Falcon Wingspan

Instruction
Manual
Falcon Wingspan Tank Floor Scanning System

The Falcon Wingspan is designed for use in large

storage tanks that have a clean floor, free of any tars,
thick oils, asphalts, or any substance that may become
adhered to the base of the Wingspan. These would
result in a loss of performance by the Wingspan. For
tanks that may have this risk, a TesTex Falcon Senior
Tank Floor Scanning System is recommended.

Table of Contents

Handle Bar Assembly………………………………………….………………2-3

Battery Box Assembly…………………………………………….……………..4

Battery Charging…………………………………………………….…………..5

Handlebar and Battery Box Attachment………………………………………6

Electronic Boxes…………………………………………………..……………..7

Scanner Pod Removal and Installation ……………………..…………………8

Falcon Wingspan Instruction Manual rev 1.2 June 2009

1
Wingspan Handlebar Assembly

Figure 1: Handlebar Unit. Note the crossrails are

on the same side of the unit.

The Wingspan handlebars come in three sections. At each connection there are
nylon plastic connectors that will slide into the adjacent section. Black nylon connectors
identify the bottom section while the middle section has white connectors. The top
section will not have any connectors installed. To assemble, first ensure that all cross
rails area aligned on the same side of the handlebars, then slide the connectors into each
other. The cross rails will allow various components to be mounted to the handlebars.

Top Section

White Connectors
Middle Section

Black Connectors

Bottom Section

2
Wingspan Handlebar Assembly

Figure 2: Equipment mounted on Handlebars

G
A C D

B H

E
F
______________________________________________________________________________

A – 1 ¾” 8-32 Cap Screw E – 1” 8-32 Cap Screw

B – 2” 8-32 Cap Screw F – Handlebars
C – Laptop Shelf G – Knurled Nuts
D – 1” Plastic Spacers H – Falcon Mark II Electronics

3
Wingspan Battery/Battery Box Assembly

Figure 3: Complete Battery Box

The Wingspan battery box holds two 12V-12AH lead acid batteries and features
two 12V power outlets as well as a circuit breaker. The power outlets allow a laptop to
be used when operating the Wingspan in DC power mode.
The first step in installing the batteries into the battery box is to rap each battery
with the rubber sleeve then put a battery strap on each of the batteries. This will allow
the batteries to be easily installed and removed from the battery box.

Figure 4: Battery with strap Figure 5: The side opposite the TesTex
label is the back of the box

Once the straps are on the batteries you will then need to place the correct
connectors to the correct terminals; black wire to black terminal, red wire to red terminal.
With these connected, the batteries can be placed into the battery box. It will be a snug
fit. The battery terminals will face the rear of the battery box, as shown in the image
above (Figure 6).

4
Wingspan Battery Charging

Figure 6: Charging cable attached to Battery box.

The batteries for the Wingspan can be charged without being taken out of the
battery box. This is done through the lead coming from the battery box. A battery
charging cable is attached to this lead. The charging cable has a four-pin connector on
one end and two leads coming from it on the opposite end. A battery charger is attached
to the corresponding lead.

5
Wingspan Handlebar and Battery Box Attachment

The handlebar and battery box can be attached to the Wingspan by using the
mounting brackets located on the front side of the Wingspan. The battery box will sit
between the ends of the handlebar on the front of the Wingspan. There is a black plastic
mounting block on each side of the battery box. These will let the battery box fill the gap
between mounting brackets located on the Wingspan. There are connector pins attached
to the Wingspan to fasten the handlebar and battery box in place.
First, place the battery box into place and insert the back pins to hold the battery
box securely in place. Next, place the handlebars into the slotted area with the laptop
shelf facing the front of the Wingspan. Hold the handlebars vertical to insert the
connector pins. You may have to move the handlebars around a bit to line up the holes in
the mounting brackets with the hole in the handlebars. The connector pins should be
inserted the entire way into the bracket to ensure the security of the battery box.

Figure 7: Mounting bracket on battery box Figure 8: Mounting bracket on Wingspan with pins
holding handlebar and battery box in place.

6
Wingspan Electronic Boxes

Falcon 2000 Mark II Electronics:

When operating the Wingspan in DC power mode, only have the DC switch on.
The indicator light will illuminate to show power is on. When operating in AC power
mode only have the AC power switch turned on. A laptop can be plugged into the AC
power outlet when operating in AC mode.

Wingspan Mux Box:

7
Wingspan Pod Removal/Installation

4 3
1 2

Figure 9: To remove a pod, four (4) screws at the top corners need to be taken out; for these are the only ones holding the pod
into place.

Individual scanner pods may be removed if necessary. To do this, first turn over
the Wingspan. Once exposed, removal of the pods may begin. There are a total of four
(4) screws holding each pod in place that will have to be removed. Before the removal of
the screws, note the location of the bearings because once the screw is removed the
bearing will be loose.

Figure 10: The wire connection of a removed pod.

Once the screws are removed from both sides of the pod, the pod can be pulled
out of the pod enclosure. The final step for removal is to unscrew the connector.
Twisting the collar of the connector can do this.
When installing a replacement pod, the process is reversed. The removal and
installation process is the same on all pods in the Wingspan.