Thermo Scientific Neslab Merlin M 25 Owner's manual

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Installation
Operation
Basic Maintenance
NESLAB MerlinNESLAB Merlin
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Recirculating ChillersRecirculating Chillers
Recirculating ChillersRecirculating Chillers
Recirculating Chillers
Thermo ScientificManual P/N U00753 Rev. 11/15/06

Thermo Fisher Scientific
Control Technologies
25 Nimble Hill Road
Newington, NH 03801
Tel : [phone] or
[phone]
Fax : [phone]
www.thermofisher.com/tc
Statement of Copyright
Copyright © 2006 Thermo Fisher Scientific. All rights reserved.
This manual is copyrighted by Thermo Fisher Scientific.
Users are forbidden to reproduce, republish, redistribute, or resell any materials from this
manual in either machine-readable form or any other form.
Control Technologies
Sales, Service, and Customer Support
25 Nimble Hill Road
Newington, NH 03801
Tel : [phone]:00 am to 5:00 pm
(Eastern Time), Monday through Friday.
Fax : [phone]
[email protected]
Dieselstrasse 4
D-76227 Karlsruhe, Germany
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Fax : [phone]
Hotline: [phone]
Building 6, No. 27
Xin Jinqiao Rd., Shanghai 201206
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Fax : [phone]
info. [email protected]

NESLAB Merlin Series i
ThermoScientific
Contents
Preface ...............................................................................................................................iii
Compliance ......................................................................................................... iii
WEEE/RoHS..................................................................................................... iii
After-sale support .............................................................................................. iv
Feedback .............................................................................................................. iv
Warranty .............................................................................................................. iv
Unpacking............................................................................................................. v
Safety Warnings .................................................................................................. vi
Quick Reference Operating Procedures ......................................................... ix
Chapter 1 Description .......................................................................................................... 1
Specifications ....................................................................................................... 2
Chapter 2 Installation and Operation................................................................................ 7
Site ......................................................................................................................... 7
Electrical Requirements...................................................................................... 8
Plumbing Requirements ................................................................................... 10
Fluids ................................................................................................................... 11
Filling Requirements ......................................................................................... 12
Reservoir Tank Isolation Valves/Open Tank Circulation .......................... 12
Controller ........................................................................................................... 13
Start Up/Shut Down ........................................................................................ 15
Setup/Tuning Loop.......................................................................................... 18
Chapter 3 Options ............................................................................................................... 21
Communication Connector............................................................................. 21
Remote Start/Stop............................................................................................ 22
External Temperature Sensor ......................................................................... 23
Reservoir Level Warning/Fault....................................................................... 24
Low Pump Flow Warning/Fault .................................................................... 24
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

ii NESLAB Merlin Series
Contents
ThermoScientific
PD Pressure Relief Valve ................................................................................ 29
Pump Strainer ................................................................................................... 30
PD Pump Motor Lubrication ........................................................................ 31
Storage ............................................................................................................... 32
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 iii
ThermoScientific
Preface
Listed to:
UL 61010-1 2nd Edition
CSA C22.2 #6101.1 2nd Edition
Products tested and found to be in compliance with the requirements
defined in the EMC standards defined by 89/336/EEC as well as Low
Voltage Directive (LVD) 73/23/EEC can be identified by the CE Mark
on the rear of the unit. The testing has demonstrated compliance with the
following directives:
zLVD, 73/23/EEC IEC/EN 61010-1
zEMC, 89/336/EEC IEC/EN 61326-1
For any additional information, refer to the Declaration of Conformity
that shipped with the unit.
Compliance
This product is required to comply with the European Union’s Waste
Electrical & Electronic Equipment (WEEE) Directive 2002/96/EC . It
is marked with the following symbol:
Thermo Fisher Scientific has contracted with one or more recycling/
disposal companies in each EU Member State, and this product should be
disposed of or recycled through them. 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
WEEE/RoHS

iv NESLAB Merlin Series
Preface
ThermoScientific
Thermo Fisher Scientific is committed to service both during and after the
sale. If you have questions concerning operation, contact our Sales
Department. If your unit fails to operate properly, or if you have questions
concerning spare parts or Service Contracts, contact our Service
Department.
Before calling, please obtain the following information:
zunit BOM number (see page 32)
zunit serial number
zunit software version ( see page 26)
zvoltage of power source
The unit’s BOM and serial number are located on the name plate label on
the rear of the unit.
We appreciate any feedback you can give us on this manual. Please e-mail
us at [email protected]. Be sure to include the manual
part number and the revision date listed on the front cover.
Units have a warranty against defective parts and workmanship for 24
months from date of shipment. See back page for more details.
After-sale Support
Feedback
Warranty
BOM#: XXXXXXXXXXXX
S/N: XXXXXXXXX
XXX VOLT XX HZ X PH X.X AMP
R134A X.XOZ HIGH XXX PSI LOW XXXPSIG

Preface
NESLAB Merlin Series v
ThermoScientific
Unpacking Retain all cartons and packing material until the unit is operated and found
to be in good condition. If the unit shows external or internal damage
contact the transportation company and file a damage claim. Under ICC
regulations, this is your responsibility.
Out of Box Failure
An Out of Box Failure is defined as any product that fails to operate in
conformance with sellers published specifications at initial power up. The
unit must be installed in accordance with manufacturer's recommended
operating conditions within 30 days of shipment from the seller.
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.

vi NESLAB Merlin Series
Preface
ThermoScientific
Warnings are posted throughout the manual. These warnings are
designated by an exclamation mark inside an equilateral triangle and text
highlighted in bold. Read and follow these important instructions. Failure
to observe these instructions can result in permanent damage to the unit,
significant property damage, or personal injury or death.
The lightning flash with arrow symbol, within an equilateral triangle, is
intended to alert the user to the presence of non-insulated "dangerous
voltage" within the unit's enclosure. The voltage may be of significant
enough magnitude to constitute a risk of electrical shock.
Make sure you read and understand all instructions and safety precautions
listed in this manual before installing or operating your unit. If you have
any questions concerning the operation of your unit or the information in
this manual, please contact our Sales Department (see After-sale Support).
Never place the unit in a location where excessive heat, moisture, or
corrosive materials are present. S
The unit construction provides protection against the risk of
electrical shock by grounding appropriate metal parts. The
protection may not function unless the power cord is connected to a
properly grounded outlet. It is the user's responsibility to assure a
proper ground connection is provided. S
Never connect the process fluid inlet or outlet fittings to your
building water supply or any water pressure source. S
On units with MD pumps never completely restrict flow to your
application. Dead-heading the pump will damage its coupling and
require pump replacement. S
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. S
Do not use automotive antifreeze. Commercial antifreeze contains
silicates that can damage the pump seals. Use of automotive
antifreeze will void the manufacturer’s warranty. S
Safety Warnings

Preface
NESLAB Merlin Series vii
ThermoScientific
In addition to the specific warnings listed on the previous page the
following general warnings also apply to your unit:
Performance of installation, operation, or maintenance procedures
other than those described in this manual may result in a hazardous
situation and may void the manufacturer's warranty. S
Transport the unit with care. Sudden jolts or drops can damage the
unit's components. S
If the unit is to be transported and/or stored it needs to be drained.
If the unit is to be transported and/or stored in cold temperatures it
needs to be drained and then flushed with a 50/50 glycol/water
mixture. S
The circuit protector located on the rear of the unit is not intended
to be used as a disconnecting means. S
Observe all warning labels. S
Never remove warning labels. S
Never operate damaged or leaking equipment. S
Never operate the unit without cooling fluid in the reservoir. S
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. S
Never operate equipment with damaged power cords. S
Refer service and repairs to a qualified technician. S

viii NESLAB Merlin Series
Preface
ThermoScientific
Reservoir. See page 12.
Reservoir Access Panel.
See pages 10 - 12.
PressureGauge.
See page 15.
Controller. See page 13.
Condenser Access Panel. See page 27.
Drain. See page 10.
Circuit Protector. See page 15. Optional
CommunicationsConnector.
See page 21.
Plumbing Return Connec-
tion. See page 10.
PD Pump Pressure Relief Valve. See page 29.
Optional
Remote Start/Stop
Connector. See page 22.
ExternalTemperature
Sensor. See page 23.
PlumbingSupply Connection.
See page 10.
Indicates refrigeration system
status. See page 13.
Indicates the controller is
displaying the setpoint. Press
the arrow keys to change the
value. See pages 13 - 14.
Indicates the controller is
displaying the unit's low
temperature alarm setting.
Press the arrow keys to change
the value. See pages 13 - 14.
Indicates the controller is
displaying the high temperature
alarm setting. Press the arrow
keys to change the value. See
pages 13 - 14.
Optional. Indicates the
unit is operating in the
serial communication
or remote start/stop
mode. See pages 13 - 14
and 16.
Press to change the
displayed value. See
page 13.
Press to start/stop the unit.
See page 13.
Press to mute the alarm. See page 13.
Press to sequence through the
four indicators and accept the
displayed value. See page 13.
NOTE: None of the four indica-
tors are visible unless this key is
pressed.
Optional. Flashes to indicate the
external sensor is enabled. See
page 23.