AHCON PCI 1200 User manual

PCI 1200 –7 bar / 12 bar

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OPERATORS MANUAL - Translation
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BETRIEBSANLEITUNG - Übersetzung
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BRUGER MANUAL - Original
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OPERATORS MANUAL (GB)
- Translation
AHCON PCI 1200
Manufacturer Information
Art. No.: 0502 - 100 12 070 / 0502 - 100 12 120
Type: AHCON PCI 1200 - 7 or 12 bar
Use: Fully automatic pre-set electronic tyre gauge device for inflation of
Motorcycle wheels, passenger car wheels, van and truck wheels, as
well as industrial and agricultural wheels.
Field of operation: As individual “Fixed Computer Inflation Device”or as an integrated
fixed part of an AHCON Speed Line System, an AHCON Inflation
Station or an AHCON Safety Cage (also with Omega-Jet-System).
Technical Data: Power connection: 100 - 250 VAC –50/60 Hz.
Maximum supply pressure: 10 / 14 bar, (see type spec.).
Maximum tire Inflation pressure: 7 / 12 bar, (see type spec.).
Temperature range: -10°C to + 40°C.
Measuring accuracy: FS +/- 0.05 bar (Typical)
Exceeds EN 12645:2014
Unit of measure: bar - psi - kPa. (Pe).
Mechanical environment: M2.
Electromagnetic environment: E2.
Placing: Indoor –openly. IP31 approved.
Mounting position: Fixed, display vertical (+/- 15°).
Language: English / German
Manufacturer: FLEX1ONE A/S
Ladelundvej 37-39
DK –6650 Brørup
[phone]
E-mail: [email protected]
Distributor:

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Warnings
Be Careful! Tire inflation can be dangerous.
Use only trained personnel to perform tyre service.
AHCON PCI 1200 must be used by trained personnel only.
AHCON PCI 1200 must be used for inflation of motorcycles, passenger car wheels, van
and truck wheels, as wells as agricultural and industrial wheels only.
Inflating smaller wheels or toys, for instance; bicycle wheels, wheelbarrows, child
equipment wheels, child toys, footballs or any other kind of toys, is not allowed.
The equipment MUST be supplied with clean, dry air from a compressor air system / line.
Maximum supply air pressure for the 7 bar model is: 10 bar.
Maximum supply air pressure for the 12 bar model is: 14 bar.
AHCON disclaim all responsibility for failures occurring from working procedures, which do
not comply with procedures recommended by AHCON and / or tyre and rim
manufacturer’s recommendations (ETRTO / STRO).
Risks and Labelling
Max. Inlet pressure for the 7 bar version is 10 bar.
Max. Inlet pressure for the 12 bar version is 14 bar.
The PCI 1200 - 12 bar version may be used ONLY as a part of an AHCON Safety
Inflation Cage.
If this equipment is exposed to higher inlet pressure than specified, it may result in
equipment damage with the risk of explosions due to over-inflating.
Attention: Risk of personnel injury and equipment damage.

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Safety Precautions
Due to the requirements of the WELMEC 7.2 standard this device is protected against
occasional software errors by use of “checksum” calculations.
Because of this, the device has to be rebooted (turned off/on) at least once every week.
We recommend however that this reboot is done on a daily basis.
Safety Distance:
None for the operator. 1 meter for anyone else.
See the safety distances for AHCON - IT Stations and AHCON - Safety Cages in the
User’s Manual that accompanies these equipment.
Noise:
The noise of this equipment is less than 70 dB (A).
However, when the tire is "seating" on the rim, there can be experienced a short, sharp,
loud noise, which can be surprising and/or uncomfortable.
Use ear protection.
Safety Devices:
If the PCI 1200 is switched off or the supply power is interrupted, the air pressure will be
vented from the connected wheel.
The PCI 1200 can be equipped with Door switches and Emergency Emptying System can
be added. See Accessories.
The equipment is designed and constructed so that the user cannot be injured under
normal use if the instructions in the “Operators Manual” are closely followed.
Protective gear:
There is no requirement for special protection gear under normal use.
However, ear protection is recommended at high numbers of daily repetitions of tire
"seating".

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Warranty
For commercial trade (B2B sales between traders), only the terms of the agreement apply,
so we refer to our general terms of trade.
The product meets the specifications at the time of delivery and will be flawless with
regards to materials and workmanship for a minimum period of 24 months.
The buyer has a duty to investigate the delivered item.
Complaints must take place within 8 days after an error or a deficiency has been identified
or could have been identified.
AHCON accepts no liability to damages occurred by negligence, accidental or improper
use, lack of instruction or training, incorrect installation etc.
Components and parts related to normal wear and tear are not included by the warranty.
Product and machine parts returned to AHCON for repair or replacement must be
forwarded - carriage paid.
Dimensions and Weight
A: Height: 200 mm C: Width: 100 mm
B: Length: 250 mm Weight: 2.1 Kg

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Shipping Dimensions:
Height x Length x Width = 40 cm x 30 cm x 25 cm
Shipping weight: 4 Kg
Connections
Compressed Air Connection:
Supply pressure: Max 10 bar (Max.14 bar for the 12 bar version).
Power Connection:
Electrical power supply: 100 - 250 VAC at 50/60 Hz.
Connection:

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The following connections are all found on the back/bottom side of PCI 1200:
1. Connector for 10 meter Emergency Empting System Cable and
Emergency Stop Button. (Optional: - art. no.: 9501 3006.)
Connector with jumper (art. no.: 9700 0003) installed.
2. Connector for 24V DC Signal Lamp / Audio emitter.
(Optional: - art. no.: 4000 0130 / 4000 0135).
3. Connector for Door Stop Switch and Cable (1 door).
(Optional: - art. no.: 0502 - 1002 0012).
Connector with jumper (art. no.: 0502 - 9700 0002) installed.
4. Connector for 100-230 VAC Supply power (50-60 Hz)
with 500 mA fuse (Art. no.: 3013 1212).
5. Air Out - exhaust air with muffler/silencer (art. no.: 2031 2000).
6. Air Out –Hose nipple connector (ø7 –¼”) for tire air hose.
(Art. no.: 2022 0812)
7. Air In –Hose nipple connector (ø9 –¼”) for supply air-pressure from
compressor-line (Art. no. 2022 0913).
8. Assembly screw for the cabinet (4 pcs.).
9. Block valve.
10.Magnetic valve (Normally Closed - NC) - Inlet air.
11.Magnet valve (Normally Open - NO) - Outlet air.
12.M5 thread for mounting (3 pcs.).
Operations Guide
- Connect the 230V to the Inlet Power Connector (position 4).
- Connect pressurized air supply from the compressor (position 7).
- Connect the wheel air hose to the Tire Air out Connector (position 6).

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Screen-image immediately after turning on the PCI:
The display shows the Inflator type and software version (here; PCI 1200 –12 bar, V1.17).
This device should be restarted (turned on) once every day.
Notice the “sleep mode” that powers down the device valves and screen after 1 hour of
non-use (a connected tire will be emptied).
This does not turn off the device. Press any button to make the screen visible again.
Main screen when the PCI 1200 is ready for operation:

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Factory pre-set pressure values:
PCI 1200 - 7 bar model: P1: P2: P3: P4:
End-pressure 1.0 bar 2.0 bar 3.0 bar 4.0 bar
Over-pressure: 0.5 bar 0.5 bar 1.0 bar 1.0 bar
(Resulting Set-pressure: 1.5 bar 2.5 bar 4.0 bar 5.0 bar)
PCI 1200 - 12 bar model: P1: P2: P3: P4:
End-pressure 1.0 bar 2.0 bar 3.0 bar 4.0 bar
Over-pressure: 1.0 bar 1.0 bar 1.0 bar 1.0 bar
(Resulting Set-pressure: 2.0 bar 3.0 bar 4.0 bar 5.0 bar)
Setting Pressure values - End Pressure and Over-pressure (Set Pressure):
“End pressure” + “Over-pressure” = “Set pressure”
On the PCI 1200 display, the chosen End-pressure of the wheel is shown with large
figures together with the measurement unit. Value is stored at “Start”.
Below is a status bar indicating the development of the inflation sequence cycle.
At the bottom of the display, the chosen Over-pressure is displayed.
The four programs P1 - P4 can be individually set and saved.
The End-pressure are set directly using the + / - keys.
The “Over-pressure” value is set by pressing and holding the P1 –P4 button until it is
highlighted in the display. Now the value is set using the + / - keys.
Store the value by holding the P1 –P4 button or by starting an inflation sequence,
pressing the “Start” button.
The minimum possible over-pressure is 0.2 bar. The highest possible Set-pressure is 7.0
or 12.0 bar depending on the PCI 1200 model (7 or 12 bar).
For safety reasons, the PCI 1200 inflate to Set-pressure before End-pressure.
However, not in Auto Mode, where the wheel has been previously pressurized.
Note: If the sum of selected End-pressure and desired Over-pressure values exceed
maximum system pressure (7 or 12 bar), then the PCI will not start inflating.
For instance (7 bar version): If the End-pressure is set to 5.5 bar and the Over-pressure is
set to 2.0 bar, then the resulting Set-pressure sum is 7.5 bar.

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A warning / error message: "Set pressure too high" appears on the display at start attempt.
Press: "Stop" to interrupt and then select a different “End- or Over-pressure”.
The last used values of “End pressure”and “Over-pressure”for P1 –P4 are saved during
a power off.
Highest possible “End pressure”in the wheel depends on the PCI 1200 model:
For the PCI 1200 - 7 bar version this is 6.8 bar.
(Minimum 0.2 bar Over-pressure. Set-pressure at minimum Over-pressure: 7.0 bar).
For the PCI 1200 - 12 bar version this is 11.8 bar.
(Minimum 0.2 bar Over-pressure. Set-pressure at minimum Over-pressure: 12.0 bar).
Procedure for wheel inflation:
- Connect the wheel air-hose to the valve on the tire.
- Make sure there is good connection.
Notice:
If air is leaking from the valve under the filling sequence, the calculation of "filling time" will
be influenced and can result in error. For instance; "Max. Retries" or
“Above Set Pressure” - error message will appear on the display. Disconnect and retry.
Make sure that the valve connection is properly seated and air-tight.
Be careful!
Incorrect connection might lead to over-inflation and the risk of tire explosion.
The rubber seal in the wheel air-hose valve will wear out during use.
Replaced it regularly (depending on wear) to ensure that wheel inflation works smoothly.

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Start:
Choose one of the four inflation programs; P1 - P4.
Connect the wheel hose with the nipple on the wheel and press the "Start" button.
The inflation sequence cycle begins.
Inflation to the "Set-pressure" (selected End-pressure + selected overpressure) will follow.
When the “Set-pressure” is reached, the wheel is then deflated until the End-pressure is
reached. The Inflation sequence process can be followed by watching the "status bar"
below the selected and shown End-pressure on the PCI display. In addition, a
triangle/arrow indicates whether the wheel is inflating (arrow up) or deflating (arrow down).
The PCI 1200 adjusts the End-pressure with a typical accuracy of +/- 0.05 bar.
Jet-Functionality:
The PCI 1200 is equipped with a Jet functionality (Orange "Jet" button on the front cover).
It is used with the Omega Jet System in an AHCON TBR 1100 Inflation Cage or AHCON
IT 700/900/1000 Filling Station with compressed air tank.
This system solves the problem that tires and rims do not always fit close together and
therefore it can be difficult or impossible to pressurize the wheel (for instance after tire
change on the rim).
By pressing the "Jet" button, air from the tank is emptied instantaneously through the holes
around the Jet ring. This creates a slight overpressure in the wheel which now will close
the gap between the tire and the rim, and thereby letting air be filled into the wheel.
The "Jet" button is only active for as long as the PCI 1200 has not measured an actual
pressure in the wheel.
Auto Mode (Auto-Start):
The PCI 1200 has an Auto-start functionality.
This can be enabled / disabled in the menu point “Settings” (from software version 1.26).
Add / remove the check-sign; "√" using the + / - buttons.
Store your choice by pressing the “Menu” button.
If a prefilled wheel with an air-pressure of more than 1.5 bar is connected (2 bar in
software before version 1.26), the PCI will automatically fill to the earlier preset “End
pressure”. Notice: In this case, no overpressure is applied.

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When used together with an AHCON Safety Cage:
If Auto-Start is enabled and the attached tire has a higher pressure than the Auto-Start
threshold value of 1.5 bar (2.0 bar for software versions before 1.26), the Door Open
Safety functionality will deflate the tire to “Open Gate Safe Pressure (1.0 bar).
When the door is closed the inflation sequence will restart automatically.
End:
The filling and adjustment is completed with a beep and "OK" shown on the display.
The PCI will now display (shifting every 2 sec.) both the preset End pressure (End) and the
actual measured tire pressure (Act.).
When the OK sign is shown it is possible to manually adjust the End-pressure of the tire by
pressing the + / - key. Shortly after the “new” End-pressure is set, the PCI will commence
with the adjustment (new inflation/deflation sequence).
This will end successfully with a new OK sign and beep.
Remove air-hose form the filled wheel and connect the next one.
Stop:
The filling sequence can always be stopped by pressing the "Stop" button.
This will disrupt the filling sequence.
The wheel will deflated until the wheel air-hose is removed.
The “Stop” button is not used in normal filling procedure. Just remove the wheel air-hose
when the tire “End pressure” is reached and the PCI has signaled the OK sign.
Door Stop:
The PCI 1200 can be equipped with a “Door Stop Circuit” used together with an AHCON
Inflation cage (optional –see accessories page 17).
If this is present it is possible to prevent exposing the user to high risks in case of tire
explosion.
If the PCI 1200 is used without an Inflation cage, there is inserted a “Door Stop Jumper” in
the door stop jack of the PCI 1200 (see item 3 page 7 and 8 and accessories page 17).
Removing this jumper will have the same effect as opening a door of the Inflation cage.
The Inflation sequence will be disrupted and the tire air pressure will be vented from a
connected tire. The PCI will signal a door stop by the message; “Gate Open”.
Re-insert the jumper, close cage doors and disconnect the tire.
Start a new tire inflation sequence.

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Emergency Stop:
The PCI 1200 can be equipped with an “Emergency Empting System” (optional).
If this is present, it is possible to stop a tire inflation and vent the tire pressure from the
distance by pressing the emergency stop button.
If this is present it is possible to prevent exposing the user to high risks in case of tire
explosion.
If this system is not present, there is inserted an “Emergency Stop Jumper” in the
emergency stop jack of the PCI 1200 (see item 1 page 7 and 8 and accessories page 17).
Removing this jumper will have the same effect as pressing the “Emergency Stop Button”.
The inflation sequence will be disrupted and the air pressure will be vented from a
connected tire.
The PCI will signal an emergency stop by the message; “Emergency Stop”.
Re-insert the jumper, release the “Emergency Stop Button” and disconnect the tire.
Start a new tire inflation sequence.
Boost Functionality:
It is possible to “boost” the tire pressure above the preset “Set pressure“, in case this was
not sufficient to seat the tire properly. This is done by pressing the “+” key.
Hereby the inlet valve is manually opened for as long as the button is pressed.
This functionality is only active in the “filling sequence”, when the preset “set pressure has
been reached and the pressure is decreasing towards the “End pressure”.
Be careful!
Over-inflation is possible and can be dangerous. This could lead to tire explosion.
Menu settings:
Press the "MENU" button:
In the Menu, the following 6 menu points are available:
- 1.0 "Program P1"
- 2.0 "Program P2"
- 3.0 "Program P3"
- 4.0 "Program P3"
- 5.0 "Settings"
- 6.0 "Status"

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Scroll between the points by use of the + / - buttons.
Selection is made and saved with the "MENU" button.
Menu and menu sections/sub-sections are exited with the "STOP" button.
In the first four menu sections 1.0 to 4.0, the Over-pressure values of P1 to P4 can be set.
Minimum setting value is 0.2 bar. These values can also be set directly from the main
screen. The procedure for this and the factory preset values are described on page 10.
In section 5.0, "Settings" there are 5 sub-sections:
- 5.1 “Measure Unit".
- 5.2 "End / OK Beep".
- 5.3 "Backlight".
- 5.4 "Contrast".
- 5.5 “Auto-Start” (from software version 1.26)
- 5.6 “Offset”(from software version 1.26)
In sub-section 5.1, “Measure Unit”, the air pressure measuring unit can be chosen
between; bar, psi and kPa. The factory setting is; bar (with German language the
factory setting is locked and cannot be changed).
In sub-section 5.2, "End/OK Beep", the “OK” tone-signal at filling sequence end can
be enabled or disabled. Factory setting is "√" (enabled).
In sub-sections 5.3 and 5.4, “Backlight” and “Contrast”,the display backlight and
contrast can be adjusted up and down. The value can be selected from 0 - 100.
Factory setting is 50 for both values.
In subsection 5.5, “Auto-Start”, the Auto-Start functionality can be enabled /
disabled. Factory setting (from software version 1.26) is “disabled” (no check sign).
The Auto-Start is, if enabled, in effect on pre-pressurized tires form 1.5 bar and up
(From 2 bar and up in software versions before 1.26).
If attaching a tire with more than 1.5 bar, the PCI will Auto-Start the filling sequence
using the latest preset tire pressure values.
Notice; the PCI will inflate directly to the preset End pressure without using
overpressure.
In Subsection 5.6, the “Offset” is displayed. Offset is a value that helps target the
correct tire end pressure taking into account, that tire pressure stabilization can take
some time (often up to 30 sec.). Please contact AHCON or your AHCON product
distributor if you experience a larger than acceptable difference in measured End
pressure (actual tire pressure) versus the preset wanted End pressure.

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Recommendations on how to use the offset can then be supplied. Only a small
percentage of users have special working conditions or procedures that will benefit
from using the offset functionality.
In section 6.0 "Status" there are four sections:
- 6.1 "Sw ver.".
- 6.2 "Actual Pressure".
- 6.3 "Total Cycles".
- 6.4 "Last Service Date”.
In sub-section 6.1, “Sw ver.”, the current software version of the PCI is shown
(For instance; 1.17 or 1.21 or 1.26).
In sub-section 6.2, “Actual Pressure”, the pressure measuring accuracy of the PCI
can be checked.
When entering this menu point and connecting a pressure vessel (tire or air tank),
the PCI will show the actual air pressure of the vessel. With the + / - buttons it is
now possible to increase or decrease the air pressure in the vessel.
This way, the PCI 1200 accuracy (full range) can be compared with the measured
pressure of a reference pressure measurement instrument (Subsequent
verification).
Be aware of the accuracy of the reference pressure measurement instrument when
comparing the two pressure measurements.
In sub-section 6.3, “Total Cycles”, the total number of completed filling sequences is
shown.
In sub-section 6.4, “Last Service Date”, the number of completed filling sequences
since the last service is shown.
Calibration of PCI 1200:
Calibration is carried out at the factory before delivery. No recalibration is necessary.
All pressure values on the PCI are displayed relative to the current atmospheric pressure.
For instance: A wheel filled with 3.0 bar has a pressure of 3.0 bar above the current
atmospheric air pressure on the actual geographical location / geodetic height.
However for a more accurate measurement you have to take in account the deviation from
the expected “zero”. This zero is at 1020 mbar at 20°C at sea level.

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Error Messages
In this section the possible errors for each PCI 1200 error-messages are listed:
"Max. Retries"
- The wheel does not build pressure.
- Wheel valve connection fault.
- Insufficient tire/rim assembly.
- Compressed air connection blocked or narrowed.
- Errors in the supply of compressed air.
- Too long or too thin air-hoses to and/or from the PCI.
- Compressor fault.
Press “Stop” button, check equipment, airflow and pressure, correct - and retry.
"Above set pressure"
- The tire air pressure is higher than Set Pressure.
- The connection to the wheel valve within 1st filling sequence was not optimal.
Press “Stop” button, check and reconnect wheel valve - and retry.
"Set pressure to high"
- The sum of the chosen End pressure and Over-pressure exceeds 7.0 / 12.0 bar.
Press “Stop” button, select and set new values - and retry.
"Gate Open"
- A cage door/gate is open and the tire pressure is above 1.0 bar (measured).
- The “Door jumper” (Accessory) is missing, defective or not correct mounted.
- The door safety switch or cable-circuit is malfunctioning or damaged.
Press “Stop” button, close the door, check components/equipment, repair - and retry.
"Emergency Stop"
- The “Emergency Stop Button”(Accessory) has been activated.

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- The “Emergency Emptying System” cable circuit (Accessory) is damaged/disconnected.
- The “Emergency Stop Jumper” (Accessory) is missing, defective or incorrect mounted.
Press “Stop” button, check equipment, release “Emergency Stop Button” and retry.
"Sensor-Error"
- The pressure sensor is sending improbable values to the computer.
- Try switching the PCI off and on.
If the error persists then contact AHCON or your AHCON product dealer/distributor.
"CRC Error"
- The PCI software has detected a “Checksum” error. Try switching the PCI off and on
again. If the “CRC Error” message persists the PCI is defective.
Please contact AHCON or your AHCON dealer/distributor for repair.
Maintenance and Repair
Use only trained personnel for maintenance and repair of this equipment or contact
AHCON or your AHCON product dealer/distributor.
Regular cleaning maintenance consists solely of cleaning the PCI cover and tubing with a
lightly damp cloth with a mild solution of general purpose detergent liquid.
Contact your AHCON dealer or Flex1one A/S (AHCON) for any repair.
Accessories
Article number: Description:
0502 - 900 52 007 Wall Mounting Bracket, PCI 900/1000/1200.
0502 - 900 52 009 Wall Mounting Bracket, small, PCI 900/1200.
0502 - 100 20 010 Door switch (2 pcs.) with cable.
0504 - 950 13 006 Emergency Emptying System (Emergency Stop w/10 m cable).
0350 - 4000 0130 Signal Lamp, orange (available in other colors).
0350 - 4000 0135 Combined light and sound-giving device (color options).
0502 - 970 00 002 Door Jumper (Cable lice).
0502 - 970 00 003 Emergency Jumper (Cable lice).

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AHCON - PCI 1200 will fit on all of the following equipment (also with Jet-system):
- AHCON Speed Line Systems,
- AHCON Inflation Stations and
- Ahcon Safety Inflation Cages.
Charts
Compressed Air Chart:

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EU - Declaration of Conformity
FLEX1ONE A/S
Ladelundvej 37-39
DK –6650 Brørup
- declares that the following product:
Type: AHCON PCI 1200 - 7 / 12 bar
Art. No.: 0502 - 100 12 070 / 0502 -100 12 120
Serial no.: _______________
Production year: _______________
- has been produced in accordance with the EU-Parliament and -Council’s directives:
- 2014/30/EU of 26 February 2014 (Recast)
- 2014/32/EU of 26 February 2014 (Recast)
- 2014/35/EU of 26 February 2014 (Recast)
- 2006/42/EC of 17 May 2006 (Amending Recast 95/16/EC)
- has been produced in accordance with the following standards:
- DS/EN 12645: 2014
- DS/EN ISO 12100: 2011
- WELMEC 7.2
Date: 01.11.2019
Name: Bo Møller Signature: