Description

GE IC695CPE310

The GE IC695CPE310 is a processor module for the PACSystems RX7i series of Programmable Automation Controllers (PACs). Serving as the "computational core and control hub" of the PAC system, it integrates the real-time logic control capabilities of a PLC and the complex data processing capabilities of a PC. Its primary responsibilities include executing large-scale user programs, managing distributed I/O networks, processing multi-source data fusion, coordinating cross-system communications, and diagnosing the entire system.\

Its core function is to run multi-language control programs (such as ladder logic and structured text) based on the IEC 61131-3 standard. It collects real-time on-site signals (e.g., industrial sensor data, equipment operating status) from distributed I/O nodes, and after logical operations, process control algorithms (such as multi-loop PID), and data processing, it outputs precise control commands to drive the actions of actuators like valves and motors. Additionally, it features advanced capabilities including high-bandwidth communication, dual-machine hot standby redundancy, massive data storage, and online debugging, making it suitable for the high complexity and high reliability requirements of large and extra-large industrial automation control systems.

With its ultra-high computing performance, strong expandability, excellent redundancy design, and industrial-grade stability, this module is widely used in critical fields such as power grid monitoring, large-scale petrochemical equipment control, rail transit signal control, and integrated metallurgical automation. It is a core pillar component for building large-scale, high-end automation systems.

1. Technical Parameters

1.1 Computing Performance Parameters

• Adopts a multi-core 32-bit high-performance RISC processor with a core computing frequency of 1.2GHz, supporting a parallel processing architecture.
• Basic instruction execution speed: 0.02μs per instruction; ladder logic execution speed: 0.05μs per instruction; structured text execution speed: 0.03μs per instruction. It supports a cyclic scan cycle of ≤2ms for 100,000-step programs.
• Supports multi-task priority scheduling, with 16 task priorities configurable (8 of which are real-time tasks). Task switching time is ≤5μs, and interrupt service routine (ISR) response time is ≤1μs, meeting millisecond or even microsecond response scenarios such as power grid fault protection and chemical emergency shutdowns.

1.2 Storage Capacity Parameters

• Built-in 32MB non-volatile user program memory (Flash), supporting permanent program storage without the need for a backup battery when power is off.
• 64MB high-speed data memory (RAM), of which 32MB can be configured as a power-off retention area (backed by super capacitor + Flash dual backup, with a backup time of ≥168 hours).
• Supports a maximum external CF card expansion of 256MB for program backup, massive data log storage, firmware updates, and historical data archiving.
• Built-in 1MB high-speed cache (Cache) to improve program execution and data access efficiency.

1.3 Expansion and I/O Management Parameters

• Supports expansion via RX7i series distributed racks and remote I/O modules, with up to 16 local expansion racks and 32 remote I/O nodes connectable (supporting Profinet and EtherNet/IP remote I/O).
• Maximum supported I/O points: 32,768 digital points, 4,096 analog points.
• Supports hot-swappable I/O modules and processor modules; replacing modules during system operation does not interrupt the control process.
• Built-in distributed I/O scanner, supporting batch collection and distribution of I/O data with a scanning rate of ≥5,000 points per second. It also supports I/O data filtering and deadband configuration to reduce invalid data transmission.

1.4 Communication and Environmental Parameters

• Integrates 4 Gigabit Ethernet ports (supporting protocols such as Profinet V2.3, EtherNet/IP, Modbus/TCP, and IEC 61850 MMS), 2 RS-485 serial ports (supporting Modbus-RTU and DNP3.0 protocols), and 1 PCIe expansion slot (for expanding interface modules such as fiber optic communication and dedicated industrial buses).
• Supports Ethernet ring network redundancy (Profinet MRP, EtherNet/IP DLR) with a ring network recovery time of ≤20ms.
• Operating temperature: 0℃~60℃; storage temperature: -40℃~85℃.
• Relative humidity: 5%~95% (no condensation).
• Vibration resistance rating: IEC 60068-2-6 (10Hz~500Hz, acceleration 5g).
• Shock resistance rating: IEC 60068-2-27 (peak acceleration 15g, duration 11ms).
• Protection rating: IP20 (rack-mounted), suitable for high-integration installation environments inside control cabinets.
• Dimensions: 140mm×180mm×80mm, installed using the RX7i standard rack.

2. Functional Features

2.1 Multi-Core Parallel Computing for Complex Control

The 1.2GHz multi-core processor adopts a task-slicing parallel processing architecture, which can assign real-time control logic, data processing, and communication interaction to different cores for independent execution. For example, one core focuses on real-time computing for 100+ loop PID control, while another core handles high-speed data interaction with the SCADA system, avoiding single-core bottlenecks. It supports high-precision process control algorithms such as PID auto-tuning, fuzzy control, and Model Predictive Control (MPC), with a floating-point calculation accuracy of ±1×10⁻⁹, meeting the high-precision requirements of scenarios such as multi-variable coupled control of temperature and pressure in chemical reactors.

2.2 Global Expansion Architecture for Large-Scale Systems

It adopts a global expansion mode of "local rack + distributed remote I/O", realizing high-speed data interaction (transmission rate 1Gbps) between local and remote I/O nodes via Gigabit industrial Ethernet. According to the equipment distribution in large factories, remote I/O stations can be deployed in different workshops to reduce signal attenuation and interference during long-distance transmission. It is compatible with all types of RX7i series modules, including digital I/O, analog I/O, high-speed counters, pulse outputs, weighing modules, temperature modules, and other special function modules. It can adapt to diversified signal collection and control needs without replacing the processor, enabling flexible system expansion and controllable costs.

2.3 Triple Redundancy Design for Maximum Reliability

2.4 Multi-Protocol Intelligent Connectivity and Efficient O&M

3. Working Principle

3.1 System Initialization and Configuration Loading

After the module is installed in the local main rack, it automatically initiates multi-core processor self-test and system hardware inspection when powered on, covering key components such as processor cores, memory, communication interfaces, redundant buses, and rack buses. Upon passing the self-test, it loads user programs and system configuration parameters (e.g., I/O module model, address, communication protocol, redundancy mode, task allocation strategy) from the Flash memory. It automatically scans the local rack and all remote I/O nodes, establishes a global I/O image area and device address mapping table, and enters the operating state after initialization. Meanwhile, the standby processor synchronizes the initialization state via the redundant bus.

3.2 Parallel Execution of User Programs and Task Scheduling

Based on the preset task allocation strategy, the multi-core processor assigns tasks of different priorities to corresponding cores for parallel execution. High-priority real-time tasks (e.g., emergency shutdown logic, PID control) occupy 100% of the core’s computing power to ensure response speed, while low-priority tasks (e.g., data logging, report generation) run during idle periods. During program execution, it reads real-time collected data from each node in the global I/O image area and performs operations such as logical calculations and process control algorithms (e.g., dynamically adjusting the feed rate of a chemical reactor via PID auto-tuning algorithms). The calculation results are stored in the output image area.

3.3 Global I/O Interaction and Control Output

The distributed I/O scanner collects input signals from local and remote I/O nodes synchronously at a configurable cycle (0.1ms~100ms). After data verification and filtering, it updates the global I/O image area for program execution and calling. At the same time, it distributes the control commands in the output image area to the corresponding local or remote output modules according to device addresses, driving the actions of actuators to realize centralized control of distributed equipment. It supports an interrupt trigger mechanism: when emergency signals such as power grid faults or equipment over-limit are detected, it immediately triggers a high-priority interrupt service routine to execute protective actions quickly.

3.4 Multi-Protocol Communication and Redundancy Synchronization

4. Common Faults and Solutions

4.1 Fault 1: Dual-Machine Hot Standby Redundancy Fails to Establish, Reporting "Redundancy Synchronization Failure"

Possible Causes

• Incompatible firmware versions of the main and standby processors.
• Loose or damaged redundant bus cables.
• Inconsistent redundancy configuration parameters.
• Hardware failure of the standby processor.
• Rack bus failure.

Solutions

1. Verify the firmware versions of the main and standby processors using Proficy Machine Edition software to ensure they are identical. If not, upgrade to the same official version.
2. Check the connection of the redundant bus cables, re-tighten the terminals at both ends, and test the cable continuity with a dedicated tester. Replace with original redundant bus cables if damaged.
3. Compare the redundancy configuration parameters (synchronization cycle, switching conditions, synchronization range of the I/O image area) of the main and standby processors to ensure they are identical. Re-issue the configuration and restart the redundant system.
4. Swap the roles of the main and standby processors. If synchronization still fails when the original standby processor acts as the main processor, the processor has a hardware failure and needs replacement.
5. Inspect the main rack bus and test with a standby rack to rule out rack bus failures.

4.2 Fault 2: Remote I/O Nodes Unresponsive, Unable to Collect or Output Signals

Possible Causes

• Power failure of the remote I/O node.
• Interrupted communication link.
• Node address conflict.
• Failure of the remote I/O module.
• Incorrect remote I/O configuration of the processor.

Solutions

1. Check the output voltage of the power module at the remote I/O node to ensure it is within the standard range. Repair or replace the power supply if abnormal.
2. Test the Ethernet link between the processor and the remote node with a network tester to check for packet loss or disconnection. Re-plug the network cable or test with a different switch port.
3. Verify the addresses of all remote I/O nodes to ensure no duplicates. Reassign addresses if conflicts exist.
4. Replace the faulty node module with a standby remote I/O module. If functionality is restored, the original module is faulty.
5. Check the remote I/O configuration via programming software to confirm the node model, communication protocol, and address match the actual setup. Re-import the configuration file and restart the node.

4.3 Fault 3: Communication with Upper-Level SCADA System Interrupted, Unable to Upload Data

Possible Causes

• Loose or damaged Ethernet cables.
• Incorrect IP address or subnet mask configuration.
• Mismatched communication protocol parameters.
• Failure of the Ethernet port.
• Failure of the SCADA system’s communication port.

Solutions

1. Re-plug the Ethernet cable, test its continuity with a cable tester, and replace with a Gigabit shielded Ethernet cable if damaged.
2. Verify the IP address, subnet mask, and gateway of the processor and SCADA system to ensure they are in the same network segment with no conflicts. Test network connectivity using the ping command.
3. Confirm the communication protocol and parameters are consistent between both parties (e.g., Modbus/TCP port number and slave address, Profinet device name).
4. Switch the processor’s Ethernet port to a standby port, reconfigure, and test. If functionality is restored, the original port is faulty.
5. Connect a standby processor to the SCADA system’s communication port. If the interruption persists, repair the SCADA system’s port.

4.4 Fault 4: Abnormal Program Execution, Resulting in Logical Errors or Control Delays

Possible Causes

• Syntax or logical errors in the user program.
• Unreasonable task priority configuration.
• Severe memory fragmentation.
• High processor load.
• Program crash caused by interference.

Solutions

1. Perform syntax checks and logical simulations on the user program using programming software to locate and correct logical errors (e.g., infinite loops, conflicting interlock conditions).
2. Optimize task priority configuration: set real-time control tasks to high priority and non-real-time tasks to low priority to prevent preemption of high-priority tasks.
3. Back up the user program, format the processor’s internal memory, re-download the program, and clear fragmented data.
4. Monitor the load of each processor core via software. If the load remains ≥90%, simplify the program or increase task slicing to distribute the load.
5. Check the grounding of the control cabinet to ensure the module’s grounding resistance is ≤4Ω. Add electromagnetic shielding measures to reduce interference.