Thermo Scientific Neslab Merlin M 25 Installation, Operation, Basic Maintenance
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Thermo Scientific Neslab Merlin M 25 Installation, Operation, Basic Maintenance

Neslab merlin series recirculating chillers
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NESLAB Merlin
NESLAB Merlin
NESLAB Merlin
NESLAB Merlin
NESLAB Merlin
Recirculating Chillers
Recirculating Chillers
Recirculating Chillers
Recirculating Chillers
Recirculating Chillers
Thermo ScientificManual P/N U00753 Rev. 11/15/06
Installation
Operation
Basic Maintenance
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http://www.thermofisher.com/tc
http://www.thermofisher.com/tc
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http://www.thermofisher.com/tc
Product Service Information, Applications
Notes, MSDS Forms, e-mail.
Voice Info: (800) 258-0830

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  • Page 1 NESLAB Merlin NESLAB Merlin NESLAB Merlin NESLAB Merlin NESLAB Merlin Recirculating Chillers Recirculating Chillers Recirculating Chillers Recirculating Chillers Recirculating Chillers Thermo ScientificManual P/N U00753 Rev. 11/15/06 Installation Operation Basic Maintenance Visit our Web site at: http://www.thermofisher.com/tc http://www.thermofisher.com/tc http://www.thermofisher.com/tc http://www.thermofisher.com/tc http://www.thermofisher.com/tc Product Service Information, Applications Notes, MSDS Forms, e-mail.
  • Page 2 Thermo Fisher Scientific Control Technologies Control Technologies Sales, Service, and Customer Support 25 Nimble Hill Road 25 Nimble Hill Road Newington, NH 03801 Newington, NH 03801 Tel : (800) 258-0830 or Tel : (800) 258-0830 8:00 am to 5:00 pm (603) 436-9444 Fax : (603) 436-8411 (Eastern Time), Monday through Friday.

  • Page 3: Table Of Contents

    Additional Accessories ..................24 Chapter 4 Maintenance ..................... 25 Error Codes ....................... 25 Displaying Software Version Number ............26 Controller PID Values ..................27 Cleaning ......................27 Algae ........................28 Leaks........................28 Phase Rotation Interlock ................. 28 NESLAB Merlin Series Thermo Scientific...
  • Page 4 BOM Decoder ....................32 Temperature Sensor Calibration..............32 Chapter 5 Troubleshooting Checklist ......................37 Service Assistance .................... 39 Appendix A Water Quality Standards and Recommendations ........41 Appendix B NC Serial Communications Protocol ............47 Warranty NESLAB Merlin Series Thermo Scientific...

  • Page 5: Preface

    Further information on Thermo Scientific’s compliance with these Directives, the recyclers in your country, and information on Thermo Scientific products which may assist the detection of substances subject to the RoHS Directive are available at: www.thermofisher.com/WEEERoHS...

  • Page 6: After-Sale Support

    Be sure to include the manual part number and the revision date listed on the front cover. Warranty Units have a warranty against defective parts and workmanship for 24 months from date of shipment. See back page for more details. NESLAB Merlin Series Thermo Scientific...

  • Page 7: Unpacking

    Any Temperature Control product meeting the definition of an Out of Box Failure must be packed and shipped back in the original packaging to Thermo Scientific for replacement with a new unit; Seller to pay the cost of shipping. Customer must receive a Return Material Authorization (RMA) from Thermo Scientific prior to shipping the unit.

  • Page 8: Safety Warnings

    Never use flammable or corrosive fluids with this unit. Highly distilled and deionized water may be aggressive and cause material corrosion. Please contact Thermo Scientific before subjecting this unit to prolonged exposure to highly distilled or deionized water. Do not use automotive antifreeze. Commercial antifreeze contains silicates that can damage the pump seals.
  • Page 9 Always turn off the unit and disconnect the power cord from the power source before performing any service or maintenance procedures, or before moving the unit. Never operate equipment with damaged power cords. Refer service and repairs to a qualified technician. NESLAB Merlin Series Thermo Scientific...
  • Page 10 Remote Start/Stop tion. See page 10. Connector. See page 22. External Temperature Plumbing Supply Connection. Sensor. See page 23. See page 10. PD Pump Pressure Relief Valve. See page 29. Drain. See page 10. viii NESLAB Merlin Series Thermo Scientific...

  • Page 11: Quick Reference Operating Procedures

    . To turn the unit off press again. LED indicates the status of the refrigeration system. It illuminates to indicate the refrigeration system is removing heat from the cooling fluid. As the operating temperature approaches the setpoint, the LED will flash. NESLAB Merlin Series Thermo Scientific...
  • Page 12 After this first cleaning, we recommend a monthly visual inspection. After several months, the cleaning frequency will be established. Before cleaning the strainer, disconnect the power cord from the power source and drain the unit. NESLAB Merlin Series Thermo Scientific...
  • Page 13 For at starte kølebadet, trykkes afbryderen ned. Når kølebadet skal stoppe, trykkes ned igen. LED displayet viser kølesystemets status. Når varme fjernes fra kølevæsken, lyser displayet. Når driftstemperaturen nærmer sig setpunktet, vil LED displayet blinke. NESLAB Merlin Series Thermo Scientific...
  • Page 14 For at undgå, at filtret tilstoppes, anbefales det, at rense filtret ugen efter, køleren har været i brug første gang. Herefter bør filtret kontrolleres en gang om måneden. Inden filtret renses, skal stikket trækkes ud af stikkontakten og kølebadet tømmes for kølevæske. NESLAB Merlin Series Thermo Scientific...
  • Page 15 Pour mettre en route, apuyer sur la touche., pour éteindre appuyer à nouveau sur la même touche. Une diode LED s’allume pour indiquer que le groupe commence à refroidir et se met à flasher lorsque la température de consigne est presque atteinte. NESLAB Merlin Series xiii Thermo Scientific...
  • Page 16 La première inspection doit s’effectuer une semaine après la mise en route de l’appareil. Ensuite nous préconisons une vérification tous les mois voire moins selon l’état dudit filtre. Avant de nettoyer ce filtre déconnecter l’appareil et vidanger. NESLAB Merlin Series Thermo Scientific...
  • Page 17 Nel caso in cui il LED sia illuminato il sistema sta rimuovendo il calore dal fluido refrigerante. Quando la temperatura controllata raggiunge il set-point impostato il LED continuerà a lampeggiare. NESLAB Merlin Series Thermo Scientific...
  • Page 18 Dopo la prima pulizia controllare mensilmente le condizioni del filtro in modo da valutare un’appropriata frequenza di pulizia. “ Prima di procedere alla pulizia del filtro disconnettere la tensione di alimentazione e svuotare il serbatoio dal fluido refrigerante tramite l’apposito scarico posizionato nel retro dell’unità”. NESLAB Merlin Series Thermo Scientific...
  • Page 19 System mit Kühlflüssigkeit gefüllt ist. Um das Gerät einzuschalten, müssen Sie erst den Hauptschalter an der Rückseite des Gerätes auf „Ein“ stellen und dann drücken. Zum Abschalten des Gerätes erneut drücken. NESLAB Merlin Series xvii Thermo Scientific...
  • Page 20 Danach empfehlen wir eine monatliche Überprüfung des Filters. So können Sie nach einiger Zeit abschätzen, wie oft der Filter gereinigt werden muß. Bevor Sie den Filter reinigen, ziehen Sie den Netzstecker und entleeren Sie das Gerät. xviii NESLAB Merlin Series Thermo Scientific...
  • Page 21 “start/stop”. LED geeft de status van het koelsysteem aan. De LED gaat aan als het apparaat warmte ontrekt aan de koelvloeistof. Op het moment dat de ingestelde temperatuur wordt bereikt zal de LED gaan knipperen. NESLAB Merlin Series Thermo Scientific...
  • Page 22 één week het filter schoon. Wij adviseren een maandelijkse inspectie van het filter. Na een aantal maanden kunt u de frequentie van inspecties aanpassen. Haal de stekker uit het stopcontact voordat u het filter gaat schoonmaken. NESLAB Merlin Series Thermo Scientific...
  • Page 23 . K vypnutí jednotky opet stisknete LED kontrolka indikuje stav chladicího systému. Pokud svítí, signalizuje ze chladicí systém momentálne bezí a odvádí teplo cirkulacní kapaline. Pokud se teplota cirkulacní kapaliny priblízí pozadované operacní teplote, kontrolka zacne blikat. NESLAB Merlin Series Thermo Scientific...
  • Page 24 Po nekolika mesících se na základe zkušenosti stanoví vhodný interval kontroly cistoty filtru. Pred cištením odpojte prívodní kabel od zdroje elektrické energie a vypustte z jednotky cirkulacní kapalinu. xxii NESLAB Merlin Series Thermo Scientific...
  • Page 25 Ut fra kjøler til inntak på applikasjonen. Inn på kjøler fra uttak på applikasjonen. For å fylle systemet. Åpne deksel for reservoar og skrukork på reservoaret. Fyll opp med ren kjølevæske/vann. For anbefalt kjølevæske, se side 11. NESLAB Merlin Series xxiii Thermo Scientific...
  • Page 26 Kjølere med PD pumper er utstyrt med sil. Dersom det er partikler i systemet , beskytter silen mot ødeleggelser. Etter noe tid, bør man kontrollere/rengjøre dette filteret, deretter kontrollèr/rengjør filteret jevnlig. Tett filter vil forårsake lavere trykk i sirkulasjons systemet. xxiv NESLAB Merlin Series Thermo Scientific...

  • Page 27: Chapter 1 Description

    The label is located on the rear of the unit. See below for an example. BOM#: XXXXXXXXXXXX S/N: XXXXXXXXX XXX VOLT XX HZ X PH X.X AMP R134A X.XOZ HIGH XXX PSI LOW XXXPSIG NESLAB Merlin Series Thermo Scientific...

  • Page 28: Specifications

    Circulating at 20°C ambient, pump unloaded. Cooling capacity will vary depending on fluid temperature, ambient temperature, and cooling fluid. Units with PD 2 pumps. Units with CP 55 pumps weigh 310 pounds (141 kilograms). Thermo Scientific reserves the right to change specifications without notice. NESLAB Merlin Series Thermo Scientific...
  • Page 29 2000 1000 Temperature °C 5000 A = M 150 60Hz Fluid - 50/50 PG/Water B = M 150 50Hz 4000 C = M 100 60Hz D = M 100 50Hz 3000 2000 1000 Temperature °C Thermo Scientific NESLAB Merlin Series...
  • Page 30 M 150 (208/230V 60Hz) PD 2 CP 55 M 150 (230V 50Hz) PD 2 None M 150 (400V 50Hz) PD 2 CP 55 NOTE PD pumps should not be used with applications that are sensitive to high pressures. NESLAB Merlin Series Thermo Scientific...
  • Page 31 B=CP55 50Hz 10 12 14 16 18 7.6 15.1 22.7 30.2 37.9 45.4 53.0 60.6 68.1 75.7 Flow MD 30 60 Hz The MD 30 is not available for 50 Hz units. 11.3 15.1 18.9 Flow Thermo Scientific NESLAB Merlin Series...
  • Page 32 10. Dimension L is the distance from the unit's side to the center of the power connection. NA for M-100/150 units rated 400V/50Hz. 11. Crate dimensions for units with CP-55 pumps are 6 inches higher. All packages tested to ISTA 2B. NESLAB Merlin Series Thermo Scientific...

  • Page 33: Installation And Operation

    The unit retains its full rated capacity in ambient temperatures up to approximately 25°C (77°F). Reduce the cooling capacity 1% for every 0.5°C (1°F) above 25°C (77°F), up to a maximum ambient temperature of 35°C (94°F). NESLAB Merlin Series Thermo Scientific...

  • Page 34: Electrical Requirements

    NOTE All 60 Hertz units are UL Listed and Certified to Canadian Standards. Amperage based on extreme operating conditions. Operating in a 20°C ambient and at nominal voltage will result in a lower amperage draw. NESLAB Merlin Series Thermo Scientific...
  • Page 35 NOTE Three-phase units are not supplied with a line cord. Instructions for wiring three-phase units are located behind the power box cover. To access the power box remove the unit's top and left-side panel. Remove the screws securing the cover. NESLAB Merlin Series Thermo Scientific...

  • Page 36: Plumbing Requirements

    Tubing should be straight and without bends. If diameter reductions must be made, they should be made at the inlet and outlet of your application, not at the chiller. NESLAB Merlin Series Thermo Scientific...

  • Page 37: Fluids

    Do not use a Deionization (DI) filter with Inhibited EG or Inhibited PG. A DI filter will remove inhibitors from the solution rendering the fluid ineffective against corrosion protection. Also, inhibitors increase fluid conductivity. Refer to Appendix A for additional information. NESLAB Merlin Series Thermo Scientific...

  • Page 38: Filling Requirements

    To close the upper valve, open the reservoir access panel, to close the lower valve you must remove the side access panel. Turn the valves 90°. NESLAB Merlin Series Thermo Scientific...

  • Page 39: Controller

    Indicates refrigeration system status. It illuminates to indicate the refrigeration system is removing heat from the cooling fluid. As the operating temperature approaches the temperature setpoint, the LED will flash. The indicator is off when heat is not being removed. NESLAB Merlin Series Thermo Scientific...
  • Page 40 Save any change using . After pressing an arrow key, if is not pressed within 60 seconds the display will return to the recirculating temperature display and ignore any change. NESLAB Merlin Series Thermo Scientific...

  • Page 41: Start Up/Shut Down

    2°C of either temperature alarm setting discussed on the next page. Trying to use a setpoint within 2°C causes the appropriate indicator to flash and sounds the audible alarm twice. NESLAB Merlin Series Thermo Scientific...
  • Page 42 NOTE Enabling serial communications disables the remote start/stop feature. In either mode, the setpoint and alarm values can not be changed using the controller but they can still be viewed. NESLAB Merlin Series Thermo Scientific...
  • Page 43 The circuit protector located on the rear of the unit is not intended to be used as a disconnecting means. Always turn the unit off and disconnect it from its supply voltage before moving the unit. NESLAB Merlin Series Thermo Scientific...

  • Page 44: Setup/Tuning Loop

    The loop can also be used to set the controller's PID parameters ). The factory preset values are on page 27. Thermo Scientific recommends that only a qualified technician change PID parameters. Incorrect PID values will hamper unit performance. The heat PID is only applicable to units configured with a heater.
  • Page 45 Chapter 2 HOLD XX.X Indicates Optional Displays RS 485 only. Accept All Changes NESLAB Merlin Series Thermo Scientific...
  • Page 46 Chapter 2 NESLAB Merlin Series Thermo Scientific...

  • Page 47: Chapter 3 Options

    GND = Signal ground No connection No connection No connection No connection No connection No connection No connection TX = Transmitted data from controller RX = Received data to controller. Hardware Mating Connector AMP Part# 745492-2 or equivalent NESLAB Merlin Series Thermo Scientific...

  • Page 48: Remote Start/Stop

    Input Voltages 56 volts peak. Rating for both normally open and normally closed status relay contacts are: Maximum rated load - 1.0 Amp, 24 Volts AC/DC, resistive. Minimum permissible load - 1 ma @ 5 VDC. NESLAB Merlin Series Thermo Scientific...

  • Page 49: External Temperature Sensor

    The external probe can be used to control the high and low temperature monitors using the Setup/Tuning Loop, see page 18. NOTE If you also need to monitor status while using the external sensor, an optional Y-connector cable is available from Thermo Scientific. NESLAB Merlin Series Thermo Scientific...

  • Page 50: Reservoir Level Warning/Fault

    A cartridge indicator lets you know when the filter needs changing. Condenser Air Filter An easy to install air filter protects the condenser in dusty environments. External Strainer Accessory Kit An easy to install kit to make routine strainer preventative maintenance easier. NESLAB Merlin Series Thermo Scientific...

  • Page 51: Chapter 4 Maintenance

    These errors will clear themselves once the problem disappears. Display Indication Low temp setpoint warning/fault Low level warning, fluid below minimum fill level, see page 12 High temp setpoint warning/fault Shorted external temperature sensor (rdt2) Open exernal temperature sensor (rdt2) NESLAB Merlin Series Thermo Scientific...

  • Page 52: Displaying Software Version Number

    5. Press The display will show the revision letter, as its equivalent number, for example, = A. 6. Press Disregard this display. 7. Press The display returns to the recirculating fluid temperature. NESLAB Merlin Series Thermo Scientific...

  • Page 53: Controller Pid Values

    COOL STD TEMP UNITS LOW TEMP UNITS HEAT ALL UNITS Thermo Scientific recommends that only a qualified technician change PID parameters. Incorrect PID values will hamper unit performance. Cleaning Reservoir Periodically inspect the fluid inside the reservoir. If cleaning is necessary, flush the reservoir with a cleaning fluid compatible with the circulating system and the cooling fluid.

  • Page 54: Algae

    We recommend the use of Chloramine-T, 1 gram per 3.5 liters. Other algaecides can be harmful to the unit's internal components. Contact Thermo Scientific for additional information. A very small leak between the pump and motor is normal. If this is a new Leaks pump, allow it to run for 24 hours and reinspect.

  • Page 55: Pd Pressure Relief Valve

    NOTE The relief valve may drip if the threaded stem is backed out too far. NOTE Should the unit start to vibrate the valve setting may be the cause. Changing the pressure setting ±5 psi will eliminate the vibration. Thermo Scientific NESLAB Merlin Series...

  • Page 56: Pump Strainer

    Right-side view Rear view NOTE A small amount of fluid will come out of the internal strainer housing when the fitting is removed. Have a rag handy to put under the housing before removing the fitting. NESLAB Merlin Series Thermo Scientific...

  • Page 57: Pd Pump Motor Lubrication

    (i.e. 3-IN-ONE ® Tool Oil) to each bearing on the following schedule: Duty Cycle Oiling Frequency Continuous Once every year Intermittent Once every 2 years Occasional Once every 5 years Fill Holes (Typical) Thermo Scientific NESLAB Merlin Series...

  • Page 58: Storage

    Once the display temperature matches the reference thermometer press twice. Press until Stor is displayed, press to accept the new value. NESLAB Merlin Series Thermo Scientific...
  • Page 59 After pressing at the Stor prompt wait several seconds before proceeding to ensure that a bad calibration message does not appear. Premature use of the keypad after pressing may cancel the bad calibration error message. Thermo Scientific NESLAB Merlin Series...
  • Page 60 Chapter 4 External Sensor When using any external sensor (rtd2) for the first time, Thermo Scientific recommends a two-point calibration. This calibration will only affect the temperature read by the external sensor. Do not pick calibration points that are outside the safe operating limits of the fluid in your application.
  • Page 61 After pressing at the Stor prompt wait several seconds before proceeding to ensure that a bad calibration message does not appear. Premature use of the keypad after pressing may cancel the bad calibration error message. Thermo Scientific NESLAB Merlin Series...
  • Page 62 Chapter 4 NESLAB Merlin Series Thermo Scientific...

  • Page 63: Chapter 5 Troubleshooting

    10 seconds, the controller will power. Turn serial communications off using the procedure on page 163, and then press to turn off the controller. Press again to start the unit. NESLAB Merlin Series Thermo Scientific...
  • Page 64 Make sure the condenser is free of dust and debris, see Chapter 4, Maintenance and Cleaning. e. Verify the controller's PID values, see Setup/Tuning Loop. 4. Unit runs loudly a. Check the position of the reservoir tank valves. See Reservoir Tank Isolation Valves/Open Tank Circulation, Chapter 2. NESLAB Merlin Series Thermo Scientific...

  • Page 65: Service Assistance

    Appendix B. c. Check all wiring for proper connections or possible shorts. d. Software to verify serial communication is available from Thermo Scientific. Service Assistance If, after following these troubleshooting steps, your unit fails to operate properly, contact our Service Department for assistance (see Preface, After-sale Support).
  • Page 66 Chapter 5 NESLAB Merlin Series Thermo Scientific...

  • Page 67: Appendix A Water Quality Standards And Recommendations

    0.5 to 5.0 ppm (of NaCl). Recommendation: Initially fill the tank with distilled/deionized water. Do not use untreated tap water as the total ionized solids level may be too high. NESLAB Merlin Series Thermo Scientific...
  • Page 68 Not Recommended, Increasingly Corrosive 15.00 10.00 Operations with Stainless Steel Systems 3.00 1.00 Operations with Mixed Metals CONSULT MATERIALS ENGINEER Copper/Brass/ 0.10 Stainless Steel 0.05 °C Water Quality Considerations NESLAB Merlin Series Thermo Scientific...
  • Page 69 Inhibited water can have many types of additives including chromate that will quickly foul the cooling system. Some inhibitor additives can release the bonding agent in the carbon graphite in the PD2 pumps so they are incompatible, such as Sodium Hydroxide. NESLAB Merlin Series Thermo Scientific...
  • Page 70 NOTE: This is not the normal state of water, so if it is too pure deionized water is aggressive to metal. The result is the leaching of metallic ions from metal surfaces which causes pitting. NESLAB Merlin Series Thermo Scientific...
  • Page 71 Buna-N (Parker Push-Lok O-ring) Nitrile based synthetic rubber (Parker Push-Lok hoses) Part Number 026931 Brass Part Number 032688 Copper Part Number 003752 Ball Valve (Part Number 026981): Viton Chrome plated brass body and ball PTFE NESLAB Merlin Series Thermo Scientific...
  • Page 72 Appendix A Sealants: FasSeal Teflon tape Teflon paste Nickel Impregnated Teflon tape Rector-Seal Tplus2 Low Level/Low Flow Switches (Optiona1): Polysulphone (Part Number 026900) Low Level Brass (Part Number 026901) Low Flow NESLAB Merlin Series Thermo Scientific...

  • Page 73: Appendix Bnc Serial Communications Protocol

    9-pin connection, see Chapter 3 for pin out information. Communication cables are available from Thermo Scientific. Contact our sales department for additional information. All commands must be entered in the exact format shown in the tables on the following pages.
  • Page 74 CA 00 01 20 03 01 FF F4 E7 The checksum is the bitwise inversion of 18 (00+01+20+03+01+FF+F4) = 218 Take the LSB = 18 3 bytes to follow Bitwise inversion = E7 NESLAB Merlin Series Thermo Scientific...
  • Page 75 = 16 bit signed integer of the value being en (error number) 01 = Bad command, sent or received 02 = Bad checksum cs = the checksum of the string (see text) xx = no valid data, include in checksum NESLAB Merlin Series Thermo Scientific...
  • Page 76 1 precision, no units of measure 1 precision, °C 2 precision, no units of measure Example: The temperature of 45.6°C would be represented by the qualifier 11 hex, followed by the 2 bytes 01 C8 hex (456 decimal). NESLAB Merlin Series Thermo Scientific...
  • Page 77 High or Low Temp Bypass Low Temp/Fixed Low Temp Fault b.1 = 1 Unit Faulted* Low Flow Fault b.0 = 1 Unit Running* Low Level 2 Fault t d2 is the detail of fault d1-b.1 * mutully exclusive NESLAB Merlin Series Thermo Scientific...
  • Page 78 Thermo Fisher Scientific warrants for 24 months from date of shipment any Thermo Scientific unit according to the following terms. Any part of the unit manufactured or supplied by Thermo Scientific and found in the reasonable judgment of Thermo Scientific to be defective in material or workmanship will be repaired at an authorized Thermo Scientific Repair Depot without charge for parts or labor.

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