Modernize Legacy GE PLC Systems
Planned migration for facilities that cannot afford disruption.
TAG Solutions helps facilities modernize legacy Series 90 and RX7i control system swith a lower-risk approach built around preservation, phased execution, and controlled cutover planning.
Planned modernization gives facilities more control over timing, scope, and outage windows.
60
+
Years of Combined GE Experience
Aging PLC Systems Present Growing Operational Risk
Limited spare parts availability
Loss of internal system knowledge
Vendor and support constraints
Greater risk of forced outages
Still Running Series 90 or RX7i Controllers?
Series 90-30, 90-70, RX7i, Genius, and related legacy GE platforms
These systems remain in service across manufacturing, utilities, and public infrastructure, often supporting critical operations that cannot tolerate unnecessary disruption.
For many facilities, the question is no longer whether these systems still run. It is how to plan modernization before support constraints, parts availability, and platform familiarity make the project harder to manage.
Modernize Without Rebuilding the Entire System
TAG Solutions’ preservation-first approach focuses on minimizing unnecessary changes while modernizing Series 90 and RX7i platforms.
Preserve Ladder Logic where practical
Reuse existing wiring and compatible I/O to minimize cabinet changes
Phase migrations around plant shutdown schedules to reduce downtime
Support software migration to PACSystems RX3i to reduce conversion effort
Execute migrations with experienced GE platform engineers
Real Results:
How Deep GE Expertise Reduced Downtime by 80%
A conveyor belt manufacturer in North Carolina needed to upgrade from GE 90-30 and 90-70 PLCs. Other approaches estimated four months of downtime. TAG Solutions completed the migration in six weeks by preserving existing control logic and applying deep GE platform expertise.
Controlled Migration Through Parallel Conversion
Series 90-70 to RX3i Conversion Rack
This staged conversion approach allows existing GE 90-70 systems to remain operational while the new RX3i platform is installed, validated, and prepared for cutover. By preserving field wiring and leveraging conversion racks, downtime is planned, minimized, and controlled.
Step 1: Existing Series 90-70
Baseline system documented
and validated before transition.
Step 2: Remove Field Terminals
Field wiring preserved to reduce rework
and minimize outage scope.
Step 3: Remove Series 90-70
Legacy hardware removed after
staging preparation.
Step 4: Install RX3i Conversion Rack
Parallel hardware installed to support phased migration.
Step 5: Install Series 90-70 Field Terminals
Existing wiring integrated into new architecture.
Step 6: Close Access Door and Secure
System secured prior to validation testing.
Step 7: Exchange Completed
Cutover executed within planned outage window.
Modernize Legacy PLC Systems Without Losing Control of Your Timeline
The TAG Solutions Difference
Our Approach to Migrations
The TAG Solutions Migration Team has developed a proven strategy that will allow you to quickly and easily migrate from Series 90 and RX7i controllers and Series 90 I/O to an Integrated Modern Control System, while maintaining the existing field wiring and physical footprint in your control cabinet.
Proven GE PLC Expertise
Deep familiarity with Series 90, RX7i, and related legacy control architectures.
Shutdown-Aligned Execution
Projects planned around outages, turnarounds, and production constraints.
Phased Migration Planning
Migration paths built to reduce disruption and support staged investment.
Preservation-First Approach
Focus on reusing working infrastructure, wiring, and logic where practical.
Integrated Engineering Support
Controls, networking, SCADA, and electrical expertise under one team.
Lifecycle Training & Support
Post-migration training and ongoing system support for your team.
Contact
Speak with a TAG Solutions engineer
Speak with a TAG Solutions engineer with direct experience migrating GE 90-30 and 90-70 control systems.