Seite 1 Thermo Scientific Merlin LR Recirculating Chiller Thermo Scientific Manual P/N U01230 Rev. 08/01/2016 Multilingual Quick Starts Multilingual Essential Safety Instructions Installation Operation Maintenance Troubleshooting Visit our Web site at: http://www.thermoscientific.com/tc Product Service Information, Applications Notes, SDS Forms, e-mail. Voice Info: (800) 258-0830...
Seite 3: Quick Starts
Thermo Scientific Merlin LR Recirculating Chiller Thermo Scientific Manual P/N U01230 Rev. 08/01/2016 Multilingual Quick Starts Multilingual Essential Safety Instructions Installation Operation Maintenance Troubleshooting Visit our Web site at: http://www.thermoscientific.com/tc Product Service Information, Applications Notes, SDS Forms, e-mail. Voice Info: (800) 258-0830...
Seite 4 Thermo Fisher Scientific 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 (603) 436-9444 Sales: 8:00 am to 5:00 pm Fax : (603) 436-8411 Service and Support: 8:00 am to 6:00 pm Monday www.thermoscientific.com/tc through Friday (Eastern Time)
Seite 5: Inhaltsverzeichnis
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 Merlin LR Series i Thermo Scientific...
Seite 6 Decommissioning/Disposal ................36 Shipment Storage ....................36 Chapter 5 Troubleshooting....................37 Checklist ......................37 Service Assistance ....................39 Appendix A Water Quality Standards and Recommendations ........41 Appendix B NC Serial Communications Protocol ............47 Declaration of Conformity Warranty Merlin LR Series Thermo Scientific...
Seite 7: Preface
Thermo Fisher Scientific has contracted with one or more recycling/ disposal companies in each EU Member State, dispose of or recycle this product through them. Further information on Thermo Fisher Scientific’s compliance with these Directives is available at: www.thermoscientific.com/WEEERoHS Merlin LR Series Thermo Scientific...
Seite 8: After-Sale Support
Warranty Thermo Scientific Merlin chillers have a warranty against defective parts and workmanship for 24 months (12 months for positive displacement pumps) from date of shipment. See back page for more details.
Seite 9: Unpacking
Box Failure must be packed and shipped back in the original packaging to Thermo Fisher Scientific for replacement with a new chiller; Seller to pay the cost of shipping. Customer must receive a Return Material Authorization (RMA) from Thermo Fisher prior to shipping the chiller. Merlin LR Series Thermo Scientific...
Seite 10: Safety Warnings
Fisher before subjecting this chiller to prolonged exposure to highly distilled or deionized water.  Do not use automotive antifreeze. Commercial antifreeze contains silicates that can damage the pump seals. Use of automotive antifreeze voids the manufacturer’s warranty.  Merlin LR Series Thermo Scientific...
Seite 11 Always turn off the chiller and disconnect the power cord from the power source before performing any service or maintenance procedures, or before moving the chiller.  Never operate equipment with damaged power cords.  Refer service and repairs to a qualified technician.  Merlin LR Series Thermo Scientific...
Seite 60 Plumbing Return Connection. See page 10. Connector. See page 22. External Tempera- Plumbing Supply Connection. See page 10. ture Sensor. See page 23. PD Pump Pressure Relief Valve. See page 29. Drain. See page viii Merlin LR Series Thermo Scientific...
Seite 61: Quick Reference Operating Procedures
. To turn the chiller 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 set point, the LED flashes. Merlin LR Series Thermo Scientific...
Seite 62: Temperature Adjustment
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 chiller. Merlin LR Series Thermo Scientific...
Seite 63 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. Merlin LR Series Thermo Scientific...
Seite 64: Wartung
Überprüfung des Filters. So können Sie nach einiger Zeit abschätzen, wie oft der Filter gereinigt werden maß. Bevor Sie den Filter reinigen, ziehen Sie den Netzstecker und entleeren Sie das Gerät. Merlin LR Series Thermo Scientific...
Seite 65: Mise En Route
Pour mettre en route, a puy er 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. Merlin LR Series xiii Thermo Scientific...
Seite 66: Réglage De La Température
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 du dit filtre. Avant de nettoyer ce filtre déconnecter l’appareil et vidanger. Merlin LR Series Thermo Scientific...
Seite 67 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. Merlin LR Series Thermo Scientific...
Seite 68 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. Merlin LR Series Thermo Scientific...
Seite 69: Messa In Servizio
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. Merlin LR Series xvii Thermo Scientific...
Seite 70: Impostazione Della Temperatura
“ 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”. xviii Merlin LR Series Thermo Scientific...
Seite 71 LED geeft de status van het koelsysteem aan. De LED gaat aan als het apparaat warmte on trekt aan de koelvloeistof. Op het moment dat de ingestelde temperatuur wordt bereikt zal de LED gaan knipperen. Merlin LR Series Thermo Scientific...
Seite 72: Temperatuurinstelling
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. Merlin LR Series Thermo Scientific...
Seite 73: Instalace
. K vypnutí jednotky opět stisknete LED kontrolka indikuje stav chladicího systému. Pokud svítí, signalizuje ze chladicí systém momentálně běží a odvádí teplo cirkulační kapalině. Pokud se teplota cirkulační kapaliny přiblíží požadované operací teplotě, kontrolka začne blikat. Merlin LR Series Thermo Scientific...
Seite 74: Pravidelná Údržba
čistěni filtru se doporučuje v mesicnich intervalech. Po několika mesicich se na zaklade zkušenosti stanoví vhodný interval kontroly čistoty filtru. Před cistenim odpojte povodni kabel od zdroje elektrické energie a vypusťte z jednotky cirkulační kapalinu. xxii Merlin LR Series Thermo Scientific...
Seite 75 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. Merlin LR Series xxiii Thermo Scientific...
Seite 76: Periodisk Vedlikehold
Kjøle re med PD/T1 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 sirkulasjon systemet. xxiv Merlin LR Series Thermo Scientific...
Seite 77: Chapter 1 Description
Description Chapter 1 The Thermo Scientific Merlin LR Recirculating Chiller is designed to provide a continuous supply of cooling fluid at a constant temperature and flow rate. The chiller consists of an air-cooled refrigeration system, plate heat exchanger, recirculating pump, polyethylene reservoir, and a microprocessor controller.
Seite 78: Specifications
Setup/Tuning Loop, see page 18. 3. Circulating at 20°C ambient, pump unloaded. Cooling capacity will vary depending on fluid temperature, ambient temperature, and cooling fluid. 4. Chillers with PD pumps. Chillers with CP55 pumps weigh 310 pounds (141 kilograms). Merlin LR Series Thermo Scientific...
Seite 79 M 75 (230V/50Hz) None M 150 (230V/ 60Hz) CP55 M 150 (230V 50Hz) None M 150 (400V 50Hz) CP55 None NOTE PD pumps should not be used with applications that are sensitive to high pressures.  Thermo Scientific Merlin LR Series...
Seite 80 D=PD2, 50Hz Flow A=CP55, 60Hz B=CP55, 50Hz 10 12 14 16 18 20 15 23 30 38 45 53 60 68 76 Flow MD30, 60 Hz The MD30 is not available for 50 Hz chillers. Flow Merlin LR Series Thermo Scientific...
Seite 81 10. Dimension L is the distance from the chiller's side to the center of the power connection. NA for M-150 chillers rated 400V/50Hz. 11. Crate dimensions for chillers with CP-55 pumps are 6 inches higher. All packages tested to ISTA 2B. Thermo Scientific Merlin LR Series...
Seite 82 Chapter 1 Merlin LR Series Thermo Scientific...
Seite 83: Chapter 2 Installation And Operation
Direction of Airflow Excessively dusty areas should be avoided and a periodic cleaning schedule should be instituted (see Chapter 4, Maintenance). Optional air filters are available, contact our Service Department. See Preface, After-Sale Support. Thermo Scientific Merlin LR Series 7...
Seite 84: Electrical Requirements
NOTE Three-phase chillers are not supplied with a line cord. Instructions for wiring three-phase chillers are located behind the power box cover. To access the power box remove the chiller's top and left-side panel. Remove the screws securing the cover.  8 Merlin LR Series Thermo Scientific...
Seite 85 NOTE Three-phase chillers are not supplied with a line cord. Instructions for wiring three-phase chillers are located behind the power box cover. To access the power box remove the chiller's top and left-side panel. Remove the screws securing the cover.  Merlin LR Series 9 Thermo Scientific...
Seite 86: Plumbing Requirements
All chillers have a ball-valve reservoir drain located on the rear. Add the desired length of tubing to the drain valve. To help prevent any spillage from your application, consider installing external isolation valves on the supply and return lines. 10 Merlin LR Series Thermo Scientific...
Seite 87: Approved Fluids
Also, inhibitors increase fluid conductivity.  When using the Merlin LR chiller to circulate through aluminum, use a compatible corrosion inhibitor to prevent galvanic corrosion. Fluid viscosity should be 50 cSt or less at the lowest temperature used.
Seite 88: 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°. 12 Merlin LR Series Thermo Scientific...
Seite 89: 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 flashes. The indicator is off when heat is not being removed. Merlin LR Series 13 Thermo Scientific...
Seite 90 Save any change using . After pressing an arrow key, if is not pressed within 60 seconds the display returns to the recirculating temperature display and ignores any change.  14 Merlin LR Series Thermo Scientific...
Seite 91: Start Up/Shut Down
2°C of either temperature alarm setting discussed on the next page. Trying to use a set point within 2°C causes the appropriate indicator to flash and sounds the audible alarm twice.  Merlin LR Series 15 Thermo Scientific...
Seite 92: Temp Alarms
 NOTE Enabling serial communications disables the remote start/stop feature. In either mode, the set point and alarm values can not be changed using the controller but they can still be viewed.  16 Merlin LR Series Thermo Scientific...
Seite 93: External Sensor
The circuit protector located on the rear of the chiller is not intended to be used as a disconnecting means.  Always turn the chiller off and disconnect it from its supply voltage before moving it.  Merlin LR Series 17 Thermo Scientific...
Seite 94: Setup/Tuning Loop
Changes made in the Tuning/Setup Loop take affect when is pressed at prompt. Pressing at the prompt aborts all changes. 18 Merlin LR Series Thermo Scientific...
Seite 95 Chapter 2 HOLD XX.X Indicates Optional Dis- plays To select rtd2 ensure remote probe is properly connected to rear of chiller. Accept All Changes Merlin LR Series 19 Thermo Scientific...
Seite 96 Chapter 2 20 Merlin LR Series Thermo Scientific...
Seite 97: Chapter 3 Options
RS-232 COMM No connection No connection GND = Signal ground 6 -9 No connection TX = Transmitted data from controller RX = Received data to controller. Hardware Mating Connector AMP Part# 745492-2 or equivalent Merlin LR Series 21 Thermo Scientific...
Seite 98: Remote Start/Stop
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. 22 Merlin LR Series Thermo Scientific...
Seite 99: 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 Fisher.  Merlin LR Series 23 Thermo Scientific...
Seite 100: 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. 24 Merlin LR Series Thermo Scientific...
Seite 101: Chapter 4 Maintenance
- Interrupt errors during runtime. BOM invalid. Functional/ Machine errors These errors clear themselves once the problem disappears. Display Low temp set point warning/fault. Low level warning, fluid below minimum fill level, see page 12. High temp set point warning/fault. Shorted external temperature sensor (rdt2). Open exernal temperature sensor (rdt2). Merlin LR Series Thermo Scientific...
Seite 102: Displaying Software Version Number
The display shows the remaining digits to the left of the decimal, for example: 4. Press The display shows the decimal point and the digit to the right of the decimal point, for example, . 5. Press The display shows 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. Merlin LR Series Thermo Scientific...
Seite 103: Controller Pid Values
After initial installation we recommend a monthly visual inspection of the condenser. After several months, the cleaning frequency will be established. Use care cleaning the condenser fins, they can be easily bent.  Thermo Scientific Merlin LR Series...
Seite 104: Power Cable Mating Ends
Reverse any two line conductors on the line side of the main circuit breaker. Never remove the green ground wire.  Reconnect the chiller to its power source. If it will not start, contact our Service Department. Merlin LR Series Thermo Scientific...
Seite 105: Pd Pressure Relief Valve
NOTE The valve may drip if the threaded stem is backed out too far.  NOTE If the chiller starts to vibrate the valve setting may be the cause. Changing the pressure setting ±5 psi will eliminate the vibration.  Thermo Scientific Merlin LR Series...
Seite 106: Pump Strainer
Brass Cap Brass Cap (some ¾" chillers (some ¾" chillers only) only) Screen Screen Fitting Fitting " or ¾" " or ¾" 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.  Merlin LR Series Thermo Scientific...
Seite 107: Bom Decoder
99 = T1 263 = M33 16 = 230/60 2 = RS232 & Rmt Start 264 = M75 25 = 230/50 4 = LL/LF, RS232 & Rmt 266 = M150 26 = 400/50 5-wire Start Thermo Scientific Merlin LR Series...
Seite 108: Temperature Sensor Calibration
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.  Merlin LR Series Thermo Scientific...
Seite 109 Chapter 4 rtd1 = internal sensor rtd2 = optional external sen- sor, see next page Thermo Scientific Merlin LR Series...
Seite 110 Enter the Calibration Loop by pressing and holding and then pressing the three times. The display reads CAL. Press and the display reads rtd1, then press and the display reads rtd2. To calibrate the high-end temperature press and the display reads r2H. Press again and the display flashes between r2H and the current probe temperature. rtd1 = internal sensor, see previous page rtd2 = external sensor Merlin LR Series Thermo Scientific...
Seite 111 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 Merlin LR Series...
Seite 112: Decommissioning/Disposal
-25°C to 60°C (with packaging), and <80% relative humidity.  If the chiller is stored for more than 90 days it must be flushed with clean fluid before operating.  Merlin LR Series Thermo Scientific...
Seite 113: Chapter 5 Troubleshooting
10 seconds, the controller will power. Turn serial communications off using the procedure on page 16, and then press to turn off the controller. Press again to start the chiller. Merlin LR Series 37 Thermo Scientific...
Seite 114 Make sure the air intake and discharge are not impeded and the ambient temperature does not exceed +35°C. d. 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. Merlin LR Series Thermo Scientific...
Seite 115: Service Assistance
Service Department for assistance (see Preface, After-sale Support). Before calling, please obtain the following information: chiller BOM number  chiller serial number  chiller software version (page 26)  voltage of power source  Merlin LR Series 39 Thermo Scientific...
Seite 116 Chapter 5 Merlin LR Series Thermo Scientific...
Seite 117: 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. Merlin LR Series 41 Thermo Scientific...
Seite 118 Not Recommended, Increasingly Corrosive 15.00 10.00 Operations with Stainless Steel Systems 3.00 Operations with 1.00 Mixed Metals CONSULT MATERIALS ENGINEER Copper/Brass/ 0.10 Stainless Steel 0.05 °C Water Quality Considerations Merlin LR Series 42 Thermo Scientific...
Seite 119 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. Merlin LR Series 43 Thermo Scientific...
Seite 120 50/50 Inhibited Propylene/ Water (-15°C to +35°C) Same issues as with uninhibited propylene and inhibited ethylene glycol. Deionized water 1-3 MΩcm, compensated (+5°C to +35°C) Deionized water has had the conductive ions that cause galvanic corrosion between dissimilar metals removed. Merlin LR Series 44 Thermo Scientific...
Seite 121 Ball Valve: Viton Chrome plated brass body and ball PTFE Sealants: 95/5 solder Bcup 5 brazing Anaerobic Mythacrylate Ester Low Level/Low Flow Switches (Optiona1): Polysulphone Low Level Brass Low Flow Continued on next page Merlin LR Series 45 Thermo Scientific...
Seite 122 Appendix A Tank Fittings: Brass Strainer Bronze 304 Stainless Steel Mesh Tank Cap: Nylon Merlin LR Series 46 Thermo Scientific...
Seite 123: Appendix Bnc Serial Communications Protocol
Communication cables are available from Thermo Fisher. Contact our sales department for additional information. All commands must be entered in the exact format shown in the tables on the following pages. The tables show all commands available, their format Merlin LR Series 47 Thermo Scientific...
Seite 124 If the command is not understood or the checksums do not agree, the controller responds with an error command. Otherwise, the controller responds with the requested data. If the controller fails to respond within 1 second, resend the command. Merlin LR Series Thermo Scientific...
Seite 125 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 Merlin LR Series Thermo Scientific...
Seite 126 = 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 Merlin LR Series Thermo Scientific...
Seite 127 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). Merlin LR Series Thermo Scientific...
Seite 128 High or Low Temp Bypass Low Temp/Fixed Low Temp Fault b.1 = 1 Chiller Faulted* Low Flow Fault b.0 = 1 Chiller Running* Low Level 2 Fault t d2 is the detail of fault d1-b.1 * mutully exclusive Merlin LR Series Thermo Scientific...
Seite 130: Warranty
Thermo Fisher Scientific warrants for 24 months (excluding Positive Displacement pumps which are warranted for 12 months) from date of shipment the Thermo Scientific Merlin chiller according to the following terms. Any part of the chiller manufactured or supplied by Thermo Fisher Scientific and found in the reasonable judgment of Thermo Fisher to be defective in material or workmanship will be repaired at an authorized Thermo Fisher Repair Depot without charge for parts or labor.
Seite 132 Thermo Fisher Scientific 81 Wyman Street P.O. Box 9046 Waltham, Massachusetts 02454-9046 United States www.thermofisher.com...

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