Description
Product Introduction
The GE Emerson PACSystems RX3i IC695GCG001 is a specialized Genius Communications Gateway designed to protect your plant’s existing infrastructure investments. It serves as a seamless hardware bridge, allowing modern PACSystems RX3i controllers to read, write, and manage legacy Series 90-30 and Genius I/O blocks across a standard Genius serial bus network without requiring a complete field rewiring overhaul.
Plugging into an RX3i expansion chassis or remote rack, the IC695GCG001 converts high-speed Genius bus protocol packets into standard Ethernet/PROFINET data frames bound for the primary CPU. This gateway enables migration away from obsolete Series 90-30 CPUs or GE Genius Bus Controllers (IC693BEM331) while keeping hundreds of field-proven Genius I/O blocks and field cables intact in the cabinet.
Key Technical Specifications
| Parameter | Value |
| Module Type | Network Gateway / Bus Interface Module |
| Supported Network | GE Genius I/O Bus |
| Genius Bus Data Rates | 38.4 Kbps, 76.8 Kbps, 153.6 Kbps (standard), 153.6 Kbps (extended) |
| Max Genius Devices | Up to 31 Genius I/O blocks per gateway channel |
| Upper Network Protocol | PROFINET / Ethernet to RX3i CPU |
| Backplane Requirements | Operates in RX3i Universal or Expansion Backplanes |
| Diagnostics | LED Indicators for OK, LAN, Genius Bus Status, and Faults |
| Shield / Grounding | Dedicated shield terminal for Genius twinaxial cable grounding |
| Power Consumption | Draws power from internal RX3i backplane (+3.3 VDC / +5 VDC) |
| Operating Temperature | 0°C to 60°C (32°F to 140°F) |
Application Scenarios & The “Trench” Experience
When upgrading an aging PLC system, ripping out hundreds of hardwired Genius I/O blocks scattered across a large facility is an absolute nightmare. The labor, downtime, and risk of wiring errors during a full rip-and-replace often make total panel upgrades cost-prohibitive.
- Pulp & Paper Mills – Modernizing main process control CPUs while retaining distributed Genius block drop racks across long conveyor drives.
- Automotive Stamping Plants – Upgrading central PLC-5/90-30 controllers to RX3i without rewiring massive press automation I/O junction boxes.
- Water Treatment Plants – Interfacing legacy Genius field drops at remote filter beds back to a central RX3i CPU rack over existing twinax cabling.
Field Case Study: A steel mill wanted to replace its obsolete Series 90-30 CPUs with new RX3i controllers, but rewiring over 40 Genius I/O blocks across four remote motor control centers (MCCs) would have required a two-week total outage. By installing IC695GCG001 gateways, engineers swapped out the main CPU rack and linked directly to the existing Genius bus. The plant completed the control system upgrade during a scheduled 24-hour weekend outage—saving over $200,000 in installation labor and downtime.
IC695GCG001
IC695GCG001
Transparency SOP: Quality Assurance & Testing
Legacy network gateways handle critical field communication traffic. Every IC695GCG001 unit undergoes hands-on testing on our Genius network test rigs before it ships to your job site.
- Inbound Mechanical Check: Inspect housing latches, backplane pins, terminal strip alignment, and confirm OEM serial labels and revision marks.
- Backplane Handshake: Mount the module into an RX3i chassis and verify clean PCI/serial bus enumeration in PAC Machine Edition (PME).
- Genius Bus Communication Test: Connect the GCG001 over shielded twinaxial cable to an active array of Genius I/O blocks (e.g., IC660TBA/TBD series).
- Data Frame & Rate Verification: Verify stable token passing, zero packet drop, and error-free polling at all baud rates (38.4K to 153.6K baud) under heavy simulated I/O noise.
- Anti-Static ESD Packaging: Seal the module in an anti-static shielding bag with fresh desiccant and box inside custom dense foam packaging.
The Veteran’s Tech Trap Guide (Crucial Value-Add)
⚠️ Watch Out for Termination Resistor Setup on the Genius Bus! The Genius serial bus is a daisy-chained network using shielded twinaxial cable. You MUST install a 75-ohm, 100-ohm, or 120-ohm termination resistor (matching cable impedance) across the serial bus terminals at both physical ends of the line. Skipping this causes signal reflection and intermittent packet loss!
❗ Set Unique Device SBA (Serial Bus Address) Numbers! Every device on a Genius network—including the IC695GCG001 gateway—must have a unique Serial Bus Address from 0 to 31. If you configure the gateway with the same SBA as an existing field block or old bus controller, network communication will collapse instantly.
⚠️ Check Shield Grounding Carefully! Genius bus networks are notoriously sensitive to shield ground loops. Ensure the twinax shield is grounded firmly at ONE end of the cable run only (usually at the gateway) to prevent noise-induced dropouts.
Frequently Asked Questions (FAQ)
Q: Does the IC695GCG001 replace the legacy IC693BEM331 Genius Bus Controller?
A: Functionally, yes. While the IC693BEM331 was a direct plug-in card for Series 90-30 racks, the allows modern RX3i systems to communicate with legacy Genius I/O networks, bridging the gap between old field hardware and new controllers.
Q: How do I configure the module?
A: The module is configured through PAC Machine Edition (PME) software under the RX3i hardware configuration tree, where you assign its SBA, network baud rate, and scan list parameters.
Q: What cable should be used for the Genius bus connections?
A: Always use approved shielded twinaxial cable (such as Belden 9880 or equivalent standard Genius bus cable) with proper impedance ratings to ensure stable data transmission.
Q: Can I run multiple modules in a single RX3i rack?
A: Yes. You can install multiple gateway modules in an RX3i rack to manage multiple independent Genius network loops if your plant has a high density of legacy field blocks.
Q: What warranty is provided with this gateway?
A: Every new surplus and fully bench-tested pre-owned module shipped from our warehouse comes backed by a full 12-month replacement warranty.
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