GE IC698CPE020-CC | RX7i Central Processing Engine | Obsolete Spare Parts & Risk Assessment
GE IC698CPE020-CC | RX7i Central Processing Engine | Obsolete Spare Parts & Risk Assessment - Image 2
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GE IC698CPE020-CC | RX7i Central Processing Engine | Obsolete Spare Parts & Risk Assessment

  • Model: IC698CPE020-CC
  • Brand: GE (formerly GE Fanuc Intelligent Platforms, now part of Emerson)
  • Core Function: Central Processing Engine (CPU) for the RX7i programmable automation controller (PAC), supporting high-speed logic, motion, and redundancy
  • Lifecycle Status: Obsolete (End-of-Life declared by Emerson)
  • Procurement Risk: Very High – no longer manufactured; limited availability from secondary sources with inconsistent testing documentation
  • Critical Role: Primary controller in RX7i-based systems; failure results in complete loss of logic execution, I/O scanning, and communication—leading to unplanned plant shutdowns
Category: SKU: GE IC698CPE020-CC

Description

Key Technical Specifications (For Spare Parts Verification)

  • Product Model: IC698CPE020-CC
  • Manufacturer: GE Fanuc / GE Automation (now Emerson)
  • System Family: RX7i PAC Platform
  • Processor Type: Intel-based embedded CPU (300 MHz class)
  • Memory: 16 MB user program memory, 8 MB data memory (non-volatile via onboard battery-backed SRAM)
  • Redundancy Support: Yes – supports hot-standby redundant CPU configuration with IC698CRE020
  • Backplane Interface: 32-bit, 50 MHz RX7i backplane bus
  • Communication Ports: Built-in RS-485 (serial), plus support for Ethernet modules (e.g., IC698CMM020)
  • Power Consumption: Approx. 5.5 A @ 5 VDC from backplane
  • Operating Temperature: 0°C to 60°C
  • Battery Type: BR2032 lithium coin cell for SRAM backup (field-replaceable)

System Role and Downtime Impact

The IC698CPE020-CC serves as the central brain of the RX7i control system, commonly deployed in power generation, water/wastewater, oil & gas, and heavy manufacturing. It executes ladder logic, manages distributed I/O racks, coordinates motion over SERCOS or Profibus, and interfaces with HMI and SCADA via Ethernet. In non-redundant installations, a failure of this CPU halts all control functions instantly—stopping pumps, conveyors, valves, or turbines. Even in redundant setups, degradation of the primary unit can trigger unnecessary switchover events, increasing operational risk. Given its role in continuous processes, unplanned downtime due to CPU failure can incur losses exceeding tens of thousands of dollars per hour.

 

Reliability Analysis and Common Failure Modes

Despite robust industrial design, units aged 10–20 years exhibit predictable failure patterns:

  • Battery-backed SRAM corruption: The BR232 battery depletes over time (typical life: 5–7 years). If not replaced proactively, program and configuration data are lost during power cycles.
  • Electrolytic capacitor aging: Internal DC/DC regulators use capacitors that dry out, causing voltage instability, random reboots, or failure to boot.
  • Backplane connector fatigue: Repeated thermal expansion/contraction leads to intermittent contact with the rack, manifesting as “I/O not responding” or watchdog faults.
  • Firmware lockup: Rare but possible due to memory bit flips or EMI-induced processor stalls, especially in electrically noisy environments.

Design vulnerabilities include reliance on a single backup battery and lack of built-in diagnostics for early capacitor wear. For preventive maintenance, technicians should:

  • Replace the backup battery every 4–5 years during scheduled outages
  • Monitor CPU status LEDs for “RUN,” “OK,” and “BATT” warnings
  • Perform annual firmware integrity checks using Proficy Machine Edition
  • Ensure cabinet temperature remains below 50°C to extend component life
GE IC698CPE020-CC

GE IC698CPE020-CC

Lifecycle Status and Migration Strategy

Emerson has officially discontinued the RX7i platform, including the IC698CPE020-CC, with support redirected toward the PACSystems RX3i and RXi2 families. No new units are produced, and factory repair services are no longer available. Continuing to operate with this CPU introduces significant risk: no access to genuine spares, inability to recover from configuration loss without backups, and growing difficulty sourcing compatible programming software licenses.

As an interim measure, facilities may:

  • Secure tested, functional units from certified surplus vendors with full boot-and-logic verification
  • Maintain up-to-date program backups in multiple formats (including GDB and source code)
  • Implement external watchdog relays to force safe shutdown if CPU communication is lost

For long-term sustainability, Emerson recommends migrating to the PACSystems RXi2 platform. This path typically involves:

  • Replacing the CPU and backplane with RXi2-compatible hardware
  • Reusing existing I/O modules where possible (via adapter kits in some cases)
  • Converting logic using Proficy’s project migration tools, followed by rigorous functional testing
  • Upgrading operator interfaces to leverage modern cybersecurity and remote access features

Given its central role in process control integrity, the obsolescence of the IC698CPE020-CC demands immediate attention through either strategic sparing or inclusion in a formal control system modernization roadmap.

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