VICI DBS HK PLUS Series User manual

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HK PLUS
USER MANUAL www.vicidbs.com
Version 1.03.0000
TECH SUPPORT
Europe, Asia, Africa, Australia & New Zealand:
[e-mail]
USA, Canada, Central & South America:
[e-mail]
Italy
ser[email protected]
VICI AG INTERNATIONAL
Parkstrasse 2
CH-6214 Schenkon
Switzerland
tel: [phone]
fax: [phone]
web: www.vicidbs.com
APPLICABLE MODELS
This manual is applicable to the following models:
• HK Plus 100
• HK Plus 160
• HK Plus 250
Version 1.03.0000

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USER MANUAL www.vicidbs.com
Version 1.03.0000
TABLE OF CONTENTS
1. VERSION HISTORY................................................................................................................................ 4
2. INTRODUCTION.................................................................................................................................... 4
2.1. SYMBOLS DEFINITION .......................................................................................................................4
3. SAFETY.................................................................................................................................................. 5
3.1. NOTES OF FCC COMPLIANCE...........................................................................................................5
3.2. CORRECT USE ....................................................................................................................................5
4. WARNING ............................................................................................................................................. 5
5. SPECIFICATIONS ................................................................................................................................... 6
5.1. FUNCTIONALITY.................................................................................................................................7
6. INSTALLATION AND INITIAL START UP ............................................................................................... 8
6.1. RECEIVING THE GENERATOR ............................................................................................................8
6.2. PACKING LIST.....................................................................................................................................8
6.3. PLACING THE GENERATOR...............................................................................................................8
6.4. GAS CONNECTIONS..........................................................................................................................9
6.5. ELECTRICAL CONNECTIONS ............................................................................................................9
6.6. INITIAL START-UP .............................................................................................................................10
6.6.1. Filling the Water Tank...............................................................................................................10
6.6.2. Installing the Deionizer Bag .....................................................................................................11
6.6.3. Starting the Generator .............................................................................................................12
7. OPERATION......................................................................................................................................... 13
7.1. LCD DISPLAY ..................................................................................................................................... 13
7.1.1. Layout of the Display................................................................................................................13
7.1.2. First Row - Status Information .............................................................................................13-14
7.1.3. Second Row - Pressure Information .........................................................................................15
7.1.4. Third Row - Hydrogen Flow .....................................................................................................15
7.1.5. Fourth Row - Water Quality......................................................................................................15
7.1.6. Start/Stop - Reset Button .........................................................................................................15
7.1.7. Exit - Menu Button ...................................................................................................................15
7.2. MENU OPERATION........................................................................................................................... 16
7.2.1. Congure Parameters .........................................................................................................17-18
7.2.2. Diagnostic Display....................................................................................................................18
7.2.3. Special Functions .....................................................................................................................19

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8. RETURNING THE GENERATOR...................................................................................................... 19-20
9. MAINTENANCE................................................................................................................................... 20
9.1. ROUTINE MAINTENANCE ................................................................................................................20
9.1.1. Cleaning ...................................................................................................................................21
9.1.2. Water Relling ..........................................................................................................................21
9.1.3. Deionizer Bag Replacement.....................................................................................................21
9.1.4. Installing the New Deionizer Bags ...........................................................................................21
9.2. MAINTENANCE KITS........................................................................................................................21
10. FLUIDIC DIAGRAM & SPARE PARTS LIST ......................................................................................... 22
10.1. FLUIDIC SCHEMATIC DIAGRAM & PARTS......................................................................................22
10.2. SPARE PARTS LIST .....................................................................................................................23-25

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2. INTRODUCTION
This manual provides operation and maintenance instructions for the VICI DBS®HK Plus series hydrogen
generators.
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
1. VERSION HISTORY
VERSION DATE COMMENT/CHANGE
1.00.0100 January 10, 2017 VICI DBS layout, initial release
1.01.0000 December 20, 2018 Update
1.02.0000 March 4, 2019 Layout and photo updates
1.03.0000 June 10, 2020 New layout, images and graphics, VICI Gig Harbor Group

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3. SAFETY
3.1. NOTES OF FCC COMPLIANCE
3.2. CORRECT USE
This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant
to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful
interference in a residential installation. This equipment generates, uses and can radiate radio frequency
energy and, if not installed and used in accordance with the instructions, may cause harmful interference
to radio communications. However, there is no guarantee that interference will not occur in a particular
installation.
If this equipment does cause harmful interference to radio or television reception, which can be determined
by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more
of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the distance between the equipment and the receiver.
• Connect the equipment to an outlet on a circuit different from that to which the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.
The hydrogen generator is designed to produce hydrogen for laboratory use. The unit should only be used
for this purpose, according to the specications and instructions provided in this manual. In particular, the
following warnings must be observed at all times:
• Indoor use only.
• Never operate the unit at temperatures below 0ºC. This will cause irreversible damage to the electrolysis
cell.
• Use only pure water (see “Filling the water tank”).
• Operate the unit in a room with sufcient ventilation (see “Placing the unit”).
• Always unplug the unit from the mains power supply before accessing the internal components for service
or repair work.
4. WARNING
Any changes or modications to this equipment not expressly approved by the
manufacturer may void the user’s authority to operate the equipment.

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5. SPECIFICATIONS
HYDROGEN
FLOW RATE AT STANDARD
TEMPERATURE AND PRESSURE (STP)
(20O C, 1 BARG)
CELL-TYPE: PROTON- EXCHANGE
MEMBRANE (PEM) - 100% TI
CELL PART-NUMBER (PN)
HK Plus 100 0-100 cc/min Cell-pn: DB-Cell-MI-V3
HK Plus 160 0-160 cc/min Cell-pn: DB-Cell-MI-V3
HK Plus 250 0-250 cc/min Cell-pn: DB-Cell-MI-V3
MAX OUTLET PRESSURE 7 barg (102 psig)
PURITY 99.999%+
POWER CONSUMPTION AND
WEIGHT (DRY)
HK Plus 100 75 W 13 kg
HK Plus 160 95 W 13 kg
HK Plus 250 140 W 13 kg
INPUT VOLTAGE 110-120 V / 60 Hz 220-240 V / 50 Hz
FUSE 4A (5 x 20)
PRESSURE ACCURACY 0.1 bar (± 0.5 %)
MICROPROCESSOR
CONTROLLED DISPLAY
Graphic Display- Touch Screen, 128 x 64 pixels
INDEX OF PROTECTION IP2X
OPERATION CONDITIONS:
- TEMPERATURE
- RELATIVE HUMIDITY
15°C to +35°C
0-80%, non condensing
OVER VOLTAGE
CATEGORY
II
POLLUTION DEGREE 2
NOISE LEVEL 46 dB(A)
CASE DIMENSIONS MM (IN) 230W x 507H x 370D (9W x 20H x 15D)

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5.1 FUNCTIONALITY
The hydrogen generator produces pure hydrogen (and oxygen as a by-product) by the electrolysis of water.
The key element of the generator is an electrochemical cell which contains a solid polymer electrolyte. No
free acids or alkalines are used. Deionized or pure distilled water is the only liquid which will come into
contact with the cell. As this is consumed it must be relled from time to time as required.
The hydrogen is passing the hydrogen/water separator and the permeation drying tube. The pressure is
controlled by current. The hydrogen then passes through the outlet port at the rear.
WATER
TANK
HYDROGEN
PRESSURE
RELIEF
HYDROGEN
OUTLET
PRESSURE
SENSOR
GAS/LIQUID
SEPARATOR
HYDROGEN
CELL
DRAIN
PORT
WATER PUMP
FLOW SENSOR
PERMEATION
DRYING MEMBRANE
PERMEATION
DRYING MEMBRANE
SHUTOFF
VALVE

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6. INSTALLATION AND INITIAL START UP
6.1. RECEIVING THE GENERATOR
6.2. PACKING LIST
6.3. PLACING THE GENERATOR
All units have been carefully inspected before transport. Visual checks for damage and functional tests should
be performed upon receipt. Any damage must immediately be noted and reported. The generator must only
be returned according to the shipping instructions provided.
ATTENTION: Conserve the ORIGINAL packaging is case of a return.
List of items included in the shipment:
QUANTITY DESCRIPTION
1 Hydrogen generator
1 Instruction USB key
1 Deionizer bag set
1Water drain with exible tubing
1 Power cable
1 USB cable
The hydrogen generator must be placed on a at, leveled, vibration- and shock-free surface. Do not place the
generator near a heat source, as this may cause the generator to overheat. The unit must not be in contact
with any other objects on any side, and the air inlet must not be blocked. Leave at least 30 cm of free space
at the rear for ventilation. Do not operate the generator in a sealed or unventilated room, near open ames
or other sources of ignition. Do not operate the generator at temperatures below 0ºC (32ºF). Operation is
guaranteed at temperatures between 15ºC (59ºF) and 35°C (95ºF).
• Normal precautions as for any hydrogen supply should be taken when using the
generator.
• DO NOT use in sealed or unventilated rooms.
• DO NOT use near open ames or other sources of ignition.

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6.4 Gas Connections
Pure dry hydrogen at regulated pressure is available at the
hydrogen outlet port at the rear of the generator. This port must
be connected to 1/8” tubing using a stainless-steel or copper
Swagelok connector. Teon connectors are not suitable. The
pressure at this port is adjusted and shown on the display. The
hydrogen relief port and the hydrogen vent at the rear of the unit
can be connected to an exhaust hood or another venting system.
Remove the cap from the H2vent.
IMPORTANT: Remove the plug from the hydrogen vent before
operating the unit. Keep these plugs for transporting the unit.
The line from the relief port should never be
connected in such a way that back pressure can
develop.
6.5 Electrical Connections
Check the setting of the voltage selector at the rear of the unit.
The set voltage is indicated in the white square next to the power
socket. To change the voltage, proceed as follows:
• Use a small screwdriver, remove the voltage selector insert.
• Move the voltage selector to the correct voltage indicated by
the white arrows.

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6.6 Initial Start-Up
6.6.1 Filling the Water Tank
To ll the water tank, remove the cap underneath the slider of
the water tank. Carefully ll the tank with distilled or deionized
water.
The conductivity of the water used in the generator must not
exceed 2 µS/cm.
Fill the tank to the maximum level indicator. Close the slider
cap.
WARNING: Do not ll the water tank higher than up to the maximum mark.
CAUTION: To prevent contamination of the cell assembly, it is important to use only
deionized or distilled water in the generator. Water containing metallic impurities will
contaminate or damage the cell and will void the warranty.

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6.6.2 Installing the Deionizer Bag
The deionizer bags have been designed for high water purifying capacity. Use the rst set of 2 bags in the
new hydrogen generator for about 2 months of operation.
After the rst exchange, you can use the deionizer bags for up to 6 months or less depending on the water
conductivity.
After having lled the tank with distilled or deionized water, 2 deionizer bags must be placed in the tank.
Inspect the bags thoroughly for holes or tears, indicated by loose deionizer beads on the outer surface.
If the bags are damaged, discard and replace them with new ones. Use only original parts as listed in the
spare parts list. Wash the deionizer bags in deionized water before proceeding.
Insert the free end of the “T” fastener through the hole in the center of the holder, until it is securely
fastened. The bags must not block the outlet at the bottom of the tank. Once wet, the bags must not be
desiccated.

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6.6.3 Starting the Generator
Once the previous operations have been performed, the generator is ready for operation.
1. Check that the tank is lled with deionized water.
2. Check that the hydrogen outlet connector is tightly tted.
3. Turn the power switch to the “ON” position.
4. Enter the desired set pressure, using the menu buttons and selecting “Pressure Adjust”.
5. Press the “Start” button to start the unit (if the unit has been congured for “Auto Start” - see
Conguration - it will start automatically).
6. The unit will immediately begin to build up pressure. The LCD display will show the message “Reaching
Normal Pressure”, and the H2 ow bar will indicate maximum ow (fully illuminated).
7. Wait until the “Act Pressure” reaches the set value. These values are shown on the LCD display. It may
take a few minutes to reach the set operating pressure.
If the generator does not build up pressure as required, the unit will shut down. Refer
to the troubleshooting table.
Once the pressure reaches the set value, the LCD display will
show the message “Normal Pressure” and the H2 ow bar will
indicate no ow (no segments illuminated). This indicates that
there are no gas leaks with in the generator itself.
• Open the shutoff valve. The outlet pressure will fall initially.
The pressure drop and the duration are depending on the
volume consumed by the external equipment connected to
the generator.
• After the initial pressure drop, the outlet pressure should
stabilize at the set pressure. A continuous pressure drop
indicates a gas leak in the external equipment, or a too high
hydrogen consumption. Check the external equipment for
leaks or excessive hydrogen consumption.
• The generator is now in normal operating mode.

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7. OPERATION
7.1 LCD Display
All the important information is shown on the display.
7.1.1 LCD Dis play
The LCD display provides the following information:
7.1.2 First Row - Status Information
The rst row shows the current status of the generator. The
information can be divided into 3 groups:
Information: Displays normal operating status.
Pre-Alarm: Indicates that a maintenance intervention will soon
be required; accompanied by an audible signal.
Alarms: Indicates that a maintenance intervention is
required and that the generator has been shut
down; accompanied by an audible signal.

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MESSAGE DESCRIPTION TYPE ACTION
Standby Device ready for H2production Information Press Start
Reaching Internal
Pressure
Device producing H2and increasing
pressure to the internal set pressure.
Hydrogen valve is closed.
Information
Ready Device is at internal pressure point and
holds pressure. Some H2is used to re-
generate the dryer system.
Information
Reaching External
Pressure
Device producing H2and increasing
pressure to the internal set pressure. H2
valve is open.
Information
Normal Flow Device producing H2and has reached
set pressure with H2 owing
Information
Rell Water Water level approaching alarm threshold Pre-Alarm Fill the tank with water.
Change Water The conductivity of the water has ex-
ceeded 20µS/cm
Pre-Alarm Drain and rell the tank. Change
the deionizer bags.
Check Auto Rell Internal water tank cannot be lled with-
in the autorell timeout.
Pre-Alarm Check and rell external tank. In-
crease the auto rell timeout.
Clock Failure The clock is not set.
If the generator is disconnected for
more than 2-4 week, the time setting
may be lost.
Pre-Alarm Set clock.
Low Int. Pressure The internal pressure cannot be reached Alarm Check for internal leaks.
Low Out Pressure The external pressure cannot be reached Alarm Check for external leaks. Check
max. H2consumption.
Low Ext. Pressure The external pressure cannot be hold Alarm Check for external leaks. Check
max. H2consumption.
Low Water Level There is not enough water in the tank Alarm Rell the tank.
Bad Water The conductivity of the water has ex-
ceeded 25µS/cm
Alarm Drain and rell the tank. Change
the deionizer bags.
High Cell Voltage High cell voltage Alarm Notify service agent, cell must be
replaced.
Water Flow Error Too less water ows through the cell and
ow meter
Alarm Check to make sure water is in the
tank. Call service to check if the cell
or owmeter is blocked.
PS Temp High Temperature on the main board reaches
70°C
Alarm Check to make sure all fans are
working and air stream is not
blocked.
Dryer Failure Communication failure between
dryer module and main board
Alarm Check cable.
Shock/Fall The G-force sensor is activated due too
high force example earthquake
Alarm Check connections, tubing, etc.
before restarting the generator.

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7.1.3 Second Row - Pressure Information
“Act” is the actual pressure of the hydrogen, whilst “Set” is the set pressure. The pressure can be increased
using the up arrow button, or decreased using the down arrow button.
7.1.4 Third Row - Hydrogen Flow
This row displays the current quantity of hydrogen being produced. Each point represents about 10 % of
maximum capacity. This graph also indicates approximately how much hydrogen is being consumed by the
connected equipment.
NOTE: Only the last point on the ow graph will ash. This indicates that the generator is producing at
maximum capacity. During normal operation, this should not be the case, as it indicates that the consumption
is near the maximum limit and the unit may shut-down if consumption increases further. Maximum ow is
normal when the unit is building up pressure.
7.1.5 Third Row - Hydrogen Flow
This graph shows the quality of the water. With more than 3 points illuminated, water quality is good.
If only 3 or less points are illuminated, the conductivity of the water is around 10µS/cm (pre-alarm level).
If only 1 or no point is illuminated, the conductivity of the water is equal to or greater than 25µS/cm (alarm).
The generator will be shut down.
7.1.6. Start/Stop - Reset Button
The “Start/Stop” button places the generator in normal operating mode from “Standby” and vice-versa. It
is also used to re-start the unit after an alarm. When the problem causing the alarm has been resolved, the
generator must be reset using the “Reset” button. Afterwards, the generator can be re-started by pressing
the “Start/Stop” button.
7.1.7. Exit - Menu Button
“Exit” returns to previous display

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7.2 Menu Operation
The status of the generator is shown on the main screen of the graphic display.
The main screen has three options at the bottom, corresponding to the three buttons on the unit and the
touch screen, which are used to run the various functions and access the conguration and diagnostics of
the generator, following the tree structure shown in the gure below.

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7.2.1 Congure Parameters
Item Description Options/Range Default
Set Clock Adjust the internal clock - -
Low Pressure Error* Percentage of total pressure that needs to
be reached for activating the low pressure
0-100% 30%
Pressure Rise Sets how fast the pressure must increase 0.01 - 4.2 barg/min
0.2 - 60 psig/min
0.09
14
Pressure Drop Delay Sets a delay in seconds to ignore a pressure
drop (override low pressure alarm)
2 - 10 min 2
Auto Start After powering on the generator, all the
parameters are set back to the status before
power was shutdown. Example:
1. The system is running, producing
hydrogen and the outlet valve is open
2. Shut down
3. Power re-started
4. The system starts to run and then opens
the valves automatically after reaching the
internal pressure
Yes/No No
Beeper Sets whether the audible signal is activated
in the event of an alarm
On / Off On
Cascading Mode Sets the cascading mode. (see cascading
for more details)
None/ Normal / Ext.
P control
None
N Gen H2 in Cas-
cading
Sets the number of generators in the cas-
cading chain
1-10 1
ID Number Sets the ID-Number 1-10 1
Remote Start/Stop
Mode
Congures the remote Start/Stop function Start/Stop, Start only,
direct control
Start/
Stop
Remote Relay Mode Congures the remote relay contacts Normally open (NO)
Normally closed (NC)
NC
Auto-Rell If set to “On”, the pre-level water alarm is
used to trigger an external pump or valve
to rell the water tank
On / Off Off

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Pre Alarms in List If set to “Yes”, the pre-alarms are also
shown in the alarm log. The last 20 alarms
are logged.
Yes/No No
Pressure Units Sets the desired unit for the pressure mea-
surement
barg/psig/kPa barg
Temp. Units Sets the desired unit for the temperature
measurement
°C and °F °C
Volume Units Sets the desired unit for the volume mea-
surement
scm (standard cubic
meters)
scf (standard cubic
feet)
scm
Lock Keyboard Keyboard will be locked after the generator
is in the main window for more than 20s. To
unlock, press the unlock key and hold for 5s
Yes/No No
Set Default Values Sets all conguration parameters to default
7.2.2 Diagnostic Display
ITEM DESCRIPTION
Production Tot. Total production of hydrogen
Operating Time (h) Total number of operation hours
Wat. Quality (μs) Actual water conductivity
Int. Press. Actual internal pressure
Cell Voltage (V) Actual cell voltage
Cell Current (A) Actual cell current
PS. Temp. Actual temperature of the main board
Cell Voltage Peak (V) The maximum voltage the cell ever reached
PS. Temp. Peak The maximum temperature the main board reached
Pump Flow (l/min) Actual ow of water

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7.2.3 Special Functions
ITEM DESCRIPTION
System Test This offers several test functions - see below
Internal Leak Test The outlet valve is closed, the pressure is set to the maximum. When the
maximum gas pressure is generated, the production is stopped and the
pressure drop is measured during 2 minutes. The pressure drop should be
below 0.7 bars or 10 psi.
Important: The leak test will only work if the generator is in standby mode.
External Leak Test Works similar to the internal leak test except that the outlet valve is open and
the test pressure is equal to the set pressure.
This function can be used to test the external gas lines
Important: The external leak test will only work if the generator is in standby
mode.
Flow Test This function sets the outlet valve to provide a certain ow
adjustable from 0 to 100% of maximum ow.
Important: This function will only work if the generator is in standby mode. It
will take approx. 2 minutes to get a stable ow!
Complete System Test Combination of all tests above
Hardware Options Not available for user (password protected) Contact dedicated service orga-
nization
8. RETURNING THE GENERATOR
First contact your local distributor or your local service organization before sending any gas generators back.
If you need to return products to VICI AG International for maintenance and/or repair, please note the
following important requirements:
• The completed “Return Authorization Form” (https://www.vici-dbs.com/pages/returns-and-repairs) must
be sent to VICI AG International (e-mail or fax) for approval before an RMA-No (Return Authorization
Number) can be issued. All returned products must be accompanied by a completed “Decontamination
Report”. Remove all adapters, ttings or similar accessories that are not an integral part of the gas
generator. VICI AG International will not be responsible for lost or damaged items that are not an integral
part of the gas generator.
• The gas generator must be drained of any uids and residues and securely packed. As part of the service/
repair request, you are responsible for the decontamination prior to shipping.
• The decontamination report must be signed by a person authorized to take responsibility that the
information provided on the form is correct.
• The completed “Decontamination Report” must be secured to the outside of the shipping box.

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These requirements are necessary because the health and safety of our staff is of paramount importance.
If any returned gas generator does not comply with the above requirements, VICI AG International reserves
the right to quarantine or return the gas generator at the customers expense.
If following the inspection and quotation you decline the repair, you may be subject to a service fee to cover
product decontamination, disassembly, cleaning and evaluation.
Please also be advised that by sending your gas generator back to us, you have authorized us to disassemble
the gas generator for inspection and/or failure analysis. If the gas generator is subsequently deemed not
repairable or you decline the repair and request the gas generator to be returned, we cannot ensure that it
will be reassembled to working conditions.
We are sure that you share our concern for the safety of our personnel and we request your full cooperation in
carrying out these few extra steps prior to returning any products to VICI AG International.
If anything is not clear or you have further questions, please contact the VICI AG International technical
support team under [email protected].
Please also provide full details of the problem, including the model and serial numbers of your gas generator.
Instructions will then be provided for the service or the return of the unit. If the warranty has expired, or the
fault is due to misuse of the unit, all repair and shipping costs are to be paid by the customer. All other costs
are also borne by the customer, except as otherwise expressly agreed upon.
IMPORTANT: The manufacturer reserves the right to change or modify its products without prior notice.
• If the generator needs to be transported, make sure that the water tank is
completely empty.
• Close the water tank with the cap. Use the ORIGINAL packing material.
• The generator should be transported in an upright position; this warning should be
marked at the outside of the shipping box.
9. MAINTENANCE
With proper care and maintenance, your hydrogen generator should provide you with years of trouble-free
operation. There are no adjustments to be made to the generator. The only routine service operations are
those described below.
Nonetheless, the generator should be inspected approximately every 3 years. Contact your supplier.
9.1 Routine Maintenance
The following section describes the maintenance operations required for the correct operation of the
hydrogen generator.