VICI DBS GT ULTRA ZERO AIR GENERATOR User manual

1
Version 1.03.0000
APPLICABLE MODELS
This manual is applicable to the following models:
• GC Plus 1500
• GC Plus 3000
• GC Plus 6000
• GC Plus 15000
• GC Plus 30000
Version 1.03.0000
GT ULTRA ZERO AIR GENERATOR
USER MANUAL

2
GT ULTRA ZERO AIR GENERATOR
USER MANUAL www.vicidbs.com
Version 1.03.0000
TABLE OF CONTENTS
1. VERSION HISTORY................................................................................................................................ 4
2. INTRODUCTION.................................................................................................................................... 4
2.1. SYMBOLS DEFINITION .......................................................................................................................5
3. SAFETY.................................................................................................................................................. 6
3.1. PERSONAL SAFETY INSTRUCTIONS..................................................................................................6
3.2. INSTRUMENT SAFETY INSTRUCTIONS .............................................................................................6
4. SPECIFICATIONS................................................................................................................................... 7
5. ENGINEERING DESIGN OVERVIEW.................................................................................................. 8-9
5.1. FUNCTIONALITY...............................................................................................................................10
5.2. CONTROL BOARD............................................................................................................................ 11
6. INSTALLATION .................................................................................................................................... 12
6.1. PACKING LIST ................................................................................................................................... 12
6.1.1. Items Not Included in Standard Shipping................................................................................13
6.2. UNPACK UNIT AND OPEN COVER .................................................................................................. 13
6.3. INSTALL 1/4” EXTERNAL INLET FILTER ........................................................................................... 13
6.4. CHECK VOLTAGE SETTING.............................................................................................................. 13
6.5. UNIT POSITIONING.......................................................................................................................... 14
6.6. CONNECT AIR SUPPLY..................................................................................................................... 15
6.7. CONNECT OUTPUT.......................................................................................................................... 15
6.8. LEAK CHECK..................................................................................................................................... 16
7. OPERATION......................................................................................................................................... 16
7.1. CONNECT POWER AND START UNIT.............................................................................................. 16
7.2. WARMING UP....................................................................................................................................16
7.3. NORMAL OPERATION...................................................................................................................... 17
7.4. STARTUP TROUBLESHOOTING AND SYSTEM FAULTS ................................................................... 17
7.4.1. Inlet Pressure Low ....................................................................................................................17
7.4.2. Inlet Pressure High ...................................................................................................................18
7.4.3. Catalyst Temperature Low........................................................................................................18
7.4.4. Catalyst Temperature High.......................................................................................................18
7.4.5. Catalyst Life Cycle Expired.......................................................................................................18
7.4.6. Dryer Switch Valve Failure........................................................................................................18
7.4.7. Menu Options ..........................................................................................................................19
7.5. SHUTDOWN PROCEDURE................................................................................................................20

3
GT ULTRA ZERO AIR GENERATOR
USER MANUAL www.vicidbs.com
Version 1.03.0000
8. MAINTENANCE................................................................................................................................... 20
8.1. MAINTENANCE KITS ........................................................................................................................20
8.1.1. Annual Maintenance Kit ...........................................................................................................21
8.1.2. Three Year Catalyst Replacement Kit .......................................................................................21
8.2. FILTER REPLACEMENT .....................................................................................................................22
8.2.1. Annual Pre-lter Element Replacement ...................................................................................22
8.2.2. Annual High Grade In-Line Particulate Filter Replacement......................................................23
8.2.3. Three Year Catalyst Chamber Replacement.......................................................................24-25
8.2.4. NOxReplacement ...................................................................................................................26
9. TROUBLESHOOTING........................................................................................................................... 27
9.1. ERROR CODES ON MAIN BOARD....................................................................................................28
9.2. LEAKS................................................................................................................................................28
10. FLUIDICS DIAGRAM.......................................................................................................................... 29
11. SPARE PARTS LIST............................................................................................................................. 30

4
GT ULTRA ZERO AIR GENERATOR
USER MANUAL www.vicidbs.com
Version 1.03.0000
1. VERSION HISTORY
VERSION DATE COMMENT/CHANGE
1.00.0100 January 10, 2017 VICI DBS layout, initial release
1.00.0200 January 17, 2017 Drawing changed from functional principle
1.01.0000 December 21, 2018 Update
1.02.0000 March 19, 2019 Layout and photo updates
1.03.0000 June 3, 2020 New layout, images and graphics, VICI Gig Harbor Group
2. INTRODUCTION
The GT Ultra Zero Air generator produces laboratory grade puried air for various GT-detection systems
(e.g. FID, NPD, FPD) and dedicated analyzers. Designed with safety and convenience in mind, this system
will generate puried air from an existing in-house oil-free compressed air supply, eliminating the need for
inconvenient high-pressure gas cylinders.
Eliminating gas cylinders reduces operating costs associated with materials, labor and down-time.
The GT Ultra Zero Air generator will remove HC pollutants to less than 0.1 ppm. Operation of the generator
is very economical since it is consuming reasonable quantities of compressed oil-free air and electricity. This
complete turnkey system is engineered with the highest quality components, is easy to install and requires
only minimal annual maintenance.
NOTICE: This manual is intended to provide technical guidance on the installation, operation and
maintenance of the GT Ultra Zero Air generator. Do not attempt to install or operate this product without
having fully read and understood the information presented. If you have any questions, please contact your
dealer.
WARNING: Any misuse of this product will void the manufacturer’s warranty.

5
GT ULTRA ZERO AIR GENERATOR
USER MANUAL www.vicidbs.com
Version 1.03.0000
2.1 Symbol Denitions
SYMBOL DESCRIPTION
General warning. Caution is necessary when operating the device or control
close to where the symbol is placed, or to indicate that the current situation
needs operator awareness or operator action in order to avoid undesirable
consequences.
The manual must be consulted in all cases where this symbol is marked on
the device.
Risk of asphyxia. Caution is necessary when operating the device in a not
sufciently ventilated area.
Oxidant material. Caution is necessary due to the presence of oxidant material.
WEEE symbol. When discard this product, it must be sent to separate collection
facilities for recovery and recycling.
Fuse. Notify replaceable fuse place.
OR
OR
OR

6
GT ULTRA ZERO AIR GENERATOR
USER MANUAL www.vicidbs.com
Version 1.03.0000
3.1 Personal Safety Instructions
When using your GT Ultra Zero Air generator, basic safety precautions should always be followed, including
the following:
• For indoor use only.
• Use only as described in this manual. Use only manufacturer’s recommended
attachments.
• Do not let the cable hang over the edge of a table, bench or counter or come in contact
with hot manifolds or moving fan blades.
• The quantity of dust in the ambient Air can be very different from one place to another.
We recommend to replace the dust lters every 4000 hours. In some dusty areas, this
maintenance needs to be performed more frequently.
• Clogged dust lters may damage the generator or give a bad Air quality.
• The plug of the power cable must be disconnected in case of an emergency, it must be
easily accessible at all times.
• If the GT Ultra Zero Air is not used strictly as specied by VICI DBS, the protection plan
may become compromised or void.
3.2 Instrument Safety Instructions
• Read all instructions.
• ALWAYS WEAR SAFETY GLASSES when working with this equipment. Everyday eye
glasses have only impact resistant lenses. They are NOT safety glasses.
• Avoid touching hot parts to avoid burns.
• Do not operate equipment with a damaged cable or if the equipment has been dropped
or damaged – until it has been examined by a qualied serviceman.
• Never use the cable to pull the plug from the wall socket. Grasp the plug and pull to
disconnect.
• If an extension cable is necessary, a cable with a current rating equal to or higher than
that of the equipment should be used. Care should be taken to arrange the cable so that
it will not be tripped over or pulled.
• Let the equipment cool completely before putting away. Loop the cord loosely around
equipment during storage.
• To reduce the risk of re, do not operate equipment in the vicinity of open containers
with ammable liquids.
• To reduce the risk of electric shock, do not use on wet surfaces or near water.
• Use the GT Ultra Zero Air Generator only as described in this manual and as
recommended by the manufacturer. Use only manufacturer’s recommended
attachments.
3. SAFETY

7
GT ULTRA ZERO AIR GENERATOR
USER MANUAL www.vicidbs.com
Version 1.03.0000
GT PLUS
1500
GT PLUS
3000
GT PLUS
6000
GT PLUS
15000
GT PLUS
30000
Flow mL/min 1500 3000 6000 15000 30000
Purity - hydrocarbons <0.1 ppm
Purity - CO <0.1 ppm
Purity - CO2 <5 ppm
Purity - NOx <0.1 ppm
Purity - SOx <0.1 ppm
Purity - O3 <0.1 ppm
Dewpoint oC (oF) -50 (-58)
Inlet pressure barg (psig) 4.5 to 10 (65 to 145)
Outlet pressure barg (psig) 1 (15) drop from inlet
Inlet air quality Clean dry compressed air ISO8573-1:2010 Class 1.2.1
Max HC in 100 ppm
Max CO in 50 ppm
Technology Platinum catalyst
LED indicators Power on/off, system ready, errors
Warm up time (minutes) 45
Electrical supply 110-120V 60Hz / 220-240V 50Hz
Power consumption (watts) 220 565 565 565 565
Dimensions mm (in) 550W x 410H x 230D (21.6W x 16H x 9D) 630W x 470H x 310D (24.8W x 18.5H x 12.2D)
Weight kg (lbs) 10 (22) 15 (33) 15 (33) 25.5 (56) 25.5 (56)
Shipping dimensions mm (in) 650W x 390H x 560D (25.6W x 15.3H x 22D)
Shipping weight kg (lbs) 14 (31) 19 (42) 19 (42) 30 (66) 30 (66)
Operating temp oC (oF) 15 to 35 (59 to 95)
Inlet connection 1/4” Compression
Outlet connection 1/8" Compression
Certication CE, FCC, MET (UL and CSA compliant)
MODELS & SPECS
4. SPECIFICATIONS

8
GT ULTRA ZERO AIR GENERATOR
USER MANUAL www.vicidbs.com
Version 1.03.0000
5. ENGINEERING DESIGN OVERVIEW
The GT Ultra Zero Air generator utilizes a 5-stage process to purify ambient air into ultra zero grade air. All
main components are manufactured with high grade stainless steel, oriented neatly in the cabinet for easy
access and service.
Stage 1: Preltration and Pressure Regulation
Air is initially passed through a highly efcient combination coalescing/particulate pre-lter to ensure only
quality air enters the system. The pre-lter removes bulk moisture and larger particulates greater than 5
microns in size. The lter is supplied with an automatic oat drain to remove periodic moisture build up.
The air pressure is then regulated with an adjustable forward pressure regulator, pre-set to 7 bar. This
pressure is monitored by the control board with an electronic pressure sensor. The minimum allowable
pressure is 4.5 bar; the maximum 8 bar. If the air supply is interrupted or if the regulator fails or is tampered,
the control board will illuminate the yellow external LED and close the outlet valve, disabling the system.
Stage 2: Air Dryer
Air is next passed into a dual column pressure swing adsorption air dryer to remove water vapor and carbon
dioxide. While one of the dryer columns is active, the other is regenerating by back-purging with excess air.
The adsorbed water and carbon dioxide are vented to the atmosphere in this process. A solenoid valve,
driven by the control board, automatically switches the air supply to the newly regenerated column when this
process is completed.
Air pressure to dryer “B” is monitored by a dedicated pressure transducer on the control board to ensure
proper switching is taking place. When dryer “B” is in the purge cycle, the pressure should be atmospheric.
When it is in the generative cycle, the pressure should match the inlet. The control board will disable the
system if proper dryer switching is not taking place, and will disable the system if a problem is detected.
Stage 3: NOxScrubber
From the dryer, air is channeled into a scrubber to reduce NOxlevels to less than 0.1 ppm through an
adsorption process. The NOxscrubber media, contained in a cylinder, becomes saturated after one year of
service and must be replaced.

9
GT ULTRA ZERO AIR GENERATOR
USER MANUAL www.vicidbs.com
Version 1.03.0000
Stage 4: Hydrocarbon and CO Removal
Air is next channeled into a stainless steel catalyst chamber where background hydrocarbons and carbon
monoxide are oxidized. This chamber is lled with a highly efcient platinum catalyst, heated to very high
temperatures to ensure hydrocarbon removal to less than 0.1 ppm.
Catalyst temperature is a critical factor in the purication process. The temperature is monitored and
controlled with a digital thermostat on the control board. A type “K” thermocouple is embedded in the
catalyst chamber to provide the temperature measurement. Any time the catalyst temperature is outside of
the specied limits, appropriate LEDs are illuminated.
Stage 5: Final Filtration
A nal high-grade lter is used to remove 99.99% of particulates greater than 0.5 microns in size. This will
ensure that no harmful particles will be able to enter your analyzer.
Outlet Solenoid valve
A solenoid valve, driven by the control board, enables or disables output ow of the system. The valve is
always closed when power is off during warm up of the unit, or when the control board detects a system fault.
Faults include low or high inlet pressure, low or high catalyst temperature, expired catalyst time and dryer
valve switching failure.
Pressure Controls
Both inlet and outlet pressure regulators supplied with the unit are pre-set at the factory for your convenience.
With a source pressure between 4.5 bar – 10 bar the inlet pressure regulator limits the inlet pressure of the
system to 7 bar (minimum 4.5 – maximum 7.5). At the output, the forward pressure regulator is set to deliver
ultra zero grade air at a pressure of 6 bar. This setting can be lowered if desired.

10
GT ULTRA ZERO AIR GENERATOR
USER MANUAL www.vicidbs.com
Version 1.03.0000
5.1. FUNCTIONALITY
COOLING
SYSTEM
ZERO AIR
OUTLET
H2O/CO2
TRAP
OUTLET
FILTER
CATALYST
COMPRESSED
AIR INLET
NOx/SOx
TRAP
INLET FILTER

11
GT ULTRA ZERO AIR GENERATOR
USER MANUAL www.vicidbs.com
Version 1.03.0000
5.2. CONTROL BOARD
The control board performs the following functions:
1. Controls the warm up of the catalyst: The control board tells the user if catalyst is warming up properly
and when the catalyst has reached the set temperature.
2. Operates the pressure-swing dryer valve: The control board automatically switches the pressure-
swing dryer valve every 4 minutes, and monitors the pressure in the dryer cylinders to ensure that proper
switching occurred. If the control board detects that proper switching did not occur, then a fault is
indicated by the red external LED, and the output ow is disabled.
3. Monitors critical system parameters: The control board serves as a QA monitor, continuously checking
for proper inlet pressure and catalyst temperature to ensure Ultra Zero Air purity specications are always
met.
4. Digital thermostat: The control board limits the maximum temperature to 650°C to preserve the
functionality of the heating element. Without a thermostat, temperatures would often exceed this
limit, especially if the air supply is interrupted. With the control board, you never have to worry about
overheating.
5. Catalyst life cycle alarm: The control board reminds you when the 3-year life cycle of the catalyst is
exceeded. After 3 years, the red external “Check System” LED begins to ash. From this time, the
operator has 60 days to replace the catalyst or the control board will stop the system.

12
GT ULTRA ZERO AIR GENERATOR
USER MANUAL www.vicidbs.com
Version 1.03.0000
6. INSTALLATION
Air Inlet Air Outlet
Key LockOn/Off Switch LED Indicator Lights
6.1 Packing List
• GT Ultra Zero Air generator, completely assembled and fully burned in, ready for installation
• High quality inlet air lter to remove particles and bulk moisture from air before entering the generator
• 1 Power cable
• 2 Fuses 220 VAC
• 1 Installation kit consisting of:
• 1 male to male adapter to attach your inlet lter to the generator
• 2 machine screws with matching nuts and split lock washers to mount the generator
• 2 door keys to lock the generator

13
GT ULTRA ZERO AIR GENERATOR
USER MANUAL www.vicidbs.com
Version 1.03.0000
6.1.1. Items Not Included in Standard Shipping
NOTE: The inlet air lter assembly supplied with the unit can also be used to de-pressurize the system by
pressing the pin-valve in the base of the lter housing.
• Additional Filtration may be required depending on the quality of the air supply. The pre-lter of the
generator will remove nominal amounts of moisture and particulates. If the air supply has excessive
moisture, oil or particulates, then additional lters should be installed.
• 1/4” tting to install into the supplied pre-lter. The exact type will depend on the supply tubing or
hose from the air source. A hose clamp is recommended if exible tubing is used.
• 1/8” tting to install into the bulkhead tting at the output of the unit. The exact type will depend on
the transport tubing or hose of the GC-detection system or analyzer. A hose clamp is recommended if
exible tubing is used.
6.2. UNPACK UNIT AND OPEN COVER
6.3. INSTALL 1/4” EXTERNAL INLET FILTER
• Remove plastic 1/4” inlet & 1/8” outlet port plugs.
• Apply Teon pipe sealant tape to both sides of the supplied 1/4” male to male adapter.
• Thread adapter to output side of the air lter assembly. Do not over tighten.
• Attach air lter assembly to input side (left side) of the generator, and secure.
CAUTION: Remove plastic protective cover from outside AND inside unit before
plugging in and powering up the unit.
6.4 Check Voltage Setting
Check the setting of the voltage selector on the side of the unit. The set voltage is indicated in the little
window on the inlet power lter.
To change the voltage setting, proceed as follows:
• Using a small screwdriver, remove the voltage selector insert.
• Replace fuses:
VOLTAGE SETTING FUSE
240 VAC 4 AT
120 VAC 6 AT
• Replace the voltage selector insert so that the white arrow points to the correct voltage.

14
GT ULTRA ZERO AIR GENERATOR
USER MANUAL www.vicidbs.com
Version 1.03.0000
6.5 Unit Installation
The GT Ultra Zero Air Generator can be installed two different ways. Either placed on a surface, like a table or
lab bench, or mounted to a wall.
A. On a table/lab bench:
For optimum ventilation allow at least 150 mm (6 inches) clearance on either side of the unit.
B) Mounted to a wall:
• Drill holes 200 mm (7.87 inches) apart into the wall and
insert the supplied mounting screws. Tighten only enough
so there is approximately 1/4” extruding from the surface.
• Hold the generator up to the extruding screws and insert the
unit over the screws through the keyholes. Let the unit slide
downwards as the screws slide up into the keyhole slots.
WARNING: Do not tighten screws fully. It must be possible to remove the generator
from a permanent structure without the use of tools.
mm
mmmm

15
GT ULTRA ZERO AIR GENERATOR
USER MANUAL www.vicidbs.com
Version 1.03.0000
6.6 Connect Air Supply
The GT Ultra Zero Air generator requires a continuous supply of dry, oil-free compressed air with a pressure
between 4.5 (65.3 psig) and 10 barg (101.5 psig) for proper operation.
The air supply inlet pressure can be regulated with an adjustable forward pressure regulator, pre-set to 7 barg
(101.5 psig). The minimum allowable pressure is about 3 barg (43.5 psig); the maximum 10 barg (145 psig).
It is important that the air supply be maintained at room temperature and
dew point, and free of oils, hydrocarbons and particulates. If the compressed
air supply for the generator has excess moisture, oil or particulates, the inlet
lter may need premature replacement and the unit may be damaged. Install
extra coalescing and particulate ltration upstream from the unit if necessary.
6.7 Connect Output
• The output bulkhead of the GT Ultra Zero Air generator is located on the right side of the unit. It requires a
1/8” diameter tting to attach the tubing or hose to the GC-detection system or analyzer air inlet port.
• In order to maintain the purity of the air from your GT Ultra Zero Air generator, stainless steel tubing or
instrument grade Teon tubing should be used to connect the generator to the GC-detection system
or analyzer air inlet port. Copper tubing can also be used, but should be pre-cleaned or heated with a
propane torch while blowing nitrogen through it. All plastic hose should be instrument grade and free of
contaminants to avoid outgassing hydrocarbons or other pollutants over time.
• Maximum outlet ow rate is 1.5 L/min with 7.5 barg (101.8 psig) inlet pressure and no external restrictions.
Actual outlet ow rate will depend on additional system pressure losses, if any.
WARNING: Maximum inlet pressure 10 barg (145 psig). Do not adjust the outlet
regulator on the unit without using an accurate pressure gauge (3-7 barg)
WARNING: The catalyst chamber can be contaminated
by high concentrations of lead, sulfur, phosphorous
compounds, heavy metals, chlorinated solvents and
chlorinated hydrocarbons. Extra care should be taken to
avoid introducing such compounds to the system. Any
contamination from oil, water or any of the substances
mentioned above will void the warranty.
WARNING: Do not use PVC or any other non-instrument grade plastic tubing
anywhere in your system. Many plastics will out-gas hydrocarbons and will
contaminate your puried air.
Lift and turn to
adjust pressure

16
GT ULTRA ZERO AIR GENERATOR
USER MANUAL www.vicidbs.com
Version 1.03.0000
6.8. LEAK CHECK
Before powering the generator, perform a leak check on the external plumbing.
• Open supply air valve to pressurize the system.
• Apply certied liquid detectors to all external ttings and check for air bubbles.
• Tighten any leaky connections. Additional Teon tape may be required in some cases.
7.2. WARMING UP
After power-up, the system goes through a warm-up cycle.
The yellow “Warm-up/Check Pressure” LED ashes at 1 Hz, indicating the system is in warm-up mode. If
the catalyst temperature is above the minimum level of 485°C and no faults are detected, the system will
go immediately to operation mode. This quick-start feature is for customer convenience when power is
interrupted only for short periods, and a full warm-up cycle is not required. Warm-up cycle takes 45 min.
GT Ultra Zero Air generator is designed to run continuously. Continuous operation preserves the
performance of the catalyst. Shutdown should only be performed for maintenance.
Verify that:
• “POWER” green LED is on
• “WARM UP” yellow LED is ashing
7. OPERATION
7.1. CONNECT POWER AND START UNIT
To start unit:
• Insert the female end of the supplied power cord to the power supply connection on the left side of the
unit, and plug the male end into a properly grounded socket.
• Power up the unit using the power switch on the unit.
• For the rst 3 seconds, all panel LEDs will be illuminated. This veries proper operation of the control
board rmware and the LEDs.

17
GT ULTRA ZERO AIR GENERATOR
USER MANUAL www.vicidbs.com
Version 1.03.0000
7.3. NORMAL OPERATION
When the system is in operation mode, the green “System Ready” panel LED is illuminated and the outlet
valve is open, supplying continuous Ultra Zero Air. During operation mode, the microcontroller continuously
monitors the inputs. If a fault occurs, the system will enter into a particular fault state if it is not corrected
within the specied time.
Verify that:
• “POWER” green LED is on
• “READY” green LED is on
7.4. STARTUP TROUBLESHOOTING AND SYSTEM FAULTS
If there are any improper conditions detected by the control board, the unit will not come out of the warm up
cycle. Instead, fault conditions are indicated by the panel LEDs.
Any of the following conditions will prevent the unit from going to operation mode:
• If catalyst heater temperature is still below the minimum threshold, then a low temperature fault is
indicated by the red “Check System” LED.
• If the catalyst has expired, the system does not start the warm-up cycle. The processor immediately
ashes the red “Check System” LED. If the catalyst is within 2 months of expiring, then the red “Check
System” LED will ash, but the system will still start to operate.
• If a low or high inlet pressure condition exists, then a fault is indicated and the outlet valve will remain
closed. The yellow “Warm up / Check Pressure” panel LED is illuminated steadily.
• If the dryer valve is not switching properly, then a fault is indicated and the outlet valve will remain closed.
The red “Check System” LED is illuminated steadily.
• During normal operation, if any of the following conditions occur, the control board will indicate a fault or
warning and close the outlet.
7.4.1. Inlet Pressure Low
Low inlet pressure warnings are indicated by a steady yellow “Check Pressure” panel LED on the cabinet. If
pressure is not restored to a minimum of 4.5 bar within three minutes, the control board automatically closes
the outlet valve, shutting off the Ultra Zero Air supply from the generator. The control board will continue to
monitor the inlet pressure, and will automatically restore the unit to normal operating mode when pressure is
within range.

18
GT ULTRA ZERO AIR GENERATOR
USER MANUAL www.vicidbs.com
Version 1.03.0000
7.4.2. Inlet Pressure High
The maximum pressure that can be supplied to the unit is 10 bar. However, the inlet pressure regulator
reduces inlet pressure to an adjustable level. The regulators are pre-set at the factory at 7 bar. The maximum
allowable regulated inlet pressure is 7.5 bar. This condition is monitored by the control board.
A high inlet pressure fault can occur if the inlet pressure regulator fails or has been tampered. Warnings are
indicated by a steady yellow “Check Pressure” panel LED on the cabinet. If pressure is not restored to the
proper range within three minutes, the control board automatically closes the outlet valve, shutting off the
Ultra Zero Air supply from the generator. The control board will continue to monitor the inlet pressure, and
will automatically restore the unit to normal operating mode when pressure is within range.
7.4.3. Catalyst Temperature Low
A low catalyst temperature fault illuminates the red “Check System” panel LED on the cabinet. Low catalyst
temperature will also prevent the unit from coming out of the warm up cycle, and will result in a fault after one
hour if the warm up fails.
7.4.4. Catalyst Temperature High
The on-board thermostat is designed to limit the catalyst temperature to 650°C. An over-temperature fault
occurs if this limit is exceeded for more than 10 minutes. This could indicate that the thermostat circuit or the
catalyst thermocouple are not functioning properly. This fault is indicated by the red “Check System” panel
LED on the cabinet.
7.4.5. Catalyst Life Cycle Expired
The life cycle of the catalyst is maximum 3 years, starting at the time of shipment from the factory. After 3
years, the control board will ash the red “Check System” LED as a warning. From this time, the operator has
60 days to replace these components or the control board will close the outlet valve, and continue to ash
the red “Check System” LED.
7.4.6. Dryer Switch Valve Failure
The proper operation of the dryer switch valve is determined by monitoring the pressure on one of the dryer
cylinders. The pressure should alternate between high and low values as the valve cycles. If this does not
occur, then the control board illuminates the red “Check System” LED, and closes the outlet valve.

19
GT ULTRA ZERO AIR GENERATOR
USER MANUAL www.vicidbs.com
Version 1.03.0000
Condition Warm-up /
Check Pressure
Ready Check
System
Outlet
Port
YELLOW GREEN RED
System Off: CLOSED
System General:
Power Control:
Power Fault: OFF OFF OFF CLOSED
Heater Control: If catalyst temperature exceeds
650°C, the catalyst power will be shut down
Heater Control Fault: If catalyst temperature exceeds
the allowed maximum of 650°C
OFF OFF ON CLOSED
Fault: Catalyst Replacement:
After 3 years 1 Blink
Hz
OPEN
After 3 years plus 60 days OFF ON CLOSED
Startup:
Quickstart Mode (0 to 3 minutes max.) Blink 1 Hz OFF OFF CLOSED
The control board will continuously check whether
catalyst temperature is within limits. If yes, other
faults will be checked; will go to Operation Mode
if no faults are found. If catalyst temperature is not
within limits, the warm-up cycle will continue for 40
more minutes.
Warm-up Mode (3 to 40 minutes max.) Blink 1 Hz OFF OFF CLOSED
System Fault: Catalyst temperature is low at the 40
min. checkpoint
OFF OFF ON CLOSED
Operation:
Normal Device Operation OFF ON OFF OPEN
Inlet pressure control: If pressure is out of range, unit
will enter fault condition after 3 min.
Check Pressure: Inlet pressure low (< 4.5 bar) ON ON OFF CLOSE
Check Pressure: Inlet pressure high (> 8 bar) ON ON OFF CLOSE
Fault: Inlet pressure low (< 4.5 bar) ON ON ON CLOSE
Fault: Inlet pressure high (> 8 bar) ON ON ON CLOSE
7.4.7. Menu Options

20
GT ULTRA ZERO AIR GENERATOR
USER MANUAL www.vicidbs.com
Version 1.03.0000
7.5. SHUTDOWN PROCEDURE
Before performing any service or maintenance, be sure to complete the following steps:
• Turn off power using the switch of the unit.
• Disconnect the outlet tubing, and freely run air through the unit for several minutes to cool the catalyst.
Allow a minimum of 2 hours to cool the catalyst before replacing it.
• Shut off air supply.
• De-pressurize the unit and disconnect power source before servicing.
8.1. MAINTENANCE KIT
8. MAINTENANCE
WARNING: Before service is performed, make sure that the following conditions are
met:
1. System shut down has been performed according to instructions above.
2. Supply air pressure has been shut off with an in-line valve.
3. Line pressure has been released with an in-line relief valve.
4. Unit has been shut-off and isolated from electrical power.
TYPE DESCRIPTION FREQUENCY PART-NUMBER
Consumables Annual maintenance kit for
GT-1500
Every 12 months DB-10376
Annual maintenance kit for
GT-3000 and GT-6000
Every 12 months DB-10377
Annual maintenance kit for
GT-15000 and GT-30000
Every 12 months DB-10378
Service Kit 3-Year catalyst replacement kit for GT-1500 Every 3 years DB-10380
3-Year catalyst replacement kit for GT-3000 Every 3 years DB-10382
3-Year catalyst replacement kit for GT-6000 Every 3 years DB-10384
3-Year catalyst replacement kit for GT-15000 Every 3 years DB-10386
3-Year catalyst replacement kit for GT-30000 Every 3 years DB-10388