GE IC695ALG626 Replacement/Upgrade for PACSystems RX3i

Product Overview

GE IC695ALG626 Replacement/Upgrade Solution for PACSystems RX3i: Smooth Transition from Legacy Analog I/O

The GE IC695ALG626 is an 8-channel HART-enabled analog input module designed for the PACSystems RX3i platform. As GE Intelligent Platforms (now Emerson Automation Solutions) continues to evolve its control system portfolio, many facilities running legacy Series 90-30 or early RX3i configurations are facing end-of-life notices on their existing analog I/O infrastructure. The IC695ALG626 serves as a direct upgrade path — offering HART protocol support, improved signal resolution, and full compatibility with the Universal Backplane (IC695CHS016 / IC695CHS012) used across the RX3i rack family.

For plants currently operating with the older IC694ALG221 or IC694ALG222 analog input modules in a Series 90-30 chassis, migrating to the IC695ALG626 within an RX3i architecture requires careful attention to wiring termination. The IC695ALG626 uses a 40-pin terminal block interface, and field wiring from legacy TBQC or TBCH terminal assemblies may need to be re-mapped to the new connector pinout. In most cases, existing 4–20 mA field loops can be retained without replacing transmitters, significantly reducing retrofit cost and downtime.

HART communication is one of the key advantages of the IC695ALG626 over earlier non-HART analog modules. With HART pass-through enabled via the PACSystems RX3i CPU (IC695CPE302 or IC695CPE330), engineers can perform remote device configuration, diagnostics, and calibration of HART-capable field instruments — such as pressure transmitters, flow meters, and level sensors — directly from the control system without breaking the 4–20 mA loop. This eliminates the need for a separate HART modem or handheld communicator during routine maintenance.

From a system architecture perspective, the IC695ALG626 integrates seamlessly into mixed-module RX3i racks alongside digital I/O modules (IC695MDL664, IC695MDL740), communication modules (IC695ETM001 for Ethernet/IP, IC695PBM300 for PROFIBUS-DP), and the RX3i power supply (IC695PSA040 or IC695PSD040). The module occupies a single slot in the universal backplane and draws power directly from the rack bus — no external 24 VDC supply is required for the module itself, simplifying cabinet wiring and reducing panel space requirements.

For facilities upgrading from a GE Series 90-70 platform, the migration to PACSystems RX3i with the IC695ALG626 typically involves re-engineering the analog I/O map in the Proficy Machine Edition (PME) programming environment. The IC695ALG626 supports configurable input ranges (±10 V, 0–10 V, 0–20 mA, 4–20 mA) per channel, which provides flexibility when re-mapping legacy analog references. Channel-by-channel HART enable/disable settings allow the module to coexist with non-HART legacy transmitters during a phased migration, avoiding the need for a full cutover in a single maintenance window.

Physical installation is straightforward: the module slides into any available slot in the IC695CHS016 16-slot chassis or IC695CHS012 12-slot chassis and is recognized automatically by the RX3i CPU upon power-up. No jumper settings or DIP switches are required. The module’s LED indicators provide real-time channel status, fault detection, and HART communication activity — reducing the time required for field commissioning and loop verification.

For control cabinets with limited space, the IC695ALG626’s single-slot form factor is a significant advantage over older multi-slot analog modules. When combined with a marshalling panel using IC694TBB032 or equivalent terminal bases, the overall cabinet footprint can be reduced while maintaining full field wiring accessibility for maintenance personnel.

Compatibility Comparison Table

Seamless Upgrade Solutions

A successful migration to the IC695ALG626 rarely involves a single module swap. In practice, the upgrade is part of a broader system modernization effort. The IC695CPE302 or IC695CPE330 CPU module serves as the central controller coordinating all I/O activity, and its firmware version must be compatible with the IC695ALG626’s HART pass-through feature — verify PME hardware configuration files are updated accordingly. The IC695ETM001 Ethernet module enables EtherNet/IP communications for SCADA integration, replacing older IC693CMM321 serial communication modules that are no longer supported in modern DCS environments.

On the power side, the IC695PSA040 (120/240 VAC input) or IC695PSD040 (24 VDC input) power supply modules provide stable rack bus power for the IC695ALG626 and co-installed modules. If the existing cabinet uses an IC693PWR321 power supply from a Series 90-30 rack, a new RX3i-compatible power supply must be sourced as part of the chassis upgrade. For distributed I/O applications, the IC695NIU001 network interface unit allows remote RX3i racks to be connected over EtherNet/IP, extending the reach of the IC695ALG626’s analog inputs to field junction boxes without running long analog cables back to the main control room.

Signal conditioning and isolation are often required when migrating legacy analog loops. Signal isolators or loop-powered barriers may be needed between the field transmitter and the IC695ALG626 input terminals, particularly in hazardous area installations where IS (intrinsically safe) barriers were previously used with the Series 90-30 system. Terminal multiplier modules and marshalling panels compatible with the 40-pin connector format simplify field wiring organization during the cutover phase.

Retrofit Guidance FAQ

Q: Can I reuse existing field wiring from my Series 90-30 analog input modules?
A: In most cases, yes. Existing 4–20 mA two-wire or four-wire loops can be reconnected to the IC695ALG626’s 40-pin terminal block. Verify the pinout mapping in the IC695ALG626 User Manual (GFK-2578) against your existing termination drawings before cutover.

Q: Do I need to modify my ladder logic program when replacing IC694ALG221 with IC695ALG626?
A: The analog reference addresses (%AI) will need to be re-mapped in Proficy Machine Edition if the module slot position changes. HART-specific function blocks must also be added if HART pass-through is required. A full I/O map review is recommended before going live.

Q: Is the IC695ALG626 compatible with PROFIBUS-DP networks?
A: The IC695ALG626 itself is a local rack module and does not communicate over PROFIBUS-DP directly. However, it can coexist in the same RX3i rack as the IC695PBM300 PROFIBUS master module, allowing the RX3i system to manage both local HART analog inputs and remote PROFIBUS-DP field devices simultaneously.

Q: How much panel space does the IC695ALG626 require?
A: The module occupies one slot in the IC695CHS012 or IC695CHS016 universal backplane. Its single-slot form factor is more space-efficient than older multi-slot analog modules, making it suitable for panel retrofits where DIN rail or rack space is limited.

Q: What is the commissioning procedure after installation?
A: After physical installation, configure the module in Proficy Machine Edition by adding it to the hardware configuration tree, setting per-channel input ranges and HART enable flags, and downloading the updated configuration to the CPU. Perform a loop check on each channel using a calibrator before returning the system to service.

Warranty Assurance

Every IC695ALG626 unit shipped by TOPNLMS is covered by a 12-month warranty from the date of delivery. Prior to shipment, each module undergoes functional verification including power-up self-test, channel signal integrity check, and HART communication validation. Units are shipped in anti-static packaging with protective foam inserts to prevent transit damage.

If a unit is found to be defective upon arrival or fails within the warranty period under normal operating conditions, TOPNLMS will arrange a replacement or full refund. Our after-sales response time is within 24 hours on business days. We maintain stock of IC695ALG626 and related RX3i modules in our Xiamen warehouse, enabling fast dispatch to minimize your system downtime. For urgent replacement requirements, expedited shipping options are available to most destinations worldwide.

For procurement inquiries, compatibility verification, or technical pre-sales support, contact our team directly. We can assist with cross-referencing legacy part numbers, confirming firmware compatibility, and sourcing complementary modules required for your migration project.