Falcon 1600

Operating Manual – Falcon 1600
16 channel Analogue Input Module
falcon - 1600
01 05 09 13
02 06 10 14
CH NO PROCESS VALUE
03 07 11 15
RXD TXD L1 L2 L3 L4 R1 R2 04 08 12 16
PROG CONTROL STATUS
Manual Falcon 1600 Page 1 of 45

Scan Electronic Systems, Pune www.scanelectronicsystems.com
INDEX
Sr. No. Chapter Name Page

Number
1 Technical Specifications
2 About the System
3 Menu 1 – No. of Channels for Scanner
4 Menu 2 – Skip Channels
5 Menu 3 – Linearisation
6 Menu 4 – Decimal Point Position
7 Menu 5 – Zero Value for each Channel
8 Menu 6 – Span Value for each Channel
9 Menu 7 – Limits for each Channel
And Alarm / Control output operation
10 Menu 8–Serial Communication Parameters
11 Menu 9 – Set Display Update Time
12 Menu 10 – Set Display Mode
13 Menu 11 – Load Default Settings
14 Menu 12 – Pass-Code for Unit
15 Menu 13 – Enter Control Relay Operation
16 Modbus Data Structure
17 Indications
18 Calibration Procedure
19 Trouble Shooting
20 Precautions / Card replacement
21 System Information
22 System Connector details / Internal Wiring
23 Application notes / Connection Diagrams
24 Program Flow Chart
25 Ethernet Port scanner –
Features, programming and Connections

SYSTEM MMI
1. Keyboard: System is provided with four keys, PROG, UP, DOWN

and ENTR/ACK.
Key Operation flow chart is as follows.
STEP KEY Operation

1 Enter and Exit Programming
PROG Mode
2 Scroll Menus or digits or

options.
3 Select Menu to Modify.

Or Set Parameter value.
And Acknowledge Common
Alarm
2. Seven Segment LED DISPLAY:

Programming Menus:
Menu number is displayed on 2 digit.
Menu Name is displayed on 5 digits.
Process Parameters:
Channel number is displayed on 2 digits.
Process value is displayed on the 5 digits.
3. LEDs:
There are four types of LED indications
1. For Serial communication TXD and RXD LEDs.
2. For Ethernet connection L1 to L4 LEDs.
3. For Common Alarm Relay Indication R1 / R2 LED.
4. For each Control Output status or Alarm status of each channel.
NOTE:
In Program mode:
1. Channel scanning and any control / Alarm action is stopped.
2. If any key is not accessed by user for more than 10 seconds unit
EXITS program mode and starts channel scanning.

Setting Parameter value in Program mode:

Follow steps given below in each menu.
STEP KEY Operation

1 Enter Program Mode
PROG
2 Select Menu to Modify.

System displays Old value
3 Change Digit from 0 to 9 or

scroll Option.
Set digit and go to next digit

4 setting. Press at each digit to
keep the value same.
--- Follow step 3 & 4 till all digits are
5
set.
--- After this if value is acceptable,
system exits that menu.
6 Else it remains in same menu to
enter correct value.
Again set correct value.
Scroll Menus for another
7 parameter
or go to step 7.
Exit Program Mode.

PROG
8

MENU Operation
Menu Activity Value
01. Chnls Set number of channels to 1 to 16 or as per
scan and display. number of channels
provided in unit.
02.SHIP Skip particular channel to Yes or No
skip from scanning and
display.
03. Lin Set input scaling type Int or EHt
as Internal or External of
particular channel
04.dPPOS Set Decimal Point position 1 to 4
for indication of particular
channel
05.Zero Enter ZERO value for mA ± SPAN value set
or Volt type of input of
particular channel
06.SPAn Set SPAN for mA or Volt 1 to 9999
type of input of particular
channel
07. LIMIt Set Alarm or Control limits As per SPAN or
of particular channel Default range of input
type.
08. SbP Set Serial communication
parameters
08.Stn 01 – Station ID 1 to 16
08. 9600 – Baud rate 300 to 38400
08.P. none – Parity None / Odd / Even
09.dut Set channel display 1 to 240 seconds
scroll time
10.Sdn Set channel display Auto / Manual
scroll mode
11.LdS Load Default settings Default factory
settings are loaded
12.PASS Enter Pass code for 0000 to 9999
programming access
13.rLELAY Set Control output Int or EHt
operation.
On Internal Control
Settings or from External
serial communication PC

Basic System Parameters to program:
Some parameters are used for basic operation of a unit. Set these parameters first and
then set channel settings.
Follow the procedure given below
1. Press PROG key and enter Program mode

2. Set number of channels in scanner. (menu 1)
This decides consecutive number of channels that are used for
indication and control.
3. Set Serial Communication Parameters as required. (Menu 8)
4. Set Channel scroll time in AUTO mode. (Menu 10)
5. Set Scroll mode AUTO or MANUAL. (Menu 11)
6. Set Relay Operation Internal or External (menu 13)
7. Give Pass Code for Programming access if required.
8. Press PROG key and exit.
Programming of Channel Parameters:
Some parameters are associated with any channel. User must set these parameters
properly as required for each channel.
NOTE: User must enter Channel number as desired first and then access the setting
menu further. If you press ENTR key at the displayed channel number then parameter is
set for that channel only.
User must give proper channel number in all these menus.
Follow the sequence below to set the channel properties.
1. Press PROG key and enter Program mode

2. Set SKIP parameter. Yes is skipped and No is not skipped
3. Set LIN: Internal or External as required.
4. If set External Linearised – then do following, else go to step 5.
1. Set Decimal Point position from menu 4 “DPPOS”
2. Set SPAN first from menu 6 “SPAN”
3. Set ZERO from menu 5 “ZERO”
Note:
Whenever you enter SPAN mode, ZERO value is reset to 0000. You have to set
ZERO again if required.
5. Set Limits for the same channel as per requirement for Alarm or
Control indications. (Menu 7)
6. Exit program mode or set another channel.

Following are illustrations of different parameters used in Externally linearisaed

channel and its implications.
------------------------------------------------------------------------------------------------
Decimal Point : DPPOS for indication
Example: Say Display value is 1000 then
Display on Display on
DPPOS set DPPOS set
unit Unit
1 1000 3 10.00
2 100.0 4 1.000
------------------------------------------------------------------------------------------------
Displayed value Calculation using ZERO and SPAN value
For mA input: (4 – 20 range)
ZERO
This value corresponds to the 4.00 mA input.
SPAN
This value corresponds to the 20.00 mA input.
Value calculation as per ‘ZERO and SPAN values

Calculated Displayed Value =
((SPAN - ZERO)* ((Input mA*100) - 400)/1600)) + ZERO
Example 1: SPAN = 3000 and ZERO = 0000, DPPOS = 1
Input mA Indicated Value

00.00 to 04.00 0000
8.00 750
12.00 1500
16.00 2250
20.00 3000

00.00 to 04.00 1000
8.00 1500
12.00 2000
16.00 2500
20.00 3000

For Volt input: (0 - 1V range for example)
ZERO
This value corresponds to the 0.000 V input.
SPAN
This value corresponds to the 1.000 V input.
Value calculation as per ‘ZERO and SPAN values

Calculated Displayed Value =
((SPAN - ZERO)* Input Volt) + ZERO
Input Vdc Indicated Value

0.000 0000
0.250 750
0.500 1500
0.750 2250
1.000 3000
Input Vdc Indicated Value

0.000 1000
0.250 1500
0.500 2000
0.750 2500
1.000 3000

Linearisation Settings for different types of inputs:
1. RTD : The linearisation is only Internal.

If user selects External option, the unit does not accept it.
2. mA and Volt : The linearisation can be Internal or External.

In Internal Linearisation, the actual mA / Volt value is
displayed during scanning.
In External linearisation, the input mA / Volt value is
scaled as per programmed value of Zero and Span .
Example,
Internal Mode for mA value:

00.00 to 04.00 OPEN
8.00 8.00
12.00 12.00
16.00 16.00
20.00 20.00
External Mode: SPAN = 3000 and ZERO = 0000, DPPOS = 1

00.00 to 04.00 0000
8.00 750
12.00 1500
16.00 2250
20.00 3000
3. Thermocouple : The linearisation can be Internal or External.

In Internal Linearisation, actual mV output from
sensor is displayed during scanning.
In External linearisation, actual Temperature value
is displayed.
For example,
Say K type thermocouple is connected to channel 1 and actual process temperature to
be measured is 100 °C.
Mode Indicated Engineering

Value Unit
Internal 03.00 mV
External 100 °C

Serial Communication
Menu 8 is used to set different parameters of serial communication.
Press ENTR key to set ID number first.

Present DIP setting number is displayed.
Set switch position to indicate required ID number.
ID SETTINGS
4 way DIP switch is given on back side to set ID number.
Maximum ID number can set is 16. ID number calculation is in HEX format. Switch 1 is
D0 up to D3 switch 4.
ID NO. DIP SWITCH POSITION

4 3 2 1
1 OFF OFF OFF OFF
2 OFF OFF OFF ON
3 OFF OFF ON OFF
4 OFF OFF ON ON
5 OFF ON OFF OFF
6 OFF ON OFF ON
7 OFF ON ON OFF
8 OFF ON ON ON
9 ON OFF OFF OFF
10 ON OFF OFF ON
11 ON OFF ON OFF
12 ON OFF ON ON
13 ON ON OFF OFF
14 ON ON OFF ON
15 ON ON ON OFF
16 ON ON ON ON
After ID is set, System displays present Baud Rate.

Press UP/DOWN key to scroll different baud rates from 300 to 38400.
Press ENTER to set the required one.
After this PARITY is displayed.

Press UP/DOWN key to scroll options from NONE/ODD/EVEN.
Press ENTER to set the required one.
System exits this menu.

For RS485 or Ethernet port only ID number is different, all other parameters are
same. Refer to Ethernet setting given here after.
MODBUS data structure for serial communication
Address Data
40001 Indicated Value of Channel 1
Extra data for mA input channels only:

40017 mA / Volt Value of Channel 1
For control output status only:

40035 Control output status (Read/Write)
Value received in MODBUS is without decimal point.

Negative value is in 2’s complement form.

FALCON 1600 – ETHERNET

In FALCON 1600 scanner with Ethernet port some features of RS485 port scanner are
not available. Also there are some changes in connections details.
Features not available:
1. Common Alarm : Only One output.
2. ID setting: For Serial communication ID setting through DIP
switch is of no use as unit has IP address.
All remaining Hardware & software features/ programming is same as standard

RS485 scanner.
Serial Port setting for Ethernet:
RTU side:
There are two ports on RTU side: RS485 2 wire and Ethernet. User can use either
RS485 or Ethernet connection for serial communication with PC.
PC side:
On PC side Ethernet port is provided on RJ connector. Connect LAN cable to this port.
If you are connecting scanner directly to PC LAN port then use cross LAN cable.
If you are connecting scanner through HUB then use straight LAN cable.
Configuring the Ethernet port in FALCON:

While dispatching, the scanner is programmed for some default settings as given in this
manual.
The configuration software is provided on a separate CD. Use this software to make
LAN and serial port settings in scanner Ethernet port.
Installing DS manager software:

Insert the CD given in CD drive and run setup from the directory
(Tibbo-3.66) to load the DS manager on your PC.
The software is loaded as TIBOO on your PC. Make short cut of DS manager on
desktop.
LED indications:
Rx / Tx (Green / Red): Receive and transmit signal indications on RTU side.
L1 (ER) Output LED output 1, Red Ethernet status LED
L2 (EG) Output LED output 2, Green Ethernet status LED
L3 (SG) Output LED output 3, Green status LED
L4 (SR) Output LED output 4, Red status LED, Watchdog reset line
Programming the Ethernet:
1. Connect the scanner on LAN and power up.

2. Run DS manager software on PC.
3. If your connection is OK it detects the scanner on LAN and displays in its pop up
window as shown.
Main Screen of DS Manager software:

When you run the DS manager software and scanner is connected on LAN then it
automatically detects it and shows this main display.
If software does not found any scanner on LAN then it displays the message and does
not allow any settings etc.
When scanner is detected DS manager shows its present IP address and other
information as shown. Also the settings displayed in each screen are default
programmed.

Press Settings button for programming the scanner.

Display shows the following screen.
Network settings.
Consult your EDP person for these settings.

Normally user has to set IP address / port and protocol as required. If above settings are
ok for your network then do not disturb them.

Serial Settings:
Here also set the Baud rate, Parity and Data bits same as RTU settings. Keep all other
settings as it is.

Outbound packets:
These settings are also default and to be changed only if your protocol demands it.
After you finished these settings press OK button, this will load these settings in scanner.
You can change IP address by pressing Change IP button in main screen.

ALARM and Control Output Limit settings and Operation
Menu 7 is used to set the limits for each channel’s ALARM or CONTROL settings.
Depending on option ordered setting parameter changes.
There are few different options in a way Relay internal or external work.
User can have any one of these option as ordered.
Logic Options
Alarm Annunciation Common Alarm Annunciation –
1 relay output
Common Alarm Annunciation –
2 relay outputs (Ch1-8 and ch9-16)
Alarm annunciation output per
channel
1 relay per channel external
with 1 common alarm relay
Alarm for each Alarm output per channel
channel 1 relay per channel external
Alarm / Trip 2 relay per channel operating on
ALARM and TRIP settings
(Maximum 8 analogue channel
system can be given)
Control 1 relay output per channel operating
on H/L limits as control (OFF/ON).
And One common Control Relay

output
For Multi relay outputs:
The relay card is external for 8 channels. At the back of the scanner there are two 9 pin
D type male connectors.
One for channel 1 to 8 and second for channel 9 to 16 respectively.
Connect the relay card to the scanner with given cable and give 24 VDC
external supply to the relay card.

Common ALARM Annunciation logic
Parameter Options
Logic 1. Alarm Annunciation
or
2. Alarm for each channel
Limit settings HIHI / HI / LO / LOLO (setting is + or -)
5th digit is sign.
After entering 4 digit value, toggle 5th digit by
‘UP’ key for + (0) or – indication.
Indications Common Relay status LED : R1 and
Individual channel Alarm Status LEDs: 01 to 16
Acknowledge MANUAL: ACK key or AUTO: on input value.
Outputs One Common Relay R1
Or
R1 for Channel 1 to 8 and R2 for Channel 9 to 16
And / Or
External One relay Per channel as alarm
annunciation.
ALARM detection:
The alarm is generated on the HH and LL settings made for each channel.
Alarm is removed depending on H and L settings made for each channel. Thus H and L
settings act as dead band for HH and LL settings.

Alarm Annunciation Operation:

MANUAL ACK mode:
Common Alarm Relay Status (R1/R2) Input signal status
ON (Alarm detected) For Input Value > HH
Or Input Value < LL
OFF (Alarm Acknowledged) After pressing ACK key
Alarm LED and external Alarm relay Status for Input signal status
each channel
LED Blinking (Indicates Alarm detected) For Input Value > HH
External relay made ON/OFF) Or Input Value < LL
LED ON After pressing ACK key and
(Indicates Alarm acknowledged and still present) Input value is still
External relay kept ON Input Value > HH
Or Input Value < LL
LED OFF (Indicates Alarm removed) Input Value < H
External relay made OFF Or Input Value > L
AUTO ACK mode: (or Alarm for each channel)

Common Alarm Relay Status (R1/R2) Input signal status
ON (Alarm detected) For Input Value > HH
Or Input Value < LL
OFF (Alarm Acknowledged) For Input Value < H
and Input Value > L
and after pressing ACK key
Alarm LED and external Alarm relay Input signal status

Status for each channel
LED ON (Indicates Alarm detected) For Input Value > HH
External relay made ON Or Input Value < LL
LED OFF (Indicates Alarm removed) For Input Value < H
External relay made OFF and Input Value > L

ALARM – TRIP logic

Parameter Options
Logic Alarm and Trip outputs per channel
Limit settings AH / AL / TH / TL (setting is + or -) 5th digit is
sign.
Indications Individual channel Status LEDs: 01 to 16
Acknowledge MANUAL: ACK key OVERRIDE
Outputs External TWO relays Per channel as
alarm and trip indications.
ALARM / TRIP detection:

The alarm is generated on the AH and AL settings made for each channel.
The Trip is generated on the TH and TL settings made for each channel.
Alarm / Trip is removed after input value is below AL / TL setting respectively, or by
manual override ACK key.
Logic Relay / LED assignment

ALARM R1 – Alarm Channel 1
LED1 – Alarm channel1
TRIP R2 – Trip Channel 1
LED2 – Trip channel1
The same is continued for remaining channels.
One 8 channel relay card have channels 1 to 4 (Alarm + Trip)
Second 8 channel relay card have channels 5 to 8 (Alarm + Trip)
Operation:
Alarm Relay and LED Input signal status

ON (Alarm detected) For Input Value > AH
OFF (Alarm Acknowledged) For Input Value < AL
Or
after pressing ACK key
TRIP Relay and LED Input signal status

ON (Trip detected) For Input Value > TH
OFF (Trip Acknowledged) For Input Value < TL
Or
after pressing ACK key
The relay is turned ON again when input goes below ‘L’ limit and again crosses ‘H’
limit.

CONTROL Logic
Parameter Options
Logic Control outputs per channel
with common Control Output (Optional)
Limit settings H / L (setting is + or -) 5th digit is sign.
Indications Individual channel Status LEDs: 01 to 16
Outputs External one relay Per channel
And One common Control Relay Output
(Optional)
Operation:
Control Relay and LED Input signal status

Per channel
At Power ON If Input Value < H
Relay / LED is turned ON
Relay / LED is turned OFF When Input Value > H
Relay / LED is again When Input Value < L
Turned ON
Common Control Relay and Input signal status

LED
At Power ON If all channels Input Value < H
Common Relay / LED is
turned ON
Common Relay / LED is When any one Input Value > H
turned OFF
Common Relay / LED is again When all channels Input Value < L
turned ON

MENU 11 -- Load Default Settings
Display shows ‘ 11.LdS ’
In this menu, all the programmed values are removed and loaded by factory set values.
Following changes takes place
1. The linearisation mode for all channels is initialized to Internal.

2. The decimal point position for all channels are initialized to required
displayed engineering value positions.
3. The pass-code is cleared.
Press ENTR key, All above parameters are initialized to factory set values.
User has to be sure before selecting this menu as all old settings are reset.
Press PROG key to return to main menu and start scanning of channels or Press
UP/DOWN keys to scroll menus.

MENU 12 -- Enter Pass-Code for the unit
Display shows ‘ 12.PASS ’
This menu is used to lock the programming of the unit.

When the unit is shipped to customer, the pass-code is 0000.
This means that the unit is free for programming parameters.
After programming the unit as per requirement user can lock the programming by
entering any 4 digit numeric value as pass code.
At first, Press ENTR key,
Display will show ’12.n.0000’ and the last digit is blinking.
This means that the unit is asking to give new pass-code. If user enters 0000, then this
pass-code is used to unlock the unit from programming. If user enters any non-zero
value, then it will be treated as new pass-code.
Enter Pass code by key functions.
User should be aware of the fact that he should always remember this new pass-
code. Or otherwise the programming of the unit is totally restricted and the unit
will function as per the old settings done in the PROG Mode.
When user want to change the old pass-code,

Press ENTR key, Display shows ’12.o.0000’ and the last digit is blinking.
This means that the unit is asking old pass-code. User has to enter the old pass-code
correctly. If any wrong pass-code is entered,
the display shows, ’12. Err’
Press Enter key to exit.
If user enters correct pass-code then unit again asks for new pass-code. User should
enter the required numeric value by using Up/Down and Enter key as explained above.
If by chance the pass-code is not remembered by the user and the unit is locked
for programming, then ask us by written mail or fax with proper designation in the
factory by the user. The master pass-code will be informed in the same format to
user.
Press PROG key to return to main menu and start scanning of channels or Press
UP/DOWN keys to scroll menus.

MENU 13 -- Enter Control Relay Opeartion
Display shows ‘ 13. rELAY ’
This menu is applicable only for the system having control outputs.
This menu decides the control output operation either from the system or from external
PC command on serial port.
Press ENTR key system displays old setting as
’13. Int’
Press UP/DOWN key to toggle the option.

Press ENTR to set the option.
‘Int’ is for Internal operation and ‘EHt’ is for External operation.
In internal mode Control outputs are operated by system depending on Limit settings.
In External mode Control outputs are operated by PC software on serial port.
MODBUS Operation:
The address in MODBUS is 40035. The control outputs are bit wise
i.e. Control output 1 is bit D0 and Control output 16 is bit D16.
Use write command to set the output. Data 0 is output OFF and 1 is output ON.

INDICATIONS
Input Type Sensor Indication Value on

Condition or on Unit MODBUS
Input Value
RTD Pt100 3 OPEN OPEN 4010
wire (Any one wire)
Input > 401.0 OVER 4010
Input < - 50.0 OPEN
4-20 mA Input < 4.00 OPEN 400
Internal LIN Input > 21.60 OVER 2160
4-20 mA Input < 4.00 OPEN As per ZERO
set
External LIN Input > 21.60 OVER As per SPAN set
Thermocouple Input Short Ambient Ambient
Any type Temperature Temperature
Input > Max. OVER Max. Range
Range value
Input < Min. Under Min. Range
range value
Any terminal Fluctuating Same value as
open or both any value displayed
terminal open
DC Volt Input < 0.000 OPEN 0000
Internal LIN Input > 10% OVER Max. Range
more than value
Max. range
DC Volt Input < 0.000 OPEN As per ZERO
set
External LIN Input > 10% OVER 10% more than
more than as per SPAN set
Max. range
Ranges for thermocouples in °C
Thermocouple Type Minimum Range Maximum Range

J - 210 1200
K - 270 1372
R - 49 1767
S - 49 1767
T - 200 400
B 0 1820
E - 270 1000
N - 260 1300

Calibration Procedure
Important Instructions:
01. Always use Standard calibrator (master source) to feed input while
calibration.
02. For mA and Volt input types always keep system indication as
internal to display actual mA or Volt value and then calibrate.
03. Each channel has separate trim pots for Calibration.
04. Refer to component diagram or top plate sticker for trim pot
positions.
05. There is a calibration sticker pasted on top plate trim-pot cutout.
Calibration date and next due date is mentioned on it.
To access trim-pots, Pill off dotted line sticker part of required
channel row. After Calibration is over again paste the same properly.
06. Note Calibration date on Sticker for your reference.
07. ZERO trim pot :
Adjusts ZERO reading for the channel (for RTD / mA / Volt inputs)
Adjusts Ambient temperature value at 00.00 mV input for
Thermocouple channel.
08. SPAN trim pot: Adjusts reading for the channel.
09. Keep Unit powered ON for at least 10 minutes before you start
calibration.
10. Each time you turn the trim-pot, wait for reading to stabilize.
Follow the same until you get correct reading on display.
------------------------------------------------------------------------------------------------
Calibration Sequence: Follow the sequence given below for input calibration for
any channel.
01. Remove External Input connected to that channel.

02. Connect input from Standard source to that channel
as per input type.
03. Turn ON unit for 10 minutes.
04. Press PROG key and Enter Program mode of unit.
05. Set Linearisation = Internal (Menu 4) for that channel
06. Press PROG key and Exit program mode
07. Feed Input to the channel.
08. Make calibration for selected input type as per procedure given.
09. Follow instructions 1 to 8 for another input type calibration
10. Now set the unit as per your system requirement again.

For mA channels:
1. Set Internal linearisation for channel to be calibrated.
2. Give 5.00 mA input and adjust ZERO trim pot to display
between 5.00 to 5.01
3. Now give 20.00 mA input and adjust SPAN trim pot to display
between 19.99 to 20.00
For Volt channels:

1. Set Internal linearisation for channel to be calibrated.
2. Give 0.100 V input and adjust ZERO trim pot to display
between 0.099 to 0.101.
3. Now give 1.000 / 4.000 / 5.000 V (as per range given) input and
adjust SPAN trim pot to display between
a. 0.999 to 1.001
b. 3.999 to 4.001
c. 4.999 to 5.001 as per the range
For RTD channels:

1. Give 0°C input from standard source and adjust R TD ZERO
Trim-pot to display reading between – 000.2 to + 000.2 °C
2. Now give 200.0 °C input and adjust RTD SPAN trim pot to display
reading between 200.0 to 200.5 °C
3. Repeat 1 & 2 points till you get mentioned results
4. If your operating range is Low say 0 to 100 °C,
then you can adjust SPAN at 100.0 °C giving the same input
from standard source.
This gives more improved accuracy in that operating range.

For Thermocouple channels:
J / K / E thermocouple – Input range in mV : 00.00 to 80.00

R / S / T / B thermocouple – Input range in mV: 00.00 to 25.00
1. Keep Lin as External.

Give 00.00 mV input from standard source and adjust ZERO trim pot
to display ambient temperature.
2. Now give 50% input of range for respective type of thermocouple
and adjust SPAN trim pot to display correct temperature.
The mV value calculation is as follows:

Use Standard Thermocouple table for reference.
mV to feed to channel = mV for temperature to indicate – mV for ambient temperature

for the set type of thermocouple.
Example:
Say type of Thermocouple is K and ambient temperature is 30 °C.
So for system to display 200°C, you should feed mV from above formula as Referring to
standard K type thermocouple table
mV to feed to channel = 8.137 – 1.203

= 6.934 mV

TROUBLE-SHOOTING OF SCANNER AT SITE
Blank Display on POWER ON

1) Check correct system supply is 230 or 110 VAC.
2) Check FUSE status at the back.
3) Open the top plate and check the cable connections from DIGITAL CARD to
power supply card.
SCANNER is not communicating with PC

1) Check communication parameters in scanner as well as at PC end
software are same.
2) Check COM PORT of PC is working
3) Check serial cable is OK.
4) Check the connections from scanner to RS232 to RS485 converter
are correct
5) Check the signals are coming to scanner. Check the blinking of RX
and TX LEDs on converter and scanner.
For Ethernet scanner:

1. Check IP address settings of scanner. Check if scanner is getting
identified on network. Use “ Ping” command from PC dos prompt.
2. Check LAN cable using LAN cable tester.
3. If HUB / Switch is used in-between, check its port is working.
SCANNER does not show analog values for particular channels

1) Check connections are correct for that channel.
2) Check actual analog input at the terminals is present as programmed
for that channel.
3) Check by giving analogue input from standard calibrated source.
4) Open the SCANNER and check internal card fitting is intact.
For T/C range scanner does not show ambient for 00 mV

1. Check CJC Sensor soldered on connector board from the backside.
Is in proper condition. If found broken leads then you have to
replace with new sensor.
2. Check if Linearisation for that channel is made as Internal.
It must be set as External to display Temperature reading.
SCANNER resets after some interval

The Scanner works on linear power supply.
It’s operating range is ±10% of supply option given (230 or 110 VAC)
When supply goes below this range scanner resets continuously.
Give proper stabilized mains supply to unit with proper earth.

PRECAUTIONS
Before Power On the system, please ensure that proper earthing is connected to the
system, also supply is ok and connected with correct polarity.
Make sure that system is programmed for all its parameters with correct values, types
etc. as per your requirement.
When you are connecting the inputs or changing the inputs, keep the system in
power off condition.
Before connecting sensor to the scanner set that particular channel to proper input
type.
For mA, mV and Thermocouple types, if you are not using that channel then do not
keep it open. Short + and – ve terminals of that channel on given connector.
For Thermocouple inputs do not use GROUNDED type sensor.

If you are using open type thermocouple sensor then confirm the
electrical isolation of open tip from external media. Else system input
gets damaged.
The same is applicable for RTD sensor also confirm the isolation of all
three wires from sensor body and earth.
For mA input: Scanner has 18 Ohms fixed internal resistance for

each channel as shunt resistance. Follow given rules for safety.
1. If Input is connected in reverse fashion scanner displays ZERO
2. Do not connect external transmitter supply directly at the input.
3. If there are more indicators with scanner in same loop of one
transmitter, take total loop load resistance into consideration as to
fit with transmitter’s output load capacity.
4. Also for same condition, GND / -ve terminals of external supply,
indicators in series with scanner should not be common with body
or earth point.
All signal inputs must be isolated from their source when derived from separate
system. It should not have any relation with Earth or electrically hot media. Else
system input gets damaged.
All sensor wires must be shielded with proper earth to shield.

Do not run sensor cables parallel to the high voltage / current cables.
Sensor cables should cross such high voltage cables in 90 degrees.
Keep minimum 6 to 8 inches distance between Signal and power
cables.

EARTHING :-
Use separate earthing for POWER and SIGNAL earth.

i.e. POWER earth should be made common to the separate earth pit
made for Mains power.
Make sensor SHIELD common to instrument earth pit at least 100
meters away from power earth pit.
Keep shield open at sensor end and connect at instrument end.
This will avoid any power noise to override the input signal.
Check that supply Earth is not floating.
Earthing used for Instrument should not be used for Welding etc.
This may lead to instrument damage.
Normal Operating Supply Voltages

Give stabilized supply to the system, use ISOLATION transformer if
necessary for supply noise problem.
Live – Neutral – 230 VAC ±10%

Live – Earth – 230 VAC ±10%
(if you do not get this value then your earth may be floating)
Earth – Neutral – 1 to 5 VAC
(Voltage above this indicates improper earthing)
For supply voltage below 205 AC system does not work. There may
be erratic display, no display or system resets continuously.
If system fails due to any problem in any condition to perform its task then contact us
for repairing of the system and do not try to make any diagnosis by giving power to
the system.
System is provided with Fuse protection for mains supply.

Fuse rating is 230VAC, 200mA small glass fuse.
If you found that fuse is burnt out, then first find out the reason for
that, where Over voltage, short circuit etc. Remove that cause and
then replace the fuse. A spare fuse is given with the system.
System has Mains line filter at the supply input with MOV protection. At high voltage
spicks, continuous high supply voltage beyond limit of MOV (normally 275 VAC), it
gets short and fuse burns out.
So in such condition check on multi meter (Ohms range) that Live
and Neutral terminals show resistance above 80 Ohms.
For dead short (0 Ohms) condition do not replace fuse as it indicates
that Filter MOV is short. You have to replace Filter.

How to Change input signal cards in Falcon 1600
Refer to the Internal diagram given in the manual. Input card position is shown in the
diagram.
Type of input card (RTD / Thermocouple / mA / Volt) is mentioned on the sticker pasted
on top plate. Also you can cross check the type of card from card
component layout given.
Follow the procedure as follows:
01. Make the scanner OFF.

02. Remove all connections of sensors/serial/mains etc. from back of
scanner.
03. Remove the scanner from the panel and keep it on table.
04. Keep the scanner in vertical position with bezel on the tabletop.
05. Remove the four mounting screws of back side.
06. Remove plastic fitting plate gently.
07. Remove Top plate of scanner and remove scanner module from
box.
08. Place scanner horizontally. Remove Mounting screws on top PCB
and Remove TOP PCB.
09. Now pull the card to be removed.
10. Place the new card in same position with proper orientation. Card
have right angle connector at bottom. Make sure that all pins are
placed properly in the female part on bottom PCB.
11. Fit the TOP PCB with all input card hold properly in cutouts.
Fit the mounting screws on TOP PCB.
12. Now Insert the scanner module in BOX and then insert the top plate
gently from the back side.
13. Place the plastic cover again and fit the scanner with all four
mounting screws. Check the scanner on the table itself for proper
operation and then place in panel.

SYSTEM INFORMATION
SR. NO.
Mfg. DATE
SUPPLY
Serial Port
Alarm / Control
Outputs
Channel No. Input Type Channel No. Input Type

01 09
02 10
03 11
04 12
05 13
06 14
07 15
08 16
Standard Accessories supplied:
Sr. No. ITEM QTY

01 Spare Fuse 200 mA, 230 VAC 01 no.
02 Mounting Clamps 02 nos.
03 3 pin Female connector (Supply) 01 no.
04 2 pin Female connector (RS485) 01 no.
05 Operating Manual with Warranty Certificate 01 no.
06 Calibration report 01 no.

APPLICATION NOTES:
SLAVE UNITS SCANNER RS485 CONNECTION

SCANNER 1
RS485 RS485 - RS232 MASTER
CONVERTER PC
D+
D-
RS485 RS232 RS232
D+
SCANNER 2 D-
RS485
D+
D-
SCANNER TO RELAY CARD5 CONNECTION
SCANNER RELAY 24VDC

CARD1 SUPPLY
CONROL GND 24V
O/P 1 - 8 CARD
SUPPLY
GND
24V
9 PIN - 9 PIN
RELAY
CONROL CARD2
O/P 9 -16 CARD
SUPPLY
GND
24V
9 PIN - 9 PIN

SENSOR CABLE CONNECTION TO SCANNER
SCANNER SHIELDED CABLE
SENSOR -
SHIELD TO
INSTRUMENTATION KEEP SHIELD OPEN
EARTH AT AT SENSOR END
SCANNER SIDE
POWER EARTH
FOR SCANNER
SUPPLY
KEEP POWER EARTH and INSTRUMENTATION EARTH
ISOLATED FROM EACH OTHER
THERMOCOUPLE SENSOR TYPES

USE ONLY ISOLATED SENSOR WITH SCANNER
ISOLATED TYPE SENSOR
DO NOT USE FOLLOWING GROUNDED TYPE OF

SENSORS FOR SCANNER
CLOSED TYPE SENSOR - BODY SHORT TO SENSOR
OPEN WIRE TYPE SENSOR

TWO WIRE mA TRANSMITTER CONNECTIONS

24VDC
SUPPLY
GND 24V
SCANNER
TX1
W
+
W
01 R
W +
W
02 R TX2
TWO WIRE mA TRANSMITTER CONNECTIONS

with INDICATOR / PLC IN SERIES
24VDC
SUPPLY
GND 24V
INDICATOR
SCANNER PLC etc. TX1
W
+ +
W
01 R
W
+ +
W
02 R INDICATOR TX2
PLC etc.
NOTE:
GND / -VE TERMINAL OF 24VDC SUPPLY,
INDICATOR, PLC, SHOULD NOT BE
COMMON WITH BODY / EARTH.

FOUR WIRE mA OUTPUT CONNECTIONS
SCANNER INSTRUMENTS WITH

4 WIRE OUTPUT
W
W
01 R
W
W
02 R
FOUR WIRE mA OUTPUT CONNECTIONS

with INDICATOR / PLC IN SERIES
SCANNER INSTRUMENTS WITH

4 WIRE OUTPUT
W
+
W
01 R
W
+
W
02 R INDICATOR
PLC etc.
NOTE:
GND / -VE TERMINAL OF 24VDC SUPPLY,
INDICATOR, PLC, SHOULD NOT BE
COMMON WITH BODY / EARTH.

RELAY OUTPUT CARD FOR SCANNER
CARD
LD1
RELAY 1 NC
SUPPLY
POLE
GND NO
24V
LD2
RELAY 2 NC
POLE
NO
LD3
RELAY 3 NC
POLE
NO
LD4
RELAY 4 NC
POLE
LD5 NO
RELAY 5 NC
POLE
NO
LD6
RELAY 6 NC
POLE
NO
LD7
RELAY 7 NC
RL1 RL2 POLE
RL3 RL4
RL5
NO
RL6
RL7 RL8
LD8
GND
RELAY 8 NC
POLE
CONTROL INPUTS NO
FROM SCANNER

Snubber Capacitor Connection For Relay Output
P NO
Load Coil
0.1 ELCR
Supply to Load
NOTE:
Always use ELCR capacitor given with the unit

across your load coil as shown
to avoid Signal disturbances because
of load switching.

PROGRAMMING FLOW CHART

FOR SCANNER
MAIN SCANNING MODE
PROG
Enter Program mode

1st Menu Displayed
Press any of the

following keys
PROG
Next or Previous
Menu Displayed
Same Menu Displayed Enter to program that Menu
YES Press to
scroll required
value / Option
NO Press to
More Digits set required
or Options?
value / Option

FRONT STICKER DIAGRAM

(Horizontal Model)
falcon - 1600
01 05 09 13
02 06 10 14
CH NO PROCESS VALUE
03 07 11 15
RXD TXD L1 L2 L3 L4 R1 R2 04 08 12 16
PROG CONTROL STATUS

FRONT STICKER DIAGRAM

(Vertical Model)
falcon - 1600
PROCESS VALUE CH NO
RX TX R1 R2
L1 L2 L3 L4
01 02 03 04
05 06 07 08
09 10 11 12
13 14 15 16
PROG

BACK CONNECTION DETAILS
BACK CONNECTOR DETAILS

W
T/C,
INPUT W
CONNECTIONS 01 R
W W W W
FUSE W W W W
200 CJC
mA 13 R 09 R 05 R 01 R
W W W W
W W W W
RLY
14 R 10 R 06 R 02 R
RS485
NO
ALARM
D+
W W W W
ON
P
1 2 3 4
D- W W W W
NC
DIP
15 R 11 R 07 R 03 R
LIVE NO ID SW W W W W
NEU P W W W W
NC RJ CON
ERT ETHERNET 16 R 12 R 08 R 04 R
230 VAC R2
110 VAC

FALCON 1600 - TOP VIEW
DISPLAY PCB
DIGITAL PCB
BASE and TOP PCBs
INPUT CHANNEL PCB

S -- SPAN TRIM POT Z -- ZERO TRIMPOT
FILTER PCB
CONNECTOR PCB

FALCON 1600 - SIDE VIEW INPUT CHANNEL PCBs
TOP PCB
CONNECTOR PCB
DISPLAY PCB
DIGITAL PCB
FILTER PCB
TRANSFORMER
CON or BASE PCB
CON PCB -- COMPONENT SIDE

MAINS SUPPLY SELECTION LINK
PUT AS REQUIRED - ONLY ONE
110
230
TRANSFORMER


Falcon 1600

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Operating Manual – Falcon 1600

16 channel Analogue Input Module

PROG CONTROL STATUS

Manual Falcon 1600 Page 1 of 45

Sr. No. Chapter Name Page

Manual Falcon 1600 Page 2 of 45

1. Keyboard: System is provided with four keys, PROG, UP, DOWN

STEP KEY Operation

2 Scroll Menus or digits or

3 Select Menu to Modify.

2. Seven Segment LED DISPLAY:

Manual Falcon 1600 Page 3 of 45

Setting Parameter value in Program mode:

STEP KEY Operation

2 Select Menu to Modify.

3 Change Digit from 0 to 9 or

Set digit and go to next digit

Exit Program Mode.

Manual Falcon 1600 Page 4 of 45

Manual Falcon 1600 Page 5 of 45

Basic System Parameters to program:

1. Press PROG key and enter Program mode

Programming of Channel Parameters:

Follow the sequence below to set the channel properties.

1. Press PROG key and enter Program mode

Manual Falcon 1600 Page 6 of 45

Following are illustrations of different parameters used in Externally linearisaed

For mA input: (4 – 20 range)

Value calculation as per ‘ZERO and SPAN values

Example 1: SPAN = 3000 and ZERO = 0000, DPPOS = 1

Input mA Indicated Value

Example 2: SPAN = 3000 and ZERO = 1000, DPPOS = 1

Input mA Indicated Value

Manual Falcon 1600 Page 7 of 45

For Volt input: (0 - 1V range for example)

Value calculation as per ‘ZERO and SPAN values

Example 1: SPAN = 3000 and ZERO = 0000, DPPOS = 1

Input Vdc Indicated Value

Example 2: SPAN = 3000 and ZERO = 1000, DPPOS = 1

Input Vdc Indicated Value

Manual Falcon 1600 Page 8 of 45

Linearisation Settings for different types of inputs:

1. RTD : The linearisation is only Internal.

2. mA and Volt : The linearisation can be Internal or External.

Input mA Indicated Value

External Mode: SPAN = 3000 and ZERO = 0000, DPPOS = 1

Input mA Indicated Value

3. Thermocouple : The linearisation can be Internal or External.

Mode Indicated Engineering

Manual Falcon 1600 Page 9 of 45

Menu 8 is used to set different parameters of serial communication.

Press ENTR key to set ID number first.

ID NO. DIP SWITCH POSITION

After ID is set, System displays present Baud Rate.

After this PARITY is displayed.

Manual Falcon 1600 Page 10 of 45

Extra data for mA input channels only:

For control output status only:

Value received in MODBUS is without decimal point.

Manual Falcon 1600 Page 11 of 45

FALCON 1600 – ETHERNET

All remaining Hardware & software features/ programming is same as standard

Serial Port setting for Ethernet: