GE IC695ALG106 High-Density Analog Input Module

Description

Why Your System Needs the GE IC695ALG106

In today’s high-speed industrial automation and process control environments, the ability to accurately and reliably convert real-world analog signals into digital data for the controller is paramount. Process variables like temperature, pressure, flow, and level are the lifeblood of chemical plants, power generation facilities, and manufacturing lines.The major challenge engineers face is connecting a high density of field instrumentation to the control system while maintaining signal integrity, especially when dealing with noisy environments and long cable runs. Errors in acquisition—whether from poor resolution, slow sampling, or electrical interference—can lead to poor control, wasted material, and dangerous operating conditions.

The core problem the GE IC695ALG106 is engineered to solve is delivering a high-performance, high-density solution for analog input within the GE PACSystems RX3i platform. Generic or lower-end analog modules often force engineers to compromise between channel count, accuracy, and scan rate. This GE module eliminates that compromise. It provides the capacity to handle a substantial number of critical inputs with the precision and speed required for tight-tolerance applications. It is essential in situations demanding superior I/O signal fidelity and high reliability across a compact footprint.

By utilizing the advanced architecture of the RX3i backplane, the GE IC695ALG106 ensures that raw analog data is quickly and accurately digitized and transferred to the CPU. This efficiency is a non-negotiable requirement for applications running complex control strategies that rely on fast, up-to-date information. For system integrators and control engineers focused on reducing cabinet space without sacrificing performance, the GE IC695ALG106 represents a high-value component in building a resilient and efficient industrial automation infrastructure.

How the Product Works & Fits into a System

The GE IC695ALG106 functions as a high-density, high-speed Analog Input Module specifically designed to plug directly into the universal backplane of a GE PACSystems RX3i controller. Its primary role is to serve as the interface between analog field devices (like 4-20mA transmitters, thermocouples, or voltage sensors) and the RX3i CPU. It is a key element of the I/O architecture, sitting physically in the rack and communicating with the central processor over the high-speed PCI Express backplane bus unique to the RX3i platform.

When an analog signal arrives from the field, the GE IC695ALG106 utilizes built-in analog-to-digital (A/D) converters—typically high-resolution 16-bit or better—to transform the continuous electrical signal into a discrete numerical value. The module performs essential on-board tasks, including scaling, filtering, and conversion into engineering units, which can often be configured per channel via the control platform software (like Proficy Machine Edition).

This module is designed for maximum operational flexibility. It typically supports multiple signal types (voltage or current) configurable on a channel-by-channel basis, providing versatility when integrating diverse field instruments. The high-speed communication over the RX3i backplane ensures minimal latency, meaning the data read from the field is almost instantly available to the CPU for executing control logic. Furthermore, the module usually incorporates extensive self-diagnostics, continuously checking for open circuits (e.g., broken wires), out-of-range inputs, and internal hardware faults. This diagnostic reporting is relayed to the CPU, allowing the control platform to trigger alarms or enter a safe state, thereby enhancing the overall system high reliability.

Technical Highlights Summary

Real-World Benefits

The primary advantage an engineer gains from deploying the GE IC695ALG106 is superior data integrity and operational density. By offering a high channel count in a single slot, the module effectively reduces the physical size and power consumption of the I/O subsystem compared to using multiple lower-density modules. This consolidation reduces cabinet space, simplifies wiring, and cuts down on the overall system footprint, leading to significant cost savings in panel building and physical installation.

The module’s high-resolution analog-to-digital conversion, typically 16-bit, provides the granularity needed for demanding applications.This means small changes in a process variable—a subtle temperature drift or a minor pressure fluctuation—are accurately captured and reported to the controller. This precision is what allows for tighter control loops, reducing material waste, optimizing energy use, and ultimately improving the consistency and quality of the final product. The GE IC695ALG106 is engineered for performance consistency, ensuring that measurements remain stable and accurate across the entire operating temperature range.

Furthermore, the sophisticated on-board diagnostics contribute massively to maintenance efficiency. Instead of manual troubleshooting, the module itself flags channel faults, such as a disconnected sensor wire, immediately. This capability transforms reactive maintenance into a proactive, data-driven task, ensuring long-term performance. The flexibility to individually configure each channel for different signal types (current or voltage) streamlines spare parts inventory and simplifies system design changes, reducing engineering overhead when field requirements inevitably change.⁶The seamless integration into the RX3i control platform accelerates both commissioning and ongoing configuration updates.

Typical Use Cases

The GE IC695ALG106 is widely deployed across industries that rely on continuous, high-fidelity data acquisition for safe and efficient operations. A key application is within water and wastewater treatment facilities. Here, it monitors hundreds of analog inputs from critical instrumentation such as pH sensors, turbidity meters, and flow transmitters in real-time, requiring high-channel density and exceptional signal reliability. The data drives complex chemical dosing and pump control strategies, where accuracy is directly linked to environmental compliance.

Another significant area of deployment is in the oil and gas industry, particularly in midstream applications like compressor stations and tank farms. In these challenging environments, the module handles inputs from pressure transmitters, level sensors, and custody transfer meters. Here, the focus is on critical system uptime and precise inventory tracking, often under harsh conditions. The module’s rugged design and self-diagnostics are invaluable for ensuring remote asset reliability.

Finally, the module is commonly used in power plants for turbine and boiler control systems, where measurements like steam temperature and feed-water flow are directly tied to efficiency and safety interlocks. The fast scan rate available through the RX3i backplane, paired with the density of the GE IC695ALG106, makes it the ideal choice for managing the vast number of analog inputs required for high-speed, closed-loop control in this environment.

Compatible or Alternative Products

GE IC695ALG628 – A high-speed, lower-channel count Analog Input module offering faster scan rates for extremely time-critical applications.

GE IC695ALG302 – A high-resolution RTD/Thermocouple Input module, often used alongside the GE IC695ALG106 to handle temperature-specific sensor types.

GE IC695CMM002 – The primary CPU module for the RX3i platform, necessary to process the data acquired by the GE IC695ALG106.

GE IC695ALG708 – An Analog Output module from the same family, used to provide precise control signals back to field devices like control valves.7

GE IC695LRE100 – A Universal Backplane Expansion Receiver used when the I/O needs to be distributed across multiple racks.

GE IC694ALG112 – A comparable high-density Analog Input module from the older RXi platform, which the GE IC695ALG106 is often an upgrade from.

GE IC695PBM300 – A Power Supply Module required to provide the necessary operating power to the backplane and the GE IC695ALG106.

Setup Notes & Maintenance Insights

Successful integration of the GE IC695ALG106 begins with proper configuration within the development software. Before installation, confirm the module’s logical slot address matches the physical slot in the rack and ensure the corresponding tag names and scaling parameters are correctly defined for every connected channel. Paying close attention to the input range selection (e.g., 4-20mA vs. 0-10V) in the software is vital, as a mismatch can damage the module or lead to inaccurate readings. Always use shielded, twisted-pair cabling for field wiring and ensure the shields are correctly terminated to the backplane earth connection to minimize noise pickup.

Ongoing maintenance is minimal due to the module’s solid-state design. The most important preventive measure is routinely reviewing the I/O diagnostic tables within the control software for channel health status. A persistent “Open Circuit” or “Over Range” fault on a channel indicates a problem in the field wiring or sensor, not the module itself. Physically, maintenance involves periodically checking the removable terminal blocks to ensure they are securely fastened and that no dirt or moisture is present in the cabinet that could cause intermittent connectivity issues. Unlike older systems, the GE IC695ALG106 requires no calibration pots or field adjustments; any necessary calibration compensation is managed digitally via the control software.