OGS Merlin 1000V Owner's manual

Installation & Operation Manual Merlin 1000V
Rev: 02 05-22 1
Merlin 1000V
Gas Isolation Controller with Ventilation Interlocking

Installation, Operation & Maintenance
Please read this manual carefully and retain for future use.
For specific requirements that may deviate from the information in this guide –contact your supplier.
Oceania Gas Safety
www.oceaniagassafety.com

Installation & Operation Manual Merlin 1000V
Rev: 02 05-22 2
Contents
Important Warning Statements ................................................................3
Installation.................................................................................................4
Typical Application & Location..................................................................................4
Mounting & Cabling...................................................................................................4
Circuit Board Overview .............................................................................................5
Wiring: Power Input ...................................................................................................5
Wiring: Gas Solenoid Valve .......................................................................................5
BMS Output...............................................................................................................6
Pressure Sensor........................................................................................................6
EM Remote................................................................................................................6
Gas Detector / CO2 Monitor .....................................................................................6
Fan Switches.............................................................................................................7
PD Switches / Current Monitors................................................................................7
12 VDC......................................................................................................................7
Switch Settings –Auto RST (Panel Auto Reset) .......................................................7
Switch Settings –Pressure (Gas Pressure Threshold Configuration).......................7
Switch Settings –EM SEL (Fan Switch Configuration) .............................................7
Switch Settings –Fill & Prove Time (Gas Proving Setting) .......................................8
Switch Settings –Time 1 & 2 (Automatic System Timeout Period) ..........................8
Fire Panel Integration ................................................................................................8
Operation ..................................................................................................9
Initial Power Up .........................................................................................................9
Emergency Shutoff Push Button ...............................................................................9
LED Indicators ...........................................................................................................9
Maintenance............................................................................................10
Cleaning ..................................................................................................................10
Specification ...........................................................................................11

Installation & Operation Manual Merlin 1000V
Rev: 02 05-22 3
Important Warning Statements
Warning Symbol!
Where this symbol is used, the manual must be consulted to understand the nature of any potential hazards and how to avoid
them.
Please take the time to thoroughly read this user’s guide which should be retained for future reference.
It is recommended that this device be commissioned upon installation.
Do not apply lighter gas or other aerosols to detectors –this will cause extreme damage to the gas sensing elements.
High concentrations of alcohol found in many products may damage, deteriorate, or affect the gas sensing elements of the
detectors –Avoid exposure near your devices.
Never ignore your devices when in alarm. Actuation of your alarm indicates the presence of an error or issue that requires
immediate attention.
This device requires a continual supply of electrical power –it will not work without power.
This device should not be used to substitute proper installation, use and/or maintenance of fuel burning appliances
including appropriate ventilation and exhaust systems.
Your product should reach you in perfect condition, if you suspect it is damaged, contact your supplier.
Manufacturer’s Warranty
Warranty coverage: The manufacturer warrants to the original consumer purchaser, that this product will be free of defects in
material and workmanship for a period of three (3) years from date of purchase.
The manufacturer’s liability hereunder is limited to replacement of the product with repaired product at the discretion of the
manufacturer. This warranty is void if the product has been damaged by accident, unreasonable use, neglect, tampering or other
causes not arising from defects in material or workmanship. This warranty extends to the original consumer purchaser of the
product only.
Warranty disclaimers: Any implied warranties arising out of this sale, including but not limited to the implied warranties of
description, merchantability and intended operational purpose, are limited in duration to the above warranty period. In no event
shall the manufacturer be liable for loss of use of this product or for any indirect, special, incidental, or consequential damages, or
costs, or expenses incurred by the consumer or any other user of this product, whether due to a breach of contract, negligence,
strict liability in tort or otherwise. The manufacturer shall have no liability for any personal injury, property damage or any special,
incidental, contingent or consequential damage of any kind resulting from gas leakage, fire, or explosion. This warranty does not
affect your statutory rights.
Warranty Performance: During the above warranty period, your product will be replaced with a comparable product if the
defective product is returned together with proof of purchase date. The replacement product will be in warranty for the remainder
of the original warranty period or for six months –whichever is the greatest.
Information on waste disposal for consumers of electrical & electronic equipment.
When this product has reached the end of its life it must be treated as Waste Electrical & Electronics Equipment (WEEE). Any WEEE
marked products must not be mixed with general household waste, but kept separate for the treatment, recovery and recycling of
the materials used. Please contact your supplier or local authority for details of recycling schemes in your area.
At the end of their working life, electrochemical sensors should be disposed of in an environmentally safe manner.
Alternatively, they can be securely packaged and returned to OGS clearly marked for disposal. Electrochemical sensors
should not be incinerated as this may cause the cell to emit toxic fumes.

Installation & Operation Manual Merlin 1000V
Rev: 02 05-22 4
Installation
Typical Application & Location
Installation must be carried out by a licenced, insured contractor!
Ensure that detectors are not exposed to liquid or dust contamination!
Cables must be protected against mechanical damage!
Please refer to your detector manual for important information regarding coverage, location and positioning including
areas and conditions to avoid.
The Merlin 1000V gas pressure proving system designed specifically for use in educational buildings
and Laboratories with ventilation interlocking between the ventilation system and the gas solenoid valve.
The system is compatible with both current monitors and air pressure differential switches to interlock
with up to two fans.
This panel is to be used to carry out a gas proving test on the pipe work to highlight if there is a gas
appliance open or a gas leak in the laboratory. The Merlin 1000V is designed to give the teacher full
control over the incoming gas supply with the lockable main key-switch.
The Merlin 1000V can work in conjunction with carbon dioxide, natural gas, carbon monoxide and
LPG sensors. The Merlin 1000V also has a built in “timeout” facility which will automatically shut off
the gas solenoid valve at the end of a specific time, this time can be adjusted to 2, 5, 8 hours or can be
overridden if required.
Mounting & Cabling
If mounting direct to wall - ensure the wall surface is flat to prevent base distortion!
Ensure the rear base is installed in the correct orientation as shown!
Where cable glands/conduits are used for wire entry, use 20mm (3/4 inch) max separated by at least 20mm!
Any parts that form part of the connections/installation must have a minimum fire-retardant rating of UL94v-2!
Damage to PCBs when creating cable entry points or attempting to remove the circuit board may void any warranty!
Restrain the hazardous live wiring from accidental loosening to prevent wires from moving after installation and touching
parts of opposite polarity or at low voltages!
Isolate the equipment from all hazardous live power sources before opening the cover!
1. Carefully remove the front cover from the unit by unscrewing the four bolts located at each corner. To
do this –use the socket wrench provided.
2. Remove the keys and spare parts - keep safe.
3. Mark the four screw holes located on the back of the enclosure to the wall. Ensure the wall surface is flat
to prevent base distortion. Drill out as necessary ensuring all swarf is removed from the box and holes
have smooth edges.
4. After executing the mounting and the connections –replace the front cover and insert the security caps
over the four bolts.

Installation & Operation Manual Merlin 1000V
Rev: 02 05-22 5
Circuit Board Overview
Damage to PCBs when creating cable entry points may void any warranty!
Any damage attempting to remove the circuit board may void any warranty!
Wiring: Power Input
100-240V~ Mains Power should be supplied to the [POWER / LINE IN] terminal and fused at 3A.
On connecting the mains supply to the panel, the red power LED indicator will light up –this is located
on the front cover (OGS Logo).
Wiring: Gas Solenoid Valve
Pressure sensors should be screwed to the downstream port of the valve.
100-240VAC electrical power supplied from the [VALVE OUT] connector using a 3-core cable can be
connected to a gas solenoid valve which can shut the gas supply on alarm status.
Refer to your valve manual for more information and wiring!

Installation & Operation Manual Merlin 1000V
Rev: 02 05-22 6
BMS Output
Connections are available on the board for Building Management Systems.
[NO Normally Open] [COM Common] [NC Normally Closed]
These are volt free connections.
This is a relay that changes state when the gas is on/off and can be used in conjunction with the 12V DC
output and other external relays that affect other devices and controls such as purge fans and audible
alarms etc.
Pressure Sensor
Pressure sensors should be screwed to the downstream port of the valve.
Pressure Sensors are tested and certified to AS 4628/2005.
The pressure sensor is wired to the [PRESSURE SENSOR] connector and screwed into the downstream
port of the gas solenoid valve.
Connect the pressure sensor as shown:
The sensor will monitor the gas supply pressure and if pressure drops below 0.5 or 1.2Kpa –
the gas valve will close.
See section; Switch Settings - for Pressure options
EM Remote
Connections for remote emergency shut-off or stop buttons is detailed on the circuit board as [EM
REMOTE]. This is linked out as a factory setting.
Gas Detector / CO2 Monitor
Refer to your gas detector and CO2 monitor manual for further information!
CO2 Monitors are powered via an external supply!
If no detector is being used leave the factory fitted link in.
A wiring example for a gas detector is shown.
Refer to your gas detector manual for further information.
CO2Monitor.
To connect a CO2 monitor and gas detector –wire in series and power the CO2
monitor via external mains power supply.

Installation & Operation Manual Merlin 1000V
Rev: 02 05-22 7
Fan Switches
This terminal, switches when the key is turned on and off.
This can be connected to a fan switch (supplied separately) which can provide power to fans when the
control panel is switched on.
PD Switches / Current Monitors
This terminal is used to receive an input signal from external air pressure switches or current monitors.
This terminal is linked out as a factory setting. Wiring to external air pressure switches or current
monitors should made using a two-core cable. This is a volt free connection.
12 VDC
This is a power output for external auxiliary devices when there is power at the panel and can be used to
create a relay switch with the BMS relay output. Max output: 50mA
Switch Settings –Auto RST (Panel Auto Reset)
There are various dipswitches on the front circuit board that can be adjusted to configure your system as
per the following. There is a switch located on the circuit board labelled [AUTO RST].
OFF
When power is restored after the power cut/ loss, the panel must be restarted manually. (Default)
ON
This will instruct the system to restart automatically when power is restored after power cut/loss.
Switch Settings –Pressure (Gas Pressure Threshold Configuration)
There is a dipswitch located on the circuit board labelled [Pressure].
The gas supply will be turned off if pressure will drop below threshold value continuously for 10 secs.
OFF
Low pressure threshold is set to 12 mbar. (Default)
ON
Low pressure threshold is set to 5 mbar.
Switch Settings –EM SEL (Fan Switch Configuration)
This option is not available if a fan switch is not installed!
A fan switch (Merlin FS1 or FS2 - sold separately) provides the facility to turn on fan(s) when the 1000V
panel is switched on and removes power to fan(s) when the switched off.
OFF
Instructs the system to shut down fan(s) and gas upon activation of emergency shut off button(s). (Default)
ON
Instructs the system to leave the fans on and shut off the gas supply only upon activation of emergency shut
off button(s).

Installation & Operation Manual Merlin 1000V
Rev: 02 05-22 8
Switch Settings –Fill & Prove Time (Gas Proving Setting)
Once the settings have been changed - remove power for 10 seconds.
FILL TIME: Amount of time the gas valve opens to fill the gas line on power up or reset.
PROVE TIME: Amount of time the system tests the gas line for leaks on power up or reset.
FILL TIME
PROVE TIME
OFF
5 Seconds (Default)
OFF
30 Seconds (Default)
ON
10 Seconds
ON
50 Seconds
Switch Settings –Time 1 & 2 (Automatic System Timeout Period)
Upon timeout the gas supply will be turned off.
There are two dipswitches [Time 1 & Time 2].
The system has an auto-shut down feature after a selected time. These can be configured to select the
required timeout/ shut-down period.
TIME 1
TIME 2
Timeout Period
OFF
OFF
2 Hours (Default)
ON
OFF
4 Hours
OFF
ON
8 Hours
ON
ON
Disabled
Fire Panel Integration
The Merlin 1000V can be integrated with a fire alarm to close the gas supply automatically in the event of
a fire. The volt free fire alarm signal can be wired in series with any remote emergency shut off buttons.
If there are no remote emergency shut off buttons being installed, wire this directly to the terminal
marked [EM REMOTE].

Installation & Operation Manual Merlin 1000V
Rev: 02 05-22 9
Operation
Initial Power Up
On connecting mains power, an LED on the front of the panel (OGS Logo) will illuminate red.
1. Turn the key switch to on position.
2. Testing LED will illuminate whilst the system checks for gas line.
3. Gas-On LED should illuminate if gas proving is successful.
Turn the key switch to the off position to turn the panel off.
Emergency Shutoff Push Button
The emergency shut off button is located on the front of the panel. There is also a facility for remote shut
off buttons to be wired in series on the circuit board. The emergency shut off button(s) will cut off the
gas supply when activated. To reinstate the system, the emergency shut off button(s) will need to be
reset and the panel restarted.
LED Indicators
•Gas On
When the key switch is turned on, the system will check the installation for gas leaks.
If gas proving is successful, the LED will illuminate. ON = Gas On / OFF = Gas Off
•Testing
This LED will illuminate GREEN for approximately 30 seconds when the panel is checking the integrity of
the gas installation upon start up. ON = proving the gas line, do NOT operate any appliances.
•Test Fail
Under normal working conditions this LED is off. When the panel detects a gas leak on start-up, the LED
will illuminate AMBER. Gas valve will remain closed. OFF = OK / ON = gas proving failed.
•Pressure Low
Under normal working conditions the LED is off. The LED will illuminate AMBER when pressure of the
gas supply drops below 1.2kPa for 10 secs. The gas valve will close. OFF = OK / ON = gas supply pressure low.
•Timeout
Under normal working conditions this LED is off. This LED will illuminate AMBER when auto-shut down
has occurred. OFF = OK / ON = Auto-shut down activated
•EM Stop
If an emergency shut off button (either remote or on the panel) is pressed, the LED will illuminate
AMBER and the gas will be turned off. The emergency shutoff button must be reset before restarting the
system. OFF = OK / ON = Emergency Shut-Off button activated.
•CO2/ Gas Detected
Under normal working conditions this LED is off. If the external Merlin detector connected detects gas
this will show RED, and the gas valve will turn off. OFF = OK / ON = Gas detected.
•Fan Fault
Under normal working conditions this LED is off. If a fan fault is identified for longer than 10 seconds the
LED will show RED, and the Gas valve will turn off. Fan fault will only identify when the gas is on only.
OFF = OK / ON = Gas supply has been shut off due to a ventilation fault.

Installation & Operation Manual Merlin 1000V
Rev: 02 05-22 10
Maintenance
Cleaning
Concentrations of alcohol found in many products may damage, deteriorate, or affect the gas sensing elements such as
wine; deodorants; stain removers and thinners. Other gases and substances to avoid are corrosives (i.e., chlorine &
hydrogen chloride); alkali metals; basic or acidic compounds; silicones; tetraethyl lead; halogens and halogenated
compounds!
Keep your panel in good working order - follow these basic principles.
•Remove any dust/debris from the outer enclosure regularly using a slightly damp cloth.
•Never use detergents or solvents to clean your device.
•Never spray air fresheners, hair spray, paint or other aerosols near the device.
•Never paint the device. Paint will seal vents and interfere with the device.

Installation & Operation Manual Merlin 1000V
Rev: 02 05-22 11
Specification
General
Model:
1000V
Size: (H x W x D)
7.08 x 10.03 x 3” (180 x 255 x 77 mm)
Housing Material:
ABS Polylac - PA765. UL 94 V-1
Mounting:
Indoor use - Wall Mounting
User Interface
Visual Indicators:
LED
Audible Alarm:
>70dB @ 3.28ft (1m). Quiet conditions.
Language:
English
Power Supply
Power Rating:
48W max.
Voltage Rating:
100-240V~ 50-60Hz
Internal Fuse:
T3.15A L250V
Equipment
Overvoltage Category:
II
Pollution Degree:
2
Equipment Class:
2
Environmental
Ingress Protection:
Not Formally Evaluated
Operating:
-10 ~ 50°C / 14 ~ 122°F 30 ~ 80% RH (non-condensing)
Storage:
-25 ~ 50°C / -13~122F° up to 95% RH (non-condensing)
Altitude Rating:
2000m
Wiring
Typical
Power~#18-12AWG-Tinned Copper. Current Rating: 1A Minimum
Relay: ~#18-12AWG-Tinned Copper. Current Rating: 10A Minimum
For field connections use wires suitable for at least 90°C (194°F)
Detector: #15AWG Power Pair
Other: #18-14AWG-Tinned Copper.
Approvals
Electromagnetic Compatibility and
Electrical Safety (CE / UKCA)
IEC 61010-1:2010
EMC EN 61326-1:2013
Pressure Sensor
AS 4628/2005

Installation & Operation Manual Merlin 1000V
Rev: 02 05-22 12
Installation Details
Please pass this manual to the system owner / user.
Date of Installation:
Installation Location:
Organisation:
Stamp/Signature of the installer:
We recommend all OGS gas detection equipment be commissioned by competent/trained engineers to ensure correct installation
and operation. The Merlin range of gas detectors are calibrated when manufactured, however, we strongly recommend the
detectors response and alarm signals are tested and validated once installed. This will ensure the equipment performs as intended
and is free from any unforeseen damage caused by transit/installation.
Every effort is made to ensure the accuracy of this document; however, OGS can assume no responsibility for any errors
or omissions in this document or their consequences. OGS would greatly appreciate being informed of any errors or
omissions that may be found in the content of this document. For information not covered in this document, or if there is a
requirement to send comments/corrections, please contact OGS using the contact details.
www.oceaniagassafety.com
Oceania Gas Safety
Tuakau Waikato
New Zealand
[phone]
Oceania Gas Safety is the owner of this document and reserves all rights of modification without prior notice.