Description

GE IC694BME331

The GE IC694BME331 is a processor module. Serving as the "computation and control core" of a PLC system, it mainly undertakes key tasks such as user program execution, I/O module management, data processing, communication coordination, and system diagnosis. Its core function is to run control programs written in programming languages like ladder logic and structured text to collect real-time on-site signals (e.g., sensor data, switch status) from various I/O modules. After logical and arithmetic operations, it outputs control commands to drive the actions of actuators (e.g., valves, motors). Meanwhile, it has capabilities including multi-protocol communication, redundant backup, and online programming, making it suitable for the complex needs of medium and large-scale industrial automation control systems. With its high computing speed, large storage capacity, strong expandability, and industrial-grade reliability, this module is widely used in production line control, process monitoring, and equipment linkage scenarios in fields such as automotive manufacturing, food and beverage processing, metallurgical rolling, and energy management. It is a core component for building highly reliable automation systems.

1. Technical Parameters

1.1 Computing Performance Parameters

• Adopts a 32-bit RISC processor with a core computing frequency of 800MHz.
• Ladder logic execution speed: 0.08μs per instruction; structured text execution speed: 0.04μs per instruction. It supports a cyclic scan cycle of ≤1ms for 10,000-step programs.
• Supports multi-task scheduling, which can divide 8 task priorities. The task switching time is ≤10μs, meeting the parallel processing needs of real-time control and non-real-time monitoring.

1.2 Storage Capacity Parameters

• Built-in 16MB non-volatile user program memory (Flash) that supports permanent program storage without the need for a backup battery when power is off.
• 32MB data memory (RAM), of which 16MB can be configured as a power-off retention area (backed up by a super capacitor with a backup time of ≥72 hours).
• Supports a maximum external SD card expansion of 64MB for program backup, data log storage, and firmware updates.

1.3 Expansion and I/O Management Parameters

• Supports expansion via RX3i series racks, with a maximum of 8 expansion racks connectable, and each rack can be configured with 16 I/O modules.
• Maximum supported I/O points: 8192 digital points, 1024 analog points.
• Supports hot-swappable I/O modules, allowing some I/O modules to be replaced while the system is running without affecting the operation of the main program.
• Built-in I/O scanner that supports batch collection and distribution of I/O data with a scanning rate of ≥1000 points per second.

1.4 Communication and Environmental Parameters

• Integrates 2 Gigabit Ethernet ports (supporting Profinet, EtherNet/IP, and Modbus/TCP protocols) and 1 RS-485 serial port (supporting Modbus-RTU protocol), and supports redundant configuration of Ethernet ports.
• 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 installation inside control cabinets.
• Dimensions: 100mm×160mm×60mm, installed using the RX3i standard rack.

2. Functional Features

2.1 Ultra-high Computing Efficiency, Suitable for Complex Control

The 800MHz high-frequency processor, combined with an optimized instruction set, ensures the fast execution of complex control programs. Even in scenarios with thousands of I/O points connected and multi-loop PID control running, it can still maintain a millisecond-level scan cycle. It supports complex operations such as floating-point arithmetic and trigonometric functions with an accuracy of ±1×10⁻⁶, meeting the needs of scenarios requiring high computing accuracy, such as metallurgical process control and chemical reactor temperature regulation. The multi-task scheduling function can assign control logic, data processing, and communication interaction to tasks of different priorities, preventing non-real-time tasks from affecting the control response speed.

2.2 Flexible Expansion Architecture, Reducing System Costs

It adopts a distributed architecture of "main rack + expansion racks". High-speed data interaction (with a transmission rate of 1Gbps) is achieved through the inter-rack bus. According to the on-site distribution of equipment, I/O modules can be installed in nearby expansion racks, reducing the length of signal cables and interference. It is compatible with all types of I/O modules in the RX3i series (digital, analog, and special function modules such as high-speed counters and pulse output modules). It can adapt to the collection and control needs of different signal types without replacing the processor, greatly improving system expandability and reducing later upgrade costs.

2.3 Multiple Redundancy Designs, Ensuring Reliable Operation

It supports three core redundancy modes: processor redundancy, Ethernet communication redundancy, and power supply redundancy. The dual-processor modules synchronize programs and data in real-time through the redundant bus. When the main processor fails, it can seamlessly switch to the standby processor within ≤10ms without data loss during the switching process. The Ethernet port supports ring network redundancy (e.g., Profinet MRP), and automatically switches to the standby link when the communication link fails. Combined with the RX3i series redundant power supply modules, it can realize uninterrupted switching of the power supply system, with the overall system availability reaching over 99.99%.

2.4 Full-scenario Communication and Convenient Operation & Maintenance

3. Working Principle

3.1 System Initialization and Configuration Loading

After the module is installed in the main rack, it automatically completes hardware self-test when powered on, including the status detection of the processor, memory, communication ports, and rack bus. After passing the self-test, it loads the user program and system configuration parameters (e.g., I/O module model, communication protocol, redundancy mode, task priority) from the Flash memory. At the same time, it automatically identifies all I/O modules in the main rack and expansion racks, assigns module addresses, and establishes an I/O image area. After completing initialization, it enters the running state.

3.2 User Program Execution and Task Scheduling

The core processor schedules and executes user programs according to task priorities. High-priority tasks (e.g., real-time control logic) are executed first, while low-priority tasks (e.g., data log recording) are executed when high-priority tasks are idle. During program execution, it reads real-time collected on-site data from the I/O image area and performs logical operations such as ladder logic and structured text—for example, calculating valve adjustment quantities via the PID algorithm and determining equipment start-stop conditions through interlock logic. The operation results are stored in the output image area.

3.3 I/O Data Interaction and Control Output

The I/O scanner reads input signals (e.g., sensor digital quantities, analog values) from each I/O module at a set cycle (configurable from 1ms to 100ms), updates them to the input image area for program execution and calling. At the same time, it distributes the operation results in the output image area to the corresponding output modules to drive the actions of actuators (e.g., motor starters, solenoid valves), realizing precise control of the production process. It supports interrupt-triggered I/O interaction. When a key input such as an emergency stop signal is detected, it immediately triggers the interrupt service program to quickly respond to control needs.

3.4 Communication Interaction and Status Monitoring

4. Common Faults and Solutions

4.1 Fault 1: Processor Fails to Start, Power Indicator Flashes

Possible Causes

• Abnormal voltage of the power supply.
• Damaged main program or syntax error.
• Memory fault.
• Poor contact of the rack bus.

Solutions

1. Use a multimeter to detect the output voltage of the rack power module and confirm it is within the range of 24V DC ±10%. If abnormal, repair the power supply.
2. Connect to the module via the Proficy Machine Edition software and try to upload the backup program. If a program error is prompted, rewrite or repair the program.
3. Replace with a standby processor module. If it can start normally, the memory of the original module is faulty.
4. Power off, reinsert the processor module, clean the contacts of the rack bus, and ensure good contact.

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

Possible Causes

• Incorrect configuration of the I/O module.
• Module address conflict.
• Rack bus fault.
• Hardware fault of the I/O module.

Solutions

1. Check the system configuration via the programming software to confirm that the I/O module model and address are consistent with the actual installation. If not configured, re-import the configuration file.
2. Check the addresses of all I/O modules to ensure no duplicate addresses. If there is a conflict, reassign the addresses.
3. Replace the I/O module to a standby slot. If it recovers, the bus of the original slot is faulty, and the rack needs to be repaired.
4. Replace with a standby I/O module. If it works normally, the original module is faulty and needs to be returned to the factory for repair.

4.3 Fault 3: Redundancy Switching Fails, Reporting "Master-Standby Synchronization Abnormality"

Possible Causes

• Incompatible firmware versions of the master and standby processors.
• Loose or damaged redundant bus cable.
• Incorrect configuration of synchronization parameters.
• Fault of the standby processor.

Solutions

1. Check the firmware versions of the master and standby processors via the programming software to ensure they are completely consistent. If not, upgrade to the same version.
2. Check the connection of the redundant bus cable, re-tighten the terminals, use a multimeter to detect the continuity of the cable, and replace it with an original cable if damaged.
3. Compare the redundancy configuration parameters (synchronization cycle, switching threshold) of the master and standby processors to ensure they are completely the same.
4. Switch the master-standby roles. If the original standby processor still has abnormalities when acting as the master, the processor is faulty and needs to be replaced.

4.4 Fault 4: Ethernet Communication Interrupted, Unable to Interact with Upper-Level Systems

Possible Causes

• Loose or damaged Ethernet cable.
• IP address conflict or incorrect configuration.
• Mismatched communication protocol.
• Fault of the Ethernet port.

Solutions

1. Reinsert the Ethernet cable, use a cable tester to detect the continuity of the cable, and replace it with a shielded cable if damaged.
2. Check the IP address, subnet mask, and gateway of the processor and the upper-level system to ensure they are in the same network segment and no conflict exists.
3. Confirm that the communication protocols of the processor and the upper-level system are consistent (e.g., both use Modbus/TCP), and check the protocol parameters (e.g., port number, slave address).
4. Replace with a standby Ethernet port for testing. If it recovers, the original port is faulty and needs to be returned to the factory for repair.