VICI DBS PG Plus Rack 100 User manual

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PG PLUS RACK + ZERO AIR
& GC PLUS RACK USER MANUAL www.vicidbs.com
Version 2.00.0000
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:
• PG Plus Rack 100
• PG Plus Rack 160
• PG Plus Rack 250
• PG Plus Rack 300
• PG Plus Rack 500
• PG Plus Rack 600
• DB-FH-1800 Zero Air
• DB-FH-5000 Zero Air
Version 2.01.0000
• GC Plus Rack 1800
• GC Plus Rack 5000
• GC Plus Rack 10000
• GC Plus Rack 15000

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PG PLUS RACK + ZERO AIR
& GC PLUS RACK USER MANUAL www.vicidbs.com
Version 2.00.0000
TABLE OF CONTENTS
1. VERSION HISTORY................................................................................................................................ 4
2. INTRODUCTION.................................................................................................................................... 4
2.1. SYMBOL DEFINITION .........................................................................................................................5
2.2 TRANSPORT AND STORAGE CONDITIONS ......................................................................................5
2.3. ENVIRONMENTAL CONDITIONS.......................................................................................................6
3. SAFETY.................................................................................................................................................. 6
3.1. NOTES ON FCC COMPLIANCE..........................................................................................................6
3.2. CORRECT USE ....................................................................................................................................6
4. SPECIFICATIONS ................................................................................................................................... 7
4.1. PG PLUS RACK .................................................................................................................................7-9
4.2. ZERO AIR OPTION..............................................................................................................................9
4.3. GC PLUS ZERO AIR RACK.................................................................................................................10
5. FUNCTIONALITY................................................................................................................................. 11
5.1. MOST COMMON OPTIONS............................................................................................................. 12
5.1.1. Part Numbers ...........................................................................................................................12
5.1.2. Remote Connections (I/O Board).............................................................................................12
5.1.3. Cascading.................................................................................................................................13
5.1.4. Auto Rell Option ....................................................................................................................14
6. THE UNIT............................................................................................................................................. 14
6.1. FRONT VIEW ..................................................................................................................................... 14
6.1.1. PG Plus Rack - H2 Only Model..................................................................................................14
6.1.2. PG Plus Rack - H2 + Zero Air Model.........................................................................................14
6.1.3. GC Plus Zero Air Rack ..............................................................................................................15
6.2. BACK VIEW ...................................................................................................................................... 15
6.2.1. PG Plus Rack - H2 Only Model..................................................................................................15
6.2.2. PG Plus Rack - H2 + Zero Air Model.........................................................................................16
6.2.3. GC Plus Zero Air Rack ..............................................................................................................16
6.3. TOP VIEW.......................................................................................................................................... 17
6.4. DIMENSIONS .................................................................................................................................... 18
6.5. SCHEMATICS ....................................................................................................................................18
6.5.1. Fluidics ................................................................................................................................18-20
6.5.2. Electronics...........................................................................................................................20-22
7. INSTALLATION AND INITIAL START-UP ............................................................................................. 23
7.1. RECEIVING THE GENERATOR..........................................................................................................23
7.2. PACKING LIST ...................................................................................................................................23
7.3. PLACING THE GENERATOR .............................................................................................................23
7.4. VOLTAGE SELECTION.......................................................................................................................24

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PG PLUS RACK + ZERO AIR
& GC PLUS RACK USER MANUAL www.vicidbs.com
Version 2.00.0000
7.5. GAS CONNECTIONS........................................................................................................................24
7.5.1. Hydrogen Part..........................................................................................................................24
7.5.2. Zero Air Part .............................................................................................................................25
7.6. INITIAL START-UP..............................................................................................................................25
7.6.1. Filling the Water Tank...............................................................................................................25
7.6.2. Installing the Deionizer Bag .....................................................................................................26
7.6.3. Starting the Hydrogen Generator .......................................................................................27-28
7.7. STARTING THE ZERO AIR GENERATOR ......................................................................................28-29
8. OPERATION - HYDROGEN PART........................................................................................................ 30
8.1. LCD DISPLAY .....................................................................................................................................30
8.1.1. Layout of the Display................................................................................................................30
8.1.2. First Row - Status Information ..................................................................................................30
8.1.3. Second Row - Pressure Information .........................................................................................30
8.1.4. Third Row - Hydrogen Flow .....................................................................................................31
8.1.5. Fourth Row - Water Quality......................................................................................................31
8.1.6. Start/Stop-Reset Button ...........................................................................................................31
8.1.7. Exit-Menu Button .....................................................................................................................31
8.2. MENU STRUCTURE...........................................................................................................................32
8.3. CONFIGURE PARAMETERS.........................................................................................................33-34
8.4. DIAGNOSTIC DISPLAY .....................................................................................................................34
8.5. SPECIAL FUNCTIONS.......................................................................................................................35
9. OPERATION - ZERO AIR PART ............................................................................................................ 35
9.1. CONNECT POWER AND START UNIT..............................................................................................35
9.2. WARMING UP ...................................................................................................................................35
9.3. SHUTDOWN PROCEDURE ...............................................................................................................36
10. ERROR LIST - TROUBLESHOOTING .................................................................................................. 36
10.1. HYDROGEN PART ......................................................................................................................36-37
10.2. ZERO AIR PART ...............................................................................................................................37
10.2.1. Front Panel LED .....................................................................................................................37
10.2.2. Error Codes on Mainboard.....................................................................................................38
11. MAINTENANCE................................................................................................................................. 39
11.1. ROUTINE MAINTENANCE HYDROGEN PART................................................................................39
11.2. ROUTINE MAINTENANCE ZERO AIR PART....................................................................................39
11.2.1. Maintenance Kits....................................................................................................................40
11.2.2. Annual Maintenance Kit .........................................................................................................40
11.2.3. Three-Year Catalyst Replacement Kit.....................................................................................40
11.3. ANNUAL PRE-FILTER ELEMENT REPLACEMENT............................................................................40
11.4. THREE YEAR CATALYST CHAMBER REPLACEMENT...................................................................... 41
12. RETURNING THE UNIT...................................................................................................................... 42
13. SPARE PARTS LIST............................................................................................................................. 43
13.1. HYDROGEN PART ..................................................................................................................... 43-46
13.2. ZERO AIR PART ...............................................................................................................................46

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PG PLUS RACK + ZERO AIR
& GC PLUS RACK USER MANUAL www.vicidbs.com
Version 2.00.0000
1. VERSION HISTORY
VERSION DATE COMMENT/CHANGE
1.00.0100 January 18, 2017 Layout, initial release - VICI DBS
1.01.0000 February 15, 2019 Update - VICI DBS
2.00.0000 December 15, 2020 New layout, images and graphics - VICI Gig Harbor Group
Error code implemented, spare part list corrected, minor
correction - VICI DBS
2.01.0000 May 3, 2021 Typing error between PG and NM, new spare parts list -
VICI DBS
2. INTRODUCTION
This manual provides operation and maintenance instructions for the rack models PG-100, PG-160, PG-250,
PG-300, PG-500, and PG-600 Plus hydrogen generators.
It includes the optional zero air generator 1800 / 5000 and the standalone zero air generator rack 1800, 5000,
10000 and 15000.

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PG PLUS RACK + ZERO AIR
& GC PLUS RACK USER MANUAL www.vicidbs.com
Version 2.00.0000
2.1. SYMBOL DEFINITIONS
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.
2.2. TRANSPORT AND STORAGE CONDITIONS
TEMPERATURE Minimum +4º C, Maximum +45º C
HUMIDITY < 90% RH, non-condensing
SHOCKS & VIBRATIONS DURING TRANSPORT Shocks < 1g; vibrations < 0.2g/5Hz
INSTRUMENT POSITION Horizontal
THE ABOVE-MENTIONED VALUES ARE FOR AN INSTRUMENT TRANSPORTED IN ITS ORIGINAL NEW
PACKAGING.
Recommendations for Transport
When the instrument is shipped back to the factory for repair, the generator should be packed in the original
packaging with the inlets and outlets protected against dust or particles.
OR
OR
OR

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PG PLUS RACK + ZERO AIR
& GC PLUS RACK USER MANUAL www.vicidbs.com
Version 2.00.0000
2.3. ENVIRONMENTAL CONDITIONS
OPERATING TEMPERATURE Minimum +15º C, Maximum +40º C
HUMIDITY < 80% RH, non-condensing
ATMOSPHERIC PRESSURE From 850 to 1150 hPa
EXTERNAL VIBRATIONS < 0.05g/25Hz
INSTRUMENTS POSITION Horizontal
3. SAFETY
3.1. NOTES OF FCC COMPLIANCE
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 an 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
3.2. CORRECT USE
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 always be observed:
• Indoor use only
• Never operate the unit at temperatures below 0°C (32°F). This will cause irreversible damage to the
electrolysis cell.
• Use only pure, deionized 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

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PG PLUS RACK + ZERO AIR
& GC PLUS RACK USER MANUAL www.vicidbs.com
Version 2.00.0000
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.
PG PLUS
100 RACK
PG PLUS
160 RACK
PG PLUS
250 RACK
PG PLUS
300 RACK
PG PLUS
500 RACK
PG PLUS
600 RACK
Flow mL/min 100 160 250 300 500 600
Purity >99.9996%
Dewpoint at 7 barg (100 psig) -25ºC (-13ºF)
Outlet pressure barg (psig) 0.5 to 11 (7 to 160)
Technology PEM (Proton Exchange Membrane) - 100% Titanium cell
Drying system Regenerative permeation membrane
Deionized water quality Minimum < 1 µS/cm @25ºC - 1 MΩ cm @25ºC - ASTM II
Recommended < 0.2 µS/cm @25ºC - 5 MΩ cm @25ºC - ASTM II
External water tank (liters) External 10 liter bottle and internal pump
Safety Automatic shut down - internal/external hydrogen leak,
overpressure and low water
Display Touch screen with operating parameters, system status and safety alarms
LED indicators Power on/off, system ready, errors
Interface USB mod A
Electrical supply 110-120V 60Hz / 220-240V 50Hz
Power consumption (watts) 65 95 115 130 180 280
Dimensions mm (inches) 19” Rack W x 3U H x 500D (19.6)
Weight kg (lbs) 17 (37.4) 19 (41.9)
Shipping dimensions mm (in) 720W x 375H x 565D (28.3W x 14.7H x 22.2D)
Shipping weight kg (lb) 21 (46) 23 (50)
Operating temp oC (oF) 15 to 35 (59 to 95)
Outlet connection 1/8" Compression
Certication CE, FCC, MET (UL and CSA compliant)
MODELS & SPECS
4. SPECIFICATIONS
4.1. PG PLUS RACK

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PG PLUS RACK + ZERO AIR
& GC PLUS RACK USER MANUAL www.vicidbs.com
Version 2.00.0000
Hydrogen ow rate at Standard
Temperature and Pressure
(20°C, 1 barg)
Cell-Type:
Proton Exchange Membrane (PEM)
100% Ti Cell
Part-Number (PN)
PG Plus Rack 100 0-100 cc/min Cell-PN: DB-CELL-MI
PG Plus Rack 160 0-160 cc/min Cell-PN: DB-CELL-MI
PG Plus Rack 250 0-250 cc/min Cell-PN: DB-CELL-MU1
PG Plus Rack 300 0-300 cc/min Cell-PN: DB-CELL-MU1
PG Plus Rack 500 0-500 cc/min Cell-PN: DB-CELL-MU2
PG Plus Rack 600 0-600 cc/min Cell-PN: DB-CELL-MU2
4.2. ZERO AIR OPTION
DB-FH-1800 or DB-FT-1800 DB-FH-5000 or DB-FT-5000
Flow mL/min 1800 5000
Purity - hydrocarbons + CO <0.1 ppm
Inlet pressure barg (psig) 4.5 to 10 (65 to 145)
Inlet air quality Clean dry compressed air ISO8573-1:2010 Class 1.2.1
Max outlet pressure barg (psig) 5 (73)
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) 200 550
Operating temperature 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

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PG PLUS RACK + ZERO AIR
& GC PLUS RACK USER MANUAL www.vicidbs.com
Version 2.00.0000
4.3. GC PLUS ZERO AIR RACK
GC PLUS
1800 RACK
GC PLUS
5000 RACK
GC PLUS
10000 RACK
GC PLUS
15000 RACK
Flow mL/min 1800 5000 10000 15000
Purity - hydrocarbons <0.1 ppm
Purity - CO <0.1 ppm
Inlet pressure barg (psig) 4.5 to 10 (65 to 145)
Inlet air quality Clean dry compressed air ISO8573-1:2010 Class 1.2.1
Max outlet pressure barg (psig) 1 (15) drop from inlet
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) 200 550 550 550
Dimensions mm (in) 19”W x 3UH x 500D (19”W x 3UH x 19.6D)
Weight kg (lbs) 15 (33)
Shipping dimensions mm (in) 720W x 565H x 375D (28.3W x 22.2H x 14.7D)
Shipping weight kg (lbs) 19 (42)
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

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PG PLUS RACK + ZERO AIR
& GC PLUS RACK USER MANUAL www.vicidbs.com
Version 2.00.0000
5. 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