GE IC695ACC650 Series 90-70 to RX3i 9-Slot Conversion Rack

Description

In many industrial automation environments running legacy GE Series 90-70 systems, upgrading to modern PACSystems RX3i controllers often involves significant downtime, rewiring expenses, and risks to field connections when replacing outdated I/O racks. Full system overhauls can disrupt production for days or weeks, especially in large-scale setups with extensive terminal block wiring spread across the plant floor. The GE IC695ACC650 tackles this directly as a 9-slot mechanical conversion frame that allows direct migration from Series 90-70 to RX3i I/O without removing or rewiring existing field cables. Paired with adapter cards, it preserves terminal block assemblies, enabling a slot-by-slot swap that minimizes outages to hours instead of days. Engineers turn to the GE IC695ACC650 in critical process control applications—such as power generation, oil & gas, or manufacturing—where high reliability demands uninterrupted operation during upgrades. This conversion approach supports modular integration into RX3i ecosystems, extending the life of proven field wiring while gaining access to faster, more capable RX3i modules and diagnostics in industrial automation settings requiring seamless transitions.

The GE IC695ACC650 functions as a mechanical bridge in the RX3i PACSystems architecture, physically mimicking the footprint and mounting of a Series 90-70 9-slot rack while accommodating RX3i I/O modules via optional adapter plates and cards like the IC695ACC651. It mounts horizontally or vertically using slotted brackets, integrating into existing panels or new RX3i backplanes (7-, 12-, or 16-slot). Field wiring remains connected to the original Series 90-70 terminal blocks, which interface through the adapter to the new RX3i modules—no changes to cable runs or terminations are needed. The frame includes captive screws for secure installation and a ground lug for proper earthing. In the overall automation stack, the GE IC695ACC650 sits at the physical migration layer, enabling hybrid operation during phased upgrades where legacy and modern I/O coexist until full conversion. It positions RX3i modules in the distributed control hierarchy, allowing immediate use of advanced features like PROFINET or enhanced diagnostics without disrupting the backplane or controller communication.

Selecting the GE IC695ACC650 delivers substantial gains in migration efficiency and risk reduction. Engineered for precise mechanical compatibility, it ensures long-term performance by reusing robust field wiring that has already proven reliable over years of service, avoiding the pitfalls of new terminations like loose connections or labeling errors. The frame’s design reduces engineering overhead through straightforward slot mapping and optional adapter support, allowing teams to focus on validation rather than redesign. Maintenance benefits emerge from preserved terminal access and clear grounding provisions, simplifying future troubleshooting in dense panels. In deployed systems, the GE IC695ACC650 supports sustained uptime during transitions, protecting production schedules while unlocking RX3i advantages like higher-speed processing and better diagnostics without compromising existing high-reliability setups.

The GE IC695ACC650 proves essential in facilities modernizing legacy controls under tight schedules. In power plants, it facilitates rack-by-rack upgrades for turbine or boiler I/O, maintaining critical system uptime amid regulatory demands for continuous operation. Oil & gas processing sites use it in harsh process control environments to swap discrete and analog signals without interrupting flow monitoring or safety loops. Large manufacturing lines deploy it for phased conveyor or batch control migrations, handling extensive wiring in electrically noisy conditions while ensuring fast data cycles and minimal disruption.

Compatible or Alternative Products

IC695ACC651 – I/O adapter card required for wiring interface in conversion racks.

IC695ACC652 – 5-slot conversion rack for smaller Series 90-70 migrations

. IC695CHS007 – Standard RX3i 7-slot universal backplane for new installations.

IC695CHS012 – 12-slot RX3i universal backplane for expanded systems.

IC695CHS016 – 16-slot RX3i backplane for maximum density post-migration.

IC694CHS392 – 10-slot expansion base for hybrid RX3i/Series 90-30 setups.

IC694TBB032 – Extended terminal block kit for additional wiring flexibility.

Before deploying the GE IC695ACC650, inventory existing Series 90-70 terminal blocks and adapters to confirm compatibility, ensure panel space matches the 9-slot footprint, and verify grounding paths with at least 12-AWG wire. Remove terminal blocks prior to frame mounting, torque captive screws to 2.5 N-m, and install adapters before reconnecting field wiring. Allow clearance for ventilation within the 60 °C ambient limit. For ongoing maintenance, inspect mounting brackets and ground lugs quarterly for security in vibratory environments, check adapter latches for firm engagement, and document wiring mappings during initial setup for future reference. Periodic visual checks during outages help catch any settling or corrosion early.