GE IC695CPK330-ACAS Migration-Ready CPU for Legacy RX3i

Overview

GE IC695CPK330-ACAS Migration-Ready CPU for Legacy RX3i Control Systems

The GE IC695CPK330-ACAS is a high-performance PACSystems RX3i CPU module engineered for seamless integration into legacy automation environments. Whether you are replacing an end-of-life controller, modernizing an aging control cabinet, or executing a phased migration from an older Series 90-30 or Series 90-70 platform, the IC695CPK330-ACAS delivers the processing power, communication flexibility, and backward compatibility required to minimize risk and downtime during system transitions.

This CPU module supports dual Ethernet ports and a serial RS-232/RS-485 interface, enabling compatibility with a wide range of existing field devices, HMI panels, and SCADA systems without requiring full protocol re-engineering. Its 64 MB user memory and high-speed backplane interface make it suitable for complex ladder logic, function block, and structured text programs migrated from legacy GE platforms.

When planning a retrofit, engineers must verify several critical parameters before installation: confirm that the existing RX3i rack — such as the IC695CHS016 or IC695CHS012 — has sufficient slot capacity and backplane power budget to accommodate the IC695CPK330-ACAS alongside existing I/O and communication modules. The power supply module, typically an IC695PSA040 or IC695PSD040, must be assessed for total load capacity, especially when additional modules such as the IC695ETM001 Ethernet interface or IC695PBM300 PROFIBUS master are retained in the same chassis.

Terminal wiring and field device addressing should be documented prior to any swap. If the legacy system used a Series 90-30 CPU such as the IC693CPU374, a rack adapter or I/O mapping review is necessary to ensure analog and discrete I/O modules retain their configured addresses. The IC695CPK330-ACAS supports the same RX3i backplane protocol, allowing most existing IC695 and IC694 series I/O modules to remain in place without hardware changes.

Program compatibility is a key concern during migration. Existing Proficy Machine Edition (PME) projects can be imported and re-targeted to the IC695CPK330-ACAS with minimal modification in most cases. Engineers should validate all PID blocks, motion control references, and communication subroutines after re-targeting. HMI screens built on iFIX or CIMPLICITY linked to the legacy CPU via SRTP or OPC-DA will continue to function once the new CPU’s IP address and station name are configured to match the original system settings.

Migration Compatibility Table

Retrofit Planning for Existing Automation Systems

A successful retrofit begins with a thorough audit of the existing control cabinet. When replacing a legacy CPU with the IC695CPK330-ACAS, the following components in the same rack or control panel must be reviewed for compatibility and load balance.

The IC695PSA040 power supply is the most common companion module in RX3i retrofit projects. Before proceeding, calculate the total current draw of all installed modules — including any IC695ALG600 analog input modules, IC695MDL654 discrete output modules, and IC695ETM001 Ethernet communication modules — to confirm the power supply can support the upgraded configuration. If the existing supply is undersized, an IC695PSD040 DC power supply may be substituted without rack modification.

For systems that require PROFIBUS DP communication to retain connectivity with legacy field devices or variable frequency drives, the IC695PBM300 PROFIBUS master module can be installed in an adjacent RX3i slot and configured within PME to mirror the original GSD-based device map. This approach preserves existing field wiring and eliminates the need to re-engineer device-level communication during the migration window.

In applications where the legacy system used a dedicated programming cable such as the IC690ACC901 serial programming cable, engineers should transition to Ethernet-based programming via PME once the IC695CPK330-ACAS is commissioned. This eliminates a single point of failure in the programming path and enables remote firmware updates and online program monitoring without physical access to the control cabinet.

Where I/O expansion is required as part of the modernization effort, the IC695CHS012 expansion rack combined with IC695RMX128 remote I/O modules provides a scalable path to increase discrete and analog channel counts without replacing the primary CPU or main rack. This is particularly valuable in retrofit scenarios where the original control cabinet has limited physical space for additional modules.

Downtime Control During System Migration

Minimizing production downtime is the primary concern in any legacy system migration. The IC695CPK330-ACAS supports hot-standby redundancy configurations when paired with a redundancy CPU module, allowing engineers to validate the new CPU logic in a shadow mode before cutting over from the legacy controller.

For non-redundant systems, the recommended migration sequence is: document all existing I/O addresses and program logic; export the PME project from the legacy CPU; re-target and validate the project offline against the IC695CPK330-ACAS hardware configuration; perform a bench test with representative I/O signals before installation; and schedule the physical swap during a planned maintenance window. This approach typically reduces live cutover time to under two hours for standard RX3i rack configurations.

Preserving the original program logic is critical. The IC695CPK330-ACAS retains full compatibility with ladder diagram, function block diagram, and structured text programs developed in Proficy Machine Edition, meaning that validated logic does not need to be rewritten — only re-targeted and tested. All existing HMI tag references, SCADA data points, and historian connections should be verified against the new CPU’s Ethernet configuration before the system is returned to production.

Field commissioning should include a full I/O force test, communication link verification across all Ethernet and serial ports, and a timed scan cycle check to confirm that the CPU’s 64 MB memory and processing speed meet the cycle time requirements of the original control program. Any discrepancies in scan time should be investigated before the system is released to automatic operation.

Retrofit Support FAQ

Q: Is the IC695CPK330-ACAS a direct drop-in replacement for the IC695CPK330?
A: Yes. The IC695CPK330-ACAS is functionally equivalent to the IC695CPK330 and is designed as a direct slot-compatible replacement within any standard RX3i rack. No rack modification or wiring change is required. The -ACAS suffix denotes a conformal coating variant for enhanced environmental protection in humid or corrosive industrial environments.

Q: Can I retain my existing IC694 and IC695 I/O modules after installing this CPU?
A: Yes. All IC694 and IC695 series analog and discrete I/O modules are fully compatible with the IC695CPK330-ACAS backplane interface. IC693 series modules from Series 90-30 systems require the IC695ACC650 bus adapter for use in an RX3i rack. Module addresses and I/O mapping should be verified in PME after the CPU swap.

Q: What is the lead time and support terms coverage for the IC695CPK330-ACAS?
A: Units are available from in-stock inventory and typically ship within 1–3 business days after order confirmation. Every unit undergoes functional testing and burn-in verification before shipment. A support terms confirmed by quotation is provided covering manufacturing defects and operational failures under normal industrial use conditions.

Q: How do I verify firmware compatibility before installation?
A: The IC695CPK330-ACAS ships with firmware version 9.30 or later pre-installed. Compatibility with your existing PME project can be confirmed by checking the target CPU firmware version in the PME hardware configuration. If a firmware update is required, it can be performed via the Proficy Machine Edition firmware upgrade utility over Ethernet without removing the module from the rack.

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