ION FALCO User manual

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FALCO and FALCOTAC
Instrument User Manual V1.2R
Unrivalled Gas Detection.ionscience.com
30 AÑOS AL SERVICIO DE LA INDUSTRIA

FALCO Instrument User Manual V1.2R
Unrivalled Gas Detection. Page 2 of 46 ionscience.com
Register your instrument online for extended warranty
Thank you for purchasing your Ion Science instrument.
The standard warranty of your FALCO 1.2 VOC Monitor is for one
year.
To receive your extended warranty, you must register your
instrument online within one month of purchase (terms and
conditions apply.)
Visit www.ionscience.com

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Contents
Contents...................................................................................................................................... 3
Safety..........................................................................................................................................6
Legal Notices Regarding the Safe Operation of Equipment...............................................................6
Symbols...............................................................................................................................................6
Warnings, Cautions and Information notifications ............................................................................6
Disposal...............................................................................................................................................8
Certification FTZÚ ........................................................................................................................9
Declaration of Conformity.......................................................................................................... 10
Statements ................................................................................................................................ 11
Responsibility for Correct Use ..........................................................................................................11
Warnings...........................................................................................................................................11
Quality Assurance .............................................................................................................................11
Warranty...........................................................................................................................................11
Service...............................................................................................................................................11
Introduction to FALCO................................................................................................................ 11
Technical Specification............................................................................................................... 12
Un-Packing ................................................................................................................................ 13
System Description .................................................................................................................... 13
Outputs and Communications..........................................................................................................13
RS485 Modbus Interface ............................................................................................................ 14
Installation Requirements .......................................................................................................... 15
Location Requirements.....................................................................................................................15
Power Requirements ........................................................................................................................15
Cable and Gland Requirements........................................................................................................15
Installation ................................................................................................................................ 16
Preparation for Installation ..............................................................................................................16
Dimensions for Installation...............................................................................................................16
Installing the Housing Module..........................................................................................................17
After-Installation Test.......................................................................................................................18
Installation in Zones with Explosive Atmospheres...........................................................................18
Configurations of the 4 –20 mA Current Loop............................................................................. 19
Hydrophobic Filter ..................................................................................................................... 23

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Sampling Tube Length................................................................................................................ 23
Removal of the Control Module.................................................................................................. 23
To Remove the Control Module.................................................................................................. 23
Operating the FALCO.................................................................................................................. 24
User Interface ...................................................................................................................................24
Status Light .......................................................................................................................................24
Start-Up Routine........................................................................................................................ 25
Logo Screen ......................................................................................................................................25
Info screen 1 .....................................................................................................................................25
Info screen 2 .....................................................................................................................................25
Warm up ...........................................................................................................................................25
Normal Running Mode Screen.................................................................................................... 26
Software Screens ..............................................................................................................................26
Software Flow Chart .........................................................................................................................26
Lock Screen.......................................................................................................................................27
Navigating the Menus and Selecting Menu Options........................................................................27
Menu i1.............................................................................................................................................28
Menu i2 ...........................................................................................................................................28
Menu i3 ...........................................................................................................................................29
Menu i4 ...........................................................................................................................................29
Menu i5 ...........................................................................................................................................29
Menu i6 ...........................................................................................................................................30
Menu i7.............................................................................................................................................30
Menu i8.............................................................................................................................................30
Pump Operation ...............................................................................................................................31
Calibration................................................................................................................................. 31
Zero...................................................................................................................................................31
Span 1 ...............................................................................................................................................32
Span 2 ...............................................................................................................................................33
RF (Response Factor).................................................................................................................. 33
Detection Units.......................................................................................................................... 34
Measurement Cycle ................................................................................................................... 35
Alarms....................................................................................................................................... 35

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Alarm 1..............................................................................................................................................35
Alarm 2..............................................................................................................................................36
Alarm Brightness........................................................................................................................ 36
Alarm Pulsing............................................................................................................................. 36
Relays........................................................................................................................................ 37
Relay 1 Options.................................................................................................................................37
Relay 2 Options.................................................................................................................................37
4 –20 mA .................................................................................................................................. 37
4 –20 mA Enable/Disable.................................................................................................................37
4 - 20mA Range.................................................................................................................................38
Modbus Address........................................................................................................................ 38
Status Light Brightness ............................................................................................................... 38
Service Mode .......................................................................................................................... 38
Password Lock ........................................................................................................................... 39
Servicing.................................................................................................................................... 40
Cleaning the MiniPID.................................................................................................................. 41
Use of PID Lamp Cleaning Kit A-31063.............................................................................................42
Fault Diagnostics........................................................................................................................ 42
Alarm and Fault Indications..............................................................................................................42
Fault Conditions................................................................................................................................43
Manual Log................................................................................................................................ 45
Warranty ................................................................................................................................... 45
ION Science Contact Details........................................................................................................ 46

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Safety
Legal Notices Regarding the Safe Operation of Equipment
•Whilst every attempt is made to ensure the accuracy of the information contained in this manual, ION
Science accepts no liability for errors or omissions in the manual, or any consequences deriving from
the use of information contained herein. It is provided “as is” and without any representation, term,
condition or warranty of any kind, either expressed or implied.
•To the extent permitted by law, ION Science shall not be liable to any person or entity for any loss or
damage which may arise from the use of this manual.
•We reserve the right at any time and without any notice to remove, amend or vary any of the content
which appears in this manual.
Symbols
WARNING!
USED TO INDICATE DANGER WARNINGS WHERE THERE IS A RISK OF INJURY OR
DEATH.
Caution
Used to indicate a caution where there is a risk of damage to equipment.
Information
Important information or useful hints about usage.
Recycling
Recycle all packaging.
WEEE Regulations
Ensure that waste electrical equipment is disposed of correctly.
Warnings, Cautions and Information notifications
The following Cautions apply to the product described in this manual.
Inadequate performance of the gas detection equipment described in this manual
may not necessarily be self-evident and consequently equipment must be
regularly inspected and maintained.
ION Science recommends that personnel responsible for equipment use institute
a regime of regular checks to ensure it performs within calibration limits, and that
a record be maintained which logs calibration check data.
The equipment should be used in accordance with the safety standards and
installation instructions given in this manual, and in compliance with local safety
standards.

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Protect the PID sensor from exposure to silicone vapours as this may foul the
windows of the lamps and reduce response to some gases. This can usually be
remedied by polishing the lamp window with alumina powder.
Do not use abrasive or chemical detergents to clean the Falco instrument as this
may reduce the antistatic properties of the materials used, clean it using a damp
cloth only.
The Falco must not be exposed to atmospheres known to have an adverse effect
on Thermoplastic Elastomers or Polycarbonate.
Outside the items covered in this manual, the Falco must be serviced in a Non-
Hazardous environment and by ION Science Ltd authorised service centres only.
Substitution of components may impair intrinsic safety.
Ingress Protection: Continuous exposure to wet weather conditions should be
limited to less than one day and harsh water spray conditions should be avoided.
Proper Use: If the equipment is used in a manner not specified by the
manufacturer, the protection provided by the equipment may be impaired.
The following Warnings, Cautions and Information notifications appear later in this manual where they are
applicable.
IF AN ALARM STATE IS TRIGGERED THE USER SHOULD LEAVE THE HAZARDOUS
ENVIRONMENT AND ACT IN ACCORDANCE WITH NATIONAL SAFETY
REGULATIONS.
THE CLEANING COMPOUND CONTAINS ALUMINIUM OXIDE AS A VERY FINE
POWER. THIS MAY CAUSE IRRITATION OF RESPIRATORY TRACT AND EYES.
(CAS Number 1344-28-1).
Internal components must be handled with clean hands and clean tools. The lamp
is fragile. Handle with great care. Never touch the window and do not drop.
Never refit a damaged Lamp.
The instrument MUST be re-calibrated after fitting a replacement or cleaned
Lamp.
The Falco has been designed to be used in hazardous environments

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Important note: Always check the calibration in normal running before use by
carrying out a bump test. Apply the same Zero and SPAN gas used to calibrate and
ensure the correct readings are displayed.
Disposal
•The equipment does not include any toxic materials, but if it has been contaminated by toxic
materials, then exercise due care and follow the appropriate regulations when disposing.
•Always adhere to local regulations and procedures when disposing of the equipment.
•Ion Science Ltd offers a take back service. Please contact us for more information.
RECYCLING
Recycle all Packing.
WEEE REGULATIONS
Ensure that all waste electrical equipment is disposed of correctly.

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Certification FTZÚ

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Declaration of Conformity

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Statements
Responsibility for Correct Use
Ion Science Ltd accepts no responsibility for incorrect adjustments that cause harm or damage to persons or
property. The users are responsible to respond appropriately to the readings and alarms given by FALCO.
Use the equipment in accordance with this manual, and in compliance with local safety standards.
Reduced performance of gas detection might not be obvious, so equipment must be inspected and maintained
regularly. Ion Science recommends:
•you use a schedule of regular checks to ensure it performs within calibration limits, and that
•you keep a record of calibration check data.
Warnings
1. Read and understand this Manual fully before you install or operate the FALCO.
2. For safety, the FALCO must only be operated by qualified personnel.
3. All electrical work must be only carried out by competent persons.
4. Substitution of components can result in unsafe conditions and will invalidate the warranty.
5. Surface mount fuses must only be replaced by Ion Science service centres.
Quality Assurance
The FALCO is manufactured by companies with business systems compiling to the ISO 9001 standard. That
ensures that the equipment is:
•designed and assembled reproducibly, from traceable components,
•calibrated to the stated standards before it leaves our factory.
Warranty
To receive your 2 Year Warranty, you must register within one month of purchase (Terms and Conditions
apply). You will then receive a confirmation email that your Warranty Period has been activated and
processed.
Full details, along with a copy of our Warranty Statement can be found by visiting: www.ionscience.com
Service
Ion Science recommends a twelve-month service replacement of the MiniPID sensor lamp.
Contact Ion Science or your local distributor for service options in your area.
Introduction to FALCO
The FALCO unit is a fixed detector for the continual monitoring and measuring of volatile organic compounds
(VOCs) in the atmosphere. VOCs can be dangerous as they are poisonous to humans and there is a risk of
explosion. VOCs are detectable using photo ionisation detection (PID) detector.
The FALCO’s multi coloured LED status display screen can be seen from a distance of twenty metres in direct
sunlight ensuring that personnel are alerted to hazards present.
The FALCO has five magnetic switches with LED confirmation, a high contrast OLED screen, and graphical
interface ensuring quick and easy installation and servicing.
The magnetic switches are operated with a magnetic actuator that provides the actions of up, down, left, right
and enter.

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The main display uses organic light emitting diode (OLED) technology and the status bar uses light emitting
diodes (LED). It also has a galvanically separated 4-20 mA current loop, Modbus (serial communication
protocol) and two configurable switched contacts.
For protection in explosive areas the FALCO’s Main Unit electronics are fitted in an ExD enclosure and the PID
Sensor Head utilises intrinsically safe electronics.
The FALCO has two modules:
•The Main Unit (flameproof enclosure)
•The PID Sensor Head (intrinsically safe)
The externally located intrinsically safe PID Sensor Head allows servicing and calibration in a hazardous
environment without having to isolate the power supply.
Technical Specification
Name
VOC Analyser Falco 1.2
Dimensions
h 291 mm, w 180 mm, d 125 mm
Weight
3.3 kg
Nominal Voltage
12V to 40Vdc (Powered from Safety Extra-Low (SELV))
Maximum Current
0.56 A at 12 V / 6.6 W
0.28 A at 24 V / 6.7 W
0.2 A at 40 V / 8 W
Maximum Power
8W
Typical Power
2W (depending on the LED intensity)
Supply Cables
0.5 to 2.5mm2
Maximum Contact Load
60Vdc / 2A
50Vac / 2A
Internal Voltage 4-20mA
19V ± 1V
Fuse
Fuse T 1A (blow value 35A)
Operating Temperature:
-20°C to + 50°C
Operating Humidity:
0 –100 RH% (condensing)
Storage Temperature
-20°C to +60 °C
Ingress Protection
Main Unit: IP65
Sensor Head: IP65
PID Sensor
MiniPID
II 1G Ex ia IIC
Baseefa 07ATEX0060U
Measuring Range
0 to 10ppm, 0 to 50ppm, 0 to 1,000ppm, 0 to 3,000ppm. FalcoTAC. 0 to
50ppm
T90
< 10 seconds
Accuracy
+/- 5% +/- 1 digit

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Display Screen
OLED 64x128 pixels
WEEE Compliant
Compliant with the European Waste Electrical and Electronic Equipment
directive
Certification
II 2G Ex db ib IIC T4 Gb
Class 1, Div 1 Groups ABCD T4
ISO9001:2015
All specifications quoted are at calibration point and under the same ambient conditions.
Specifications are based on isobutylene calibration at 20 °C and 1000 mBar.
Un-Packing
All equipment shipped by Ion Science Ltd is packed in containers with shock absorbing filling to protect them
against physical damage.
Remove the contents carefully and check them against the packing list. Report discrepancies between the
contents and the packing list to Ion Science Ltd. Ion Science will not be responsible for discrepancies not
reported within ten days of your receipt of the shipment.
Every FALCO (new units and those returned from a Service Centre) must have a Certificate of Calibration
before you install it.
System Description
Outputs and Communications
FALCO has six communication outputs:
•The on-board LCD and LEDs on the faceplate.
•4 - 20 mA Current Loop.
•RS485 Modbus.
•Two programmable relays.
Real-time information is displayed on the LCD and transmitted on the 4 - 20 mA and RS485 channels.
You can program two alarms to operate at a chosen concentration of gas. The alarms will display a message on
the LEDs, energise the relays, and transmit a signal on the 4 - 20 mA channel.
The alarms and relays are individually programmable to the settings required by the site policy. You can
choose either alarm to energise either relay.
Both relays can be programmed to switch 60 VDC / 2 A or 50 VAC / 2 A maximum load.

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RS485 Modbus Interface
The FALCO Modbus interface uses Modbus RTU
•9600 baud, 8 data bits, no parity, 1 stop bit.
Register
Address
Name
Function Code
Data Type
Range
Register
Qty
102
Gas concentration
3 - Read Holding
Registers
32-bit Float
±1.175494E-38 to ±3.402823E+38
2
106
Sensor
Voltage(mV)
3 - Read Holding
Registers
32-bit Float
±1.175494E-38 to ±3.402823E+38
2
108
Temperature (°C)
3 - Read Holding
Registers
16-bit Signed
Integer
-32768 to +32767
1
182
LED Brightness
3 - Read Holding
Registers
16-bit unsigned
Integer
0 to 100
1
1003
Hardware Version
3 - Read Holding
Registers
16-bit unsigned
Integer
1 to 255 (Default value 1)
1
1005
Measurement Unit
3 - Read Holding
Registers
Character
‘p’ or ‘g’ (Default value ‘p’)
1
1010
Response Factor
3 - Read Holding
Registers
32-bit Float
0.1 - 10.00
2
1012
Sensor Range
3 - Read Holding
Registers
16-bit unsigned
Integer
10, 50, 1000, 3000 (Default value
3000) FalcoTAC 50 (Default value 50)
1
1060
Cal 100
3 - Read Holding
Registers
16-bit unsigned
Integer
0 to 65535 (Default value 500)
1
1061
Cal3000
3 - Read Holding
Registers
16-bit unsigned
Integer
0 to 65535 (Default value 3000)
1

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Installation Requirements
Please make sure you understand all the installation requirements and have read the technical specification
before you install FALCO.
Location Requirements
There are many variables involved in defining the optimum location for a gas detector.
Mount the FALCO:
•in a location where it is most likely to detect the gas.
•in an area that has good air circulation. Restricting natural air current can result in delayed detection.
•on a solid, stable support, where it is accessible for servicing.
•in a vertical position, with the sensor at the bottom to help avoid rain and dust entering the sensor
chamber.
•not in direct sunlight or over a heat source (this can cause the Falco to exceed its certified internal
working temperature of 50 °C).
•not in areas likely to flood.
•In a location that has easy access for servicing.
For further guidance please consult the relevant local standards or local occupational health representatives.
INFORMATION
•If the VOCs being detected are known to be lighter than air install the FALCO unit as high on the
wall as is practical.
•If the VOCs being detected are known to be heavier than air, install the FALCO unit as low as
possible but never on the floor.
Power Requirements
Nominal Voltage:
12 V to 40 Vdc
Cable and Gland Requirements
We recommend you use screened cables e.g., multicore cable with SWA armour, or Braid Armour to protect
against EMI.
The manufacture and build of the cable glands is the responsibility of the installer. The cable glands must
conform to the certification standards required for the installation site. Install blanking plugs with the
appropriate certification standards to unused cable gland ports.
NOTE: The external terminal is to be used to ground / earth the Falco instrument. The connecting wire must be
a minimum of 4mm2.

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Installation
INFORMATION
Before installing the FALCO unit thoroughly read the technical specification contained in this User
Manual
Preparation for Installation
Before you install the FALCO, refer to the:
•Instrument User Manual
•Location Requirements
•Power Requirements
•Cable and Gland Requirements
•Dimensions for Installation
•RS485 Interface Requirements
Dimensions for Installation

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To Install the Housing Module
To install the FALCO as a complete assembly
1. Use two M8 screws to install the FALCO as a complete unit (Main Unit and Sensor Housing together) on a
solid, stable support.
2. After you install the FALCO, unscrew and remove the Front Cover. Unbolt the three bolts holding the
control module (4) from the ExD Housing Module (2). Disconnect the Control Module from its Ribbon
Connector to get access to the terminal blocks.
3. Feed the cables through the glands (1) and make the connections to the terminal blocks as you require.
Refer to Configurations of the current loop, on the following pages.
4. Seal the cables in the cable glands.
Ref Description
1 ExD Cable Gland
2 ExD Housing Module
3 Ribbon Cable
4 Control Module
5 Front Cover
6 Pump Housing Cover
7 PID Housing Cover

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5. Reconnect the Control Module to the Ribbon Connector and place into position. Replace and tighten the
three retaining bolts.
6. Screw the Front Cover back on.
7. Connect and switch on the power supply.
8. Do an After-Installation Test.
9. Calibrate the instrument.
After-Installation Test
Do a test of the relay and the 4 –20 mA systems to check for correct installation and function.
Do a "Bump Test" to verify that the sensors respond correctly to the test gas at the concentrations
programmed for Set Points 1 and 2.
A “Bump Test” does not calibrate the sensors. If the instrument does not display the gas concentration given
by the bottle, do a calibration to give the correct readings.
Installation in Zones with Explosive Atmospheres
The wiring diagram for the Falco is shown below, that covers in input power, MODBUS and Current Loop.
There are four possible configurations for the 4 –20 mA current loop depending on the installation site that
are following section.
Figure showing typical connector wiring diagram.
Example method of connection for explosive environment

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Configurations of the 4 –20 mA Current Loop
The Falco has internal power supply and current source. Depending on the installation site requirements there
are several possible configurations, see the following block diagrams and DIP switch settings to suit the
application. All configurations are galvanically isolated from the 8 –40 Vdc power supply used to power the
Falco instrument.
This DIP switch can be found near the ribbon cable and is labelled 4 - 20mA LOOP.
Falco Current Loop Configuration 1 –active current loop, using internal power supply connected to the current
source.

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Falco Current Loop configuration 2 –passive current loop, externally powered current source.
When using this configuration ensure that the current loop circuit has voltage is between 8.5 V and 12 V, at
Loop + after the resistances of the line have been taken into consideration.