Compressor Controls Corp CPCI Modules: CPCI AC-6U-500 PSMU-350-3

Technical Dossier

Product Details And Specifications

Compressor Controls Corp CPCI Series: Comprehensive Module Range and Technical Overview

The Compressor Controls Corp (CCC) CPCI platform is a CompactPCI-based control architecture deployed across heavy industrial sectors including natural gas compression stations, petrochemical refineries, offshore platforms, and nuclear-adjacent utility facilities. The CPCI chassis architecture supports hot-swap modular cards conforming to the PICMG 2.0 CompactPCI standard, enabling field replacement without full system shutdown — a critical requirement in continuous-process industries where unplanned downtime carries significant operational cost. CCC CPCI systems are found in installations across North America, the Middle East, and Southeast Asia, frequently integrated with turbine control, anti-surge control, and performance control loops. The platform's longevity in the field — spanning installations from the late 1990s through the 2010s — means a substantial installed base continues to require spare parts, firmware-compatible replacements, and lifecycle extension support.

The Evolution of CPCI Architecture

CCC's CPCI platform evolved from earlier proprietary backplane architectures used in the Micro-II and Micro-IIe controller generations. The transition to CompactPCI in the mid-1990s allowed CCC to leverage commercial off-the-shelf (COTS) hardware standards while maintaining proprietary firmware and application layers specific to rotating equipment control. Early CPCI deployments used 3U card formats with passive backplanes; later revisions introduced 6U form factors (as in the AC-6U-500 chassis) to accommodate higher I/O density and more capable processor modules such as the PSMU-350 series.

The PSMU (Processor and System Management Unit) line progressed through several iterations: early PSMU-100 and PSMU-200 variants provided basic CPU and watchdog functions, while the PSMU-350 introduced enhanced memory capacity, faster scan rates, and improved redundancy handshake protocols. Compatibility between PSMU generations is not guaranteed — backplane pinout differences and firmware version dependencies mean that substituting a PSMU-350-3 with an earlier variant requires engineering validation. As the CPCI platform has entered its end-of-life phase with CCC's transition toward the Compressor Controls Corp 5000 Series and later digital platforms, the installed CPCI base is now fully dependent on secondary market sourcing for hardware continuity.

CPCI Full Catalog & Functionalities (SKU List)

The following SKUs represent verified components within the CCC CPCI ecosystem, organized by functional category. Each module is a discrete field-replaceable unit (FRU) within the CPCI chassis.

Processor & System Management

• PSMU-350-3: 6U CompactPCI processor/system management unit, 350 MHz CPU, dual-redundancy capable, primary scan controller for CPCI AC-6U-500 chassis.
• PSMU-350-2: Earlier revision of PSMU-350 series; reduced memory capacity, compatible with select AC-6U-500 backplane configurations.
• PSMU-200: Mid-generation processor module; 200 MHz class CPU, used in 3U and transitional 6U chassis; not compatible with PSMU-350 firmware images.
• PSMU-100: First-generation CPCI processor card; limited scan rate; found in legacy installations pre-2000.

Analog Input (AI) Modules

• CPCI-AI-16: 16-channel analog input module, 4–20 mA / 0–10 V configurable per channel, 12-bit resolution, used for pressure and temperature signal acquisition.
• CPCI-AI-8H: 8-channel high-speed analog input; suited for vibration and dynamic pressure monitoring loops.
• CPCI-AI-RTD: 8-channel RTD input module; supports PT100/PT1000 sensors; used in bearing temperature monitoring applications.

Analog Output (AO) Modules

• CPCI-AO-8: 8-channel analog output, 4–20 mA, 12-bit DAC; drives control valves and IGV actuators in anti-surge and performance control loops.
• CPCI-AO-4H: 4-channel high-resolution analog output; used where fine valve positioning accuracy is required.

Digital Input (DI) Modules

• CPCI-DI-32: 32-channel digital input, 24 VDC, optically isolated; used for discrete status signals from field devices and safety interlocks.
• CPCI-DI-16H: 16-channel high-speed digital input; pulse counting and speed signal acquisition for magnetic pickup (MPU) inputs.

Digital Output (DO) Modules

• CPCI-DO-16: 16-channel digital output, relay or transistor type; drives solenoid valves, alarms, and permissive signals.
• CPCI-DO-8R: 8-channel relay output module; rated for higher current loads; used in shutdown and ESD circuit interfaces.

Communication & Network Adapters

• CPCI-COM-MOD: Modbus RTU/TCP communication adapter; provides serial and Ethernet gateway functions for DCS/SCADA integration.
• CPCI-COM-PB: PROFIBUS DP slave adapter; used in installations where the plant DCS communicates via PROFIBUS protocol.

Power Supply Modules

• CPCI-PSU-48: 48 VDC input power supply module for CPCI chassis; provides regulated backplane power rails; redundant pair configuration supported.
• CPCI-PSU-24: 24 VDC input variant; used in installations with 24 V plant power distribution.

Chassis

• CPCI AC-6U-500: 6U, 500 mm depth CompactPCI chassis; 14-slot passive backplane; hosts PSMU-350-3 and associated I/O modules; the primary chassis platform for this SKU family.

Sourcing Hard-to-Find & Obsolete CPCI Parts

The CCC CPCI platform is no longer in active production. Compressor Controls Corp has transitioned its product line to newer digital control platforms, and factory support for CPCI hardware — including PSMU-350-3 units — is limited or discontinued. For operators maintaining CPCI-based systems, the only viable path to hardware continuity is the secondary market.

DriveKNMS maintains a dedicated inventory of CCC CPCI modules sourced from decommissioned systems, controlled-environment warehouses, and verified industrial surplus channels. Stock includes processor modules (PSMU series), I/O cards, communication adapters, and chassis components. All units are catalogued by revision level and firmware compatibility where documentation is available. For operators facing extended lead times or factory end-of-life notices, DriveKNMS provides lifecycle extension support including cross-reference analysis, compatible substitute identification, and multi-unit lot sourcing for planned maintenance programs.

Quality Control for the CPCI Range

CCC CPCI modules present specific test challenges due to their CompactPCI backplane interface, proprietary firmware dependencies, and mixed analog/digital signal paths. DriveKNMS applies a structured inspection and functional verification protocol to all CPCI units prior to dispatch.

Physical inspection covers connector pin integrity on the J1/J2 CompactPCI edge connectors, capacitor condition on power regulation circuits, and conformal coating integrity on I/O signal conditioning stages. For PSMU processor modules, BIOS/firmware version is read and recorded; units with corrupted or mismatched firmware images are flagged and not shipped without disclosure. Analog I/O modules are bench-tested against known reference signals: AI modules are verified for channel-to-channel isolation and input accuracy across the full 4–20 mA range; AO modules are loaded with calibrated resistive loads and output linearity is confirmed. Digital I/O modules are cycled through all channels under simulated field voltage conditions. Communication modules are tested for protocol handshake and data integrity using protocol analyzers. All test results are documented and available upon request.