Product Core Brief
- Model:
- Brand: GE
- Series: PACSystem RX3i / Series 90-30 compatible
- Core Function: Provides 16 isolated normally-open mechanical relay contacts to switch AC and DC field loads.
- Product Type: 16-Point Isolated Relay Output Module
- Key Specs: 4 groups × 4 NO contacts | 2A per channel pilot duty | 15ms max relay operate time Note: Active hardware platform; fits IC695 main racks and IC694 serial expansion racks. Supports hot swap with compatible CPU firmware. No internal channel fuses.
Key Technical Specifications
- Channel Configuration: 16 Form A (NO) relay contacts, divided into 4 isolated groups of 4 channels
- Supported Load Voltage: 5–30 VDC, 5–250 VAC (47–63 Hz)
- Current Ratings: 2 A per output; 4 A maximum per group; 16 A module total
- Minimum Load Current: 10 mA; maximum inrush current 5 A
- Relay Response Time: ≤15 ms operate / ≤15 ms release
- Isolation: 250 VAC continuous field-to-backplane; 1500 VAC 1-minute withstand
- Power Consumption (all outputs energized): 7 mA @5 VDC backplane; 135 mA @24 VDC relay bus
- Status Indicators: 16 independent channel LED indicators
- Operating Temperature: 0°C to 60°C horizontal cabinet mounting
- Storage Temperature: -40°C to 85°C
- Form Factor: Single-width RX3i slot
- Supported Terminal Blocks: IC694TBB032, IC694TBS032
- Hot Swap Support: Yes, subject to minimum CPU firmware revision
Product Introduction
This unit switches discrete field loads such as solenoids, contactor coils and indicator lights. Mechanical relay contacts accept both AC and DC circuits, simplifying mixed-voltage control layouts on machine and process lines.
Each group maintains independent common terminals, allowing segregation of different voltage domains. The galvanic isolation blocks noise transients from field wiring from propagating onto the control backplane.
QA & Testing SOP (Transparency Building)
- Incoming Inspection: Confirm part marking and serial traceability. Inspect edge connector pins for bending; check housing for cracks and terminal interface damage.
- Live Testing: Install into validated RX3i rack, apply backplane power. Cycle each relay channel continuously against resistive loads over a 24-hour run-in period.
- Electrical Testing: Use Fluke 115 to monitor backplane supply stability. Insulation resistance testing must exceed 10MΩ between field contacts and chassis ground.
- Firmware/Config Backup: Log hardware revision. Photograph terminal wiring arrangement before disassembly.
- Final QC & Packaging: Place unit inside anti-static shielding. Attach dated QC test tag documenting channel switching results before shipment.
Installation Pitfalls & Guide (Engineer to Engineer)
❗ Load Rating Violations: Do not exceed 2A per channel or 4A per group. Overloading accelerates contact pitting and causes premature relay failure. ❗ Minimum Load Requirement: Circuits drawing less than 10mA risk unreliable contact operation. Add bleed resistors for low-current indicator circuits. ❗ Hot Swap Firmware Check: Hot swap behavior fails if host CPU runs outdated firmware. Verify revision before live removal; unsupported versions trigger rack I/O faults. ❗ ESD Dangers: Un-grounded handling can damage internal relay drive circuitry. Static faults do not always present visible external damage. ❗ Lack of Internal Fusing: No onboard channel fuses. Install external circuit protection on each field circuit to block short-circuit damage to relay contacts.
Replacement Guide:
- Pre-install: Back up hardware configuration, photograph field wiring, confirm CPU firmware supports hot swap.
- Removal: If hot swap approved, unlatch and extract module; otherwise execute lockout-tagout on rack power and field load circuits.
- Install: Seat new unit fully into backplane, engage latches, reattach terminal block and replicate all wiring connections.
- Power-on Test: Restore power, download saved configuration, cycle each output and verify no module diagnostic faults.
FAQ (Frequently Asked Questions)
Q: Does this unit support hot swapping? A: Yes, hot swap is functional when the RX3i CPU runs compliant firmware. Older firmware cannot reinitialize the bus and will register module missing alarms.
Q: Can directly replace IC693MDL940? A: Mechanically and functionally compatible for many retrofit cases. Confirm terminal block pin mapping and rack bus type before drop-in replacement.
Q: Can contacts switch inductive loads like contactor coils? A: Yes, inductive loads are permitted within rated current limits. Install freewheeling diodes for DC coils and RC snubbers for AC coils to suppress back EMF.
Q: Is there channel-to-channel galvanic isolation? A: Channels share group commons; isolation exists between groups and backplane. Individual channels within one group are not isolated from each other.
Q: What limits relay service life? A: Contact life declines sharply under inductive or lamp inrush loads. Frequent high-current switching will require more regular module inspection.
Q: Will hardware configuration transfer directly to a replacement unit? A: Configuration imports without modification. Cycle all outputs after replacement to confirm every relay operates reliably.
Q: Can this module be deployed in serial expansion remote racks? A: Yes, it works inside IC694 remote expansion baseplates as well as main IC695 controller racks. Confirm expansion rack power budget before installation.
