Why Upgrade to Emerson PACSystems RX3i?
Upgrading from the legacy GE Fanuc Series 90-30 platform to Emerson’s PACSystems RX3i controller is simpler than many facilities expect. The RX3i family provides a structured migration path which allows users to maintain existing logic programs. A typical upgrade uses a new RX3i backplane, CPU, and compatible power supply, while supported Series 90-30 I/O modules may be moved to the RX3i backplane after a compatibility review. This approach can reduce rewiring and allow existing cabinets and field connections to remain in service as 90-30 I/O modules are phased out over time to maintain factory support.
The RX3i leverages a modern, high‑speed backplane that enables data transfers over 100 times faster than the original 90‑30 equipment. Integrated Ethernet, PROFINET and other network interfaces provide secure access to real‑time data so that operators can start benefiting from Industry 4.0 initiatives almost immediately. The modular design also allows you to expand locally or remotely to support between 8 and 32 000 I/O points.
Migration becomes even more compelling when considering long‑term reliability. The RX3i’s energy‑pack backup eliminates lithium batteries and introduces hot‑swap capability for many modules. These features reduce maintenance and allow upgrades in hours rather than days.
Preserve Existing Control Code and Intellectual Property
PAC Machine Edition provides a controlled path for preserving the engineering work embedded in a Series 90-30 application. When the original project is available, or when supported project data can be retrieved from the controller, teams can back up the application, review the hardware configuration, and use the existing ladder logic as the starting point for the RX3i conversion. This helps retain process knowledge, operating sequences, interlocks, and other intellectual property that would otherwise be costly to recreate.
PAC Machine Edition can also support ongoing maintenance of compatible Series 90-30 systems before migration. During conversion, the software changes the target family to PACSystems RX3i, remaps supported hardware, converts ladder logic, and generates a target conversion report. Unsupported instructions, C blocks, and other exceptions must be reviewed, corrected, and validated before production deployment.
Best practice: Save an untouched backup of the original Series 90-30 project and controller upload before conversion. Confirm that comments, variable descriptions, source files, and other project documentation are available, because a controller upload may not reconstruct every item contained in the original engineering project.
A Simple Migration Path to PACSystems RX3i
A Series 90-30 to RX3i upgrade is a planned controller-platform migration. The migration begins with a new RX3i backplane, an appropriate RX3i power supply, and an RX3i CPU. Supported existing Series 90-30 I/O modules can then be evaluated for reuse on the RX3i backplane, helping reduce field rewiring and shorten installation time.
The table below is a part-number cross-reference for planning an RX3i migration. It identifies corresponding IC694-series parts, but it should not be interpreted as a plug-in replacement guide for the existing Series 90-30 backplane. Before installing new modules, confirm the required backplane, CPU, power supply, firmware, communications, and I/O compatibility for the complete system.
| Existing Series 90-30 Module | Corresponding RX3i Migration Module |
|---|---|
| IC693ACC300 | IC694ACC300 |
| IC693ACC310 | IC694ACC310 |
| IC693ACC311 | IC694ACC311 |
| IC693ALG220 | IC694ALG220 |
| IC693ALG221 | IC694ALG221 |
| IC693ALG222 | IC694ALG222 |
| IC693ALG223 | IC694ALG223 |
| IC693ALG390 | IC694ALG390 |
| IC693ALG391 | IC694ALG391 |
| IC693ALG392 | IC694ALG392 |
| IC693ALG442 | IC694ALG442 |
| IC693APU300 | IC694APU300 |
| IC693BEM320 | IC694BEM320 |
| IC693BEM321 | IC694BEM321 |
| IC693BEM331 | IC694BEM331 |
| IC693CHS392 | IC694CHS392 |
| IC693CHS398 | IC694CHS398 |
| IC693DNM200 | IC694DNM200 |
| IC693MDL230 | IC694MDL230 |
| IC693MDL231 | IC694MDL231 |
| IC693MDL240 | IC694MDL240 |
| IC693MDL241 | IC694MDL241 |
| IC693MDL330 | IC694MDL330 |
| IC693MDL340 | IC694MDL340 |
| Existing Series 90-30 Module | Corresponding RX3i Migration Module |
|---|---|
| IC693MDL390 | IC694MDL390 |
| IC693MDL632 | IC694MDL632 |
| IC693MDL634 | IC694MDL634 |
| IC693MDL645 | IC694MDL645 |
| IC693MDL646 | IC694MDL646 |
| IC693MDL648 | IC694MDL648 |
| IC693MDL654 | IC694MDL654 |
| IC693MDL655 | IC694MDL655 |
| IC693MDL730 | IC694MDL730 |
| IC693MDL732 | IC694MDL732 |
| IC693MDL734 | IC694MDL734 |
| IC693MDL740 | IC694MDL740 |
| IC693MDL741 | IC694MDL741 |
| IC693MDL742 | IC694MDL742 |
| IC693MDL752 | IC694MDL752 |
| IC693MDL753 | IC694MDL753 |
| IC693MDL758 | IC694MDL758 |
| IC693MDL930 | IC694MDL930 |
| IC693MDL931 | IC694MDL931 |
| IC693MDL940 | IC694MDL940 |
| IC693MDR390 | IC694MDR390 |
| IC693PWR321 | IC694PWR321 |
| IC693PWR330 | IC694PWR330 |
| IC693PWR331 | IC694PWR331 |
| Existing Series 90-30 Module | Corresponding RX3i Migration Module |
|---|---|
| IC693ACC300 | IC694ACC300 |
| IC693ACC310 | IC694ACC310 |
| IC693ACC311 | IC694ACC311 |
| IC693ALG220 | IC694ALG220 |
| IC693ALG221 | IC694ALG221 |
| IC693ALG222 | IC694ALG222 |
| IC693ALG223 | IC694ALG223 |
| IC693ALG390 | IC694ALG390 |
| IC693ALG391 | IC694ALG391 |
| IC693ALG392 | IC694ALG392 |
| IC693ALG442 | IC694ALG442 |
| IC693APU300 | IC694APU300 |
| IC693BEM320 | IC694BEM320 |
| IC693BEM321 | IC694BEM321 |
| IC693BEM331 | IC694BEM331 |
| IC693CHS392 | IC694CHS392 |
| IC693CHS398 | IC694CHS398 |
| IC693DNM200 | IC694DNM200 |
| IC693MDL230 | IC694MDL230 |
| IC693MDL231 | IC694MDL231 |
| IC693MDL240 | IC694MDL240 |
| IC693MDL241 | IC694MDL241 |
| IC693MDL330 | IC694MDL330 |
| IC693MDL340 | IC694MDL340 |
| IC693MDL390 | IC694MDL390 |
| IC693MDL632 | IC694MDL632 |
| IC693MDL634 | IC694MDL634 |
| IC693MDL645 | IC694MDL645 |
| IC693MDL646 | IC694MDL646 |
| IC693MDL648 | IC694MDL648 |
| IC693MDL654 | IC694MDL654 |
| IC693MDL655 | IC694MDL655 |
| IC693MDL730 | IC694MDL730 |
| IC693MDL732 | IC694MDL732 |
| IC693MDL734 | IC694MDL734 |
| IC693MDL740 | IC694MDL740 |
| IC693MDL741 | IC694MDL741 |
| IC693MDL742 | IC694MDL742 |
| IC693MDL752 | IC694MDL752 |
| IC693MDL753 | IC694MDL753 |
| IC693MDL758 | IC694MDL758 |
| IC693MDL930 | IC694MDL930 |
| IC693MDL931 | IC694MDL931 |
| IC693MDL940 | IC694MDL940 |
| IC693MDR390 | IC694MDR390 |
| IC693PWR321 | IC694PWR321 |
| IC693PWR330 | IC694PWR330 |
| IC693PWR331 | IC694PWR331 |
Note: CA (Conformally Coated) and LT (Low Temperature) variants of these modules are also available.
If your system includes communications modules, expansion racks, Genius I/O, specialty modules, redundancy, unsupported instructions, or part numbers not listed in the table, request a migration compatibility review before selecting hardware. Relevant Solutions can review the installed system and help define the required RX3i backplane, CPU, power supply, I/O, communications, application conversion, testing, and commissioning scope.
Also, if you have other GE controls products (90-70, Rx7i, VersaMax, etc) also reach out as many of those system have similar migration paths.
Why Upgrade From GE Fanuc 90‑30 to PACSystems RX3i?
Upgrading from the GE Fanuc 90‑30 to the PACSystems RX3i offers significant improvements in performance, reliability, and connectivity. The RX3i platform supports modern industrial communication protocols and provides enhanced scalability for growing system demands. This upgrade allows facilities to leverage advanced technology while preserving existing investments in hardware.
Modern Communications:
Integrated Ethernet, PROFINET, Modbus/TCP and other protocols provide secure connectivity and support for edge analytics. This enhances data visibility and lays the foundation for digital transformation.
High performance and scalability:
The RX3i’s modular, high‑speed architecture supports rapid and consistent data transfer. Systems can scale from just 8 I/O points up to 32 000 points without changing the controller family.
Compatible and cost-effective:
Supported legacy Series 90-30 I/O modules may be reused on the new RX3i backplane after compatibility verification. The migration still requires an RX3i backplane, CPU, and appropriate power supply. New IO modules are always recommended to obtain the best system reliability and support. If new IO modules are used, the 9030 terminal assemblies can be removed from the 9030 and placed on the Rx3i module.
Improved reliability:
The RX3i’s modular, high‑speed architecture supports rapid and consistent data transfer. Systems can scale from just 8 I/O points up to 32 000 points without changing the controller family.
Conversion Process Overview
The RX3i migration path can reduce rewiring, but the application and system architecture must still be reviewed carefully before the new hardware is placed into service. Emerson’s Application Conversion Guide recommends the following high-level steps:
- 1. Prepare your application: PACSystems does not support the Series 90-30 END instruction. Replace this with jumps or separate program blocks. Check analog modules—older versions of IC693ALG220/221/222 require an external 24 V supply or replacement. Ensure the CPU is placed correctly in the RX3i rack; double-width CPUs occupy two slots and may require reconfiguration.
- 2. Convert the target in PAC Machine Edition: Use the programming software to change the project family from Series 90-30 to PACSystems RX3i. The tool generates a conversion report, which lists hardware remapping and unsupported instructions. Review the report carefully to address any flagged issues.
- 3. Verify hardware and logic changes: The conversion adjusts slot assignments because RX3i CPUs and power supplies use two slots. Some service requests (such as SVC_REQ #41 and SVC_REQ #48) are not supported and must be omitted or rewritten. Ensure logic that references the CPU slot or uses fault table service requests is updated to reflect the new slot location.
- 4. Test and deploy: Thoroughly test your application in a non-production environment to confirm that execution timing and communications behave as expected. After validation, deploy the system and take advantage of the RX3i's faster execution and enhanced diagnostics.
Considerations and Best Practices
A successful Series 90-30 to RX3i migration depends on compatibility review, application validation, communications planning, and controlled commissioning. Use the following practices to reduce technical risk before installation and startup:
- Maintain legacy communications: When communicating with older SRTP clients, note that the RX3i redirects SRTP requests sent to slot 1 to slot 2 to maintain compatibility. For HMI or external devices, confirm that drivers can communicate with CPUs installed in slots other than 1.
- Review unsupported instructions: PACSystems does not support certain service requests (e.g., PEEK, auto-restart parameters) and programming languages such as Instruction List or Sequential Function Chart. These require manual translation or alternative logic.
- Plan for future growth: The RX3i architecture supports expansion racks and distributed I/O. Taking advantage of gigabit Ethernet and redundancy options will ensure long-term scalability and reliability.
Visual Guide to the Series 90-30 to RX3i Migration
The visual assets below provide a clear view of the migration from an existing GE Fanuc Series 90-30 system to an Emerson PACSystems RX3i platform. The images illustrate the before-and-after hardware configuration, along with the key PAC Machine Edition steps, helping maintenance and engineering teams understand the equipment, software, and configuration changes involved in the upgrade.
Watch Series 90-30 to RX3i Overview
Watch our Series 90-30 to RX3i video for a clear overview of the migration path, key hardware considerations, and the advantages of moving to Emerson PACSystems RX3i. The video provides additional context for facilities evaluating how to modernize legacy control systems while protecting existing programs, wiring, and operational knowledge.
By following these guidelines, industrial teams can modernize legacy GE Fanuc 90‑30 systems with minimal disruption, preserve existing investments and unlock the performance advantages of Emerson’s PACSystems RX3i.
Plan Your Series 90-30 to RX3i Migration
Still have questions about your GE Fanuc Series 90-30 to PACSystems RX3i migration, or need personalized guidance on compatibility and implementation?
Contact us today to discover how upgrading to Emerson’s PACSystems RX3i and our expert support can enhance your control systems, improve uptime, and accelerate digital transformation.
