Intelagard MERLIN User manual
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OPERATOR MANUAL
MERLIN® HANDCART
COMPRESSED AIR FOAM SYSTEM (CAFS)
Multi-Purpose, Portable Compressed Air Foam System
for
Fire Suppression, Decontamination & Spill Response
This document contains Intelagard proprietary information intended for use solely by the purchaser of this Intelagard
system. Reproduction is not authorized without the expressed written consent of Intelagard.
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TABLE OF CONTENTS
TABLE OF CONTENTS.......................................................................................................................3
MERLIN QUICK START.......................................................................................................................5
SECTION 1 – FRONT MATTER.........................................................................................................6
WARNING SUMMARY.....................................................................................................................7
SECTION 2 - GENERAL INFORMATION.......................................................................................10
2.0 Scope of this Manual. ...........................................................................................................10
2.1 Equipment Model Number and Name...............................................................................10
2.2 Serial Number Locations.....................................................................................................10
2.3 List Of Abbreviations/Acronyms & Terms Used In This Manual...............................11
2.4 Purpose of Equipment..........................................................................................................12
2.5 Safety, Care, and Handling..................................................................................................12
2.6 Commercial Warranty Information....................................................................................13
SECTION 3- EQUIPMENT DATA AND DESCRIPTION...............................................................14
3.0 Merlin Characteristics, Capabilities and Features........................................................14
3.1 Merlin Physical Parameters.................................................................................................15
3.2 Merlin Operational Parameters...........................................................................................16
3.3 Location of Major Components..........................................................................................17
3.4 Description of Major Components....................................................................................18
3.5 Description of Merlin Controls and Indicators...............................................................22
3.7 Nozzle Options........................................................................................................................24
SECTION 4 – INSPECTION, PREPARATION & USE OF THE MERLIN .................................27
4.0 General......................................................................................................................................27
4.1 Uncrating..................................................................................................................................27
4.2 Inventory & Inspect - Standard Equipment Shipped with the Merlin.......................28
4.4 Operating the Merlin Handcart...........................................................................................31
4.6 Considerations for Spray Operations...............................................................................34
4.8 System Shut Down................................................................................................................37
4.9 System Venting Procedure..................................................................................................37
4.10 Storage Options....................................................................................................................38
4.11 Freeze Protecting the Merlin.............................................................................................39
SECTION 5 – PREVENTIVE MAINTENANCE CHECKS.............................................................41
5.0 General......................................................................................................................................41
5.1 Merlin Periodic Maintenance Checks...............................................................................45
SECTION 6 - TROUBLESHOOTING...............................................................................................46
SECTION 7 – SUPPORTING INFORMATION...............................................................................47
7.0 General......................................................................................................................................47
7.1 Using the Merlin with a Low-Pressure Air Source........................................................47
7.2 About Air Cylinder Recharging..........................................................................................48
7.3 Cylinder Compatibility Information...................................................................................49
7.4 Merlin Decontaminant Application Capability................................................................50
SECTION 8 – FREQUENTLY ASKED QUESTIONS....................................................................51
SECTION 9 – REPAIR PARTS, REPLACEMENTS & CONSUMABLES.................................52
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9.0 Repair Parts, Replacements, Consumables & Optional Items..................................52
9.1 Merlin System .........................................................................................................................52
9.2 Merlin Spares/Repairs...........................................................................................................53
9.3 Merlin Optional Accessories/Replacement Parts..........................................................53
9.4 Merlin Consumables .............................................................................................................54
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR) ...........................55
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MERLIN QUICK START
1. Fill Fluid Tanks via Tank Ports. (See Foam Mixing and Nozzle Guidelines, Section 3
paragraph 3.8 for general mixing guidelines. Refer to solution manufacturer’s
recommendations whenever possible.)
2. Install fully charged air cylinder(s) into Cylinder Pouch. (One will operate the system;
the second can be stored there as back up.)
3. Buckle and tighten tank retention strap(s).
4. Connect Air Cylinder Coupler to Air Cylinder Valve and hand tighten clockwise. Do not
turn on air yet!
5. Ensure that push-to-connect fitting is securely attached to High Pressure Inlet fitting on
Equipment Case.
6. Unwind hose.
7. Securely attach hose to Fluid Outlet
8. Make sure that Handset with nozzle is securely attached to hose.
9. Ensure that Handset Valve is in closed position (clockwise to stop).
10.Turn on air by completely open Air Cylinder Valve by slowly turning knob counter-
clockwise to stop.
11.Briefly open the Handset Valve to allow pump to prime. Once liquid starts discharging
from nozzle, close handset by turning valve clockwise to stop.
12.Adjust Air Control Valve setting for WETTER or DRIER foam as needed.
13.Turn Flow Balancing Valve handles to desired settings.
Merlin is now ready to operate. Open Handset Valve to apply foam.
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SECTION 1 – FRONT MATTER
The Merlin Handcart provides the user with the ability to apply unexpanded (1:1) to highly
expanded (~35:1) compressed air foam that is generated from on-board liquid solution. The
Merlin is capable of creating and applying fire fighting foams, decontaminating foams and
many other foam products, without modification or performance degradation.
Used and maintained properly the Merlin is an extremely safe and effective system that
provides a single operator the ability to deploy up to ~490 gallons1of compressed air foam
from a single liquid tank fill.
The Merlin is a high pressure air unit. Although every effort has been taken to ensure the
Merlin is safe to operate, the operator MUST be aware that this system uses high-pressure
air to create and propel foam onto a target. Precautions MUST be taken to ensure operator
safety.
Operators must read this manual and be familiar with the safety considerations outlined
herein. Refer to the Warning Summary beginning on page 7 of this manual for an
explanation of potential risks.
Throughout this manual Important Procedures, Cautions and Warnings are identified by
the symbol below. Ensure the cautions, warnings and procedures specified herein are
closely followed. Doing so will help ensure your Merlin remains serviceable and can be
employed with maximum safety and effectiveness.
**NOTE**
This symbol is used throughout this manual to clearly indicate an
important procedural step or warning statement.
When accompanied with the word “WARNING” this symbol
indicates a strong possibility of severe personal injury or loss of life
if instructions are not followed.
When accompanied with the word “CAUTION” this symbol
indicates a possibility of personal injury or equipment damage if
instructions are not followed.
Heed all warnings and cautions!
1The Merlin has an operator adjustable air control valve that is used to control foam expansion, with the range
being unexpanded (1:1) up to ~35:1 expansion. Using the optional Mid-X air aspirating nozzle increases
achievable expansion up to ~70:1. The level of expansion achieved will vary based upon foam concentrate
used, quality of water supply, operator adjustment of the ‘Air Control Valve’ and foam concentrate viscosity and
quality.
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WARNING SUMMARY
This section contains general safety warnings and procedural cautions that must be
understood and consistently applied during operation and maintenance of this equipment.
FAILURE TO OBSERVE THESE WARNINGS AND CAUTIONS COULD RESULT IN
SEVERE PERSONAL INJURY OR LOSS OF LIFE AND/OR DAMAGE TO YOUR
EQUIPMENT!
WARNING! Personnel using the Merlin to respond to a fire emergency
must be educated in the basic principles of fire fighting to mitigate the risk
of performing these inherently dangerous operations.
WARNING! Before operation, ALWAYS verify that all hoses and
accessories are properly connected. Further, ALWAYS inspect the unit to
ensure the integrity of the air cylinder is not compromised and that all
lines are serviceable.
WARNING! NEVER operate a unit that has an identified air leak or worn
or damaged air lines/discharge hose. Once pressurized, a
loose/leaking/damaged connection may disconnect or rupture, potentially
causing injury.
WARNING! After operation, ALWAYS turn off the air supply and bleed
the handset hose to relieve the system of pressure. Failure to do so could
result in injury and /or system damage.
WARNING! To enhance the service life of your Merlin system, we
recommend only filtered/breathing quality air be used to charge the
Merlin's air cylinder. NOTE: This cylinder is not certified/authorized for
use as a breathing air cylinder - DO NOT USE Merlin cylinders with
breathing systems!
WARNING! NEVER deploy liquid or foam onto a charged electrical fire.
Foam, like water, is a conductive medium. Deployment of foam onto an
electrically charged fire can result in electrocution!
WARNING! ALWAYS wear eye protection while operating any
compressed air foam system!
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WARNING SUMMARY - Continued
WARNING! The Merlin Handcart is capable of deploying chemical and/or
biological decontaminating foams without modification. Personnel
performing this operation must be properly trained. Standard protective
ensemble (MOPP gear) is required at all times prior, during and after
decontamination operations.
WARNING! ALWAYS treat the Merlin as though the discharge hose is
energized. Once a system is pressurized it will remain so until the air
supply is turned off and the handset is activated to release pressure in the
lines.
WARNING! ALWAYS point the discharge device of the Merlin in a safe
direction and activate the handset to verify the system is not pressurized.
CAUTION! NEVER transport unrestrained/unsecured air cylinders. Doing
so could result in cylinder damage, potentially rupturing the high pressure
vessel. Always protect the air cylinder valve from impact, especially when
transporting and/or filling cylinder.
WARNING! NEVER fill pressure air cylinders that are out of hydrostatic
testing period. Refer to DOT regulations at all times.
WARNING! NEVER fill an air cylinder that has visible damage, unraveling
or charring of composite fiber.
WARNING! ALWAYS retest air cylinders every 5 years per DOT OFFC &
DOT-SP11194 and per TC-SU5303.
CAUTION! Open the air cylinder valve slowly to reduce impact on the
pressure regulation system! Rinse and inspect the cylinder periodically to
insure material integrity!
WARNING! NEVER use high and low pressure sources to power the
system at the same time! Doing so will result in severe damage to system!
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REVISION TRANSMITTAL PAGE
MERLIN HANDCART COMPRESSED AIR FOAM SYSTEM (CAFS)
OPERATOR MANUAL
Call, contact us through our website (www.intelagard.com) or mail questions to:
Intelagard,Inc.
Attn: Project Manager, Merlin
1275 Rock Creek Circle
Lafayette, CO 80026
TEL: 303.309.6309
DATE OF REVISION
SUMMARY OF CHANGE
PAGES CHANGED
Feb2013Majorstructureandcontentchanges Multiple
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SECTION 2 - GENERAL INFORMATION
2.0 Scope of this Manual.
This manual fully explains receiving, preparing for use, using and maintaining your Merlin
Handcart. The manual is broken down into the sections below:
Table of Contents
Merlin Quick Start
Section 1 – Front Matter: Warning Summary, Revision Transmittal Page
Section 2 – General Information
Section 3 – Equipment Data and Description
Section 4 – Inspection, Preparation & Use of the Merlin
Section 5 – Preventive Maintenance Checks
Section 6 – Troubleshooting
Section 7 – Supporting Information
Section 8 – Frequently Asked Questions
Section 9 – Repair Parts, Replacements & Consumables
Reporting Equipment Improvement Recommendations (EIR)
Type of Manual
Operator’s Manual; Provides instructions for operating and maintaining the Merlin Handcart
CAFS. (Compressed Air Foam System)
2.1 Equipment Model Number and Name
Merlin Handcart CAFS can be ordered with or without an air cylinder. (Specific model and
part numbers are included in Section 9 of this manual.)
2.2 Serial Number Locations. The serial number is located on the back of the Power
Module, centered above the mounting bracket as shown in Figure 2.1. Take the time to
write down your new system’s information here. The air cylinder serial number is located
on the data label affixed to the cylinder.
1. Merlin Serial No.
_______________________
2. Air Cylinder Serial No. (if ordered)
It is located on air cylinder, not shown
_______________________
Figure 2.1 – Merlin Serial Number Location
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2.3 List Of Abbreviations/Acronyms & Terms Used In This Manual
CAF Compressed Air Foam. Foam created by injecting air into a
surfactant-carrying liquid solution such as the many fire fighting
foam concentrates/solutions commercially available.
CAFS Compressed Air Foam System. A foam generating system that
uses compressed air as a primary energy source.
CFM/SCFM Cubic Feet per Minute/Standard Cubic Feet Per Minute –
Alternate unit of measure for volume throughput.
Concentrate A highly concentrated foam solution intended to be combined with
water in the Merlin’s liquid storage tanks.
Dry Foam
‘Dry’ foam is a term used for highly expanded foam. The more air
injected into the surfactant solution the greater the foam
expansion. Dry foam contains more air and requires less liquid to
create.
Expansion Ratio
The ratio of foam volume created after expansion to the liquid
volume present before expansion. A 1:1 ratio means the liquid
has not been expanded. A 15:1 ratio means the liquid has been
expanded to 15 times its original volume.
High-Pressure
Air
The Merlin can accept air from one of two sources – a high-
pressure air source or an air compressor. The high pressure air
cylinder, rated at 4350/4500-PSI is the source of the Merlin’s
high-pressure air supply.
Low-Pressure Air The Merlin can accept air from one of two sources – a high-
pressure air source or an air compressor. Air compressors are
the source for low-pressure air.
Solution As used in this manual "solution" refers to a either a water + foam
concentrate mixture or an undiluted foam solution.
PSI Pounds per Square Inch – Unit of measure for pressure.
Wet Foam ‘Wet’ foam is a term used for unexpanded or minimally expanded
foam. Wet foam contains less air and requires more liquid to
create.
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2.4 Purpose of Equipment
The Merlin Handcart CAFS is a multiple use, self-contained foam delivery apparatus
specifically designed for rapid, mobile response to fire emergencies and hazmat response
missions. The Merlin is capable of creating and applying foam solutions as an independent
system, using only on-board resources (liquid and air). The Merlin also has the ability to
connect to an external air source (air compressor) in lieu of a high-pressure air cylinder.
Utilizing an external air source eliminates the operational limitations imposed by using a
limited on-board containerized air supply.
The Merlin is capable of applying numerous foam solutions, including but not limited to Class
A & B firefighting foams (including long duration proteins, AFFF and AR-AFFF),
decontaminating foams such as EasyDECON® DF200, moldicides and many new wetting
agents and combination A/B firefighting agents.
If you are unsure of the suitability of a foam concentrate or it’s compatibility with the Merlin
system, contact Intelagard before using the concentrate in the unit.
For additional information on capabilities and employment modes see Sections 3 (Equipment
Data and Description) and 4 (Inspection, Preparation & Use of the Merlin) of this manual.
2.5 Safety, Care, and Handling
WARNING! The Merlin Handcart uses high-pressure, containerized air as an
energy source to create and propel foam onto a target. Before operation,
ALWAYS verify that all hoses and accessories are properly connected.
Further, ALWAYS inspect the unit to ensure the integrity of the air cylinder is
not compromised and all lines are serviceable.
2.5.1 High Pressure Air. The Merlin system uses a high-pressure air cylinder as the
container for air energy that creates and propels foam onto targets. Users MUST ALWAYS
exercise appropriate cautions when filling, transporting and using high-pressure air cylinders.
The cylinders provided by Intelagard are carbon-fiber wrapped for added safety, and the
installed air cylinder valve includes a burst disk. In the event a cylinder is overcharged, the
burst disk will rupture at ~6750 psi, venting the air into the atmosphere. Intelagard’s air
cylinders are manufactured to Department of Transportation (DOT) standards, which require
a cylinder be capable of withstanding 3.33 times operating pressure without incident (3.33 x
4500 psi). The DOT special permit number is provided on the cylinder label. Always use
cylinders that meet DOT standards in the Merlin. The Merlin also has a low pressure port for
utilizing power from a compressor.
SAFETY must always be foremost in the operators mind to prevent accidents or incidents
that could lead to system damage and/or personal injury. Read and observe all safety
warnings in this manual and NEVER attempt to operate a Merlin CAF system with an air leak.
If escaping air is heard once the system is pressurized, turn off the air supply, activate the
handset to release trapped air and fluid and then thoroughly inspect the system to identify
the source of the air leak – do not use a Merlin with an air leak!
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2.5.2 Hazardous Materials. The Merlin ships with the air cylinder (if purchased)
empty; therefore there are no hazardous material restrictions on transport or storage of the
Merlin Handcart. Fire foam concentrates are also free of restrictions on transport and
storage. Intelagard provides concentrate MSDS’s on request, and a MSDS is enclosed in all
foam concentrate cases.
The Merlin is suitable for use with a multitude of foam concentrates therefore it is not possible
to address all possible contingencies within this manual. If purchasing Class A or B fire foam
concentrates or EasyDECON® DF200 through Intelagard these materials are
environmentally safe and also impose no restrictions on transport or storage beyond standard
temperature considerations for long-term storage.
In the interest of personnel safety and system integrity users must take the time to familiarize
themselves with the qualities of the solutions they will apply with the Merlin Handcart by
thoroughly reviewing the MSDS provided with the foam concentrates.
2.6 Commercial Warranty Information
Intelagard provides a limited commercial warranty included in the purchase agreement and/or
contract. Contact your contracts or procurement manager for a copy of the warranty.
Intelagard’s commercial warranties are available on our webpage, www.intelagard.com.
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SECTION 3- EQUIPMENT DATA AND DESCRIPTION
Section 3 Contents:
3.0 Merlin Characteristics, Capabilities and Features
3.1 Merlin Physical Parameters
3.2 Merlin Operational Parameters
3.3 Location of Major Components
3.4 Description of Major Components
3.5 Description of Merlin Controls and Indicators
3.6 Merlin Modes of Operation
3.7 Nozzle Options
3.8 Foam Mixing and Nozzle Guide
3.0 Merlin Characteristics, Capabilities and Features
3.0.1 The Merlin is a self-contained, independently functioning and transportable
Compressed Air Foam (CAF) generation apparatus, highly suited for fire and hazardous
vapor suppression, liquid spill response, and military and civil decontamination operations.
The Merlin is designed to apply foaming solutions for fire suppression (Class A & B),
decontamination, hazardous material remediation, biohazard control, toxic material spill
remediation, cleaning and mold control, as well as many other applications
3.0.2 The Merlin is capable of applying most commercially available foam concentrates,
including Class-A, long-duration protein, AFFF, AR-AFFF, decontaminating foams, and many
new wetting agents and combination A/B agents. The Merlin has many additional
applications, including application of non-foaming liquid solutions and air-aspirated foam with
simple nozzle changes and control adjustments. Contact Intelagard for recommended
foaming agents or with any questions regarding system capabilities.
3.0.3 The Merlin is powered by means of air energy, provided by an approved air
cylinder or external air compressor2. Filtered, breathing quality air is injected into an approved
surfactant solution to create foam, which is propelled onto a target via the air energy that also
drives the internal pump subsystem. Intelagard offers DOT-approved 66 cu. ft., 4350/4500-
psi, carbon-fiber wrapped air cylinders with the Merlin. If other air cylinders are used in the
Merlin, they must meet Intelagard’s criteria to avoid voiding the system's warranty. See
Section 7.3 for air cylinder compatibility information.
WARNING! NEVER use high and low pressure sources to power the system at
the same time! Doing so will result in severe damage to system!
2To operate the Merlin without performance degradation an air compressor must be capable of providing 12-
CFM of filtered air at 100-110 psi. See Section 7. Paragraph 7.1 for additional information
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3.1 Merlin Physical Parameters
System Specifications.
COMPLETE SYSTEM:
Dry Weight: System: ~80.7 lbs3(without fluid or air cylinder)
Full Weight: ~224 lbs (with 14 gal fluid and 1 full air cylinder)
Dimensions: ~49.25” H x 19.25” W x 23.75” D (height measurement will change
with tire inflation and tire choice)
TANK:
Liquid Capacity: (2) 7 gallon tanks (measured to top of sight tube)
Material: Molded Polypropylene
Closure (Cap): Lanyard retained, vented, poly construction, 3” diameter
PUMP:
Combined Flow: ~10 gallons per minute4(gpm) liquid flow rating
Pressure: 100 psi Optimum, 110 psi Maximum
Construction: Glass reinforced poly housing with Santoprene internals
AIR INJECTION (Foam Expansion Control):
Adjustable by mechanical valve, 90 degrees rotation, wet/dry setting
COMPRESSED AIR FOAM (CAF) MANIFOLD:
Expansion: 1:1 (liquid application) to ~35:15
Air Consumption: ~9.5 scfm Max6
Resupply Ratio: ~1:1 MAX (14-gal tank load emptied per full air cylinder)7
Output Stream: ~105 gallons per minute finished foam
Output Throw Distance: ~40 ft MAX8
3Intelagard cylinder adds ~13 lbs.
4The Merlin pumps are individually rated to dispense ~5-gallons of liquid per minute. When working in
conjunction with the CAF components pump flow is reduced by as much as 35%.
5Achievable expansion ratio depends on foam solution composition. Concentration and concentrate quality will
affect finished foam expansion.
6Air consumption varies according to foam solution make-up and wet dry setting. Re-supply ratio based on 66
cu. ft, 4500psi cylinder.
7The tank to cylinder resupply ratio will vary according to foam solution, nozzle selection and system settings
(wet/dry).
8Wet/Dry settings, foam product, nozzle used, wind and other factors will significantly affect foam throw
distance.
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3.2 Merlin Operational Parameters
OPERATIONS PARAMETERS
Structure,
Woodland Fire
Fighting
Class-A Foam. Foam expansion ratio should be adjusted via the Air Control Valve to
determine the best setting for the situation. See Foam Mixing and Nozzle Guidelines,
Section 3.8 for more recommendations.
Vehicle, Tire and
Fuel Fires
Class B (AFFF or AR-FFF) foam. Foam expansion ratio should be adjusted via the Air
Control Valve to determine the best setting for the situation. See Foam Mixing and
Nozzle Guidelines, Section 3.8 for more recommendations,
Decontaminant
Solution,
EasyDECON®
DF200
EasyDECON DF200 is available in a three-part formulation that ships in 5 gal, 100 gal
and 500 gal configurations. Add Part 1 to Tank A, Part 2 to Tank B, and finally, Part 3 to
Tank A when ready to deploy. (Shelf life of the EasyDECON DF200 is significantly
degraded once Part 3 is added to Part 1.) Do not dilute with water. Apply at
expansion ratio best suited for the target area and agent challenge. Use the fan spray
nozzle to apply foam to vertical surfaces.
Flow / Capacity /
Throughput
14 gal (total) fluid tanks can yield up to ~490 gal of finished foam with the Air Control
Valve adjustment set fully to the ‘dry’ setting using a smooth bore nozzle (~35:1
expansion9). Foam expansion is a function of the amount of air injected into a liquid
solution. A higher “wet” setting will use more liquid and less air. A higher “dry” setting
will use more air, and less liquid. Optimum settings must be determined by the operator
based upon the environment, mission and specific challenges presented. As air
consumption varies based upon the wet/dry setting, operators can expect to empty the
fluid tanks approximately one time on a fully charged air cylinder. If ‘wetter’ foam is
being applied the air supply will last comparatively longer than when applying ‘dry’ foam.
Set-up Times
Tank Refill Time: ~1-2 minutes
Pumping time: Subject to system settings
System PMCS: < 10 minutes
System Start-Up: < 1-2 minutes
System Shutdown: < 1 minute
Configure for external air: < 2 minutes
Foam Projection
Distance Projection distance is a function of wet/dry settings, foaming agent, air source, nozzle
used and weather. With standard equipment, projection distance is up to ~40 feet10
Operating Pressure 100 psi optimal, 110 psi maximum
Low Pressure Air
(Air Compressor)
Requirements
Compressor must provide a minimum of 12-scfm at 100 psi optimum, 110 psi maximum.
Owner/operators should test their compressor to determine suitability for use with the
Merlin
Foam Expansion System: 1:1 (unexpanded) up to ~35:1 (35 times original liquid volume). With Mid-X
Nozzle: up to ~ 70:1 is achievable
Accessories See section 9 of this manual
Table 3.2.1 - List of Merlin Operational Parameters
9Achievable expansion varies based upon concentrate and nozzle used and operator chosen system settings.
10 Throw distance can vary significantly based upon foam concentrate, water quality, wet/dry settings, air quality,
nozzle used and weather.
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3.3 Location of Major Components
Figure 3.3.1 - Location of Major Components
ITEM COMPONENT FUNCTION
1AirCylinderand
NozzlePouch
MoldandmildewresistantCordura®fabricpouchforcylinderstorageandnozzle
storage
2AirCylinder
RetentionStrapsRetentionstrapstoholdcylindersinplaceforsafestorageandtransport
3AirCylinder(s)and
Valve(s)
4350/4500psicarbonfiberwrapped,66cu.ft.aircylinder;StandardUScylindersare
equippedwithCGAvalveswithburstdisk(DINfittingsavailableonrequest)
4PortableHandcartAluminumhandcarton10"pneumatic*tireswithextendedhandleforeasier
movement.(*solidrubbertiresavailableuponrequest)
5
ControlPanel/
Removable
EquipmentCase
Controlpanelincludes aircontrolvalve,flowbalancingvalvesforfluidtanksand
cylinderpressuregauge.EquipmentcasehousesfunctionalcomponentsoftheMerlin,
andcanberemovedforremoteoperations.
6LowPressureAir
ConnectionConnectionforlowpressureauxiliaryairsource
7HighPressureAir
Connection
Connectionforhighpressureaircylinder.Connectstocylinderwith"highpressurewhip
line"
8Handset/Hose
Assembly
20'x3/4"IDhose,shipswithfullporthighperformancehandsetattached.Nozzle
attachestohandsetviaquickconnectfitting
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ITEM COMPONENT FUNCTION
9Nozzle
Nozzlesareinterchangeable,andusedtotailorfoamapplicationtothemission–see
Section3paragraph3.7foradditionalinformationMerlinshipsstandardwith12mm
SmoothBoreNozzle.
10DischargePortPortwherefoamexits Merlin totheattachedhose/hosehandsetassemblyconnected
viaquickconnectfitting
11FluidTanks(2)
Twin7gal(measuredtotopofsighttube)tanksaremoldedfromhighgrade
polypropyleneresins.Configuredwithsighttubesforfluidlevelmonitoring.Includes
drainplugforeasycleaning.
12FluidPortsandCaps3"capscoveringtheMerlin'stankfillingports.Capsareventedandlanyardretained
13FlowBalancing
ValvesValvesadjustfluidflowforindividualMerlinfluidtanks
14AirControlValveAnadjustabledial,labeledWetterFoamandDryerFoam.Usedtoselecttheamountof
airinjectedintothefoamthuscontrollingthefoamexpansionratio.
Table 3.3.1 – Merlin Major Components.
3.4 Description of Major Components
#1. Air Cylinder and Nozzle Pouch: The air cylinder(s) are held in the Merlin cart unit in an
attached, padded ballistic cloth pouch and polyethylene sheet. Two standard cylinders can be
accommodated at the same time. This allows for efficient recharging of the air supply if the
Merlin is being used for extended deployment. The cylinders are placed in the pouch, valve
end up, and one cylinder is connected to the system.
#2. Air Cylinder Retention Straps: There are two cylinder retention straps on the handcart
cross member directly above the pouch. These straps must be buckled and tightened around
the cylinder(s) to ensure secure transport of the cylinders and operator safety.
#3. Air Cylinder(s) and Valve(s) - Intelagard air
cylinders are 4350/4500 psi carbon fiber wrapped
high pressure air cylinders. Our air cylinders ship
with the valve installed (CGA or DIN) and are ready
to be filled upon receipt by customer. Our standard
cylinders have a DOT or CE label around the cylinder
body and are certified for use only with Intelagard CAF systems. These carbon composite
cylinders have a 15-year service life, and must be hydro-statically tested every five years per
DOT test criteria. The date of manufacture and the service pressure rating can be found on
the DOT label. The valves incorporate a burst disk, designed to rupture at approximately
6750 psi in the event of over-filling. Per DOT regulations high-pressure cylinders are
manufactured to withstand overfilling to 3.33 times operating pressure. 4350 cylinders have
been manufacturer-approved for filling to 4500psi. Always inspect cylinders for damage prior
to re-charging. Cylinders incorporate a serial number on the data plate.
WARNING! To maintain the integrity of the system Intelagard recommends
using only quality, filtered air to charge our cylinders. Never use a Merlin air
cylinder as a breathing air cylinder! Only persons trained in the proper use of
air compressors and cascade systems should refill air cylinders!
Figure 3.4.1 – Air Cylinder
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#4. Portable Handcart: The Merlin is mounted to a rugged aluminum handcart that allows
the user to comfortably transport the unit, whether full or empty. The standard 10” pneumatic
tires are mounted on alloy wheels for movement over uneven terrain. The tire pressure
should be maintained at a minimum pressure of 30 psi, with a maximum pressure of 50 psi.
The extended aluminum handle allows for proper balancing of the system while transporting.
Custom bracketing has been designed to allow for secure connection of the tanks, cylinder
pouches and equipment modules. Optional semi-pneumatic and hard rubber tires, as well as
larger tires and wheels are available from Intelagard.
#5. Control Panel / Removable Equipment Case: The control panel located on the front of
the removable equipment case is configured for effective use by personnel in Personal
Protective Equipment (PPE). The controls on the panel include the air control valve (for
wetter and drier foam expansion consistency), the flow balancing valves for Tank A and Tank
B, and the cylinder pressure gauge.
The equipment case can be easily and quickly removed from the Merlin by detaching the four
quick connect fittings located on the back of the case, and removing the pins holding the case
and bracket to the handcart. Once removed, the case can be carried to remote locations and
connected to a high or low pressure air source, and to bulk fluid storage (via optional fluid
drafting hoses) for large scale operations. The case houses the functional components of the
Merlin system including various calibrations and adjustments that require special equipment
and procedures to change. These settings are factory preset.
WARNING! Opening this enclosure improperly may lead to injury, death or
equipment damage!
The equipment case may only be opened and serviced by factory authorized
personnel. Breakage of the factory seal by unauthorized personnel will void equipment
warranty!
#6. Low Pressure Air Connection: Merlin users with an
available compressed gas supply (nitrogen or
compressed air) can operate the Merlin system by
bypassing the internal regulation system and supplying
regulated low pressure directly to the Merlin via the
equipment case low pressure air connector. A
compressed gas supply regulated to 110psi MAX can be
connected via the quick-disconnect fitting. An external
compressor must provide a minimum of 12-scfm at 100
psi optimum, 110 psi maximum. Owner/operators should
test their compressor to determine suitability for use with
the Merlin.
#7. High Pressure Air Connection: Below the low pressure connection is a male quick-
disconnect for high pressure connection to the equipment case. Cascade cylinder systems
Fig.3.4.2 High and Low Pressure
Air Connections
MR012013.4
20
Fig 3.4.3 High performance handset
Fig 3.4.4 Trigger Handset
and SCBA type cylinders can be connected here by using the high pressure whip line
included with the Merlin system. The high and low pressure connections are gender-
alternated and different in connection shape. They are not interchangeable. One end of the
high pressure whip line connects to the equipment case and the other connects to the
cylinder valve.
#8. Handset and Hose Assembly: The Merlin ships with a standard 20’ long x 3/4” diameter
hose and high performance handset assembly. The handset comes pre-installed on the hose.
The system connection end of the hose is equipped with a quick-connect coupling to make
connection to the discharge port quick and easy. The tip of the handset incorporates a quick-
connect coupling for multiple available nozzles.
The discharge hose has a high degree of chemical compatibility. The discharge hose is rated
for up to 300 psi (20.7 bar) of pressure. The hose also has a flame resistant outer jacket.
Owners/operators should adhere to the guidelines set forth in NFPA 1962 “Standard for the
Inspection, Care and Use of Fire Hose, Couplings, Nozzles and the Service Testing of Fire
Hose”. 8.1 High performance handset Configuration -
Standard): The high performance handset ships
standard with the Merlin, and is connected to the 20’
hose with a stainless steel quick-connect fitting. Once
the unit is filled with foam solution and the air cylinder
is secured in place and opened, all that is required to
operate the system is to safely aim the handset and
open the valve by turning clockwise to stop. This
handset requires two hands to operate. One hand firmly grasps the pistol grip handle at the
base of the valve, while the other hand rotates the valve handle counterclockwise (forward) to
turn on and clockwise (upward) to turn off. The system will dispense foam as long as the
valve is open, and will cease when the valve is closed, or when components are exhausted.
8.2 Trigger Handset (Optional): The trigger
handset is a rapid-action valve that is operable by
one hand. It consists of a handset trigger valve that
is operated by squeezing the trigger with the index
finger. This handset trigger has a locking tab
(dependent upon order specifications) that allows the
user to lock the handset in the open position by
pressing the top portion of the trigger. To disengage the lock, squeeze in and down on the
top section of the trigger, allowing the lock tab to release. Use of this handset with the Merlin
will result in reduced throw distance, but is recommended for use with decontaminent
solutions such as EasyDECON DF200. Call Intelagard or your local distributor for more
information.
The handset hose attaches to the discharge port on the Merlin with a stainless steel quick-
connect fitting. When not in use, the hose should be stored by coiling it around the metal
hose bracket located on the front of the fluid tanks.
NEVER pull the Merlin using the hose!
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