GE Fanuc IC698CRE030 Retrofit CPU Redundancy for Legacy Systems

GE Fanuc IC698CRE030 Retrofit CPU Redundancy for Legacy Systems

The GE Fanuc IC698CRE030 is a PACSystems RX7i CPU Redundancy Memory Xchange Module engineered to deliver seamless hot-standby redundancy within the IC698 rack architecture. As industrial facilities face the growing challenge of maintaining aging Series 90-70 control platforms, the IC698CRE030 provides a proven retrofit path that preserves existing program logic, rack infrastructure, and field wiring while introducing the reliability and processing power of the PACSystems RX7i platform. For modernization engineers managing legacy PLC migrations, this module represents one of the most cost-effective and low-risk upgrade solutions available in the GE Fanuc ecosystem.

The IC698CRE030 operates within the PACSystems RX7i chassis — the IC698 series rack — and works in conjunction with the IC698CPE030 or IC698CPE040 CPU modules to establish a fully redundant controller pair. When one CPU detects a fault, the redundancy memory exchange mechanism ensures bumpless switchover, protecting continuous production without operator intervention. This capability is especially critical in retrofit scenarios where the original Series 90-70 system lacked hardware redundancy and where unplanned downtime carries significant operational and safety consequences.

Upgrade Compatibility Table

Retrofit Planning for Existing Automation Systems

A successful IC698CRE030 retrofit begins well before the module arrives on site. Modernization engineers should start by auditing the existing Series 90-70 rack configuration, documenting every slot assignment, I/O module address, and inter-rack communication link. The IC698CRE030 installs into the PACSystems RX7i rack alongside the primary and secondary CPU modules — typically the IC698CPE030 — and requires that both CPUs share identical firmware revisions to enable stable memory exchange synchronization.

Power supply capacity is a critical checkpoint. The IC698PSA100 (100W) power supply is sufficient for smaller rack configurations, but facilities running fully populated 17-slot racks with high-density I/O — such as the IC698MBR002 Genius Bus Controller or multiple IC694MDL754 discrete output modules — should verify that the IC698PSA350 (350W) supply is installed to handle peak load. Undersized power supplies are a leading cause of intermittent redundancy faults during switchover events.

Backplane slot addressing must be reconfigured in Proficy Machine Edition when migrating from a Series 90-70 hardware configuration. Engineers should export the original Series 90-70 program from the legacy IC693CPU374 or IC693CPU364 controller before decommissioning, then use PME’s hardware configuration import tools to map existing I/O references to the new RX7i rack layout. Analog input modules such as the IC694ALG220 and discrete I/O modules like the IC694MDL340 are often retained in the field junction boxes and connected via terminal blocks to the new rack — confirming terminal wiring compatibility before cutover eliminates the most common source of retrofit delays.

Communication architecture migration deserves particular attention. Many legacy Series 90-70 systems relied on Genius Bus (IC660) fieldbus networks managed by a Genius Bus Controller. During retrofit, engineers must decide whether to retain the existing Genius network via an IC698MBR002 Genius Bus Controller in the new RX7i rack, or migrate field devices to Ethernet-based I/O using IC695ETM001 Ethernet modules. Either path is supported by the IC698CRE030 redundancy architecture, but the decision affects HMI screen updates, tag database migration in iFIX or CIMPLICITY SCADA, and the overall commissioning timeline.

Signal isolators and surge protection devices installed between field instruments and I/O terminals should be inspected and tested during the retrofit window. Replacing aging DIN-rail mounted signal isolators and verifying fuse integrity in the power distribution panel reduces the risk of nuisance faults appearing after the new system goes live. Programming cables and USB-to-serial adapters compatible with PME should be on hand for on-site configuration adjustments.

Downtime Control During System Migration

Minimizing downtime during an IC698CRE030 retrofit requires a phased cutover strategy. The recommended approach is to pre-configure and bench-test the complete RX7i rack assembly — including the IC698CRE030, both CPU modules, power supply, and all I/O modules — before the scheduled maintenance window. Load the converted program into the primary CPU, verify I/O forcing functions, and simulate switchover events in the test environment to confirm bumpless redundancy operation.

On cutover day, the field wiring transition from the legacy Series 90-70 terminal blocks to the new rack should be executed module by module, with each I/O group verified before proceeding to the next. Retaining the original Series 90-70 rack in a powered-down but connected state during the first 24–48 hours of live operation provides a rapid fallback option if unexpected compatibility issues arise. Once the RX7i system has demonstrated stable operation through at least one full production cycle, the legacy hardware can be formally decommissioned.

The IC698CRE030’s hot-standby architecture means that once both CPUs are synchronized, any subsequent hardware fault — whether in the primary CPU, a backplane connector, or a power supply — triggers automatic switchover in under 10 milliseconds, protecting the production process without operator intervention. This level of fault tolerance is a significant operational improvement over the non-redundant Series 90-70 configurations that many facilities are replacing.

All IC698CRE030 units supplied by NINERMAS are tested prior to shipment and covered by a 12-month warranty. Long-term inventory availability is maintained to support ongoing spare parts programs and future retrofit phases.

Retrofit Support FAQ

Q1: Is the IC698CRE030 a direct drop-in replacement for Series 90-70 redundancy hardware?
The IC698CRE030 is not a pin-compatible drop-in for Series 90-70 redundancy modules, as it operates within the PACSystems RX7i (IC698) rack architecture. However, it is the recommended upgrade path for Series 90-70 systems requiring redundancy, and GE Fanuc’s Proficy Machine Edition software provides migration tools to convert existing Series 90-70 programs to the RX7i platform with minimal manual rework.

Q2: What commissioning steps are required after installing the IC698CRE030?
After physical installation, engineers must configure the redundancy parameters in Proficy Machine Edition, synchronize firmware versions on both CPU modules, and perform a controlled switchover test to verify bumpless operation. Communication links — including Ethernet and any retained Genius Bus connections — must be validated before returning the system to production.

Q3: Can the IC698CRE030 be used in a system with mixed IC694 and IC698 I/O modules?
Yes. The PACSystems RX7i platform supports mixed I/O configurations. IC694-series I/O modules can be installed in IC694 expansion racks connected to the RX7i main rack via the IC693CBK001 or IC694CBK001 expansion cables, allowing facilities to retain existing I/O investments while upgrading the CPU and redundancy architecture.

Q4: What warranty and supply continuity does NINERMAS provide for the IC698CRE030?
Every IC698CRE030 unit is covered by a 12-month warranty from the date of shipment. NINERMAS maintains stock inventory to support both immediate replacement needs and long-term spare parts programs. Units are functionally tested before dispatch, and our technical team can provide compatibility confirmation and installation guidance for your specific retrofit application. Contact sale@ninermas.com for availability and lead time.