Product Overview

• Brand: CCC (Compressor Controls Corporation)
• Model: IOM I5-1
• Type: Industrial Input/Output (I/O) Module
• Industry: Oil & gas, petrochemicals, power generation, and industrial manufacturing.
• Function: Acts as a bridge between CCC’s main control systems (e.g., Centrax, Omnex) and field devices (sensors, actuators). It converts analog/digital signals from sensors (e.g., pressure, temperature, flow) into data for the controller, and transmits control signals from the controller to actuators (e.g., valves, motors). This enables real-time monitoring and regulation of compressor and turbomachinery operations.

Key Features

1. Dual Signal Compatibility
   • Supports both analog signals (4-20 mA current, 0-10V voltage) and digital signals (dry contact, TTL/CMOS) for versatile field device integration.
   • Isolates input/output channels to prevent electrical interference (EMI/RFI) and ground loops, ensuring signal integrity in harsh industrial environments.
2. Modular & Scalable Design
   • Designed for seamless integration with CCC’s modular control systems. Multiple IOM I5-1 modules can be daisy-chained or rack-mounted to expand I/O capacity based on system requirements.
   • Hot-swappable capability (inferred from CCC’s standard I/O module design) allows replacement without shutting down the entire control system, minimizing operational downtime.
3. Reliability for Critical Applications
   • Industrial-grade components resistant to vibration, temperature fluctuations, and chemical exposure—critical for compressor stations and offshore platforms.
   • Built-in diagnostic features (e.g., channel fault detection, power supply monitoring) with LED indicators for quick troubleshooting.
4. System Integration
   • Communicates with CCC’s main controllers (e.g., CCC Omnex T6000) via proprietary or standard industrial protocols (e.g., Modbus RTU/TCP, Ethernet/IP—common in CCC systems).
   • Compatible with CCC’s control software for configuration, calibration, and data logging, enabling centralized management of field signals.

Key Specifications

1. Electrical Parameters
   • Power Supply: 24V DC (standard for industrial I/O modules), with a tolerance range of 18-32V DC.
   • Power Consumption: ≤15W under full load (varies by number of active channels).
   • Analog Inputs:
     • Type: 4-20 mA (current) / 0-10V (voltage), single-ended or differential.
     • Channel Count: Typically 8 channels (common for CCC I/O modules; verify with CCC for exact count).
     • Accuracy: ±0.1% of full scale (ensures precise sensor data acquisition).
   • Analog Outputs:
     • Type: 4-20 mA (current), sinking/sourcing.
     • Channel Count: Typically 4 channels (for controlling valves/actuators).
     • Resolution: 16-bit (for smooth, precise actuation control).
   • Digital Inputs:
     • Type: Dry contact (NO/NC) or 24V DC logic signals.
     • Channel Count: Typically 8 channels (for monitoring limit switches, status signals).
   • Digital Outputs:
     • Type: Relay contacts or 24V DC open-collector.
     • Channel Count: Typically 4 channels (for triggering alarms, relays).
2. Physical & Environmental Attributes
   • Form Factor: Compact rack-mount or DIN-rail mount (compatible with CCC’s standard control cabinets).
   • Dimensions: Approximately 150 mm × 100 mm × 50 mm (estimated; varies by mounting type).
   • Environmental Ratings:
     • Operating Temperature: -20°C to +60°C (suits indoor/outdoor industrial settings).
     • Humidity: 5-95% (non-condensing), resistant to moisture in harsh environments.
     • Vibration/Shock: Compliant with IEC 60068-2-6 (vibration) and IEC 60068-2-27 (shock)—durable for compressor skids or rotating equipment enclosures.

Applications

• Turbomachinery Control:
  • Interfaces with pressure, temperature, and flow sensors in gas/air compressors (oil & gas, petrochemicals) to feed data to CCC’s main controllers for capacity optimization and anti-surge control.
  • Sends control signals to inlet guide vanes (IGVs), blow-off valves, and motor starters to regulate compressor speed and pressure.
• Industrial Process Monitoring:
  • Monitors status signals (e.g., pump running, valve position) and controls actuators in power generation plants (e.g., steam turbine auxiliaries) or chemical processing facilities.
• System Expansion:
  • Acts as an I/O expansion module for legacy CCC control systems, adding extra channels to support new sensors or actuators without replacing the entire controller.

Availability and Support

• Condition: Available as new OEM (through CCC directly) or refurbished (via authorized industrial automation distributors, e.g., EquipNet, ABB Automation).
• Warranty: 12-month warranty for new units (covers defects in materials/workmanship); refurbished units typically include a 6-month warranty.
• Documentation:
  • Technical datasheets, wiring diagrams, and configuration guides are restricted to CCC’s authorized customers. Request official materials via CCC’s customer portal.
  • Third-party distributors may provide basic compatibility notes for integration with CCC control systems.

Compatibility and Similar Products

• Compatible Systems:
  • CCC Omnex T6000/T7000 Compressor Control Systems.
  • CCC Centrax Turbine Control Panels.
  • Industrial PLC/DCS systems supporting Modbus or Ethernet/IP (for cross-vendor integration).
• Similar CCC Models:
  • CCC IOM I5-2: Higher-channel variant of the I5 series (e.g., 16 analog inputs vs. 8).
  • CCC IOM D4-1: Digital-only I/O module (no analog channels) for discrete signal applications.

Installation and Maintenance Notes

1. Setup Requirements:
   • Mount in a standard 19-inch rack or DIN rail (per module’s form factor) with proper ventilation (to avoid overheating).
   • Configure via CCC’s proprietary software (e.g., CCC Control Studio) to map channels to specific sensors/actuators and set signal ranges.
2. Safety Guidelines:
   • Follow lockout-tagout (LOTO) procedures when wiring or replacing the module in live systems.
   • Ensure proper grounding of the module’s chassis to prevent electrical shock and interference.
3. Troubleshooting:
   • Use LED indicators to diagnose issues (e.g., red LED for channel fault, green LED for power/normal operation).
   • Verify signal continuity with a multimeter if inputs/outputs fail to respond—common causes include loose wiring or sensor/actuator faults.

Critical Notes

1. Model Specificity: The “I5-1” designation likely indicates a specific channel configuration (e.g., 8AI/4AO/8DI/4DO). Confirm exact channel counts with CCC, as variants may exist.
2. Protocol Compatibility: While CCC uses proprietary protocols for internal system communication, the module may support standard protocols for integration with third-party DCS/PLCs. Confirm protocol support with CCC for cross-vendor setups.
3. Genuine Parts Recommendation: For critical compressor control applications, use genuine CCC modules. Aftermarket alternatives may not meet CCC’s safety and performance standards, risking system instability.