPC-DA and OPC-UA server connections. Operators monitoring process variables through Proficy Plant Applications or third-party DCS integration points experience no data discontinuity during redundancy switchover, as the Ethernet communication path is maintained transparently by the IC695ETM001 interface module. This architecture supports the engineering requirement for zero-visible-impact switchover in operator display environments.

The IC698CRE020 is supplied with a 12-Month Warranty covering manufacturing defects, firmware integrity, and module-level functional performance. Each unit undergoes pre-shipment functional testing including redundancy link verification, CPU synchronization handshake validation, and power-on self-test (POST) confirmation. Stock availability is maintained for immediate dispatch, with standard lead times of 3–7 business days for international shipments. All units are packaged in ESD-protective materials with full documentation including module revision history and firmware compatibility notes.

A complete PACSystems RX7i redundant control architecture built around the IC698CRE020 typically incorporates the following modules and components across all system layers:

At the control layer, dual IC698CPE040 CPU modules serve as the primary and secondary controllers, with the IC698CRE020 managing the synchronization handshake and state-transfer protocol between them. The IC698CHS017 seventeen-slot backplane provides the physical rack infrastructure for both controller racks, supporting full I/O module population without slot restrictions.

At the power layer, redundant IC698PSA350 power supply modules — one per rack — ensure that a power supply failure in either the primary or secondary rack does not trigger an unplanned process interruption. The IC698CRE020 monitors power status across both racks and incorporates power fault conditions into its redundancy state machine.

At the I/O layer, IC698MDL740 32-point 24VDC discrete output modules and IC698ALG728 16-channel analog I/O modules populate the I/O slots of both racks. The IC698CRE020 ensures that I/O state tables are synchronized across both CPUs on every scan cycle, so that field device outputs remain consistent regardless of which CPU is currently active.

At the communication layer, IC695ETM001 Ethernet TCP/IP interface modules provide the primary SCADA and HMI communication path, while IC695PBM300 PROFIBUS DP master modules manage fieldbus communication to remote I/O stations and intelligent field devices. The IC698CRE020 coordinates communication module state during switchover to prevent fieldbus communication interruption.

At the HMI layer, GE Proficy HMI/SCADA — iFIX operator stations connect to the redundant controller pair via OPC-UA, with the active CPU transparently serving all HMI data requests. Operator displays show no indication of switchover events, maintaining process visibility continuity.

At the protection and diagnostic layer, the IC698CRE020 provides built-in redundancy health diagnostics accessible via the Proficy Machine Edition programming environment, including primary/secondary status LEDs, switchover event logging, and redundancy link integrity monitoring. These diagnostics support rapid fault isolation during commissioning and long-term maintenance cycles.

The IC698CRE020 is deployed across a broad range of high-availability industrial control applications where process continuity is a non-negotiable engineering requirement:

In power generation and transmission facilities, the IC698CRE020-based redundant architecture manages turbine control, generator excitation, and substation automation sequences where an unplanned controller failure would result in generation loss or grid instability. The sub-100ms switchover time meets the response requirements of power system protection relays and SCADA supervisory systems.

In petrochemical and refinery environments, the IC698CRE020 supports continuous process control for distillation columns, reactor temperature loops, and compressor surge control systems. The hot-standby redundancy architecture eliminates the need for planned process shutdowns during controller maintenance, reducing annual downtime costs and improving overall equipment effectiveness (OEE).

In water and wastewater treatment plants, the IC698CRE020 manages pump sequencing, chemical dosing control, and SCADA telemetry for distributed treatment facilities. The redundant architecture ensures that critical process interlocks — including high-level shutoffs and chemical feed controls — remain active even during controller switchover events.

In mining and metals processing operations, the IC698CRE020 supports conveyor control, crusher sequencing, and flotation cell management in environments characterized by high vibration, dust, and electrical noise. The fiber-optic redundancy link provides immunity to the electromagnetic interference common in mining electrical environments.

In packaging and discrete manufacturing lines, the IC698CRE020 enables high-speed production line control with redundancy switchover times that are transparent to servo drive and motion control systems coordinated via the IC695ETM001 Ethernet interface.

Q1: Is the IC698CRE020 compatible with both IC698CPE030 and IC698CPE040 CPU modules, and are there firmware version requirements for redundancy operation? A: Yes, the IC698CRE020 is compatible with both the IC698CPE030 and IC698CPE040 CPU modules. For redundancy operation, both CPUs in the primary and secondary racks must run identical firmware versions, and the IC698CRE020 firmware must be compatible with the installed CPU firmware release. GE Proficy Machine Edition version 8.0 or later is recommended for redundancy configuration and online monitoring. NANKMOS supplies IC698CRE020 units with documented firmware revision information to support compatibility verification prior to installation.

Q2: What is the recommended maintenance procedure for the IC698CRE020 in a live redundant system, and how does the 12-Month Warranty apply to field-replaced modules? A: In a live redundant system, the IC698CRE020 can be replaced in the secondary rack while the primary rack maintains process control, following GE's documented hot-standby maintenance procedure. After replacement, the new module performs an automatic synchronization sequence with the primary CPU before the system returns to full redundancy status. The 12-Month Warranty covers the replacement IC698CRE020 from the date of shipment from NANKMOS, and applies to manufacturing defects and functional performance under normal operating conditions. Warranty claims are processed with full RMA support and expedited replacement dispatch.

Q3: How does the IC698CRE020 handle redundancy switchover in architectures that include PROFIBUS DP fieldbus networks, and what is the impact on connected field devices? A: During a redundancy switchover event, the IC698CRE020 coordinates the transfer of PROFIBUS DP master control from the primary IC695PBM300 module to the secondary rack's IC695PBM300 module. The switchover is managed within the sub-100ms window, which is within the watchdog timeout tolerance of most PROFIBUS DP slave devices. Field devices — including remote I/O stations, variable frequency drives, and intelligent transmitters — typically experience no communication interruption visible at the process level. For applications with strict fieldbus timing requirements, NANKMOS recommends pre-commissioning switchover testing to validate field device behavior under the specific network configuration.