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PG PLUS RACK + ZERO AIR
& GC PLUS RACK USER MANUAL
TECH SUPPORT
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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
Version 2.00.0000
•
PG Plus Rack 500
•
PG Plus Rack 600
•
DB-FH-1800 Zero Air
•
DB-FH-5000 Zero Air
1
www.vicidbs.com
VICI AG INTERNATIONAL
Parkstrasse 2
CH-6214 Schenkon
Switzerland
tel:
+41 41 925-6200
fax:
+41 41 925-6201
web: www.vicidbs.com
•
GC Plus Rack 1800
•
GC Plus Rack 5000
•
GC Plus Rack 10000
•
GC Plus Rack 15000
Version 2.01.0000
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Table of Contents
Related Manuals for VICI DBS PG Plus Rack 100
Summary of Contents for VICI DBS PG Plus Rack 100
- Page 1 +41 41 925-6201 Italy web: www.vicidbs.com service@vicidbs.com Version 2.01.0000 APPLICABLE MODELS This manual is applicable to the following models: • PG Plus Rack 100 • PG Plus Rack 500 • GC Plus Rack 1800 • PG Plus Rack 600 •...
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Page 2: Table Of Contents
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 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. - Page 3 PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 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.
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Page 4: Version History
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... -
Page 5: Symbol Definition
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 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. -
Page 6: Environmental Conditions
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 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. -
Page 7: Specifications
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com WARNING: Any changes or modifications to this equipment not expressly approved by the manufacturer may void the user’s authority to operate the equipment. 4. SPECIFICATIONS 4.1. PG PLUS RACK PG PLUS PG PLUS PG PLUS... -
Page 8: Zero Air Option
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com Hydrogen flow rate at Standard PG Plus Rack 100 0-100 cc/min Cell-PN: DB-CELL-MI Temperature and Pressure PG Plus Rack 160 0-160 cc/min Cell-PN: DB-CELL-MI (20°C, 1 barg) -
Page 9: Gc Plus Zero Air Rack
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 4.3. GC PLUS ZERO AIR RACK GC PLUS GC PLUS GC PLUS GC PLUS MODELS & SPECS 1800 RACK 5000 RACK 10000 RACK 15000 RACK Flow mL/min 1800 5000 10000... -
Page 10: Functionality
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 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. -
Page 11: Most Common Options
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 5.1. MOST COMMON OPTIONS 5.1.1. Part Numbers OPTION PART NUMBER BOARDS/INTERFACES I/O Board DB-10155 Remote Control RS232 (software + cable) DB-PH200-107 Remote Control USB (software + cable) DB-PH200-108 CASCADING OPTION Cascading Hardware Kit... - Page 12 PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 5.1.3. Cascading This option requires the I/O board option. The RS-485 interface allows up to 10 generators to be operated in parallel mode. The generators are connected to an external non return valve to a gas line. The pressure must be controlled with an external pressure regulator.
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Page 13: The Unit
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 5.1.4. Auto-Refill Option Auto refill is standard in the rack version with a filling pump. As an option a valve can be factory installed to connect the generator to a pressurized deionizer water line. A maximum pressure of 4.5bar is allowed. 6. -
Page 14: Back View
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 6.1.3. GC Plus Zero Air Air Outlet Pressure Gauge Air Information Display Service Indicator Air Outlet Pressure Regulator Air On/Off Switch 6.2. BACK VIEW 6.2.1. PG Plus Rack - H Only Model Outlet Relief Valve REMOVE PLUG BEFORE USE... -
Page 15: Gc Plus Zero Air Rack
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 6.2.2. PG Plus Rack - H + Zero Air Model Outlet Relief Valve REMOVE PLUG BEFORE USE Compressed Air Inlet Zero Air Outlet Outlet IO Board Option 110/230 V Inlet External Water USE CORRECT FUSE... -
Page 16: Top View
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 6.3. TOP VIEW Version 2.00.0000... -
Page 17: Dimensions
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 6.4. DIMENSIONS 133.4 mm (5.3 in) 500 mm (19.7 in) 482.6 mm (19 in) 6.5. SCHEMATICS 6.5.1. Fluidics 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. - Page 18 PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com System: PG Plus Rack Date: THIS DOCUMENT AND THE INFORMATION WHICH Rev.: IT CONTAINS SHALL NOT BE USED, EXPLOITED Description: water and hydrogen flow diagram Created: 06.10.2020 OR SOLD, AND SHALL NOT BE REVEALED OR ECN no: DISCLOSED TO OTHERS WITHOUT THE EXPRESS...
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Page 19: Electronics
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com GC PLUS RACK P/N 1800 5000 10000 15000 INLET FILTER DB-10567 PRESSURE REGULATOR DB-RH200-015 FLOW RESTRICTOR DB-5000-0051 DB-5000-0052 DB-5000-0106 DB-5000-0107 CATALYST OVEN DB-10494 DB-10495 DB-10642 DB-10643 COOLING COIL DB-RH200-026 DB-RH200-027 DB-10424... - Page 20 PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com PG PLUS RACK P/N 100/160/250 500/600 POWER INLET DB-H200-045 POWER SUPPLY DB-PH200-003 DB-PH200-004 I/O BOARD DB-10155 DISPLAY BOARD DB-10648 DISPLAY MEMBRANE DB-H200-042 PG PLUS RACK MODEL MAIN BOARD INLET FAN OUTLET FAN DB-RH201-008...
- Page 21 PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com GC PLUS RACK MODEL LED DISPLAY BOARD MAIN BOARD MAIN SWITCH 1800 DB-NGT000-019 DB-NGC004-016 DB-H200-040 DB-RH200-001 5000 10000 or Rack Date: THIS DOCUMENT AND THE INFORMATION WHICH IT CONTAINS SHALL NOT BE USED, EXPLOITED 15000 OR SOLD, AND SHALL NOT BE REVEALED OR...
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Page 22: Installation And Initial Start-Up
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 7. INSTALLATION AND INITIAL START-UP 7.1. RECEIVING 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. - Page 23 PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 7.4 Fuses and Voltage Settings • Use only 240 V AC or 120 V AC settings and change fuses if needed. • Turn off the instrument before changing the voltage or fuse. Fuse values depend on voltage and device settings.
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Page 24: Gas Connections
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 7.5. GAS CONNECTIONS 7.5.1. Hydrogen Part 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 brass Swagelok connector. Teflon connectors are not suitable. -
Page 25: Zero Air Part
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 7.5.2. Zero Air Part Install compressed air with a ¼” tubing to AIR IN. The air quality must meet the minimum specification according ISO8573-1:2010 Class 1.2.1. The pressure must be between 4.5 to 10 bar (65 to 160 psig). The AIR OUT is a 1/8”... -
Page 26: Installing The Deionizer Bag
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 7.6.2. Installing the Deionizer Bag In order to protect the cell from bad water quality, it is necessary to use a deionization bag. Inspect the bag thoroughly for holes or tears, indicated by loose deionizer beads on the outer surface. -
Page 27: Starting The Hydrogen Generator
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 7.6.3. Starting the Hydrogen Generator Press the ON/OFF button to start the hydrogen flow (button will illuminate). When it is ready the button will change color and the following screen will appear. -
Page 28: Starting The Zero Air Generator
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com The generator will first build the internal pressure. Wait until it reaches 100% before moving on to the next step. At this point, make sure that you have connected the outlet Hydrogen to your GC or application. - Page 29 PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com Place the dust filter the right way (follow the arrow) Outlet for condensed water The air will flow through the zero air generator, even if the ON/OFF button is OFF. At this point, make sure that you have connected the Air outlet to your GC- or other application.
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Page 30: Operation - Hydrogen Part
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 8. OPERATION - HYDROGEN PART 8.1. LCD DISPLAY 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 part of touch screen, which are used to run the various functions and access the configuration and diagnostics of the generator. -
Page 31: Third Row - Hydrogen Flow
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 8.1.4. 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. -
Page 32: Menu Structure
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 8.2. MENU STRUCTURE The Menu following the tree structure shown in the figure below. Status: Normal Flow Press act: 6.2 set: 6.2 Bar Menu Flow Water Pressure adjust Configure Open Start... -
Page 33: Configure Parameters
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 8.3. CONFIGURE PARAMETERS SELECTION DESCRIPTION OPTIONS DEFAULT Set Clock Adjust the internal clock Low Press Error* Percentage of total pressure that has to be 0-100% exceeded to activate the low pressure alarm Pressure Rise Sets how fast the pressure should increase. -
Page 34: Diagnostic Display
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com (CONTINUED FROM PREVIOUS PAGE) SELECTION DESCRIPTION OPTIONS DEFAULT Volume Units Sets the desired unit of measure for the scm (standard cubic volume meters) scf (standard cubic feet) Lock Keyboard If set to YES, the keyboard will be locked au- YES / NO... -
Page 35: Special Functions
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 8.5. SPECIAL FUNCTIONS SELECTION DESCRIPTION System test Select a test function below Internal leak test The outlet valve is closed, the pressure is set to the max., when the pressure reaches the max., production is stopped and the pressure drop is measured over 2 minutes. -
Page 36: Shutdown Procedure
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 9.3. SHUTDOWN PROCEDURE Before performing any service or maintenance to the zero air generator, be sure to complete the following steps: • Turn off power using the switch of the unit. •... -
Page 37: Zero Air Part
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com Low Ext. Pressure The external pressure cannot be hold Alarm Check for external leaks. Check max. H consumption. Low Water Level There is not enough water in the tank Alarm Refill the tank. -
Page 38: Error Codes On Mainboard
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com CONDITION WARMUP/CHECK READY CHECK SYSTEM PRESSURE YELLOW GREEN LED STATUS LED STATUS LED STATUS Power fault Heater control fault: if catalyst temperature exceeds maximum allowed 650ºC Catalyst replacement warning: At 3 years Blinking 1Hz At 3 years, 2 months... -
Page 39: Maintenance
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 11. 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. -
Page 40: Maintenance Kits
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com 11.2.1. MAINTENANCE KITS TYPE DESCRIPTION FREQUENCY PART NUMBER CONSUMABLES Replacement cartridge for Inlet and Outlet Every 12 months DB-10161 filter SERVICE KITS 3-year catalyst replacement kit for 1.8L Every 3 years DB-10437 3-year catalyst replacement kit for 5L... -
Page 41: Three Year Catalyst Chamber Replacement
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com Diagram 1 Diagram 2 Diagram 3 Diagram 4 Pull Apart Push Unscrew Turn Pull and Replace Element Filter NOTE: More frequent replacement of the inlet filter may be required depending on the quality of the air supply. -
Page 42: Returning The Unit
12. RETURNING THE UNIT Please contact first your local distributor or your local service organization before sending any gas generators back to VICI DBS. If you need to return products to VICI for maintenance and/or repair, please note the following important requirements: •... -
Page 43: Spare Parts List
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com Thank you for your cooperation and please contact VICI if anything is not clear or you have further questions. 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. - Page 44 PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com DB-RH201-008 Main board for RPGH2-100 plus DB-RH202-008 Main board for RPGH2-160 plus DB-RH203-008 Main board for RPGH2-250 plus DB-RH204-008 Main board for RPGH2-300 plus DB-10521 Main board for RNMH2-450 plus DB-RH205-008 Main board for RPGH2-500 plus DB-RH206-008...
- Page 45 PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com DB-10243 Service kit for DB-RH200-004 pump DB-10244 Service kit for DB-RH200-005 pump DB-RH200-018 Internal Water Tank with cable and fittings RACK/FID-S DB-RH200-024 External handle Rack DB-RH200-025 Cell red+black power cables RACK/FID-S DB-10232 502, 1/8"...
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Page 46: Zero Air Part
PG PLUS RACK + ZERO AIR & GC PLUS RACK USER MANUAL www.vicidbs.com DB-10648 Display touch screen FID-S/Rack PG/NM incl. cable DB-5000-0147 Retrofit kit for H2 PG Generator DB-ISO028 Insulating Tube for Dryer NM - precut (kit of 30 pcs.) DB-RAC025 push in connector L-bow 1/8", M5 DB-RAC041...
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