The CCC FAN-10-2 is an intelligent fan module exclusively designed for the Vanguard Series 5 control system manufactured by Compressor Controls Corporation (CCC) in the United States. Serving as the core heat dissipation unit for the rack-mounted controllers of this series, it provides forced air cooling for CPU cards, I/O cards and power supply modules inside the cabinet. It ensures the thermal stability and operational reliability of the system under high-load and long-term continuous operation in industries such as oil & gas, chemical engineering and electric power.
Hardware Specifications & Structure
1. Physical Parameters
Dimensions: Standard cPCI 6U height, 19-inch rack mounting, depth of approximately 250mmWeight: Approximately 2.5kgInstallation Method: Vertically inserted into dedicated slots of the Series 5 cabinet; supports hot swapping (online replacement without shutdown)Heat Dissipation Layout: Front air intake and rear air outlet, matching the cabinet air duct design to form a forced convection cooling channel.
2. Fan Unit
Fan Quantity: 2 high-speed DC fans (Model: 120×38mm, double ball bearing)Rated Voltage: 24VDC (uniformly powered by the cabinet power supply module)Power Consumption: 15W per single fan, total power 30WRotation Speed: 0～3000 RPM (PWM intelligent speed regulation)Airflow: Maximum 180 CFMAir Pressure: Maximum 4.5 mmH₂ONoise Level: ≤58 dB(A) (full-speed operation)Bearing Type: Double ball bearing (MTBF ≥ 50,000 hours @ 25℃).
3. Control & Interfaces
Main Control Chip: 1GHz high-performance processor, integrated with temperature monitoring and PWM speed regulation control logic
Monitoring Functions
- Real-time monitoring of internal cabinet ambient temperature (-20℃～+60℃)
- Fan speed feedback (independent monitoring for each fan with abnormality alarm)
- Overcurrent, overvoltage and short-circuit protection
Communication Interfaces
- Internal Bus: cPCI bus, communicates with the main control card to upload temperature, speed and fault information
- External Interface: RS-485 (optional), supports remote monitoring and configuration
Status Indication: LED indicators integrated on the front panel (Power, Run, Fault, High Temperature Alarm).
4. Environmental Adaptability
Operating Temperature: -20℃～+60℃ (industrial wide-temperature design)Storage Temperature: -40℃～+85℃Relative Humidity: 5%～95% (non-condensing)Ingress Protection: IP20 (finger contact protection and dust resistance)Vibration Resistance: Compliant with IEC 60068-2-6 standard (10～150Hz, 0.15mm amplitude).
Core Functions & Working Principle
Intelligent Temperature Control and Speed Regulation
Built-in high-precision temperature sensors collect internal cabinet temperature in real time.
- Temperature ＜ 35℃: Fans run at low speed (≈1000 RPM) for low noise and energy saving.
- 35℃～50℃: Linear speed adjustment (1000～2500 RPM) to balance heat dissipation and noise.
- ＞50℃: Full-speed operation (3000 RPM), with high-temperature alarms triggered and uploaded to the system HMI.
Fan Redundancy & Fault Alarm
Adopts 1+1 dual-fan redundant design. If one fan fails, the other automatically runs at full speed to ensure uninterrupted heat dissipation.It independently monitors the speed of each fan. When the speed drops below 500 RPM or no signal feedback is detected, an immediate fan fault alarm will be activated, including red LED flashing, system log recording and remote notification.
Hot-Swap & On-Site Maintenance
Hot-swap supported. The faulty module can be removed and replaced directly without shutting down the control system. The whole replacement takes less than 1 minute and will not affect continuous unit operation.
System Integration & Data Interaction
It communicates in real time with Series 5 main control cards (such as MCP-1001) via the cPCI bus, uploading data including temperature, fan speed and fault codes.
Fully compatible with CCC TrainTools® configuration software. Users can check fan operating status, temperature curves and fault history on the HMI, with remote diagnosis and parameter configuration available.
Application Scenarios & Compatible Systems
Compatible Systems:Full range of Vanguard Series 5 controllers (Models: 5000, 5100, 5200, 5300, etc.)
Typical Industrial Applications:
- Oil & Gas: Long-distance natural gas pipeline compressors, LNG liquefaction plant compressors
- Chemical Industry: Centrifugal compressors, steam turbine-driven process units
- Power Industry: Combined-cycle gas turbines, steam turbine power generation control
- Air Separation: Compressor control for large-scale air separation units
FAQ (Frequently Asked Questions)
Q1: What are the possible causes and solutions when the FAN-10-2 fan module alarms with a flashing red LED?A: Common causes and troubleshooting:
- Fan stall or damage: Power off the device and check for foreign objects blocking the fan. Manually rotate the fan blades; replace the module if it cannot turn freely.
- Speed sensor failure: The fan runs normally but provides no speed feedback. Module replacement is required.
- Abnormal power supply: Insufficient 24VDC input (below 22V). Inspect the cabinet power module and wiring connections.
- High ambient temperature: Blocked air inlets or heavily dust-clogged filters. Clean the filters and ensure unobstructed ventilation.
Q2: Is the FAN-10-2 compatible with the legacy Series 4 system?A: Not compatible.The Series 4 system uses a VME bus, while Series 5 is upgraded to a cPCI bus with different hardware interfaces and communication protocols.The dedicated cooling module for Series 4 is the FAN-8-1, which cannot be used as a direct replacement.
Q3: Does the fan module support offline testing?A: Yes.Connect 24VDC power via the dedicated test fixture (CCC P/N: TEST-FAN10-2) and simulate temperature signals to verify fan speed regulation and alarm functions. Test data can be read through the RS-485 interface.
Q4: Is system shutdown required when replacing the FAN-10-2 module?A: No shutdown required.The module supports hot swapping. While the system remains online, press the latch on the module front panel, remove the old unit, and fully insert the new module.The system will automatically recognize and resume normal operation. The entire replacement process takes less than 1 minute.
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