FALCON SG2K Modules | SG2K-1T Power Supply

Technical Dossier

Product Details And Specifications

FALCON SG2K Series: Comprehensive Module Range and Technical Overview

The FALCON SG2K series is a modular distributed control system (DCS) platform deployed across global heavy industry sectors including petrochemical refineries, nuclear power generation facilities, offshore oil & gas platforms, and large-scale chemical processing plants. Its rack-based architecture supports hot-swap capability and redundant backplane communication, making it a preferred platform for continuous-process environments where unplanned downtime carries significant operational and safety consequences. Installed base units remain active in facilities across North America, Europe, and Asia-Pacific, with many sites operating original hardware beyond the manufacturer's standard support window.

The Evolution of SG2K Architecture

The SG2K platform was introduced as a second-generation successor to FALCON's earlier SG1K rack system, transitioning from parallel backplane communication to a serial token-ring bus architecture that reduced wiring complexity and improved noise immunity in high-EMI industrial environments. Early SG2K revisions (Rev A/B) used proprietary FALCON bus protocol operating at 1 Mbps; later revisions (Rev C onward) introduced dual-redundant bus paths and increased throughput to 5 Mbps. The platform's I/O subsystem was designed around a 16-slot main rack with up to four expansion racks per node, supporting mixed analog and digital I/O in a single chassis. Compatibility between early and late revisions requires attention to firmware alignment: Rev A CPU modules are not firmware-compatible with Rev C I/O expanders without an intermediate bridge adapter (SG2K-BA). As the SG2K series has entered its end-of-life phase, FALCON's recommended migration path is toward the SG4K platform; however, the capital cost and engineering scope of full migration means the majority of installed SG2K sites continue to operate on original hardware with third-party lifecycle support.

SG2K Full Catalog & Functionalities (SKU List)

Power Supply Modules

• SG2K-1T: 24VDC primary rack power supply, 10A output, redundancy-capable
• SG2K-1TR: Redundant companion power supply for SG2K-1T hot-swap pair
• SG2K-2T: 48VDC high-capacity power supply for expansion rack configurations

CPU / Controller Modules

• SG2K-CPU1: Single-processor controller, 256KB user memory, Rev A/B compatible
• SG2K-CPU2: Dual-processor redundant controller, 1MB user memory, Rev C+
• SG2K-CPU3: High-speed controller with onboard Ethernet port, 4MB memory

Analog Input (AI) Modules

• SG2K-AI8: 8-channel 4–20mA analog input, 12-bit resolution, HART-passive
• SG2K-AI16: 16-channel analog input, configurable 0–10V / 4–20mA per channel
• SG2K-AI8H: 8-channel HART-active analog input with field device diagnostics

Analog Output (AO) Modules

• SG2K-AO8: 8-channel 4–20mA analog output, 13-bit resolution, loop-powered
• SG2K-AO4H: 4-channel HART-enabled analog output with valve positioner support

Digital Input (DI) Modules

• SG2K-DI16: 16-channel 24VDC digital input, sink/source configurable
• SG2K-DI32: 32-channel high-density digital input, 120VAC compatible variant available

Digital Output (DO) Modules

• SG2K-DO16: 16-channel relay digital output, 2A per channel, Form-C contacts
• SG2K-DO32: 32-channel transistor digital output, 0.5A per channel, 24VDC

Communication Adapters

• SG2K-CM1: Modbus RTU/ASCII communication adapter, RS-485 interface
• SG2K-CM2: PROFIBUS DP slave adapter, up to 12 Mbps
• SG2K-CM3: Ethernet/IP adapter, 10/100 Mbps, DLR ring topology support

Sourcing Hard-to-Find & Obsolete SG2K Parts

FALCON officially discontinued active production of the SG2K series. Standard manufacturer support, including firmware updates and new-unit supply, is no longer available through OEM channels. DriveKNMS maintains a dedicated inventory of tested SG2K modules sourced from decommissioned plant equipment, controlled-environment warehousing, and verified secondary-market channels. For end-users operating SG2K-based systems beyond the OEM support window, DriveKNMS provides: direct unit replacement for failed modules, cross-reference identification for unlabeled or damaged units, firmware version matching to ensure backplane compatibility, and long-term supply agreements for facilities requiring multi-year parts coverage. Units including the SG2K-1T, SG2K-CPU2, SG2K-AI8H, and SG2K-CM2 are among the highest-demand obsolete SKUs and are held in stock where available.

Quality Control for the SG2K Range

The SG2K backplane uses a proprietary token-ring serial bus that requires functional validation beyond standard power-on testing. DriveKNMS applies a multi-stage test protocol to all SG2K modules prior to shipment: (1) Visual inspection for capacitor degradation, PCB corrosion, and connector pin integrity; (2) Bench power-on test with current-draw profiling against factory specification; (3) Backplane communication test using a live SG2K rack with known-good CPU and bus terminator to verify token-passing and data integrity; (4) For analog modules, calibration verification across the full input/output range using traceable reference instruments; (5) For power supply modules including the SG2K-1T, load regulation testing at 25%, 50%, 75%, and 100% rated output with ripple measurement. Modules that fail any stage are quarantined, documented, and not returned to inventory.