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Service/Parts Manual - D and S Vending Inc.

1. 810002 2 Bearing 2 916012 3 5 8 Keps N t 2 tel eie cc lae ccr e nettes 905016 4 Self Tapping 1 4 20 X 1 a u eme 901003 5 Carriage Bolt 1 4 20 X 11747 901008 6 Keps Nut 1 47 20 heat sages kin 905002 7 Flat Washers uama atit get tee 904002 8 Bottom Hinge 010040 9 Tops Hinge e am aa aS ae tede 010016 10 Door Roller Spacer once 010015 11 Door Roller Bracket iiit ene SEE NOTE 2 12 SEE NOTE 2 13 Door Roller Lat t Rete tb tis SEE NOTE 2 14 Retainer Ring 5 32 906005 15 e is usi eut eese dedic tede qi de eene ie SEE NOTE 1 16 Mor EEE EE SEE NOTE 1 17 T Handle Body 3 ie eet ed e RU SEE NOTE 2 18 fe SEE NOTE 2 19 T Handle St dio dni feeit ine SEE NOTE 2 20 SDF Su sss i de ER beatus aqha qasa s aka bea SEE NOTE 2 21 Retainer RING sities aia nieces eae asa SEE NOTE 2 22 EN ess 010028 23 Latch Strike Merlin IV oo u au asas qaa SEE NOTE 2 24 Square Nut 3 4 1 22 13 905005 25 Latch Strike Assemb
2. L X V S uA NV X gt E COIN MECH fe of DETAIL B 9 r I I F I LE LD 2A235 088 003RV DETAIL A r Gi bru JO 76 Merlin IV Service amp Parts Manual SECTION 7 EXPLODED VIEWS AND PART NUMBERS RVMC RVCD Center Door Changer Vault ITEM DESCRIPTION PART NUMBER 1 Changer Vault Brace dee epi paqakuna 161518 2 Cable Sleeve At Each End Of 906015 3 eae aa a eee E era Ea A ra oN RERNE 911032 4 Coin Chute Assembly CDC Wide Vender 161590 5 Button Lever Assembly Coin Return Lever CDC see detail A 161593 E NBorm D 141524 6 Coin Chute 79 57 ete anden 161527 stu ee ea dei to velie de ya es ES sm kam C is 162502 7 Changer Plug Bracket 010561 8 Panel tese e E cede boue d 010531 9 Control Board uusha qasiqa doe de erik 836134 10 Hopper Mounting
3. 231519 14 Goin CUP CD Grech he teak atero dte eitis 231505 15 Anti Theft Plate CDC 305501 16 Goin Hopper WP Lu nas mime ober etemei ua 303502 Coin Chute Bracket 79 CDC Not 161527 Water Block Coin Chute DP CDC Not Shown 161536 Merlin IV Service amp Parts Manual 89 SECTION 7 EXPLODED VIEWS AND PART NUMBERS Flat Horizontal Display Door Front 1 D A235 072 003RV 90 Merlin IV Service amp Parts Manual SECTION 7 EXPLODED VIEWS AND PART NUMBERS Flat Horizontal Display Door Front ITEM DESCRIPTION PART NUMBER 1 Door Welded Assembly Flat Display 72 278552 2 Right Vandal Panel 72 eene nennen nnns 011501 3 Coin Return Cup Welded Assembly 012 012595 4 Button Panel Flat Display 10 Select 278502 5 Rain Guard Wide Venders 2 010518 6 noniine eI REOR 902004 7 Left Vandal Panel 79 eee Rete 141002 Left Vandal Panel 72 kae cante eR 142001 8 T Sorew H8 32 Lider RE RU demand e 901001 9 TRIM Top Slde uenenum tee 032807 10 Sign Top Flat Display Cold Drink Graphics Black Graphics
4. 819028 7 Compressor Relay 1 3 H P Tecumseh Only 822042 8 Compressor Overload 1 3 H P Tecumseh Only 822010 9 Compressor Lead uu rette dte eek ttes See note 2 10 Grommets Compressor n 916015 11 Grommets Plugs eie e sn napu eea bales 815017 12 Clip e 914002 13 Thermostat edet 822001 14 SOLOW FOX 2 naaa sasa Qu t 902004 15 Evaporator Fan Shroud Assembly Airflow Wide 256035 Evaporator Fan Shroud Assembly Wide prior to 200422 256080 Evaporator Fan Shroud Assembly Airflow Narrow 264030 Evaporator Fan Shroud Assembly Narrow prior to 200422 258070 16 Evaporator Coll a eee 820002 17 Refrigeration System Merlin IV 1 3 256420 Evaporator itu pides ride needle ge pues lene npa de 256004 Condensor ShrOud u itte Lote reri ant tondere 095401 Note 2 This part is not available individually It must be ordered as an assembly Merlin IV Service amp Parts Manual 57 SECTION 7 EXPLODED VIEWS AND PART NUMBE
5. 1 pip ou ou 01 06 d ou ou LYVLS uo dwe Os ji 20 JOU er Ane foop p solo MOUS O O ale 502 dena ay Z i uodn _ 9401 9 p10991 Uy si Bunes dsp yey einsue Y90949 sek 6 9 100p uedo s K Buiuun eu si yun pip jun si Merlin IV Service amp Parts Manual 43 SECTION 6 TRAINING GUIDE Training Guide Troubleshooting Technique Objective Understand sequence of operation identify what vender is doing and compare to what it should be doing Find defective component confirm failed component repair replace component test to confirm fix Identify source path or load Distinguish between software and hardware Repairthe problem not the symptom Simple circuit Power supply source example control board Line path example display harness Device load example LED display Failure of any one results in service call Skill required is systematical logical process of elimination 1 Do I have power 2 the power get to where I want it 3 Does the device work Confirm through use of volt ohm meter Understand the impact of software on hardware Test to confirm repair Low voltage circuits are affected by harness connec tions in
6. NTE LIST 7 ASSY AVIL Toi dAVI 30 52 HJONYHOI ASSY 1SVTIV89 dAVT 8L Sha dOYG LLINN I _ASOWRESHL C 1gvmva 1 1 I SNAMOJ SNANTOO 2 NOH uvau E divi 1 Merlin IV Service amp Parts Manual 99 Printed in the United States of America Royal Vendors Publication ROYAL 833021 Rev 01 9 2005
7. Bumes eseud eu i i Suid 40840 Y8UD eseud eu eseud ou sek 0 ol 01 06 fep Powod sifon dq pen eseud euy 18 OLE 8c vz 196 108 Ja 36622 sek har ye aoe dal 10 eseud rui 1094109 peog Hun pip sseureu redo 01 sak d ooejde1 1se1 eseud jeu 1pe uoosip 10 joslas eseud eu 0108 ou SU osn Mogg diua 0106 YU d 01 sek ssouey s doedar sak Jojouruej HO yun uonoeuuoo Bnjdun gun ANG sak SI ofenunude re 108 109 eseud jeu avjda ou jun 908199 gu pue uels Sjno 10 sseuJeu mE oul 0 06 sak S8JIM OM jun pip Josuas due oeuo lt kejas gpuno s y JO euo ssousey amp 0 LE i ou eseud Buum ne seh pen HOUS 10 400 jepno iefenose 01 1 eu si eseud sak yun ufkous dwd sbunas 01 ob y se 049 pue 100 iem kejas Buluuni 2 16 saum 1 S101419 p1099J 40849 m Ue de e aseud jeu one1eDujer ous nb 2 eui jo Joop uedo
8. nakuna ber ete e lea he EA 16 3 Vender Programming U 19 The Necessity Of Correct Programming nn nn 19 Precautions To Take When Working With The Control Board n 19 Introduction To Programming ss sc u eee ner i e e ee EE ERES de FRE ERR Nee da 19 Menu Levels assist us RR PE HR e Pete eere e ee E Are 20 INTERNAL Service MENU ri e e eere Ee EE RE TERR E NE Te EE PERSE HE IRR ER RC Qe ERE 21 CASH cash counter Mode eee edere e i i eee ae RE e egeo ERE E RR VERS 21 SALE sale counter Mode edet RE HE eii RE 21 CArd card counter neon ee RE e e ROS e Pe CER GRE nee Ie EE REPRE RS 21 toKn token counter aa aaa snn GR RE ER EUR RESP ER e E etes 21 FrEE free vend accounting Mode sunset Ne SAR 22 Eror erfors Mod uns eerte tote Sama IRI A I Een eat RI WEE 22 tESt columntest vend Mode se ed e ERREUR anten 22 PriG selectiotprice MOde Z u tete sere 22 Stos space to sales Mode eerte Ee ec RUE t Ee ERE de a RS e ee RETE AEG 23 SdEP set vending depth Mode re RR et RTI 24 Con configurations Modes asken ad 24 fin return to s les Mode sanan an usu aq EAE ENEN 25 OPTION
9. Figure 6 5 Select Switch Harness 46 Merlin IV Service amp Parts Manual Door Switch Options Harness See Figure 6 7 Supplies 5 VDC from position P9 to door switch pins I and 6 and to options harnesses free vend switch no vend switch etc Door switch 1 Updates door status to control board open closed 2 Depress switch check to see if LED resets 3 Check wires at switch for correct positions Options switches 1 Allow free vend no vend etc 2 5 VDC on pins 6 and pin for option switch see wiring diagram GREEN YELLOW GROUND BLACK 24 VDC WHITE BLUE COLUMN 12 WHITE BROWN COLUMN 11 WHITE ORANGE COLUMN 10 WHITE YELLOW COLUMN 9 WHITE RED COLUMN 8 WHITE GREEN COLUMN 7 BLUE COLUMN 6 BROWN COLUMN 5 ORANGE COLUMN 4 YELLOW COLUMN 3 RED COLUMN 2 WHITE NEUTRAL BLACK KEY PURPLE 5 VDC DOOR SWITCH Y BROWN O com Figure 6 7 Door Switch Options Harness SECTION 6 TRAINING GUIDE DEX UCS Harness See Figure 6 8 Environmental Control Refrigeration Harness See Located at positions P10 Internal and P11 External Figure 6 10 Computer access point Supplies 24 VDC to refrigeration relay from position Internal read write anytime standard item P14 pins 1 and 3 External read anytime can only write when door Check for 24 VDC in rela
10. 161515 11 Transformer Assembly MIV 842147 Merlin IV Harness Transformer and Fuse to 842210 Ese 942111 12 Select Panel Plate a ua 161512 13 Port Body Welded Assembly a 303510 14 Changer Vault Welded Assembly WP 303506 15 Port Brace Welded 010515 16 Lock Cylinder Cover see detail 161532 17 T Handle Brace see detail 141513 18 COIN CUP ODIO 231505 19 Coin Hopper WP te ete 303502 20 Coin Box Coin Chute WP 1 l u uuu 303501 21 Anti Theft Plate vector a ste 161504 Anti Theft Plate CDC 305501 Anti Theft Plate Non CDC 303503 22 Security Plate Welded sse 195510 23 Coin Box Welded Assembly sse 161570 Plastic Coin BOX mieten tete eite E pde tuse dep ecu e ERO poe 815347 Coin Insert Assembly 5 2 iit eee arvingen 195560 Changer Vault Door Not Shown Optional 161534 Board Cover CDC a u Can nte kennen na nione 195518 Coin Deflector ee 16
11. EE SEE NOTE 2 22 Square Nut 3 4x1 2 13 sescenti eene ertet nnne 905005 23 Nut REINET e 010028 24 kath Strike 55 s redatto ceno tedesca M sss DOR 242031 25 Self Tapping Screw 1 4 20x1 901003 T Handle Assembly Vision 4 812277 NOTE 1 There are various parts Please specify model and serial number at the time of order NOTE 2 This part is not available individually It must be ordered as an assembly Merlin IV Service amp Parts Manual 85 SECTION 7 EXPLODED VIEWS AND PART NUMBERS CI Rear amp Button Panel Assembly Dr Pepper Vision 4 1 D A235 067 003RV 86 Merlin IV Service amp Parts Manual SECTION 7 EXPLODED VIEWS AND PART NUMBERS CI Rear amp Button Panel Assembly Dr Pepper Vision 4 ITEM DESCRIPTION PART NUMBER 1 Security Plate Welded Assembly sssssee e 242520 2 EED WindOW 06 815121 3 NUE 8 32 bernette h 905001 4 LED Display Rhet nee emi 836012 5 Hex Jam Nut 9 16 18 UNF2A emen 905019 6 Button Coin Return Lever 803031 7 Cable Sleeve e DM NR 906015 8 3 04 Diameter eee tede be 911032 9 Coin Return Spring erret rtt trt qusa Pa 914023 10 Button Levers eis oso 161509 11 Goin Return Pirineo ee
12. 56 Airflow Vend Mechanism Assembly 200422X X00001 and 2 60 Vend Mechanism Assembly before 200422XX00001 nn ns 62 Miscellaneous Assemblies tee F 64 Door Assembly Front sura der 66 Door Assembly Rear fe eue e ee aede rie federe detecta re UR 68 Select Panel Assembly eeu MANA egerit er tette tee ecd E REESE 70 RVMC RVCD Vandal Resistant Door CDC Front nennen ener enter eene rne 72 RVMC RVCD Vandal Resistant Door CDC Rear sees nnne enne nnne eren erret 74 RVMC RVCD Center Door Changer Vault annassa 76 Port Assembly Vision 4 niei edet eter rii eie ee Yee edere diee EE 78 Door Assembly Front Dr Pepper Vision 4 1 1 2 2 2 12 0 nennen nennen nennen teneret ener eren eren 80 Door Assembly Rear Dr Pepper Vision 4 eene nennen nennen nennen enne ener enne 82 Coin Insert Assembly Front Dr Pepper Vision 4 84 CI Rear and Button Panel Assembly Dr Pepper Vision 4 ener ener enne 86 Changer Vault Assembly Dr Pepper Vision 4 nn n
13. 842326 3 Serial Changer Harness uu ida thee 842079 Delivery Sensor includes harness a 836004 5 Select Switch Harness Pepsi Cola 10 Select 842190 Select Switch Harness Live Display Vender 842192 Select Switch Harness Dr Pepper Vender 842201 Main Door Harness vend motor door switch wiring 842169 7 Cabinet Harness 12 Column Mechanism Wide 842174 Cabinet Harness 10 Column Mechanism Narrow 842231 1521 and after Wide enne nennen nnns 842230 1521 and after Narrow tote dece te AG 842231 8 Merlin IV Harness Assy 117V 842151 9 Internal HH Phone Jack and Harness ees 842099 10 Temperature Sensor includes harness s 822030 11 Refrigeration Relay Harness Door Side 842236 12 Refrigeration Relay Harness Cabinet Side 842237 13 Refrigeration Relay New Style 4 prong 836130 Old Style 6sprong nitur tmc n ctr neget trece cuneo ie eerta cna 836065 14 Transformer Assembly u
14. 023107 4 Display Back Flat 278505 5 SETOW T8 3c 172 et eet 902004 6 Port Brace Wide 010515 7 1 4 20 endi REIP EEUU REESE CER 905002 8 Inner Door Hinge Bottom 010550 9 Self Tapping Screw 1 4 20 x 901003 10 Port Body Welded Assembly Flat Display 278520 11 Carriage Bolt 1 4 20 x 1 2 901007 12 Goin Box HOUSING u intet Ndure dannede edit 010537 13 Bottom Changer Door Hinge 010560 14 Bottom Coin Chute Assembly to Coin Box 012593 15 Latch Roller Bracket erred tret main 010516 16 Burst Open Latch Strike 812003 17 Pop Rivet 1 8 dia Stainless Steel 908001 18 Top Changer Door Hinge W A sse 010570 19 iiir u S s 010544 20 Lamp Panel Bottom Single 278507 21 Screw 8 32 x 1 2 w Flat Washer sse 901006 22 bEamp 20 24 long dne uo PB Mik avd net 841012 23 Ballast Single 838005 Ballast Assembly Flat Display Single Bulb 122518 24 Lamp Panel Top Double 278506 25 Ballast D
15. I I I LIOA vc TEVSTT ann Ld LE IWD SNWN109 13093 OINOHI0313 e I HOLVANYA HIONVHO SNE JOYG LLTNN m 1svTNG EELEE dv 73A ma 3 dii SNImoo dvi BA dii 73A ama 8 3 5 gt x E EE E m 3 O O AVIdSIQ 31 98 Merlin IV Service amp Parts Manual ejdsig am SCHEMATICS NWV49VI0 9NISIM
16. yore HOLIMS 4000 SS3NYVH NIV PN E PN P S PN 3 PN um LE E Z Z um Z um Z um i EI EI T 8 MOSS3HdNOO shB lon p lon op jap jo b 23 29 ss 2 le sd mer leg HOSSIHANOD HOLON HOLVHOdYAI FEIN WEIN 110 2 avon ayn ve Bn HINYOYSNYEL HOSN3S JUNLVHIANIL YOSNAS 310H9 AV 1dSIA 037 I W3AHOJSNVHL 110A 02
17. 242537 Main Door Welded Assembly Vision 4 CD 72 243550 2 Sign Dr Pepper Vision 4 Must Give of Selections SEE NOTE 1 3 Rain Guard Wide Venders eene 010518 4 Top Main Door 810002 5 Vandal Panel Right Door 79 010519 Vandal Panel Right Door 72 011501 6 Metal Trim Right amp Left 79 2222 1111 171507 7 Metal Trim and Bottom 171502 8 Trim Right and Left 79 242526 9 Trim Top nd Bottom tee aceto e ted edet shita aaa 242525 10 Carriage Bolt 1 4 20 2 901007 11 Self Drilling Screw H8X1 2 Ju ua l aus a Su emm 902004 12 Top Door Bushing Lp 803003 13 Nut 1 4220 nn paqa IUe uated ege nee deed iude 905002 14 TsBolt 1 4 20X 17 1 paces ett cba steik bene de 901037 NOTE 1 There are various parts Please specify model and serial number at the time of order Merlin IV Service amp Parts Manual 81 SECTION 7 EXPLODED VIEWS AND PART NUMBERS Door Assembly Rear Dr Pepper Vision 4 1 D A235 065 003RV 82 Merlin IV Service amp Parts Manual SECTION 7 EXPLODED VIEWS AND PART NUMBERS Door Assembly Rear Dr Pepper Vision 4 ITEM DESCRIPTION PART NUMBER 1 Main Door We
18. 845918 11 Trim Genter 55 278511 12 Sign Center Flat Display Black Graphics 845919 13 Sign Bottom Flat Display Black Graphics 845920 14 Trim beft Side ua E RR REED 019507 15 Port Trim Wide Port uu eoe eme Rb 815249 16 Port Spacer Wide Port ener nennen 815248 17 Trim Bottom 032806 18 Trim Right Slde ee ete Rt RP ECRIRE 019508 19 Carriage 1 4 20 1 2 teet tme 901007 20 Price Label Strip Top 278512 21 Price Label Strip Bottom 278515 Merlin IV Service amp Parts Manual 91 SECTION 7 EXPLODED VIEWS AND PART NUMBERS Flat Horizontal Display Door Rear SELECT BUTTON ASSEMBLY Button Panel p n 278502 mounted in door weld ass y Sign Center Flat Display p n 278508 1 D A235 073 003RV 92 Merlin IV Service amp Parts Manual SECTION 7 EXPLODED VIEWS AND PART NUMBERS Flat Horizontal Display Door Rear ITEM DESCRIPTION PART NUMBER 1 Door Welded Assembly Flat Display 72 278552 2 Pop Rivet 1 8 908004 3 Display Product
19. On ON time for discounted selections dScn Off OFF time for discounted selections FriG On OFF time for Refrigeration System Off ON time for Refrigeration System 14 1 On 1 OFF time for illumination ballast lighting 14 1 Off 1 ON time for illumination ballast lighting Lt 2 244 OFF time for illumination ballast lighting 14 2 244 ON time for illumination ballast lighting Lt 3 3 OFF time for illumination ballast lighting Lt 3 Off 3 ON time for illumination ballast lighting 67100 8 and lower only See Refrigeration Mode for newer controllers SECTION 3 VENDER PROGRAMMING To set On and Off times for the timer you must press lt enter gt upon reaching the desired Timer Setting Mode After doing this the Controller will enter into that particular Timer Setting Mode The display will show the current setting with the hour flashing This indicates that the hour can now be changed Pressing lt up gt or lt down gt allows you to change the hour of this particular setting Pressing lt enter gt will lock in the hour setting and start the minutes flashing which will indicate to you the minutes can now be changed Pressing lt up gt or lt down gt allows you to change the minutes of this setting Pressing home anytime during this process will lock in
20. fete u ua oor fce tt 901007 8 NuUt 1 4520 M 905002 9 Anti Foaming Te 931355 Enclosed Coin Cup Kit wide a 303150 NOTE 1 There are various parts Please specify model and serial number at the time of order Merlin IV Service amp Parts Manual 51 SECTION 7 EXPLODED VIEWS AND PART NUMBERS Inner Door Assembly GO 8 L D A235 043 003RV 52 Merlin IV Service amp Parts Manual SECTION 7 EXPLODED VIEWS AND PART NUMBERS ITEM N O 11 12 13 14 15 16 Inner Door Assembly DESCRIPTION PART NUMBER Inner Door Assembly 79 Wide 232640 Inner Door Assembly 79 Narrow Venders 258630 Inner Door Assembly 79 Dr Pepper Vision 4 271640 Inner Door Assembly 72 Wide Venders 262642 Inner Door Assembly 72 Narrow Venders 264630 Inner Door Assembly 72 Dr Pepper Vision 4 272640 Inner Door Gasket 79 Wide Venders 815033 Inner Door Gasket 79 Narrow Venders 815218 Inner Door Gasket 72 Wide Venders 815032 Inner Door Gasket
21. Card Counter Mode CArd 67100 9 and higher only If lt enter gt is pressed at the CArd prompt the controller will enter the Card Counter Mode The display will show CASH and the total historical amount of money made by sales using a debit or credit card in the same fashion as shown in Cash Counter Mode above Press lt up gt or lt down gt to cycle to the card vend counter display where the display will show SALE and the total historical amount of product sold using a debit or credit card Note that individual counts for each selection are not available in the Card Counter Mode If home is pressed anytime during this operation the controller will return to the CArd display From CArd pressing down will take you to SALE Pressing up will take you to toKn mg Token Counter Mode toKn 67100 9 and higher only If enter is pressed at the toKn prompt the controller will enter the Token Counter Mode The display will show CASH and the total historical amount of money made by sales using a vend token in the same fashion as shown in Cash Counter Mode above Press up or down to cycle to the token vend counter display where the display will show SALE and the total historical amount of product sold using a vend token Note that individual counts for each selection are not available in the Token Counter Mode If home is pressed anytime during this operation the controller
22. If enter is pressed when the display shows dEG the Control ler will enter the Degree Setting FriG function The display will show dEG and flash the current degree setting Pressing up or down will allow you to change the current setting Program to F for Fahrenheit Factory Setting or C for Celsius Pressing lt exit gt anytime during this process will save any change and returns you to the beginning of the dEG function where the display shows dEG From dEG pressing lt down gt will take you to Cuto Pressing lt up gt will take you to dSP Display Temperature Function dS P If enter is pressed when the display shows dSP the Control ler will enter the Display Temperature FriG func tion The display will show dSP and flash the current setting Pressing up or down allows you to change the current setting Program to 1 to display the temperature on the LED display during the sales greeting or 0 to not display the tempera ture during the greeting Pressing lt exit gt anytime during this process will save any change and returns you to the beginning of the dSP FriG function where the display shows dSP From dSP pressing down will take you to dEG Pressing up will take you to FrG Unit Disable Master On Off Function If lt enter gt is pressed when the display shows the Controller will enter the U
23. If validator accepts replace coin mechanism and test If validator accepts replace validator and test If validator accepts replace Controller and test Defective wrong cut or miswired validator harnessing credit not getting from validator to Control Board via credit wire Defective validator Defective Controller Validator switch settings if any Defective validator interface harness Defective validator Defective Controller 38 Merlin IV Service amp Parts Manual BILL ACCEPTANCE CORRECTIVE PROCEDURE Check harness for cuts or wrong connections If defective replace it Replace coin mechanism and test If it pays out test the Control Board Test Vender s manual coin payout If Vender pays out using the CPO mode but not during sales check the coin mechanism or coin mechanism harness The Control Board is more than likely not the problem Replace defective or wrong validator harness Make sure that the coin mechanism is plugged in accepts coins and the tubes are full of coins Repair or replace faulty harnessing Replace defective validator Replace defective validator Replace defective Controller Make sure that the validator harnessing is correct for your style of validator and it is plugged in wired properly Replace validator and test acceptance Replace Controller and test acceptance Refer to validator service manual or validator representative Refer to validato
24. Jam Nut 9 16 18 905019 4 Bushing for coin return button see 803030 5 Security Plate Decal Electronic 845530 6 L Secrew 1 4 20X 1 nasa uns eder e ten 901037 7 Security Plate Weld Assembly CDC Only 195510 8 COIN Plate wets iiti fe ide qe attese au tet in dvs 141516 9 Vandal Panel Cover 79 0 1 171101 Vandal Panel Cover 72 inst d Det edita 172001 Merlin IV Service amp Parts Manual 73 SECTION 7 EXPLODED VIEWS AND PART NUMBERS RVMC RVCD Vandal Resistant Door CDC Rear 1 D A235 036 003RV 74 Merlin IV Service amp Parts Manual SECTION 7 EXPLODED VIEWS AND PART NUMBERS RVMC RVCD Vandal Resistant Door CDC Rear ITEM DESCRIPTION PART NUMBER 1 Lock Cylinder Cover 161532 2 Validator Security 141521 3 Spring Hinge for Security Doors 912156 4 Pop Rivet 1 87 naa a n a beret etude 908004 5 ERN Dec tie NEU nni edd 141508 6 14 20 4 enste e d bt e toi die 905002 7 Lever apu E E Qusa ada ss 141514 8 Select Switch Harmess_ a ln u PNA u nente ner 842190 9 Button Panel Weld Assembly 10 017530
25. Setting will lock in or reprogram the Control Board for that particu lar Space to Sales Setting Upon doing this the display will automatically start sequencing through each selection followed by all the columns that are assigned to each see Example below After each selection has been shown the display will return to Stos Example If after entering a Factory Standard Setting the display flashes SL 1 and then flashes 1 then flashes 2 selection one has been assigned to Columns I and 2 only This will occur for each selection Merlin IV Service amp Parts Manual 23 SECTION 3 VENDER PROGRAMMING Custom Space To Sales Pressing lt enter gt at CStS will allow you to enter the Custom Space To Sales Mode Upon entering this mode the display will always start by flashing SL 1 Selection 1 followed by flashing each column number assigned to this selection Example The display flashes SL 1 then flashes 1 and then flashes 2 Selection 1 has Columns 1 and 2 assigned to it only Pressing lt up gt or down at this point allows you to cycle through Selections 1 through 12 with each selection showing the columns assigned to it If lt enter gt is pressed at selection the display will show Co 1 This stands for Column 1 for that particular selection Pressing up or down at this point will allow you to cycle through Columns 1 through 10 for the selection e
26. Multiple Pricing ALL Pricing Gives you the option to set one price for all selections Individual Pricing Allows you to set a different vend price for each selection If a free vend key switch is in use turned on the display will scroll FREE during the greeting instead ofthe normal vend price That is if all selections are assigned StCL mode OPERATION If enter is pressed when the display shows PriC the Controller will enter the price setting mode Single Price Operation The display will flash SPri and the current single price setting This will be the single price viewing level If enter is pressed again the display will show the current single price only If up is pressed or held the price will increase in 05 increments If down is pressed or held the price will decrease in 05 increments the desired price has been set press home to save your setting and return to the single price viewing level Pressing home from the single price viewing level will return you to the display of PriC Multiple Price Operation The display will flash ALL followed by the last price set for all selec tions If enter is pressed at this point the display will steadily show the current ALL price If lt up gt is pressed or held the price will increase in 05 incre ments If down is pressed or held the price will decrease in 05 increments After the des
27. 1 of them and closing the Vender s main door or actuating the Vender s door switch 26 Merlin IV Service amp Parts Manual Differential Cash Discounted Counter Mode diFC This mode is comparable to the Cash Mode It allows you to monitor the difference between discounted prices and regular prices The Differential Cash Discounted Counter Mode is a non resettable total count If product is sold for less than the vend price the counts will be preceded by a negative symbol If product is sold for greater than the vend price the counts will be shown normally Examples for both are Actual 1st 2nd 3rd Count Display Display Display Differential Count Type Differential 789 10 CASH 7 89 10 Cash Count Negative Differential CASH T 89 10 Cash Count Positive 789 10 OPERATION If enter is pressed when the display shows diFC the Controller will enter the Differential Cash Discounted Counter Mode The display will flash CASH and the total difference between regular vend prices and discounted prices as shown in Example 1 above Pressing lt home gt anytime during this operation will allow the Controller to return to the diFC display From diFc pressing down will take you to dS AL Pressing lt up gt will take you to SdiS CLEARINGINDIVIDUAL COUNTERS This is anon resettable counter ET Set Discount Pricing Mode SdiS This mode is used to set discount price
28. 1Hiiv Haars ao S pira Pe uoo Merlin IV Service amp Parts Manual 97 SCHEMATICS i TORE i 1 d SS3NUVH SNIBIM NIVA HOSSIYdNOD HOLON NW4 HOSSIHdNOD HOLOWNYY HOLVHOdYAI X8 HOLIMS 4000 81 89 0S9 ZS SNIGIM E E E E E E Y 6 S3HOLIMS 193135 HOSN3S 3univu3dial YOSNAS 1 HINHOSSNYEL 1 10A 022 J iga e o E ANISORERAL SOIN HINYOSSNYE
29. At this point pressing lt up gt or lt down gt will increase or decrease the minutes value Pressing lt exit gt will save the hour and minute setting for the corresponding day value and will return to the prompt for that day Pressing lt exit gt again will return you to the dAY prompt Pressing lt exit gt one more time will return you to the StoP prompt 30 Merlin IV Service amp Parts Manual SECTION 3 VENDER PROGRAMMING dEG If enter is pressed at the dEG prompt the controller will display dEGX where X will be flashing F if the controller is currently in Fahrenheit mode or if the controller is currently in Celsius mode Pressing up or down will toggle the X digit between F and Pressing exit at this point will save the displayed temperature mode and return you to the dEG prompt SetP If lt enter gt is pressed at the SetP prompt the controller will display the current set point tempera ture setting xx F or xxC depending on the degree mode setting The cold set point default is 35 F 2 C Pressing up lt down gt will adjust the temperature value by 1 F 0 5 C The set point temperature can be adjusted from 25 F through 45 F Pressing lt exit gt at this point will save the displayed temperature and return you to SetP Stor If lt enter gt is pressed at the Stor prompt the controller wil
30. Button Panel Weld Assembly 8 012510 10 STOWE aaret 901041 11 Buitton Assembly o sunsu eheu 815025 12 sees u u u RU HERR ass 815164 13 SWITCH arge a t t ted Ec eed 835012 14 SWITCH SDaGOr a erbe eere ce rec en deed qun m ER Eng 815018 15 Nub oit there 905018 16 Cash Box Guard Security 011147 17 GCoin Ret rn soprlhg sere e ehe ED Een ihe a EE te 914023 18 Button Lever Coin Return Lever a 161509 19 Foller Pin 5 7327 ii availed nik ove bnnc iD PS 811002 20 Hinge Button Lever 161508 21 Retaining Ring for 5 32 Diameter 906005 22 Button Coin Return Lever 0 803031 23 Nut 8 32 2 ose lah aid Mee hare oie dade 905001 24 T Handle Brace _ a Re u a u ue 141513 25 T Handle 2 adie cit A inii 812190 Coin Return Lever Assembly non CDC 141524 Denotes a color must be specified NOTE 1 There are various parts Please specify model and serial number at the time of order Merlin IV Service amp Parts Manual 75 SECTION 7 EXPLODED VIEWS AND PART NUMBERS RVMC RVCD Center Door Changer Vault
31. LED lead 40 Merlin IV Service amp Parts Manual MISCELLANEOUS PROBLEMS CORRECTIVEPROCEDURE Replace defective controller Check the select switch and trace the selections harness back to the Control Board Replace if necessary If cut or pinched check individual wire running from motor connection at Control Board to defective column Measure voltage at vend motor s connection of the Control Board Measure it on the individual wire for the motor attempted and the wire by itself next to the key neutral A selection must be made and hold must be displayed on the LED You should register 24 VDC at the vend motor If not replace Control Board Check transformer and power to transformer If not check LED lead Check the lead for any sign of being pinched or cut If so change the LED Remove all harnessing but LED lead and the power lead from transformer to Control Board Check the new LED before mounting it in the Vender If still bad replace the Control Board and test SECTION 5 VENDER MAINTENANCE TROUBLE Display shows sold out immediately upon pressing select button with column full of product sold out not clearing Out of Service on display Refrigeration unit runs constantly POSSIBLE CAUSE Door switch wiring incorrectly connected cut or pinched Door switch Control Board Corrupted control board Cut out temperature not set properly Temperature sensor not readi
32. be programmed correctly for the Vender to operate properly Through the Vender s electronic Control Board you will find better space to sales allocations which will increase profits through fewer sold out selections and less loading frequency Through MERLIN IV s flexibility you will profit by using the Multi Pricing and Space to Sales features you will see later in the Manual there are other features such as the ability to control vending by using a built in timer or by using an optional on off key switch Like most electronic equipment the Control Board has the ability to control most items in the vending machine It manages the operation of the Refrigeration System and even the lighting system with an optional kit MERLIN IV utilizes high torque 24 volt DC vend motors Testing has proven these vend motors to be very strong and reliable MERLIN IV s programming is done Menu Style with the menus consisting of Main Items and Sub Items Figure 1 1 is a good example of how the menu system works Cash is the first menu after pressing the mode button on the control board You can only access menu items from the menu you are in Just as the ENTER button takes you into each level the HOME button takes you back to previous menu levels each time you press it The menu system is explained in greater detail in Section 4 Vender Programming Menu Levels 1st Level Merlin MERLIN IV FEA
33. lt is necessary to program the correct depth for each selection to prevent multiple or slow vends For instance if your actual vending depth is two and you program this selection for single depth it will double vend every time OPERATION If enter is pressed when the display shows SdEP the Controller will enter the Set Vending Depth Setting Mode The display will show ALL From this point two types of settings are available the All depth setting enables you to set all depths the same such as ALL of the price mode and Individual depth setting gives you the option to set all depths individually for each selection 24 Merlin IV Service amp Parts Manual ALL Setting If enter is pressed when the display shows ALL the Controller will enter the Depth Setting Mode for ALL selections The display will steadily show ALL and flash the current depth setting Pressing up or down allows you to change the flashing depth setting between 1 or 2 Pressing lt enter gt will save changes and return you to where the display will show ALL At this time you will be able to cycle through each individual depth setting Pressing home from this level will return you to the 54 display Note If you have selection depth settings that are different but a majority of the settings are the same it is advised to set the majority setting from within the ALL setting first You w
34. or 1f power is lost to this connection you will noticeably lose all Vender functions except main door lighting including power to your LED display Power to your Coin Mechanism will not accept coins Power to your Refrigeration System compressor and condenser fan motor also will not run With this connector the wire harness can be in either position and the Control Board will not be affected PIN WIRE FUNCTION NUMBER COLOR 1 24 VOLT AC 2 NEUTRAL Merlin IV Service amp Parts Manual 13 SECTION 2 VENDER COMPONENT EXPLANATION Low Voltage Transformer Run 1476 and after will have a fuse between the transformer and the Control Board The MERLIN IV Vender uses a low voltage 75 VA transformer which reduces 110 volts AC conventional voltage to 24 volts to power the Vender s Control Board The transformer is a major contributor to the Vender s operation Without the transformer the Control Board cannot function LOCATION OF TRANSFORMER In a CDC Center Door Changer Vender the transformer is located below the Control Board The fuse is fastened to the Changer Plug Bracket In a non CDC Vender the transformer and fuse are located at the top of the main door OPERATION The transformer has a three 3 amp external fuse on a secondary circuit to protect the Control Board and the Coin Mechanism Ifthe transformer fuse blows you will lose power to the Control Board notice ably losing power to the LED Display
35. Board s coin acceptance credit payout circuit OPERATION If enter is pressed when the display shows tESt the Controller will enter the Column Vend Test Mode The display will show CO 1 Column 1 Using up or down will cycle you through all the available columns to be test vended the display may show some columns that are not in your Vender nothing will happen if a test vend is attempted from these col umns If enter is pressed the Controller will attempt to test vend from the column which is being displayed If a vend is not in progress pressing home will return you to the tESt display From tESt pressing down will take you to Eror Pressing up will take you to Note Test vends will not affect cash or sale counters Hr Selection Price Mode PriC This mode is used to set vend prices Depending on the Configurations Mode discussed later in this Section this mode will allow you to set either single or multi pricing When the configurations are set to allow single pricing only one price has to be set in the PriC Mode not individually The current price will be displayed on the LED display during the greeting If the configurations are set to allow multiple pricing per selection the display will not show the vend price during the greeting unless all selections are set to the same price You will have two options when setting prices SECTION 3 VENDER PROGRAMMING
36. Board to power the relay If the unit continues to run switch the two 2 blue connector wires coming from the main wiring harness to the two 2 other available connectors if present If not replace relay Merlin IV Service amp Parts Manual 41 SECTION 5 VENDER MAINTENANCE TROUBLE POSSIBLE CAUSE Refrigeration unit will Unit itself is defective run FrG setting not set properly Cut in Cut out settings not set properly Temperature sensor not reading correctly Short in wiring harness from Controller to refrigeration relay Refrigeration relay is defective 42 Merlin IV Service amp Parts Manual CORRECTIVEPROCEDURE Unplug the refrigeration unit from the top ofnot the main wiring harness and plug it into a direct power source If it does not run replace the refrigeration unit DANGER ELECTRIC SHOCK HAZARD When plugging in the refrigeration unit directly to a wall outlet or other power source always ensure that the vender itself is also plugged in to a grounded electrical outlet Failure to do so could cause an electrical shock possibly resulting in severe injury or even death Check FrG setting in the FriG Mode to make sure it is set to 1 If set incorrectly reprogram it to show 1 Check cut in cut out settings If set incorrectly reprogram them Test the temperature sensor by showing the temperature on the display and measuring the actual inside cabinet temperature
37. From StCL pressing down will take you to SdiS Pressing lt up gt will take you to tinE Notes When pressing a selection in the StCL Mode 1 Version 67100 3 and after the LED will display No Sale till XXXX XXXX represents the time set for the timer 2 Version 67100 2 and prior the LED will show the Greeting and Sold Out PPE Time and Timer Settings Mode tinE This mode is used mainly to turn selections lighting and orrefrigeration off and back on during predetermined times of the day and days of the week In the tinE Mode you must set the current year date hour and day of the week for the timer to operate The tinE Mode is also used to set each on and off time in which the timer will operate Within the tinE Mode there are several different functions listed below with a meaning and example for each FUNCTION PROGRAM DISPLAY MEANING EXAMPLE After Entering Mode YEar Current Year 1998 datE Current Month Day 06 08 June 8 hour Current Hour Min 13 30 1 30 pm military time SEtd Set Day of the Week SUN StOP Disable Clock CLOC then StOP daY Timer On ALL Off Days and Times dSt Display Time On dSt with setting LED flashing dLt Daylight Savings dLt with setting Time flashing This feature is used to conserve the Control Boards built in battery if Vender is in storage for long periods of time The Lithium b
38. KXXX where the X s will represent the number of all free vends over machine life If the sales amount is less than 5 digits the upper 4 digits will not be displayed Using lt up gt or lt down gt will cycle through each selection as SL N XXXX XXXX where N will indicate the selection number and the X s represent the resettable number of free vends If lt exit gt is pressed anytime during this operation the controller will return to the FrEE prompt If enter is pressed at the COSt prompt the controller will enter the free vend equivalent cost display mode by displaying SL XX XX where N will represent the selection number and the X s represent the last saved price for that selection that is not 00 00 A decimal will be displayed in the appropriate position Using up or down will cycle through each selection If exit is pressed anytime during this operation the controller will return to the FrEE prompt Eror Errors Mode Eror This mode was designed to help diagnose Vender problems Upon opening the Vender s main door the LED will flash any possible errors For a list refer to Section 6 Vender Maintenance Error Codes If there are no errors the display will flash none and after five 5 minutes of no activity will revert to the sales greeting ICE COLD The Errors Mode was designed to give a detailed description of each error and allow you to clear
39. Refrig eration Relay electronic control or from the thermostat conventional control OPERATION The rising temperature in the cooling compartment is reported to the Control Board from the Temperature Sensor See Figure 2 3 The Control Board registers the current temperature inside the Vender s cabinet When it rises equal to or above the pre programmed cut in temperature the Control Board will then complete the circuit to the Refrigeration Relay to energize its coil shown in Fig 2 3 as CR 1 The Refrigeration Relay Coil energizes and closes the contact between the common and normally open positions shown in Fig 2 3 as CR1 1 This allows power 110 VAC to travel through the Refrigeration Relay Switch and to the main wiring harness The main wiring harness will power the unit immediately When the Compressor is powered it circulates refrigerant throughout the system by pulling low pressure refrigerant vapor from the Evaporator Coil through the suction line into the Compressor The Compressor compresses it and forces it through the discharge line into the Condenser Coil The Condenser aided by the Condenser Fan Motor removes heat from the refrigerant as it flows through the Condenser Coil and releases it to the outside environ ment The dropping of the refrigerant temperature changes the vapor to liquid 16 Merlin IV Service amp Parts Manual The Evaporator Coil allows the liquid refrigerant to absorb heat from
40. Repair or replace changer harness Unplug all harnessing from the Control Board except the transformer power connection and the coin mechanism connection and test acceptance If it accepts replug each connection one at a time and test acceptance after each After a new coin mechanism has been tried and the harness has been checked for continuity replace Control Board Make sure changer is mounted correctly anda the coin return lever is in the proper position Check to ensure that the coin mechanism s acceptor is clean Contact coin changer manufacturer Replace the Control Board and test Replace coin mechanism acceptor and test If If OK check the following Check harness for cut wires or wrong connections If defective replace it Replace Control Board and test Merlin IV Service amp Parts Manual 37 SECTION 5 VENDER MAINTENANCE TROUBLE Changer will not payout coins Validator will not pull in a bill Validator takes a bill and not establishing a credit Validator takes a bill and not erasing credit POSSIBLE CAUSE Defective harness between coin mechanism and Control Board Defective coin mechanism Defective Controller Make sure that the validator harnessing is correct for your style of validator and it is plugged in properly Acceptance disabled by coin mechanism or bad harnessing validator status light is on Make sure that the changer harnessing 15 correctly connected
41. Sale Counter Mode consists of a non resettable total count and individual selection counts which are resettable depending upon the proper configuration setting see Configurations The counts will be preceded by the count type SL sale level and can be displayed in one 1 or two 2 sets of four 4 digits Examples for both types of sale counters are Count Type Actual Count 1st Display 2nd Display 3rd Display Total Sale 5 678 910 SALE 567 8910 Count Selection 678 910 SL number 67 8910 Sale Count OPERATION If lt enter gt is pressed when the display shows SALE the Control Board will enter the Sales Counter Mode The display will flash SALE and the total amount of sales made by the Vender This can be shown in two 2 sets of four 4 digits see Example 1 above Using lt up gt or lt down gt will cycle through individual selection sale counts The display will flash individual selection counts as shown in Example 2 above If home is pressed anytime during this operation the Controller will return to the SALE display From SALE pressing down will take you to CASH Pressing up will take you to CArd CLEARING INDIVIDUAL COUNTERS Ifthe Configura tions Mode is set to allow the individual counters to be reset the individual counters will reset upon reading at least one of them and closing the Vender s main door actuating the Vender s door switch
42. Specify 142001 IGI NEL P 916009 NOTE 1 There are various parts Please specify model and serial number at the time of order Merlin IV Service amp Parts Manual 67 SECTION 7 EXPLODED VIEWS AND PART NUMBERS Door Assembly Rear L D A235 049 003RV 68 Merlin IV Service amp Parts Manual SECTION 7 EXPLODED VIEWS AND PART NUMBERS Door Assembly Rear ITEM DESCRIPTION PART NUMBER 1 Fusebox Assembly u u bin eara tei 842219 2 Port Body Welded Assembly Narrow Port 273510 Port Body Welded Assembly Wide Port 303510 3 Lamp Guard Wide Venders 012514 Lamp Guard Narrow Vender Merlin IV 258505 4 Port Brace Wide Venders 010515 Port Brace Narrow Vender Merlin lV 258506 5 Transformer Assembly sse 842147 6 Coin Box Housing 1405 4 after 273540 7 Coin Box Welded Assembly 1405 amp after 815347 8 Coin Hopper wide 303502 9 Changer Door tin et e teatri id
43. and also losing power to the Coin Mechanism Coin Mechanism will not accept coins and Bill Validator will not accept a bill If you have a problem similar to this follow the procedures listed below OPERATION REQUIREMENTS The transformer operates by receiving 110 volts AC from the Vender black and red wires It transforms the 110 volts AC into 24 volts AC which is what the Control Board requires for Its operation CHECK THE TRANSFORMER AND FUSE If upon arriving at a Vender the LED display is not lit and the coin changer does not take coins or payout coins make sure the Vender is plugged in Next check the transformer s external fuse for visual damage Check for continuity across the fuse with a voltage meter or similar device If defective replace the external fuse 14 Merlin IV Service amp Parts Manual Note Merlin IV Venders made before run 1476 use an internal fuse in the transformer 1 Check the power going into the transformer at the connected red and black wires It should register 110 volts AC If not you need to check all wiring leading up to this point from the bottom of the Vender s main door The transformer may not be the problem You may have a broken wire or a bad connection 2 If110 volts is registered during Step 1 you want to measure voltage at the other end of the transformer The two 2 pin connector at the Control Board connected to position P15 should register approxi mately 24 volts AC at th
44. blown out with compressed air Condenser and For efficient operation the Condenser and Evaporator Coils must be kept Evaporator Coils clear of any dirt or foreign materials Clean dirt and lint from the Condenser and Evaporator Coils with a brush vacuum cleaner or compressed air Cabinet and Vend Steam clean as required Never use petroleum cleaners or Mechanism submerge electronics in water Note Never use petroleum cleaners or submerge electronics in water If the Controller is accidentally sprayed with water be sure to allow it to dry thoroughly before powering up the Vender WHAT TO LUBRICATE A routine cleaning schedule is the best way to insure the optimum possible operation and appearance from your MER LIN IV Vender PART CLEANING METHOD Latch Strike Nut The Latch Strike Nut should be lubricated periodically with a petroleum base grease Inner Door Gasket The door gasket comes from the factory pre lubricated but should be lubricated periodically with a silicone base grease Apply to the vertical piece of gasket on the hinged side of the inner door which touches the Vender s main door This will help prevent any peel back of the gasket which can cause air leaks into the sealed cabinet resulting in freeze ups Refrigeration The Refrigeration System is a sealed unit and does not require any System lubrication Also the Condenser and evaporator motors do not require any lubrication IMPORTANT SAFETY NOTE To prevent bodily i
45. errors followed by the descriptions for each If no errors exist none will appear on the display If lt home gt is pressed anytime during this operation the Controller will return to the Eror display From Eror pressing lt down gt will take you to CLEARING ERRORS To clear an error you must access the Eror Mode from within the Password Protected Menus Merlin IV Service amp Parts Manual 33 SECTION 4 VEND CYCLE Vend Cycle Stand By Condition Ina Stand By Condition the Vender will show the greeting and possibly the vend price if set for a single price or if all prices are set to same and a choice of other optional features on the LED display If a select button is pressed prior to reaching the vend price establishing a credit the display will show the vend price for that selection This will indicate to the customer more money is needed for that particular selection Establishing Credit As coins are inserted into the Coin Mechanism a corresponding credit count will appear on the display The Coin Mechanism will continue to accept coins until the highest vend price has been achieved All coins in excess of the vend price will be returned to the coin cup Once the vend price has been achieved the Control Board will set up a credit enabling a vend to be made for any selection equal to or less than the established credit Valid Selection The Vender s Control Board constantly sends
46. in and the second set of two digits will start flashing to indicate the minutes Example 14 31 Pressing up or down allows you to change the second two numbers of the hour Pressing home after making a change will return you to the beginning of the hour tinE function where the display shows hour From hour pressing down will take you to dAtE Pressing up will take you to SEtd Set Day Function SEtd If enter is pressed when the display shows SEtd the Controller will enter this mode displaying a day of the week Pressing up or lt down gt allows you to change the day of the week When the desired day is selected press lt home gt to select and bring you to SEtd From SEtd pressing lt down gt will take you to hour Pressing lt up gt will take you to StOP Stop Function StOP If lt enter gt is pressed when the display shows StOP the Controller will enter the Stop Clock Setting tinE function and the display will flash CLOC and StOP Pressing Merlin IV Service amp Parts Manual enter will turn offthe clock to reserve the Controller s built in battery The display will flash Off and automatically exit back to the display of StOP Pressing home anytime during this process will return you to the beginning of the Stop Clock tinE function where the display shows StOP From the StOP display pressing down will take
47. lun Joi ED Peers eoe dei 10 UMOYS Gud sol jo d 510 101 ou au s 02 eseud euy Ji 88S o1 u SI odd pue euuou bed e siepuon oso 2a s 1 eso u ul p u A 10 Aunful Josuas ssa 20 eseud eul panos ae un e Ajqissod yoous Ae eoe ule qoud sak eu pip ou sner SJIUN OY YORI 01 ue SSNED os OP ou sbuijes a bu 01195 SI 08 ejnrej RNO eoujos e d d amp 198UU0D Qno eins ayew pue e 0 ui ose s asy EC ka sax POUSBUIS 100 0119 pue WAN 4590 eu zey nsu SSQUJEYS 3SVHd TWN ld eoJnos JAMOd JO 1 9 ino oseud eu sak 0 Sino 10 P ops ueuw 1osu s yooyo ou 045 AUDI eui S L y V H M 1 4 MIOHS ejda 214199719 uo ONILOOHSI3T19NOYUL 4 Eston dq aseud Dunes dsp NOILIVYIODIYH3VP xo SUM u O fa bu 91 u 7 4 3 WB1601d gu 195 IN
48. parts for your Vender and when contacting a Royal Vendors service representative The Control Board identification decal is shown in Vender Identification of Section 1 OPERATION REQUIREMENTS The Control Board requires approximately 24 volts AC from the low voltage transformer described later in this Section This will allow the Control Board to function and to supply power to all the Vender s components listed below OPERATION Upon receiving the appropriate voltage from the transformer the Control Board will issue informa tion to some components receive information from some components and communicate both ways with some components The Control Board issues instructions and or voltage to LED Display Vend Motor only when vend motor is to run Refrigeration Relay for use with Electronic Refrigeration Control The Control Board receives information and or voltage from Select Switches logic level Door Switch logic level Delivery Chute Sensor Temperature Sensor for use with Electronic Refrigeration Control The Control Board communicates both ways with Coin Mechanism Bill Validator optional Debit Card Reader optional Hand Held Computer optional CONTROL BOARD PINOUTS The MERLIN IV Control Board has several electrical pinouts a set up mode button a delivery sensor adjustment trimpot a delivery sensor adjustment indicator lamp and various other electronic components all of which have
49. through individual selection sale counts The display will flash individual selection counts see Example 2 above If home is pressed anytime during this operation the Controller will return to the SALE display From SALE pressing down will take you to Eror Pressing up will take you to rtn if present Return to Sales Greeting Mode This mode is used to exit the External Menu and return to the Sales Mode where the display flashes the greeting ICE COLD or PEPSI COLA along with any other display options OPERATION If enter is pressed when the display shows rtn the Controller will revert to the Sales Mode and the greeting will be displayed From rtn pressing down will take you to Sale Pressing up will take you to Eror FPS Errors Mode Eror This mode was designed to help diagnose Vender problems Upon entering this mode the display will flash any possible error for a list refer to Section 6 Vender Maintenance Error Codes Ifthere are no errors the display will momentarily flash none and revert to Eror on the External Menu Errors cannot be cleared from this External Errors Menu They have to be cleared from the Internal Menu OPERATION If enter is pressed when the display shows Eror the Controller will enter into the Errors Descriptive Display Mode At this point the display will show any and all current Vender
50. will allow you to toggle X between 1 enabled and 0 disabled Pressing enter will save the displayed setting and return you to the non editable Enb prompt Use up to proceed to the next prompt Strt Merlin IV Service amp Parts Manual 29 Strt If lt enter gt is pressed at the Strt prompt the controller will enter the start energy conservation time setting routine Upon entry into this routine the display will show dAY Pressing exit at this point will return to the Strt prompt without saving any changes If lt enter gt is pressed at the dAY prompt the controller will enter the day of the week setting routine Upon entry into this routine the display will show ALL representing every day of the week Pressing up or lt down gt will rotate through Sun Mon tuE Wed thu Fri Sat or ALL Pressing lt enter gt at any of these prompts will cause the controller to enter the hour minute time setting routine for that day The display will show the current four digit hour and minute setting in 24 hour format The hour setting will be flashing to indicate that it can be modified Pressing lt up gt or lt down gt will increase or decrease the hour Pressing lt enter gt will stop the hour from flashing and cause the minutes to flash indicating that they can be modified At this point pressing lt up gt or lt down gt will inc
51. with a thermometer or by opening closing door to see If the temperature changes If found defective replace temperature sensor Unplug the two 2 pink connector wires coming from the Control Board and measure voltage You should read approximately 24 volts DC from one 1 of the wires If not locate the shorted wire to be either on the door side or the cabinet side of the harness and correct or replace defective harness Test the relay by making sure all connections are made for the refrigeration unit the refrigeration relay and the Control Board Next go into the FriG mode Check the Compressor by pressing enter when you get to CnPr and pressing lt enter gt again when the display flashes CnPr and On If the unit does not come on switch the two 2 wires coming from the main wiring harness to the two 2 other available connectors 1f present If not replace relay REFRIGERATION FLOW CHART SECTION 5 4 SI JOSUSG eseud euy 1 Bunjes 01na 0106 5 5 ejdsip GUO oseud BULL peer 62 nno Ly eq eu Teu 0106 qseud jeu uym 80015 yun Lg 0109 Nu papueuuooai si jo d SIY 10 eseud peui prog 0106 eu Ji ees 0 y pip epou Gl of j sof 1 oDueuo UN meu cu reg E baioo UO
52. 1526 Merlin IV Service amp Parts Manual 77 SECTION 7 EXPLODED VIEWS AND PART NUMBERS Port Assembly Dr Pepper Vision 4 1 D A235 063 003RV 78 Merlin IV Service amp Parts Manual SECTION 7 EXPLODED VIEWS AND PART NUMBERS Port Assembly Dr Pepper Vision 4 ITEM DESCRIPTION PART NUMBER 1 Port Body Welded Assembly WP 303510 2 Anti Theft Plate 303503 3 Coin Cup pl OD GE EE 273570 4 Port Spacer 815020 5 SIN ae GE SEE NOTE 1 6 Port Trim VWP pears 815249 7 Ier E 2 3 2 a 273508 8 Anti Fo aming Label hu eat 931355 9 NUT 420 sed 905002 10 Carriage Bolt 1 4 20 2 901007 11 SCIOW 3 8 92X3 8 aai o dle 901011 NOTE 1 There are various parts Please specify model and serial number at the time of order Merlin IV Service amp Parts Manual 79 SECTION 7 EXPLODED VIEWS AND PART NUMBERS Door Assembly Front Dr Pepper Vision 4 LD 2A235 064 003RV 80 Merlin IV Service amp Parts Manual SECTION 7 EXPLODED VIEWS AND PART NUMBERS Door Assembly Front Dr Pepper Vision 4 ITEM DESCRIPTION PART NUMBER 1 Main Door Welded Assembly Vision 4 CDC 79
53. 5 066 003RV 84 Merlin IV Service amp Parts Manual SECTION 7 EXPLODED VIEWS AND PART NUMBERS Coin Insert Assembly Front Dr Pepper Vision 4 ITEM DESCRIPTION PART NUMBER 1 Validator Vault Welded Assembly 242530 2 Nut 1 4 20 eme 905002 3 Retaining Ring C Clip asteisia i 912157 4 Lock Cylinder 161532 5 Self Tapping Screw 8 32 3 8 901011 6 TsHaridle Ho sirnig riter tiet tnnt 812190 7 Brass Hex Washer cedet iae 2 8 T Bolt 1 4 20X4 asst cot sati iet ore t os ite toes 901037 9 Spring 2n ect Le n eer LS eL SEE NOTE 2 10 Piny THAN aan ettet estes eae eae 912133 11 VAM E SEE NOTE 1 12 ole dp EEE SEE NOTE 1 13 T Handle Body oM Reset dte eitis 812134 14 Stud SEE NOTE 2 15 PED POMS IE 916032 16 Security Plate Decal Dr Pepper Vision 4 845765 17 Security Plate Welded Assembly 242520 18 Bushing Button Coin Return a enne 803030 19 Hex Jam Nut 9 16 18 UNF2A 905019 20 Button Coin Return Lever 803031 21 le D
54. 5 2502 DESIGN PRESSURES 300 HS 156LS 115V 60HZ 4PH G LISTED REFRIGERATED VENDING MACHINE 66E9 SUITABLE FOR OUTDOOR USE Figure 1 3 How to read a serial number fig 1 3 The vender s model number contains two important pieces of information The machine type such as RVCDE Royal Vendors Cold Drink Electronic It also contains the vendor model number such as 650 10 capacity of 650 twelve ounce cans 10 selections The vender s serial number contains three important pieces of information It contains the Production Run number such as 1466 The serial number also contains the vender number from within the such as 01489 Lastly the serial number contains a date code such as BK The first initial B represents the quarter of the year that the vender was produced A Jan Feb Mar B Apr May Jun C Jul Aug Sept D Oct Nov Dec The second initial K represents the year that the vender was produced 1988 1989 1990 1991 1992 1993 1994 1995 1 1996 J 1997 K 1998 L 1999 2000 N 2001 CREDIT AND REPLACEMENT POLICY CREDITS OR REPLACEMENTS WILL BE ISSUED ON WARRANTY ITEMS IF THE PROPER PROCE DURES ARE FOLLOWED 1 Royal Vendors will pay shipping charges on all parts covered under this warranty when transportation has been made the most economical way within the continental US regular ground UPS An ARS Authorized Return Service sticker w
55. 7 and 12 while watching the Control Board s Sensor Adjust ment Indicator Lamp The light should blink solidly upon impact If not turn the sensor adjustment screw clockwise in 1 4 turn increments to increase the sensitivity and test after each turn If the indicator lamp still does not light turn the adjust ment screw clockwise for many turns If the indica tor lamp does not light change the sensor assuming the Control Board has power and is working 3 Ifthe Sensor Adjustment Indicator Lamp lights properly during Step 2 change the Control Board Merlin IV Service amp Parts Manual 15 SECTION 2 VENDER COMPONENT EXPLANATION Refrigeration System Your Vender s Refrigeration System comes as a com pletely sealed unit and should never be cut or tapped into or the warranty will be voided IDENTIFICATION The refrigeration unit is responsible for the cooling of your sealed cabinet and the products loaded within it The refrigeration unit s base plate compressor condenser coils and condenser fan motor are mounted in the bottom warm section of the Vender s cabinet The heat exchange or suction line extends into the upper cold section of the Vender s cabinet where the evaporator coil is mounted in front of the evaporator fan motor OPERATION REQUIREMENTS The Refrigeration System requires 110 volts AC from the main wiring harness for it to operate The main wiring harness will get its voltage for the unit from the
56. 72 Narrow Venders 815219 Port Door Frame iere a m d e D ecd 815191 Port Boro vrien sf dets 815192 Pork Door Rod saus n e ekte 811028 Elastic Stop NUt 905006 Burst Open Lateh ega 812002 B shing VIP Lugg dimit Le ERE Ec tede 916003 Cable Glampu nu q i enti e ita eerie 916004 1 8 e 908002 Inner Door Bushing iiio tt encre eee a gd e genu 815026 Inner Door Hinge 010520 832 tiet edt ete tom donee es 905001 Self Drilling Screw W Washer a 902001 Inner Door Hinge Bottom 010550 Self Tapping 1 4 20 X 1 enne 901003 Space to Sales Decal M IV 10 column vender 931301 Space to Sales Decal M IV 12 column vender 931302 Merlin IV Service amp Parts Manual 53 SECTION 7 EXPLODED VIEWS AND PART NUMBERS Main Door Hinge Lifter amp T Handle Assemblies N 5 m E a av Oo N LD A235 044 003RV 54 Merlin IV Service amp Parts Manual SECTION 7 EXPLODED VIEWS AND PART NUMBERS Main Door Hinge Lifter amp T Handle Assemblies ITEM DESCRIPTION PART NUMBER 1 Universal 164550
57. 88 Flat Horizontal Display Door Front sese enne enne nnne nennen nennen enter asss 90 Flat Horizontal Display Door Rear eese nennen e ae Esi E Spe enne nne 92 Flat Horizontal Display Select Pane l 2 Da mna aS sra asee eesin ua aS 94 Programming Flowcharts II 96 SchematiCS EE EEE SE 98 Merlin IV Service amp Parts Manual 3 SAFETY SEGMENT ROYAL VENDORS COMMITMENT TO SAFETY Royal Vendors is committed to safety with all of our product designs We are committed to notifying the user of a possible danger involving the improper handling or maintenance of our venders The servicing of any electrical or mechanical device involves potential dangers both to those servicing the equipment and to users of the equipment These dangers can occur because of improper maintenance or usage The purpose of this safety segment is to alert everyone servicing Royal equipment of poten tially dangerous areas and to provide basic safety guidelines for proper upkeep The service manual contains various warnings that should be carefully read to minimize the risk of personal injury This manual also contains service information to insure that proper methods are followed to avoid damag ing the vender or making it unsafe It is also important to understand these warnings provide general guidance only Royal could not possibly know evaluate or advise of all of the concei
58. AL MENU If Con 21556 LY kuns ket 25 ECO Exact change mode eir UN ee 25 CPO com p yout Mode rere tette eere he ERI se AERE EE 25 UFE coin tube fill Mode tte REESE ER 25 dSAL discounted sale counter Mode n eere enne enne 26 diFc discounted differential cash counter Mode sse eene 26 5415 discounted selection price Mode J sse eene 26 StCL set timer controlled selections 11 2 2 200 006 syao anecep iei 27 tinE time nd timer settings Mode us aste Ri e E ie de e e 27 refrigeration parameters Mode 2 2012 2 2 52 00 000000000000000000000000000000000000 29 PAS External Menu password setting Mode nsrrrnnrnrrrnvrvnvrnvrrnrrsnrrnrrrnnrnnrrnnrnnrrsernnrrsernsennesnnrsnrssnesnnesnessnrsnsennenn 32 LAnG international language setting Mode 32 rin return 10 sales Mode 4 am ausente ob etait eer p nd ed rore n beides 32 External Menu accessible while in the greeting mode ansa 33 SALE s alecounter eee 33 rin retutn to s les Mode 5 eet e aca vei eee 33 Er t errors Modes e eee Re e ERO Urt EEG PEU 33 2 Merlin IV Service amp Parts Manual TABLE OF CONTENTS CONTINUED 4 Vend asus 34 Stand by Condition na ninapa u
59. Decrease Previous Etc 3 ENTER Save Accept OK Etc press and release less than two 2 seconds 3 HOME Exit Escape Return press amp hold Etc for two 2 seconds or greater MENU SYSTEM When programming you must first use the three programming buttons listed above to maneuver through menus and sub menus before you will be allowed to accomplish your task Each menu consists of various items or modes such as the Pric Mode Selection Price Setting Mode or the StoS Mode Space to Sales Setting Mode There are currently two different main menus available 1 INTERNAL Service MENU This menu is available only with the 5 main door open It is accessed upon pressing the Control Board s mode button Merlin IV Service amp Parts Manual 19 SECTION 3 VENDER PROGRAMMING This menu contains all the programming modes such as the Selection Price Setting Mode and Space to Sales Mode 2 OPTIONAL MENU This mode is available when Con 2 is set to 1 Menu Levels NOTE The order of the submenus will be somewhat different from the following on board revisions prior to 67100 X Refer to the programming flowcharts at the end of the manual for older revisions INTERNAL Service MENU MODE CASH SALE CArd toKn FrEE Eror tESt Pric StoS SdEP Con DESCRIPTION Cash Counter Mode Used to access the total and individual cash counts Sale Counter Mode Used to acc
60. FL you must use the CPO Mode to payout coins Coin Tube Fill Mode tUFL This mode is used to keep inventory of the exact coin tube levels as each coin is inserted During this mode the LED display will register each coin as it is inserted in no particular order and report its value to the Vender s Control Board The Control Board will in turn remember the Coin Mechanism s coin tube levels and automatically deduct a coin each time a coin is paid out through CPO Mode or during a vend This mode can only be used if a Multi Drop Bus Coin Mechanism is in use OPERATION If enter is pressed when this display shows tUFL the Controller will enter the Coin Tube Fill Mode The LED display will go blank allowing the Merlin IV Service amp Parts Manual 25 SECTION 3 VENDER PROGRAMMING deposit of nickels dimes or quarters through the coin insert or coin acceptor inlet chute If home is pressed anytime during this operation the Controller will return to the tUFL display From pressing down will take you to Pressing up will take you to dSAL Note The use of the Coin Mechanism s Manual Coin payout buttons is discouraged to keep from corrupting the coin counts As long as the sales greeting is scroll ing the manual buttons cannot be used Discounted Sale Counter Mode dSAL This mode is very similar to the Sale Counter Mode It allows you to manually extract the am
61. Parts Manual pick up another load of product This allows a quick vend less than three 3 seconds for the next customer Note The Control Board will go through a learning process known as the Learning Mode It will be reset either on power down up or a door opening closing This allows the Vender 5 Controller to decide which is the front or rear product The Learning Mode acts in conjunction with the depth setting to allow for an automatic reload after the rear can has vended How it works The Controller will notice the first long timed out vend cycle during the learning process From this the Controller will know the very next vend will be the front product Column Sequencing Ifa selection has multiple columns assigned to it the same column is vended each time the selection button is pressed until the number of times vended is equal to the depth of the column Then that selection proceeds to the next column assigned This is to allow the columns to vend evenly Sold Out Upon selection the display will cycle to show the vend progress After ten 10 to twelve 12 seconds if a drop of product is not detected the display will show sold out A sold out may be due to 1 The column attempted is jammed therefore product does not drop 2 The column attempted is genuinely sold out or 3 The sensor is out of adjustment and does not detect the product drop 4 Ifany or all selection doesn t have a column ass
62. R O Y A L V E N DO RS Merlin V SERVICE A N D PARTS MANUAL ROYAL V NDORS ROYAL VENDORS Inc 426 Industrial Blvd Kearneysville WV 25430 USA CUSTOMER SERVICE 800 931 9214 1 304 728 7056 Royal Vendors Inc 426 Industrial Boulevard Kearneysville WV 25430 2776 USA Customer Service 304 728 7056 or Toll Free 800 931 9214 Fax 304 725 6579 E mail technicalinquiry royalvendors com parts royalvendors com Web page www royalvendors com Merlin IV Service amp Parts Manual 1 TABLE OF CONTENTS SAFETY SEGMENT sann Re 4 1 General Information ea see ee ea 6 Introduction to Merlin TV ee ire ne ten tior RR ER hee de ini a 6 Merlin IV anan nsn Te Bist bal ce E Pe Sol alae veie rt qo wo 6 Vender Identification u u u recidere center Re RH o PUE Tes EUR i aces n qaa 7 Credit and Replacement Policy iie te c Rn coh N edd berti e an d ceo oie 8 Voltage Requirements pte oe Bin Beeb aes a ha Wal aoc edt saeco ences oce Eten 8 2 Vender Component Explanation u 9 Merlin IV Control Board Including Pinouts 9 Low Transformer ice ottobre o cet e ette kapers 14 Delivery Chute Sensor Including Adjustment n n nsn 15
63. RS Evaporator Fan Motor Assembly I D A235 006 003RV 58 Merlin IV Service amp Parts Manual SECTION 7 EXPLODED VIEWS AND PART NUMBERS Evaporator Fan Motor Assembly ITEM DESCRIPTION PART NUMBER 1 Fan Blade Counterclockwise newer 810077 Clockwise 810045 2 RE EEE 905002 3 I eec cm 939037 4 Motor 35 W 115 839033 5 Machine Screw 8 32 x 1 2 901038 6 FanPlal Leiden tei diee rectus 010058 7 Well Nut ta ng 905026 8 Fan Mounting 231005 9 Sems Screw 28 32 x 3 8 esses nennen 901011 10 Evaporator Fan Motor Assembly CCW includes Items 1 9 303121 11 SmartFan Evaporator Fan Assembly 200211 and after 231060 Merlin IV Service amp Parts Manual 59 SECTION 7 EXPLODED VIEWS AND PART NUMBERS Airflow Vend Mechanism Assembly 200422XX00001 and after 60 Merlin IV Service amp Parts Manual SECTION 7 EXPLODED VIEWS AND PART NUMBERS Airflow Vend Mechanism Assembly 200422XX00001 and after ITEM DESCRIPTION PART NUMBER 1 Vend Mechanism Assembly Airflow 79 Vender 12 column 261710 72 Vender 12 column 262740 42 Vender 10 COlumh sua ura referre ae basa us 264730 2 Backsp
64. Refrigeration activity 15 based on the signal reported to the Control Board from this sensor Pin 2 PIN WIRE FUNCTION NUMBER COLOR 1 BLACK TEMP SENSOR 5 VOLT DC SUPPLY 2 KEY KEY 3 WHITE TEMP SENSOR SIGNAL 4 RED TEMP SENSOR 5 VOLT RETURN TO COMM Auxiliary Temperature Sensor Position P13 This pinout may be available in the future but as of this Service Manual printing it is not available PIN WIRE FUNCTION NUMBER COLOR 1 5 3 2 3 KEY 4 Environmental Controls Position P14 The wiring harness connecting this pinout powers the Refrigeration Relay to power the refrigeration unit Itis also respon sible for powering any optional relays such as the Refrigeration Heater Relay Evaporator Fan Relay Illumination sign lighting Relay and a 24 volt DC counter It powers each relay and counter by providing a constant 24 volts DC to each relay from Pin 1 Upon activation the Control Board will remain neutral for each relay or counter from either Pin 2 3 4 6 or 7 PIN WIRE FUNCTION NUMBER COLOR 8 24 VOLT REGULATED DC 7 IMPULSE COUNTER 6 2X6 FLUORESCENT LIGHT RELAY 5 KEY FAN RELAY OUT 4 2X4 FAN RELAY 3 2X3 COMPRESSOR RELAY 2 2X2 HEATER RELAY 1 2X1 24 VDC 24 Volt AC Power In Position P15 The two 2 wire harness connecting this pinout come from the Low Voltage Transformer Itis imperative the correct harness be connected to this pinout If this harness is not con nected
65. TURES Field proven reliable impact delivery sensor detects the vend to cancel vend cycle Patented learning mode for quick vending Direct drive DC vend motor in each column drives each column s vend rotor No vend mechanism adjustments are necessary to change from 1202 cans to 1602 200z bottles All that is needed is to change the depth setting in the programming and product retainers rear spacers adjustments User friendly menu style programming e Hand Held Computer HHC programming and data retrieval e Realtime clock calendar to control built in timer can display time on LED MERLINIV supports Multi Drop Bus Coin Mecha nisms bill validators and card readers Allows programmable space to sales Custom or Factory settings Capable of setting full escrow to vend even ifa column jams External menu allows access to sales vend counts and error information 2nd Level 3rd Level 6 Merlin IV Service amp Parts Manual Figure 1 1 SECTION 1 GENERAL INFORMATION Both total historical and individual resettable vend and cash counters MERLIN IV can display the sale vend and cash totals historical on the LED upon opening the Vender s main door for easy access VENDER IDENTIFICATION Your MERLIN IV vending machine can be easily identified by taking note of the following three items 1 Vender Serial Plate mounted on the exte
66. WS AND PART NUMBERS Miscellaneous Assemblies Rear View of Vender L D A235 047 003RV 64 Merlin IV Service amp Parts Manual SECTION 7 EXPLODED VIEWS AND PART NUMBERS Miscellaneous Assemblies ITEM DESCRIPTION cene cene cce trn nerunt 1 Refrigeration System 2 Delivery Chute Sensor 3 Delivery Chute Liner Wide Vender Narrow Vender 4 Delivery Chute Wide Narrow Vender 5 Tension Clips 6 Rivets 1 8 v ionic eem ON tC RA Dor 7 Evaporator Cover Smartfan 200422 and after 256033 Smartfan prior to 200422 2 2 022222 0 000000000000 000000000000 256025 35W Evaporator Fan Motor Assembly 256004 8 Self Tapping Screw 1 4 20x1 sss 901003 9 Self Drilling Screw 88 1 2 2 0 1 100 902004 10 SUP CIPS T 906007 11 Pepsi Door Weld Assembly 10 Sel 79 Wide Vender prior to 1533 227510 Cold Drink Door W A 10 Sel 79 W V prior to 1533 216510 PC CD Door W A 1533 and after 79 WV PC CD Door W A 1533 and after 72
67. WV PC CD Door W A 1533 and after 72 NV 12 Inner Door Assembly 79 Wide Vender Inner Door Assembly 79 Narrow Vender Inner Door Assembly 72 Wide Vender Dr Pepper Vision IV 272640 Inner Door Assembly 72 Narrow Vender 264630 13 Pop Rivel funn tsar eme Tode eee ET dence 908018 14 Door Switch 1521 and 835019 15 Door Switch Actuator aa s kayma 231009 16 Evaporator Fan Housing Wide Vender 256080 Narrow Vender eite eap ae kapa 258070 17 Inner Door Cover Assembly Wide Vender 815259 18 Latch Strike Assembly 19 Bracket Ch te Locator etc t Pepe ett 141014 20 Can Chute e ede EE edens 010017 21 PC Board Cover 141903 22 Right Cabinet Vandal Panel 79 specify color 012122 72 specify color 011002 23 Left Cabinet Vandal Panel 79 specify color 010022 72 specify color uu u uuu uuu 011001 24 Mech Support WA eee Ue 256013 25 Mech Support 39 Deep ert eee eto reda e ded atte ee qatay 058001 26 In Line Filter Assembly 011124 27 Main Wiring 842063 28 Chute Assemb
68. a logic level signal to the common position of each select switch When a selection is made the selection switch closes This allows the low voltage signal to travel from the switches common position through the switch and out the normally open position of that switch to the select switch s harness connection on the Control Board Vend Sequence At this time if there has not been a previous sold out the Control Board distributes 24 volts DC through the door and cabinet wiring harnesses and directly to the coil of the chosen vend motor Simultaneously the display will scroll This is an indication to the customer a vend is in progress and to please wait As the vend motor receives power it will turn the rotor in an attempt to vend acan Product Delivery As the can or bottle drops onto the product delivery chute the vibration from the impact will allow the delivery sensor to send a low voltage signal to the Vender s Control Board This indicates that a product has been vended After the Control Board receives the sensor s signal it will take into account how the Vender is pro grammed set depth and will act accordingly Ifthe first can has just vended the Control Board will kill all power to the vend motor at the exact same time that an impact is registered this avoids a multiple vend of the next product to the rear of the cabinet As the next can vends the Control Board will cycle the vend motor to 34 Merlin IV Service amp
69. a u eh li e e re ie e t e He e e e Te ERR 34 Establishing Credit eene es ede RR THERE EIE ERE EE TREE LAORE RE EUR 34 Valid Selection 3 b a wile nente ie ERU E oen ee HR HER 34 Vend Sequence endete nen de e n aa e EO esse UT ERR TREE a 34 Product Delivery aei tete ERSTER ESTE 34 Column sequencing sone ee 34 Sold O i u Saa 34 Resetting Sold Out Selections o tee ERR NR RE A Dre t EE 34 5 Vender Maintenance oasen 35 General Maintenance auto ah TANG Koranen Skee 35 Using The Vender s Error Code System ue es e t te e eR tee tte ee ted ett 36 Error Codes EM METTRE 36 Troubleshootthg n DRE et ae 37 Refrigeration Troubleshooting Flow Chart 4 6 Training GUd men 44 7 Exploded Views and Part Numbers 48 Control Board Wire essensen eee 48 Port Assembly tese eee er 50 Inner Door oed eerte tete d ab E eti a e att vitet bitte ttes 52 Main Door Hinge T Handle And Door Lifter Assemblies 54 Refrigeration System Assembly 56 Evaporator Fan Motor Assembly nn
70. acer Assembly Airflow 79 261720 72 Xender ss salpa tee fe E eerte eter 262750 3 Backplate Airflow Stack 79 Vender 261711 72 Wide Vender Re ete een ied 332704 72 Narrow Vender aoe EH eee eens 264732 4 Product Retainer Left 79 Vender 810093 T2 Ree E oe elt 810095 5 Product Retainer Right 79 810092 eg autores 810094 6 Funnel Angle 810243 7 Rotor Rod A 803035 8 ROTOT C EE 813027 9 Vend Motor eine 839031 10 Rod Retalhier z uit ee E er 256714 11 Screw 40 32 X 3 8 eet 901011 12 Product rasa sa ore e NER DU eti statseid 332702 13 Self Drilling Screw 902004 Hitch Pin Clip some venders have pins 906023 14 Case Support eite te dee tese dere e Ee en aula 811026 Front Rotor Bearing oorr ii 915156 Rear Rotor Bearing 915222 Front Rotor Assembly incl rotor front rotor bearing and motor 332730 Rear Rotor Assembly incl rotor rear rotor be
71. ar tinE function where the display shows YEAr From YEAr pressing down will take you to dLt Pressing up will take you to dAtE Date Function dAtE If lt enter gt is pressed when the display shows dAtE the Controller will enter the date setting tinE function and the display will show the current date with the first two numbers of the date flashing to indicate the month Example 03 00 Pressing up or lt down gt allows you to change the first two numbers of the date If lt enter gt Is pressed from this point the first two numbers of the date lock in and the second set of two digits will start flashing to indicate the day Example 03 28 Pressing up or down allows you to change the second two numbers of the date Pressing home anytime during this process saves any change and returns you to the beginning of the date tinE function where the display shows dAtE From pressing down will take you to YEAr Pressing lt up gt will take you to hour Hour Function hour If lt enter gt is pressed when the display shows hour the Controller will enter the hour setting tinE function and the display will show the current hour in military time with the first two numbers ofthe hour flashing Example 14 00 Pressing up or down allows you to change the hour If enter is pressed from this point the first two numbers of the hour lock
72. aring and motor 332740 Anti bridging Spacer 815392 Anti bridging Spacer Rear 815393 Anti friction sheet etapa aee roter nee abe 915197 Rubber Retainer 915217 Rear Can Retainer anti tilt Spring 810054 Merlin IV Service amp Parts Manual 61 SECTION 7 EXPLODED VIEWS AND PART NUMBERS Vend Mechanism Assembly prior to 200422XX00001 L D A235 046 003RV 62 Merlin IV Service amp Parts Manual SECTION 7 EXPLODED VIEWS AND PART NUMBERS Vend Mechanism Assembly prior to 200422XX00001 ITEM DESCRIPTION PART NUMBER 1 Vend Mechanism Assembly 12 Col 79 Vender 256710 Vend Mechanism Assembly 12 Col 72 Vender 262720 Vend Mechanism Assembly 10 Col 79 Vender 258710 Vend Mechanism Assembly 10 Col 72 Vender 264710 2 Gase Support Wide aus de C eee iens 811026 Self Drilling 902004 Hitch Pin Clip some venders have pins 906023 4 Rubber Strip s itio toute oe seal 915199 5 1 8 Q
73. attery shelf life is three 3 years with the clock turned on and ten 10 years with it off OPERATION If lt enter gt is pressed when the display shows tinE the Controller will enter the Time and Timer Settings Mode and the display will show Y Ear Press ing up or lt down gt allows you to cycle through each tinE function Pressing lt home gt while the display is showing any of the earlier listed tinE functions will return you to the tinE display When completely finished with all tinE functions pressing home from the tinE functions menu returns you to the code level where the display shows tinE Pressing down will take you to StCL Pressing lt up gt will take you to FriG Merlin IV Service amp Parts Manual 27 SECTION 3 VENDER PROGRAMMING 28 Year Function YEAr If enter is pressed when the display shows YEAr the Controller will enter the year setting tinE function and the display will show the year with the first two numbers of the year flashing Example 19 98 Pressing up or down allows you to change the first two digits of the year If lt enter gt is pressed at this point the first two numbers of the year lock in and the second set of digits start to flash Example 19 98 Pressing up or lt down gt allows you to change the second two digits of the year Pressing home saves any change and returns you to the beginning of the ye
74. current configuration setting to start flashing Pressing up or down while the current configuration setting is flashing allows you to toggle the configuration setting between 0 and 1 If changes are made to a configuration pressing lt enter gt will return you to the Configuration List Level and save any change Follow the above process for all configurations which you wish to set When done pressing lt home gt will return you to the Con display From Con pressing down will take you to SdEP Pressing up will take you to rtn if C2 is set to 0 or to ECO if C2 is set to 1 mn Return to Sales Greeting Mode rtn This mode is used to exit the Service Menu and return to the Sales Mode where the display flashes the greeting ICE COLD or PEPSI COLA along with any other display options OPERATION If enter is pressed when the display shows rtn the Controller will revert to the Sales Mode and the greeting will be displayed From pressing down will take you to Con Pressing up will take you to CASH Optional Menu Items Exact Change Value Mode ECO This mode controls the Exact Change Only light If the machine cannot make change for the value or lower specified in this mode the Exact Change Only lamp will light Note 67100 X Board and later versions OPERATION If enter is pressed when the display shows ECO the Contro
75. d REOR 811024 12 ee eben 161508 13 5 32 Retainer RING Q uqu rint Rer depen 906005 14 Pop Rivet 1 8 AIUMINUM 908004 15 Coin Chute Cover ene emm nnne 242517 16 Coin Slot an en rt DD Ep REEL 242513 17 Coin Plate 141516 18 Coin Chute Assembly includes 15 amp 14 242570 19 Self Tapping Screw 8 32 3 8 enne 901011 20 Lever Stop DP iste esee z uki e tee equa dee 242521 21 Validator Cover Assembly DP rr 100504 22 Button Assembly DP 72 u a u g al yala uk ta ee hana a ERR 810052 23 Washer Select Button DP Part of Button Assembly 915230 24 Nut Select Button DP Part of Button Assembly 915229 25 Switch Holder DP Part of Button 915225 26 Switch Miniature a 835001 27 Flavor Card Strip Assembly DP Vision 4 815228 28 Sign Dr Pepper Vision 4 must give of selections SEE NOTE 1 29 Button Bracket Welded Assembly 242550 30 Fl vor Card Strap u DP mie temen 242536 Select Button Assembly Complete includes 22 25 242580 Butt
76. ded PIN WIRE FUNCTION NUMBER COLOR 15 GREEN YELLOW GROUND 14 BLACK VEND MOTOR COMMON Source 13 BLUE WHITE VEND MOTOR 12 12 BROWN WHITE MOTOR 11 11 ORANGE WHITE VEND MOTOR 10 10 KEY PP 9 YELLOW WHITE VEND MOTOR 79 8 RED WHITE VEND MOTOR 78 7 GREEN WHITE VEND MOTOR 77 6 BLUE VEND MOTOR 6 5 BROWN VEND MOTOR 5 4 ORANGE VEND MOTOR 74 3 YELLOW VEND MOTOR 3 2 RED VEND MOTOR 2 1 GREEN VEND MOTOR 1 Features Connection Position P9 The wiring harness connecting to this pinout travels from the Vender s door switch through the bottom of the Vender s main door and to the Control Board Pinout P9 is also used for the optional free vend and no vend key switch kits PIN WIRE FUNCTION NUMBER COLOR 1 WHITE FEATURE PLUG SWITCH COMMON 2 KEY 3 OPTIONAL FREE VEND SWITCH INPUT 4 OPTIONAL NO VEND VEND DISABLE INPUT 5 OPTIONAL OPTION SWITCH INPUT 6 PURPLE DOOR SWITCH INPUT 12 Merlin IV Service amp Parts Manual DEX UCS Connection Position P10 The three 3 wire harness connecting to this pinout comes from the Hand Held Computer jack located inside the Vender s main door near the Control Board The Hand Held Computer HHC plugs into this jack to read and write information from the Vender s Control Board If the HHC is not operating properly check this harness for bad connec tions at the solder joints Also check to ensure the insulator is not cracked from over tig
77. desig nated position codes The following section outlines all the Control Board s pinouts by showing for each The pinout position code as found on the Control Board Example P15 The name purpose of the pinout Example 24 volt power connection A paragraph describing in detail the pinouts purpose and its function and e A table describing the pin number wire number and function of each position The word key refers to the small plastic insert plugged into a position of the connector The purpose of the key Is to prevent connecting the harnessing backwards or upside down The keyed position is a blank position within the pinout no pin in which a key is inserted Some pinouts may have several blank positions with a key plugged into one or more of the positions You can use the key to determine which end of the pinout is Pin 1 Merlin IV Service amp Parts Manual 9 SECTION 2 VENDER COMPONENT EXPLANATION Control Board P1 DISPLAY 0 DEX2 0000 00 SAH LIMS NOLLDYATAS m JO 000 000000 BEEN 105125 doid td SAHOLIMS 6d OOOOOO o s IP E 0000 00 P15 POWER IN 24 AC P3 M D B Figure 2 2 MERLIN IV CONTROL BOARD Standard LED Display Interface Position P1 The four 4 wire harnesses connecting to this pinout travel from the Vender s LED to the Control Board It allows the Control Board to send p
78. dual vend counts This menu may come in handy for a location manager who does not have access to the inside of the Vender but wishes to report problems and get vend counts Programming CANNOT be done through this menu After five 5 minutes without activity if money is inserted or if the coin return lever is actuated the Control Board will revert to the Sales Mode the LED will show the greeting SALE Sale Counter Mode SALE This mode is very similar to the Cash Counter Mode The Sale Counter Mode allows you to manually extract the amount of product vended from your Vender up to 99 999 999 vends The Sale Counter Mode consists of a non resettable total count and individual selection counts These are resettable depending upon the proper configuration setting see Configurations The counts will be preceded by the count type and can be displayed in one 1 or two 2 sets of four 4 digits Examples for both types of Sale Counters are as follows Count Actual 1st 2nd 3rd Type Count Display Display Display Total Sale 5 678 910 SALE 567 8910 Count Selection 678 910 SL number 67 8910 Sale Count OPERATION If lt enter gt is pressed when the display shows SALE the Control Board will enter the Sale Counter Mode The display will flash SALE and the total amount of sales made by the Vender possibly in two 2 sets of four 4 digits see Example 1 above Using lt up gt or lt down gt will cycle
79. e equipment when moving a vender Always wear eye protection and protect your hands face and body when working near the refrigeration system Use only authorized replacement parts Be aware of inherent dangers in rocking or tipping a vender SECTION I ELECTRICAL HAZARDS GENERAL ADVICE Careless or improper handling of electrical circuits can result in injury or death Anyone installing repairing loading opening or otherwise servicing a vender should be aware of this precaution Apply all of the normal pe when handling electrical circuits such as Refrigeration servicing to be performed by qualified personnel only Unplug the vender before servicing Replace electrical cords if there is any evidence of fraying or other damage Keep all protective covers and ground wires in place Plug equipment into outlets that are properly grounded and polarized where applicable and protected with fuses or circuit breakers of the correct size All electrical connections must be dry and free of moisture before applying power WARNING ALWAYS TEST TO VERIFY PROPER GROUNDING PRIOR TO INSTALLATIONIN ORDER TO REDUCE THERISKOFELECTRICALSHOCKAND FIRE SAFETY SEGMENT SECTION II ELECTRICAL HAZARDS A Servicing with Power Off For maximum safety unplug the power cord from the wall outlet before opening the vender door This will remove power from the equipment and avoid electrical hazards Service personnel should remain aware of possible
80. e password 3 To disable the external password set one of the four 4 digits to 0 or a selection that 1s not available as described in Hint 2 32 Merlin IV Service amp Parts Manual OPERATION If enter is pressed when the display shows PAS the Controller will enter the External Password Setting Mode The display will show the current external password with the first number of the four to extreme left of display flashing Pressing up or down allows you to change the flashing digit If lt enter gt is pressed the second number from the left will start flashing By doing this you lock in any changes made to the first digit and you are now able to change the second digit Follow the same process for every digit If the fourth digit is flashing and lt enter gt is pressed you will return to PAS Pressing home any time during this process locks in your setting and returns you to the PAS display From PAS pressing down will take you to FriG Pressing up will take you to LAnG International Language LANG Setting Mode LAnG The MERLIN IV Vender gives you the opportunity to set an international languages of English French Spanish Hebrew or German to show vending messages such as sold out to the customer OPERATION If enter is pressed when the display shows LAnG the Controller will enter the International Language Setting Mode The display will show the cu
81. e u sas pne e 010544 10 Ballast Assembly 79 Wide Vender Non CDC 012940 72 Non GDC ite iet e ede ea 013920 TO DO ii oe ite eee detail testen s data 198920 195910 11 Lamp 010517 12 Lampholder R iret nente et 842003 13 Bottom Lampholder iini niente 842004 14 Changer Door Hinge Assembly 010570 15 Changer Door Hinge Assembly Bottom 010560 16 Bottom Inner Door Hinge n 010550 17 Latch Roller Bracket u iconic entrer hne iones 010516 18 Burst Open Latch Strike 812003 19 Self Tapping Screw 1 4 20x1 901003 20 Self Drilling Screw 48 32 a 902004 21 Carriage Bolt 1 4 20 901007 22 Keps Nut 1 4 20 vs eee 905002 23 Sems Screw 8 32 3 87 901011 24 Pop Rivet EE 908004 25 Bottom Coin Chute Assembly To Coin Box Wide Port 303501 Narfow POM E 012593 26 Hopper Chute Assembly Coin Cup 012538 27 Door Rodi dou es AS um Rie REESE du
82. erate a problem exists within the sealed unit DANGER SEE IMPORTANT NOTE IN BOX BELOW 2 Ifthe sealed refrigeration unit runs when plugged into an external power source the problem more than likely lies between the Control Board the Refrigera tion Relay and the main wiring harness For troubleshooting this circuit refer to Section 6 Vender Maintenance Troubleshooting Refrigeration Problems ELECTRIC SHOCK DANGER When plugging in the refrigeration unit directly to a wall outlet or other power source always ensure that the vender itself is also plugged in to a grounded electrical outlet Failure to do so could cause an electrical shock possibly resulting in severe injury or even death REFRIGERATION SYSTEM FLOW CHART High pressure gas i i Suction line Condenser Discharge line Compressor Gas changing to liquid Changing from high to low pressure liquid p Evaporator Capillary Liquid changing to a gas Accumulator Figure 2 4 18 Merlin IV Service amp Parts Manual SECTION 3 VENDER PROGRAMMING Vender Programming THE NECESSITY OF CORRECT PROGRAMMING Your MERLIN IV Vender must be programmed correctly for it to operate properly There are other modes that may not interfere with normal operation of the Vender or you may not notice the abnormal operation if they are not programmed
83. errors 22 Merlin IV Service amp Parts Manual OPERATION If enter is pressed when the display shows Eror the Controller will enter into the errors descriptive display mode At this point the display will show any and all current Vender errors followed by the descriptive errors for each If no errors exist none will appear on the display but will revert back to the sales greeting after five 5 minutes of no activity If home is pressed anytime during this operation the Controller will return to the Eror display From Eror pressing down will take you to FrEE and pressing up will take you to tESt CLEARING ERRORS To clear an error wait until the error to be cleared is shown on the LED display Then immedi ately press the up or down button and hold it in for at least two 2 seconds and the error will disappear Follow this procedure for each error Column Test Vend Mode tESt EESE This mode is used to vend test by column not by selection After entering into this mode you will have to pick the column which is desired to be tested By pressing the lt enter gt button the Control Board will vend from that column No money is needed This mode will test the Control Board s ability to distrib ute 24 volts DC to the proper vend motor upon command It will also test the mechanical part of the vending circuit such as the vend motor and rotor It does not test the Control
84. ess the total and individual vend counts Card Counter Mode Used to access the cash and sales counts of all card vends Token Counter Mode Used to access the cash and cost counts for all token vends Free Vend Accounting Used to access the cash and cost counts for all free vends Errors Mode Used to read and clear Vender errors Test Vend Mode Used to free test vend from columns Price Setting Mode Used to program selection prices Space to Sales Mode Used to program columns to vend from select buttons Set Vending Depth Used to program vending depth per selection Configurations Mode Used to set Vender options Return to Sales Used to return to the sales greeting mode if Con 2 is set to 0 20 Merlin IV Service amp Parts Manual Optional Menu t con 2 is set to 1 ECO CPO tUFL dSAL diFc SdiS StCL FriG PAS Exact Change Only Mode This mode controls the Exact Change Only light Coin Payout Mode Used to payout coins from Coin Mechanism Tube Fill Mode Used to fill Coin Mechanism tubes Discounted Sale Counter Used with discount prices or free vend switch Discounted Differential Cash Counter Used with discount prices or free vend switch Set Discount Pricing Automatically reduces vend prices during the day uses timer Set Timer Controlled Selections Used to choose the selections to turn on off Timer Mode Used to program on off times for selections ref
85. et one turn Turning the adjustment screw clockwise makes the sensor more sensitive and counter clockwise makes it less sensitive Test vend after every 1 4 turn For Multiple Vending from all columns make sure the sensor is adjusted to the Factory specifications as listed above Next turn the adjustment screw clockwise 1 4 turn to increase sensitivity Test vend 7 12 columns watch light on the board for a good on and off flash If still Multiple Vending turn the adjustment screw an additional 1 4 turn clockwise until proper adjustment is made For Dry Vending from all columns make sure the sensor is adjusted to the Factory specifications as listed above Next turn the adjustment screw counter clockwise 1 4 turn to decrease sensitivity Test vend all columns If still Dry Vending turn the adjustment screw an additional 1 4 turn counter clockwise until proper adjustment is made TESTING THE DELIVERY CHUTE SENSOR Make sure the Vender is plugged in and the Controller has power the LED display on the front of the Vender will be lit and the Coin Mechanism will accept coins The Sensor Indicator Lamp will blink upon impact on the delivery chute Lightly tap the chute with a tool or your fist to simulate a can drop 1 Locate the Sensor Adjustment Indicator Lamp on the lower right corner of the Vender s Control Board Under normal conditions as in stand by the lamp should be off 2 Test the sensor by vending from column
86. eting Pressing home anytime during the process will save changes and return you to the dSt display From this point pressing down will take you to dAY Pressing up will take you back to dLt Daylight Savings Time Function dLt This option allows for the automatic adjustment of Daylight Savings Time If enabled the time will automatically be adjusted forward one hour at 2 00 a m 2 02 a m at the latest on the first Sunday of April and similarly adjusted back one hour on the last Sunday of October If enter is pressed at this display the Control Board will enter the Daylight Savings Time Enable Disable Mode The display will show dLt and flash the current setting Pressing up or down allows you to change the flashing setting back and forth between 0 and 1 If set to 1 Daylight Savings Time will be enabled If set to 0 Daylight Savings Time will be disabled Pressing lt enter gt anytime during the process will save change and returns you to the start of the Display Time Mode where the display will show dLt From this point pressing down will take you to dSt Pressing the up button will take you to the yEAr mode Note This is important if you are using the timer function set to 1 Refrigeration Parameters GEB le This mode is used to control the environmental aspects of the vender It controls the refrigeration system by allowing you to pr
87. flash the prompt with the word OFF if that relay is currently off or the word ON if that relay is currently on Pressing lt up gt or lt down gt will toggle the alternate display word between OFF and ON Pressing lt enter gt at this point will override that relay s current status until either the status is changed or until the rELY mode is exited completely The display will return to the relay test mode When the rELY mode is exited all relays will return to the state they were in prior to entering the mode NOTE In this feature the user has the ability to continuously turn the compressor on and off Be aware that quickly re starting the compressor can result in serious damage to the compressor 67100 8 AND BEFORE Note The FriG Mode is only applicable in venders using Electronic Refrigeration Mode However if the setting is set to 1 without the use of electronic control the display will show unnecessary FriG errors OPERATION If enter is pressed when the display shows the Controller will enter the Refrigeration Mode and the display will show Cuti Pressing up or down allows you to cycle through all six 6 FriG functions When completely finished with all program ming in the FriG Mode pressing exit while the display is showing any of the earlier listed FriG functions will return you to the FriG display F
88. hazards from hot components although electrical power is off B Servicing with Power On Some service situations may require access with power on Only fully qualified service technicians should perform power on servicing Particular caution is required in servicing assemblies that combine electrical power and mechanical movement Sudden movement to escape mechanical action can result in contact with live circuits and vice versa It is therefore important to maintain maximum clearances from both moving parts and live circuits when servicing WARNINGS 1 ONLY FULLY TRAINED PERSONNELSHOULD ACCOMPLISH POWER ON SERVICING SUCH SERVICE BY UNQUALIFIED INDIVIDUALS CAN BE DANGEROUS 2 LIGHTING CIRCUITS CAN BEHAZARDOUS ALWAYS DISCONNECT FROM POWERSUPPLY BEFORE REPLACINGA BULB ORSERVICINGTHE VENDERIN THATAREA 3 NEVERUSEA HOSE PRESSURE WASHER ORANY CLEANINGMETHODTHAT COULD WET ELECTRI CAL COMPONENTS SEE CLEANING SECTION OF MANUAL FOR SUGGESTED CLEANING METHODS IF WATER CONTAMINATION OFELECTRICALCOMPO NENTSISSUSPECTED USE QUALIFIED ELECTRICAL TESTINGEQUIPMENTANDTESTMETHODS TO ASSURETHAT VENDER IS NOTAHAZARD BEFORE APPLYINGPOWER FOR ANY REASON Merlin IV Service amp Parts Manual 5 SECTION 1 GENERAL INFORMATION General Information INTRODUCTION TO MERLIN IV The MERLIN IV can and bottle vender is capable of vending most packages It uses a Control Board to manage vending operations This Control Board must
89. htening PIN WIRE FUNCTION NUMBER COLOR 1 RED VMC TRANSMIT DEX RECEIVE DATA TIP 2 KEY 3 WHITE VMC RECEIVE DEX TRANSMIT DATA RING 4 GREEN DEX COMMON DEX UCS Connection Position P11 The three 3 wire harness connecting to this pinout comes from the external Hand Held Computer jack located on top of the welded port assembly The Hand Held Computer plugs directly into this jack while the Vender s main door is closed to read information from the Vender s Control Board Information cannot be written to the Vender s Control Board unless the Vender s door switch is in the door open position If the HHC does not operate properly check the harness for bad connections at the solder joints Also check to ensure the insulator at the jack is not cracked from over tightening PIN WIRE FUNCTION NUMBER COLOR 1 RED VMC TRANSMIT DEX RECEIVE DATA TIP 2 3 WHITE RECEIVE DEX TRANSMIT DATA RING 4 GREEN DEX COMMON SECTION 2 VENDER COMPONENT EXPLANATION Primary Temperature Sensor Position P12 The wiring harness connecting to this pinout travels from the Temperature Sensor to the Control Board The Tempera ture Sensor is mounted on the rear tank above the evaporator fan This harness is molded into the Tempera ture Sensor and should never be cut pinched or spliced together if cut If the harness is cut pinched or improp erly grounded the sensor may give the Control Board false temperature readings
90. igned it will read Sold Out The digital display will indicate sold out and flash the sold out lamp This signals to the customer to make another selection or push the coin return lever for a full refund If set for forced purchase the customer must make an initial selection Ifthe initial selection is sold out the customer will be allowed a full refund or an alternate selection If the Vender is totally sold out of a product illumination of the sold out lamp and the sold out message on the digital display will be continuous No money will be accepted into the Vender in a total sold out condition Resetting Sold Out Selections A sold out condition is only cleared by the Vender s door switch by opening the Vender s main door If a sold out condition is not cleared the Controller will not attempt to vend from that selection The display will not cycle to indicate a vend is in progress It will automatically show sold out upon pressing the select button either before or after reaching a vend price SECTION 5 VENDER MAINTENANCE Vender Maintenance General Maintenance WHAT TO CLEAN A routine cleaning schedule is the best way to insure the optimum possible operation and appearance from your MER LIN IV Vender PART CLEANING METHOD Control Board The Vender s Control Board should always be enclosed inside its cover to protect it Routine cleaning is not necessary but if desired the Controller s area may be
91. ill be sent with all warranty parts This method of shipping is preferred for returning parts to Royal Vendors 2 Credits will only be issued to warranty parts that have been ordered in advance not for parts ordered as stock NO EXCEPTIONS 3 When ordering warranty parts in advance please have the full Vender Unit Serial Number 4 copy of the Packing Slip correct Serial Number and complete Return Material Tag provided with 8 Merlin IV Service amp Parts Manual part are required for sending back parts Please complete the Return Material Tag keeping the white copy for your records and sending the yellow tag back with the attached part Make sure you have your company s name address phone number serial number and model number along with a brief explanation of the problem 5 Ifthe item returned is not under warranty it will be sent back to you at your expense or it will be scrapped 6 All warranty parts should be properly wrapped and packed securely to avoid further damage Refrigera tion units that are returned from the field and have been tapped into tampered with not packaged properly or have had the serial plate removed will void the warranty 7 If parts are not returned within 15 working days the invoice will be due in full VOLTAGE REQUIREMENTS The Vender is designed to operate at a voltage of 115 volts 60 hertz It requires a minimum of 15 amp service The service outlet voltage must not e
92. ill then be able to program the few settings that are individually different This will cut down on program time Individual Setting If up or down is pressed when the display shows ALL the Controller will cycle through each individual setting showing the selec tion number and the current setting If enter is pressed while the display is showing an individual depth setting the current setting starts flashing Pressing up or down allows you to change the flashing depth setting between 1 or 2 Pressing home locks in your setting and returns you to the individual level at the point where you entered it at the setting just changed At this time you will be able to cycle through each individual setting Pressing home from the individual level returns you to the SdEP display From SdEP pressing down will take you to StoS Pressing up will take you to Con Configurations Mode Con Con This mode is used to set Vender options dealing with pricing acceptance payback and a few other optional features While in the Configurations Mode the display will show the configuration followed by the current setting If the display shows C 1 0 this means Configuration 1 is currently set to 0 In other words the Vender is set for single pricing The configura tions are as follows CONFIG SETTINGS Cl 0 Single Pricing 1 Multiple Pricing C2 0 Hide Optional Menu Items 1 Show Opti
93. ion of the Vender s cabinet near the main wiring harness It takes neutral CR1 2 not used Refrigeration Relay Figure 2 3 Merlin IV Service amp Parts Manual 17 SECTION 2 VENDER COMPONENT EXPLANATION 4 The Compressor circulates refrigerant throughout the TESTING THE REFRIGERATION SYSTEM system by pulling low pressure refrigerant vapor from the Evaporator Coil compressing it and forcing it into the Condenser The Condenser aided by the Condenser Fan Motor removes heat from the refrigerant as it flows through the Condenser and releases it to the outside environment The dropping of the refrigerant temperature changes the vapor to liquid The Evaporator Coil allows the liquid refrigerant to absorb heat from the cooling compartment as it evaporates in the coil The falling temperature in the cooling compartment is caused by the continual circulation of refrigerant through the system removing heat from the cooling compartment and transporting it to the outside environment When the temperature drops the Temperature Sensor reports this to the Vender s Control Board When the temperature drops below the preset cut out temperature the Control Board will disable the Refrigeration Relay thus killing power to the refrigeration unit 1 The sealed refrigeration unit can be tested by unplugging it from the top of the main wiring harness and plugging it directly into a power source If unit still does not op
94. ired price has been set press home to save your setting and return to where the display flashes ALL followed by the new ALL price You may now set a few all or different individual prices if desired ndividual Pricing If up or down is pressed when the display flashes ALL followed by the current majority price setting the display will cycle through the individual price settings for each selection The display will flash the selection number followed by the price for that selection Example If selection one is set at fifty cents the display will flash 1 followed by 50 Pressing lt enter gt while a individual selection is being dis played will cause the display to steadily show the vend price for that selection to allow a change to the price Press up to increase the price value in 05 increments or down to lower it in 05 increments After the desired price has been set press home to save your setting and return to where the display flashes P X followed by the new selection price From PriC pressing down will take you to tESt Pressing up will take you to StoS Space to Sales Mode StoS This mode is a very important part of programming It will determine what column will vend upon pressing a particular select button You will use this mode to program column assignments by assigning a column or columns to each selection button that you desire
95. is end of the harness If so check the Control Board the transformer 1s good 3 If110 volts is registered during Step 1 and 24 volts AC is not registered during Step 2 you probably have a bad transformer Unplug the Vender and transformer connections at the transformer 110 volt side Unplug the transformer from the Control Board and remove it from the Vender s main door by locating the side of the transformer that has two 2 built in wires going into the plastic housing 4 Test the sensor by hitting the center of the delivery chute while watching the Control Board s Sensor Adjustment Indicator Lamp The light should blink solidly upon impact SECTION 2 VENDER COMPONENT EXPLANATION Delivery Chute Sensor Adjustment ADJUSTMENT Located below the Sensor Connector is the Sensor Adjustment Trimpot which includes an adjustment screw The trimpot is used to adjust and fine tune the sensor It is capable of turning both clockwise and counter clockwise Located directly above the trimpot is the Sensor Adjustment LED Indicator Light The indicator light is mainly used to aid in adjusting the sensor but can also be used to test its operation during product impact 1 Turn the adjustment screw clockwise until the indicator light comes on 2 Turn the screw counter clockwise until the light just goes out 3 Continue to turn the screw counter clockwise one turn Note Slight adjustments may be needed outside the factory s
96. it 811001 28 Elastic Stop Nut ian eet ne nette eie reme 905004 29 Screw 8 32x1 2 with washers 1 2 901006 Merlin IV Service amp Parts Manual 69 SECTION 7 EXPLODED VIEWS AND PART NUMBERS Select Panel Assembly Rear N ES l l I Z77727 8 Ile SJ arn lt LD A235 051 003RV 70 Merlin IV Service amp Parts Manual SECTION 7 EXPLODED VIEWS AND PART NUMBERS Select Panel Assembly Rear ITEM DESCRIPTION PART NUMBER 1 Coin Return Cup Steel sse 012595 2 PG Board Spacer co iato paena nee pa nea C De d Pe dex EZ a 916027 3 Control Board tenebo t cnt hae Ghee aaa 836101 4 Self Drilling Screw 8 18X1 2 sss 902004 5 Control Board Cover eisen hin ea ete eee ele ener Mike 141903 6 Control Panel Welded Assembly 10 Select 017530 Control Panel Welded Assembly 8 Select 012510 7 Keps Nut 8 32 sanntid stand os 905001 8 Select Switch Harness See Note 1 9 Panel Strap optional a 010531 10 SCIOW EM EE 901041 11 Spring Shield usun eio cte ced Ra Ee reete e etna iets 815164 12 Switch LI fen ente
97. ks similar to the Serial Plate shown in Figure 1 2 with the exception that the model number specified is the refrigera tion unit model as shown below There is currently one model in use Model Compressor Size Usage 8000W Super 1 3 All MERLIN IV Horsepower Venders CONTROL CHIP VERSION NUMBER The Control Chip Version Number is printed on a white decal located to the to top right of the main chip of the Control Board This number is extremely important when calling for service programming help or for matching a replacement Control Board See fig 2 2 MODEL RVCDE 650 10 mE SERIAL NUMBER AMPS 134 199936AA00006 12 5 25oz DESIGN PRESSURES 300 HS 156LS 115V 60HZ 1PH LISTED REFRIGERATED VENDING MACHINE 66E9 SUITABLE FOR OUTDOOR USE Figure 1 2 IMPORTANT NOTE To serve you better we ask you have the following items available before contacting your Royal Vendors service representative Your company s name Your company s phone number area code first Your first and last name The Vender s model number The Vender s serial number The Vender s Control Board revision number if concerning a board or programming DPS OEP It is also very important to have all of the information about your problem available when you call Merlin IV Service amp Parts Manual 7 SECTION 1 GENERAL INFORMATION MODEL RVMCE650 10 Kearneysville WV 25430 USA SERIAL NUMBER AMPS Ri134a 1466BK 01489 12
98. l Board PIN WIRE FUNCTION NUMBER COLOR 1 NOT USED 2 VMC COMMON 2 5DC RETURN TOGROUND 3 RED DROP SENSOR OUTPUT 1 4 BLACK DROP SENSOR OUTPUT 2 5 COMMON RETURN TOGROUND 6 NOT USED Selection Switches Position P7 The wiring harness connecting to this pinout carries a logic level ground signal from Pin 11 of the Control Board to the common position of each Select Switch Upon activation the Select Switch will allow the logic level signal to travel back to the Control Board This will tell the Control Board a particular switch is activated PIN NUMBER 1 2 10 11 12 13 14 WIRE COLOR WHITE YELLOW ORANGE GREEN BLUE BROWN PURPLE GREY BLACK KEY RED PINK FUNCTION SELECTION SWITCH 9 SELECTION SWITCH 8 SELECTION SWITCH 7 SELECTION SWITCH 6 SELECTION SWITCH 5 SELECTION SWITCH 4 SELECTION SWITCH 3 SELECTION SWITCH 2 SELECTION SWITCH 1 KEY SELECTION SWITCH COMMON SELECTION SWITCH 12 SELECTION SWITCH 11 SELECTION SWITCH 10 Merlin IV Service amp Parts Manual 11 SECTION 2 VENDER COMPONENT EXPLANATION Vend Motors Position P8 The fourteen 14 wire harness connecting to this pinout provides common power from the Control Board to each vend motor There 18 one wire in this harness for each vend motor to provide each motor with 24 volts DC when a selection is made Be sure that this harness is properly groun
99. l display the current storage for energy conservation mode temperature setting xx F or xxC depending on the degree dEG mode setting The default storage temperature is 60 F Pressing up or down will adjust the temperature value by 1 0 5 C The set point temperature can be adjusted from 45 F through 75 F Pressing exit at this point will save the displayed temperature and return you to Stor 45 If enter is pressed at the dSP prompt the controller will display dSPX where X will be 0 if the controller is not currently displaying the cabinet temperature 1 if the controller is currently displaying the cabinet temperature after the POS message Pressing up or down will toggle X between 0 and 1 Pressing lt exit gt at this point will save the currently displayed setting and return you to the dSP prompt SECTION 3 VENDER PROGRAMMING If enter is pressed at the rELY prompt the controller will enter the relay test mode by displaying Fan Ifthe exit key is pressed in this mode the user will return to the prompt Using up or down will allow the operator to toggle between the following modes Evaporator fan relay LitE Machine light control relay Htr Heater Kit relay CnPr Compressor relay If lt enter gt is pressed at any of these prompts the controller will alternately
100. lded Assembly Vision 4 CDC 79 242537 Main Door Welded Assembly Vision 4 CDC 72 243550 2 Lamp Bracke teins ni tci o eee mre tete oett lenit 010517 3 Top Lampholder 842003 4 Bottom Lampholder 2 842004 5 Ballast Assembly iota encore renes cie Encre ME epe dde 231560 6 Self Tapping Screw 1 4 20x1 901003 7 Screw 532 35 8 i oi s etus dt I ME egit honc NE ats oe 901011 8 Validator Vault Welded Assembly 242530 9 Button Bracket Welded Assembly DP Vision 4 242550 10 Changer Vault Welded 161523 11 Port Body Welded Assembly CDC 303503 12 Validator Vault Brace 79 edere db e Ee tens 242511 Validator Vault Brace 72 2 243501 13 Coin Box Welded Assembly Vision 4 CDC 231550 14 L tch Roller Bracket iui 242512 15 Burst Open Latch 812003 16 Bottom Inner Door Hinge semen 010550 Merlin IV Service amp Parts Manual 83 SECTION 7 EXPLODED VIEWS AND PART NUMBERS Coin Insert Assembly Front Dr Pepper Vision 4 1 D A23
101. ll wiring connections from board to refrigeration unit Check voltage at wall outlet during the peak of the load with all units 1f any others are present In circuit running SECTION 5 VENDER MAINTENANCE Merlin Troubleshooting Use the following section to troubleshoot your MERLIN IV vender in the case you have a problem in one of the following areas power acceptance coin or bill vending or refrigeration Although we have added what we felt are the most encountered problems your specific problem may not be here If this is the case please contact your local Royal Vendors service representative TROUBLE Coin mechanism will not accept coins No acceptance or rejects percentage of good coins Accepts coins but gives erratic no credit POSSIBLE CAUSE No power to Vender s main door lights not lit or no power to transformer Control Board Coin mechanism harness to Control Board is cut or disconnected Short in coin mechanism Defective Control Board Coin return lever Acceptor is dirty or foreign matter is in the path Coin changer is improperly tuned if tunable Defective Control Board If erratic or no credit Acceptor coin mechanism If no credit defective harness between coin mechanism and Control Board If no credit defective Controller COIN ACCEPTANCE CORRECTIVE PROCEDURE Check to make sure the LED and the sign lighting are lit If not check power at transformer
102. ller will enter the Exact Change Value Setting Mode The display will show the exact change value Pressing up or down allows you to adjust the value Pressing lt home gt will save the currently displayed value and return you to the ECO display From ECO pressing lt down gt will take you to Con Pressing up will take you to CPO Payout Mode This mode allows you to payout coins from the Coin Mechanisms Tubes through the Control Board This mode is mainly used because some types of coin mechanisms do not have payout buttons switches on them This can also be used as a test to confirm the Control Board s ability to payout coins will payout the same as after a sale OPERATION If enter is pressed when the display shows CPO the Controller will enter the coin payout mode and display the lowest coin value 05 Using up or down will allow the user to cycle through all coin values available for payout If up or down is pressed and held at this point a coin of the displayed value will be paid out The word PAY will be displayed as coins are paid out Coins will continue to payout as long as up or down is held If home is pressed anytime during this operation the Controller will return to the CPO display From CPO pressing down will take you to ECO Pressing lt up gt will take you to tUFL Note If you are using the tU
103. located beneath outside the cooling compartment next to the Compressor it can be seen from the front with the door open The Con denser removes heat from the high pressure vapor discharged from the Compressor and condenses it to a high pressure liquid The Condenser and Evaporator Coils have aluminum fins attached to effectively increase heat exchange surfaces Starting Relay The Starting Relay is mounted on the side of the Compressor Housing The Compressor Motor has two windings a start and a run winding To give the motor torque when it first starts the Starting Relay Switches in the additional start winding After the motor gets up to speed the relay opens the start winding and the motor continues using only the run winding SECTION 2 VENDER COMPONENT EXPLANATION Thermal Overload The Thermal Overload is a heat sensitive device mounted on the side of the Compressor Housing If the Compressor Motor gets too hot or draws an excessive amount of current the Thermal Overload will open breaking the circuit to the Compressor After the Compressor cools to a safe operating temperature the Thermal Overload will close allowing the Compressor and Condenser fan motors to restart Condenser Fan and Motor The Condenser Fan and Motor located beneath the cooling department are a forced air device using outside ambient air to cool the surface of the Condenser Coil The Condenser Fan and Motor run while the Compressor operates Evap
104. ly Merlin IV Prior to 1521 010030 1521 after ec eterne eme dete repeat en 281010 26 Flush Mount T Handle Assy used w CDC Prior to 1521 812176 21521 and after centeno 812289 27 Door Roller Assembly 141180 28 IET oM ROLE 803002 NOTE 1 There are various parts Please specify model and serial number at the time of order NOTE 2 This part is not available individually It must be ordered as an assembly Merlin IV Service amp Parts Manual 55 SECTION 7 EXPLODED VIEWS AND PART NUMBERS Refrigeration System Assembly sss uu 3 ES e RA TTS Je rt TE OPTIONAL I D A235 045 003RV 56 Merlin IV Service amp Parts Manual SECTION 7 EXPLODED VIEWS AND PART NUMBERS Refrigeration System Assembly ITEM DESCRIPTION PART NUMBER 1 Heat Exchahge et ELE Re 210425 2 Dij p T 824005 3 ED 820007 4 Condenser Fan 839010 Condenser Fam blades ete sed tassi 810014 Condenser Fan Motor Bracket a 810006 5 Screw 310 92X 2 teo e tel attt d oe 901006 6 1 3 Capacitor Start
105. ly Wide Vender 256070 Narrow Vender 258001 29 Condenser Baffle 010403 Condenser Baffle Narrow M IV 258401 30 Rear Baffle 010037 31 Condensate Pan 815368 32 SOMOS REPE ED dende sa 33 Self Drilling vene Rp 34 Drain TUBS isisisi ey 35 Door Switch Before P O 1521 Caster Kit Assembly Heavy Duty 256130 Mesh Cabinet Back Wide 141001 258004 Steel Cabinet Back Wide 010215 Steel Narrow 258005 Drain Hose Clip ert ere EYE E UE 906025 Merlin IV Service amp Parts Manual 65 SECTION 7 EXPLODED VIEWS AND PART NUMBERS Cold Drink 1533 amp before Door Assembly Front SAN 8 Sel N 268510 Left Side 79 W 032505 019507 Top Trim 032504 Pa Narrow a a 044513 52 74 Bottom Trim Wide 032504 MN Narrow 044514 032506 Ge lt Ec n RU 2 2 019508 wa L a LLLA LD A235 048 003RV 66 Merlin IV Service amp Parts Manual SECTION 7 EXPLODED VIEWS AND PART NUMBERS Door Assembly Front ITEM DESCRIPTION PART NUMBER Pop Rivet utsatte 908018 2 EE SEE NOTE 1 3 Right Vandal Panel 79 Specify col
106. ng correctly Short in wiring harness from Controller to refrigeration relay Refrigeration relay s contacts are welded together REFRIGERATION PROBLEMS CORRECTIVEPROCEDURE Check for cuts on the two 2 door switch wires going from the switch to the Control Board Also check for bad connections at the door switch the plug at the bottom of the Vender s maindoor and at the Control Board s connection Are any found If not check the door switch Check the door switch to see if it is defective If so replace it Check Control Board by shorting across the two 2 pins for the door switch wiring Control Board s option connection Does this clear the sold out condition If so replace the Control Board Press the service mode button Wait approximately 20 seconds for the board to reset Reprogram the control board Check cut out setting in the FriG mode Correct if necessary Test the temperature sensor by showing the temperature on the display and measuring the actual inside cabinet temperature with a thermometer or by opening closing door to see if the temperature changes Replace if defective Unplug one 1 of the two 2 wires coming from the Control Board to power the relay If the unit cuts off locate the shorted wire to be either on the door side or the cabinet side of the harness and correct or replace defective harness Unplug one 1 of the two 2 pink connector wires coming from the Control
107. nit Disable FriG function The display will show FrG and flash the current setting Pressing up or down allows you to change the current setting Program to 1 Electronic Refrigeration Factory Setting for the refrigeration unit to operate normally or 0 to disable unit Pressing exit anytime during this process will save any change and returns you to the beginning of the FrG FriG function where the display shows FrG From FrG pressing lt down gt will take you to dSP Pressing up will take you to Merlin IV Service amp Parts Manual 31 SECTION 3 VENDER PROGRAMMING Relay Test Function rELY If enter is pressed when the display shows TELY the Controller will enter the relay FriG function to allow you to test the various Vender relays The display will show Fan which is the test mode for the optional Evaporator Fan Motor Relay Pressing up or down allows you to cycle through each relay test mode available RELAYTEST MEANING MODEMENU Fan Evaporator Fan Relay Test requires optional kit Htr Heater Relay Test requires optional kit LitE Illumination Relay Test requires optional kit CnPr Compressor Relay Test If lt enter gt is pressed at any of the four 4 relay test modes the display will flash the name of the relay and then flash off If the relay is currently off and you wish to enable it lt enter gt here If not p
108. njury or damaging the electronics NEVER plug or unplug any electrical connectors with power applied Merlin IV Service amp Parts Manual 35 SECTION 5 VENDER MAINTENANCE Using the Vender s Error Code System The MERLIN IV Vender has a Built in Error Code Diagnostic System that will help you troubleshoot and solve problems This system is best used in conjunction with the Troubleshooting Section in the rear of this Manual The error codes shown below consist of two codes a Main Error and a Detailed Error These errors are not a replacement for your knowledge of the Vender or its operation They will only point you in the general direction of the problem Most Vender parts are independent of one another Because of this most problems can be confined to the item in question such as a LED Display Coin Changer or Select Switch the harnessing connecting it to the Control Board and the Control Board itself Upon opening the 5 main door you will enter the Service Mode The display will flash any Vender Error Codes or none if no problems exist Errors can be cleared from the Eror Mode within the Service Menu Note It is recommended the Error Codes be cleared after correcting any problem s to prevent confusion and unneces sary work in the future Error Codes MAIN DETAILED ERROR CORRECTIVE ACTION SELS SS 1 thru SS 12 sel switch closed Fix stuck button switch or replace switch CHAr CC Changer Communication Check change
109. ntered If any column is flashing this means it is assigned to the selection If a column is not flash ing then it is not assigned to the selection Pressing enter will change a column s flashing condition This allows you to assign or un assign columns If no changes are made pressing home will return you to the Space to Sales Setting list at CStS Ifa change to a selection is made pressing home will return you to the selection level where the display flashes the selection number followed by the columns assigned to that selection Follow this same procedure for all selections that you wish to program Important Note Anything done in this mode will override any previously assigned Factory Standard or Custom Settings When completely finished in Custom Space to Sales Mode pressing home will return you to StoS display From StoS pressing down will take you to PriC Pressing up will take you to SdEP Set Vending Depth Mode SdEP Since the vend motors on a MERLIN IV Vender do not have cams or switches programming electronically the vending depth is extremely necessary With older style Electro Mechanical Venders it was necessary to adjust the vend timing cam by either filling notches or rotating part of the cam to change the vending depth from triple or double to single depth With the MERLIN IV Vender you have a choice of either single or double depth for each selection and not by column
110. ogram the cut in and cut out tempera tures ofthe refrigeration unit The FriG Mode also allows you to show the current inside cabinet temperature on the LED during the greeting The temperatures shown on the LED during the greeting and programming can be changed from Fahrenheit to Celsius The FriG Mode has a relay mode allowing you to test any control ling relays in the vender evaporation fan refrigeration ballast and heater Within the FriG Mode there are several different functions as listed below 67100 9 AND HIGHER If enter is pressed at the FriG prompt the controller will enter the refrigeration control mode Using up or lt down gt you can rotate through the various refrigeration control settings Enb Strt StOP dEG SEtP Stor dSP and rELY If lt exit gt is pressed the controller will return to the FriG prompt Press lt up gt to proceed to the next prompt PAS Eb Upon first entry into FriG the controller will display EnbX If enter is pressed at EnbX X will begin to flash indicating that it can be edited If X 1 the energy conservation control will be enabled This means the cabinet temperature will be allowed to rise to the programmed storage level during pro grammed time blocks If X 0 the energy conserva tion mode will be disabled and the machine will function as normal Pressing up or down
111. on 803030 9 Hex Jam Nut 9 16 18 cese eH aus aQ uuu a us 905019 10 T Handle Assembly prior to 1521 812176 1521 and after sjanse Q a ret eere 812289 11 T Handle Body part of T Handle Assembly not available 12 Spring T Handle Assembly part of T Handle Assembly not available 13 Retainer Ring T Handle part of T Handle Assembly not available 14 T Handle Stud part of T Handle Assembly not available 15 Pin T Handle part of T Handle Assembly not available 16 Button Coin 803031 17 Retaining Ring 5 92 u_ un 906005 18 Hinge Coin Return Lever 141506 19 Pin Coin Return Lever 811002 20 Coin Return Lever u u rrt karate E 141504 21 Screw48 32 Xx3 0 Lunn s n ee Dunne 901011 22 Spring Coin Return Lever seem eene 914003 23 Nut Z8 32 1 ap oret e eite tee ben 905001 24 Ramp iiio tet re RU e RR DE HER atdet 141508 25 T HandleHOUSING inue eoe iE 812190 26 Nut 1 4 207 roe aa AS 905002 27 Lever Stop i ung ture NAA danken 141514 28 TsHandle Brace eere rl rre er e de 141513 29 Lock Gylinder Gover uin eee 161532 30 ocrew 38 18 edu Rt ERE uuu uu
112. on Lever Assembly Includes 9 13 161594 NOTE 1 There are various parts Please specify model and serial number at the time of order Merlin IV Service amp Parts Manual 87 SECTION 7 EXPLODED VIEWS AND PART NUMBERS Changer Vault Assembly Dr Pepper Vision 4 DETAIL B 1 D A235 068 003RV 88 Merlin IV Service amp Parts Manual SECTION 7 EXPLODED VIEWS AND PART NUMBERS Changer Vault Assembly Dr Pepper Vision 4 ITEM DESCRIPTION PART NUMBER 1 Changer Vault Welded Assembly WP 303506 2 Port Brace GDC eden 242503 3 Port Body Welded Assembly CDC WP 303510 4 Hopper Mounting Bracket 161515 5 Support Bracket Coin Chute 161537 6 Coin Chute Strap lt DP imeem ner ted 242516 7 Coin Chute Assembly includes 5 6 and 8 242570 8 Goin Chute Cover DP eee 242517 9 3 64 Diameter Cable u ll emm eene 911032 10 Gable Sleeve oe etre e t eee 906015 11 Changer Vault Brace sse nnn 242504 12 Coin Return Lever eee 161593 13 Coin Box Coin Chute Welded
113. on against ESD is to use anti static conductive wrist straps which ground you to the machine before touching the electronic boards If it is not possible to use these at least ground yourself before handling the electronic boards Whatever method you use always handle the electronic boards by the edges Be careful not to touch the components on the Control Board INTRODUCTION TO PROGRAMMING As mentioned earlier in The Necessity Of Correct Programming it is very important your Vender is programmed properly To do this you must understand how the system works and what it takes to program your Vender As you will see after you are able to program one or two modes you will be able to use similar procedures to program all modes MANEUVERING THROUGH LEVELS The first step to understanding MERLIN IV programming is to learn how to negotiate through and around the menu levels to accomplish your task To maneuver through the menu levels you must use the select buttons on the front of your Vender Certain buttons have different meanings You will use these buttons to move up or down through the menus You will also use certain buttons to enter onto a new menu level or to home back to a previous level These four 4 meanings that we have just mentioned are listed below along with the active button for each NOTE Programming Flowchart located in rear of manual BUTTON MEANING FUNCTION 1 UP Increase Next Etc 2 DOWN
114. onal Menu Items 0 Display errors or nonE 1 Display Sales Cash Values and existing error or nonE CS 0 No reset of individual counters Allow reset of individual counts upon reading and door switch actuation SECTION 3 VENDER PROGRAMMING C6 0 Credit will be returned if proper change cannot be made Allow vend regardless of changer tube levels change may not be paid C7 0 Will allow bill acceptance regardless of payout availability 1 Will only accept a bill if coin tubes have enough coins to cover the difference between the bill value and the maximum vend price C8 0 Escrow to vend will act as a bill changer 1 Forced attempt will not act as a bill changer C9 0 Change is automatically returned to customer after a valid vend 1 Will hold the customer s change in escrow to allow a multiple purchase C10 0 Bill escrow disabled Bill escrow enabled Cll 0 All errors displayed I Certain errors displayed C12 0 12 column mode 1 10 column mode Note C2 Version 67100 7 and after OPERATION If enter is pressed when the display shows Con the Controller will enter the Configurations Mode The display will show Configuration 1 and its setting as listed in the Configurations Description If up or down is pressed at this point the display will cycle through each configuration Pressing lt enter gt while the display shows a configuration allows the
115. or 010519 Right Vandal Panel 72 Specify 011501 4 Rain Guard Wide Venders 258504 5 Door HIG a asskspa 810002 6 Carriage Bolt 174 20X1 2 aa tle a asqa a eide 901007 7 Self Drilling Screw 8X1 2 etit dee ia notato de 902004 8 I 95crew 8 32 ananasen ELO tete at e ids 901001 9 TOP Door BUSHING ede crecen 803003 10 Left Side Trim 79 Wide Vender after 1533 141553 Left Side Trim 72 Wide Vender after 1533 142502 11 Top Trim Wide Vender after 1533 012553 Top Trim Narrow Vender 040807 12 Bottom Trim Wide Vender after 1533 012553 Top Bottom Trim 4 Narrow 2 040811 13 Right Side Trim 79 Wide Vender after 1533 012554 Right Side Trim 72 Wide Vender after 1533 013507 Right Side Trim 72 Narrow Vender sse 019508 14 Left Vandal Panel 79 Specify 141002 Left Vandal Panel 72
116. orator Coil The Evaporator Coil is located in the cooling compartment As low pressure liquid passes through the Evaporator Coil it absorbs and removes heat from the compartment as it changes to vapor The Condenser and Evaporator Coil have aluminum fins attached to effectively increase their heat exchange surfaces Evaporator Fan and Motor The Evaporator Fan and Motor are a forced air device circulating air throughout the cooling compartment and over the heat exchange surface of the Evaporator Coil The Evaporator Fan and Motor run continually Capillary Tube The Capillary Tube is located in the refrigerant line between the Condenser and Evaporator Coil The small diameter tube is used as a metering device to control the flow of liquid refrigerant to the Evaporator Coil This creates low pressure causing the refrigerant to vaporize and absorb heat as it the place of the Temperature Control thermostat used over the past several years in electro mechanical Venders The Refrigeration Relay is responsible for powering the Compressor and Condenser Fan Motors The Refrigeration Relay consists of a coil powered by the Control Board 24 volts DC and a double pole switch When the Control Board completes the circuit to the Refrigeration Relay the Relay will energize closing the contact between the common and the normally open positions When this happens power 110 volts travels from the Refrigeration Relay to the main wiring ha
117. ouble Bulb 2 nte Roth 838024 Ballast Assembly Flat Display Double Bulb 122528 26 Transformer Assembly eee entente nter enne 842147 27 Button Assembly u SSS not available 28 Washer Select Button not available 29 Nut Select Button not available 30 Holder un iu a a State not available Complete Button Assembly items 27 28 29 30 816016 31 SWITCH Miniature issues aan u a uu s 835001 32 GOIN BOX WIA u audere rte t t RE 010580 Merlin IV Service amp Parts Manual 93 SECTION 7 EXPLODED VIEWS AND PART NUMBERS Flat Horizontal Display Select Panel 1 D A235 074 003RV 94 Merlin IV Service amp Parts Manual SECTION 7 EXPLODED VIEWS AND PART NUMBERS Flat Horizontal Display Select Panel ITEM DESCRIPTION PART NUMBER 1 Door Welded Assembly Flat Display 72 278552 2 LED Display Assembly Q a u I etre trem einn 010593 3 Goin Plate ree e RERO RUE 141516 4 Security Plate Welded 216530 5 T Screw 1 4 20 X EEE EE e ie ERROR REPRE Gases 901037 6 LED Lens Part of LED Assembly 916032 7 Security Plate Decal ener 845641 8 Bushing for coin return butt
118. ount of product dispensed through your Vender during the discounted sales periods up to 99 999 999 The Sale Counter Mode consists of a non resettable total count and individual count per selection which are resettable depending upon the proper configuration setting see Configurations The counts can be displayed in up to two 2 sets of four 4 digits Examples for both total and individual counters are Discount Actual 1st 2nd 3rd Count Count Display Display Display Type Total Sale 5 678 910 SALE 567 8910 Count Selection 678 910 SL number 67 8910 Sale Count OPERATION If enter is pressed when the display shows dSAL the Controller will enter the Discounted Sales Counter Mode The display will flash SALE and the total amount of discounted sales made by the Vender This can be shown in two 2 sets of four 4 digits as shown in Example 1 above Using up or down will cycle through individual discounted sales counts for each selection The display will flash individual counts as shown in Example 2 above If home is pressed anytime during this operation the Controller will return to the ASAL display From dS AL pressing down will take you to tUFL Pressing up will take you to CLEARING INDIVIDUAL COUNTERS If the Configura tions Mode is set to allow the individual counters to be reset the individual counters will reset upon reading at least one
119. ower to and communicate with the LED If this harness is cut or disconnected the LED will go blank If this harness is pinched you may see broken segments on the LED with various segments of the display lit 10 Merlin IV Service amp Parts Manual E Prom Chip White Decal software revision PIN WIRE NUMBER COLOR 1 2 3 YELLOW GREEN BROWN RED FUNCTION DISPLAY 5 VOLT DC POWER DISPLAY CLOCK DISPLAY DATA DISPLAY 5 VOLT DC RETURN TO COMMON SECTION 2 VENDER COMPONENT EXPLANATION Multi Drop Bus Position P3 The five 5 wire serial harness connecting to this pinout provides power and communications to and from the Control Board for the Coin Mechanism the optional 24 volt Bill Validator and or the optional Debit Card Reader If this harness is cut pinched or disconnected you will noticeably lose power to the Coin Mechanism PIN WIRE FUNCTION NUMBER COLOR 1 WHITE MDB 35 VOLTS DC UNREGULATED 2 BROWN MDB 35 VOLTS DC RETURN TO COMMON 3 KEY KEY 4 BLACK RECEIVE MDB TRANSMIT 5 RED VMC TRANSMIT MDB RECEIVE 6 GREEN VMC MDB COMMON 7 BLUE NOT USED Delivery Sensor Position P4 The two 2 wire harness connecting to this pinout is a gray shielded cable harness It should never be cut pinched or spliced This harness is formed into the impact sensor mounted beneath the center of the delivery chute It travels through the bottom of the Vender s main door to the Contro
120. power at vend motor during multiple vend 24 volts DC If power is present the Control Board is at fault Check the vend motor to ensure the gearing within it is OK Ensure all products within each column are the same Enter Space to Sales and make sure the columns are set correctly according to the buttons Check wiring at the each vend motor at the bottom of the Vender s main door and at the motor s connection of the Control Board Check the wiring at each select switch and at the select switch s connection of the Control Board Check to see if the delivery sensor adjustment LED is constantly on If so turn the adjustment screw counterclockwise until adjustment LED goes out Continue to turn it counterclockwise one and a half 1 1 2 turns Replace defective sensor Merlin IV Service amp Parts Manual 39 SECTION 5 VENDER MAINTENANCE TROUBLE No vend from some but not all columns allows refund or second choice LED not lit POSSIBLE CAUSE Unplug the sensors connection from the Control Board if the adjustment LED stays on Make sure the LED display acknowledges the selection switch Individual wire that runs from the motor connection of the Control Board to the vend motor of the defective column Control Board If no power check for 24 volts AC at the Control Board s power connection Press Controller s mode button Does LED light Power the Vender down and up Does LED light
121. properly As a whole improper programming could cause the following problems MODE PROBLEM SEEN Pric Wrong prices even free vending StoS Columns not vending or wrong columns vending Con Vender options such as forced vend escrow not working properly SdEP Vender multiple vending or long vend cycles StCL If enabled with use of timer or key switch will disable selections tinE Will disable selections or Refrigeration System if turned on FriG Will keep the unit from running or allow warmer colder temperatures PAS Will keep you from accessing the external password mode LAnG Will display different languages for display messages PRECAUTIONS TO TAKE WHEN WORKING WITH CONTROL BOARD As with any printed circuit board our electronics are very sensitive to Electrostatic Discharge ESD Simply walking across a tile or carpeted floor can generate a range of 30 000 to 50 000 volts of electricity One ESD can be enough to seriously damage your Control Board or at least weaken it enough that erratic problems could occur in the future Even a discharge surge under 100 or 200 volts is enough to create shorts or problems within the circuitry of the electronics It is advised when storing the electronics that they be kept in their anti static bags even if the electronics are thought to be defective Ifa Control Board is thought to be defective and is really not it soon will be after being charged with ESD The ideal preventi
122. r harness connections TS Changer Tube Sensor Consult changer manufacturer IC Inlet Chute Blocked Check Vender s coin chute for blockage tJ Changer Tube Jam Check changer s coin tubes tube sensors CrCh Changer ROM Checksum Consult changer manufacturer ACCE EE Excessive Escrow Check for stuck coin return lever nJ Acceptor Coin Jam Check for blockage dirty sensor in acceptor LA Low Acceptance Rate Consult changer manufacturer Chut CS Chute Sensor Always On Adjust Chute Sensor refer to Section 3 StS DAxx Double Assigned Column Correct space to sales setting if necessary UAxx Unassigned Column Correct space to sales setting if necessary bUAL bS Bill Validator Sensor Remove obstruction or clean sensors biLL Bill Validator Motor Consult bill validator manufacturer bJ Bill Jam Remove jammed bill or clean bill sensors bOPn Bill Validator Cash Box Open Close bill acceptor cash box bFUL Bill Validator Cash Box Full Remove bills from cash box bC Bill Validator Communications Check bill validator harness connections FriG SEnS Temperature Sensor Check for a cut disconnected temperature sensor CoLd Sensing Temperature 3 Degrees below Cutout CnPr Not Cooling Within 30 Minutes Of Cut in ACLo Less Than 95 Volts For Greater Than 30 Minutes 36 Merlin IV Service amp Parts Manual Check for a welded contact in refrigeration relay or shorted wire from board to Refrigeration Relay Check FrG in programming and check a
123. r service manual or validator representative Replace validator and test acceptance and erasure of credit Replace Controller and test acceptance and erasure of credit SECTION 5 VENDER MAINTENANCE TROUBLE Validator takes a bill and allows payback of coins without a selection Multiple vending Wrong product vending upon selection No vend upon selection Dry vend no refund POSSIBLE CAUSE Controller s configurations not set properly If from all selections delivery sensor cut not properly grounded disconnected or improperly set Control Board sending power to motor when not supposed to Mechanical error Misload by Vender loader Space to Sales not set properly Miswired motor Miswired selection Delivery sensor Check delivery sensor harness for cuts or pinches The sensor adjustment LED will constantly be on if a cut is found CORRECTIVE PROCEDURE Access the Venders Configurations Mode and check the Forced Attempt setting Set Venders delivery sensor by turning the adjustment screw 1 clockwise until indicator lights 2 counter clockwise until it goes out 3 counter clockwise I full turn If no progress is made by adjusting replace sensor Note Slight adjustments may be needed outside the factory set one turn Turning the adjustment screw clockwise makes the sensor more sensitive and counter clockwise makes it less sensitive Test vend after every 1 4 turn Check
124. rease or decrease the minutes value Pressing lt exit gt will save the hour and minute setting for the corresponding day value and will return to the prompt for that day Pressing lt exit gt again will return you to the dAY prompt Pressing lt exit gt one more time will return you to the Strt prompt StoP If enter is pressed at the StoP prompt the controller will enter the stop energy conservation time setting routine Upon entry into this routine the display will show dAY Pressing lt exit gt at this point will return to the StoP prompt without saving any changes If lt enter gt is pressed at the dAY prompt the controller will enter the day of the week setting routine Upon entry into this routine the display will show ALL representing every day of the week Pressing lt up gt or lt down gt will rotate through Sun Mon tuE Wed thu Fri Sat or ALL Pressing lt enter gt at any of these prompts will cause the controller to enter the hour minute time setting routine for that day The display will show the current four digit hour and minute setting in 24 hour format The hour setting will be flashing to indicate that it can be modified Pressing lt up gt or lt down gt will increase or decrease the hour Pressing lt enter gt will stop the hour from blinking and cause the minutes to flash indicating that they can be modified
125. ressing either up lt down gt allows the display to flash the name ofthe relay and then flash off If the relay is currently off and you wish to test the circuit by turning it on lt enter gt here Ifthe circuit tested does not work you have five 5 minutes in Test Mode to check voltage Pressing exit from within any relay Test Mode if after a test will allow you to return to the Relay Test Mode Menu where the display will show the name of the relay menu you were just in Pressing lt exit gt from a point on the Relay Test Mode Menu returns you to the beginning of the Relay Mode where the display shows TELY External Menu Password Setting Mode PAS With the MERLIN IV Vender you have the capability to access both total historical and individual selection can counts externally You are also able to read Vender errors externally errors cannot be cleared externally The PAS Mode gives you the option to change the external password to any of your select buttons in a four digit combination or you may decide it best to use the factory setting of 1 3 2 4 earlier software versions used 4 2 3 1 If you do decide to set your own password and happen to forget it just access this menu and the current password will be displayed HELPFUL HINTS 1 Password numbers range from 0 to 9 2 If your Vender only has seven selections you cannot use 8 9 or 0 in your password or you will not be able to enter th
126. rigeration and lighting Refrigeration Mode Used to adjust temperatures and test refrigeration operation External Password Mode Used to set a pass word to access External Menu Language Mode Used to change the display to international languages Return to Sales Used to return to the sales greeting mode door closed state EXTERNAL MENU MODE DESCRIPTION SALE rtn Eror Sale Counter Mode Used to access the total and Individual vend counts Return to Sales Used to return to the sales greeting mode door closed state Errors Mode Used to read and clear Vender errors SECTION 3 VENDER PROGRAMMING Internal Service Menu Opening the Vender s main door and pressing the Control Board s mode button will allow you to access the Internal Menu This section completely outlines all the Internal Menus including descriptions and operation instructions for each mode After five 5 minutes without activity the Control Board will revert to the Sales Mode the LED will show the greeting Note The following menu order pertains to 67100 7 and higher control board Cash Counter Mode CASH CASH This mode allows you to manually extract the amount of cash taken into the Vender through product sales up to 999 999 99 The Cash Counter Mode consists of a total count which is non resettable Individual selection counts are resettable depending upon the proper configuration setting see Configura tions The co
127. rior left side of the Vender door 2 Refrigeration Serial Plate mounted on the kick plate of the refrigeration unit and 3 Control Chip Revision Number mounted on the right side of the Control Board VENDER SERIAL PLATE Note There are two types of serial plates issued see figure 1 2 and 1 3 VENDER SERIAL PLATE The vender s main serial plate shown in figures 1 2 and 1 3 is located on the exterior left side of the vender s main door and has the following information Vender model number Vender serial number Amps required by vender Unit charge of R134A Refrigeration design pressures The vender s model number contains two important pieces of information The machine type such as RVCDE Royal Vendors Cold Drink Electronic It also contains the vender model number such as 650 10 capacity of 650 twelve ounce cans 10 selections How to read a serial number fig 1 2 The first 4 numbers represent the year the vender was produced The 5th and 6th numbers represent the week within the year the vender was produced The Ist letter represents the style of vender The 2nd letter represents the location the vender was built The last five numbers represent the model built with in that week REFRIGERATION SERIAL PLATE The Refrigeration Serial Plate is located at the bottom of the Vender s cabinet in front of the Condenser coil It is mounted to the refrigeration unit kick plate It loo
128. rness for the refrigeration unit REFRIGERATION CYCLE 1 rising temperature in the cooling compartment is reported to the Control Board through the Tempera ture Sensor 2 The Control Board registers the current temperature inside the Vender s cabinet When it rises equal to or above the pre programmed cut in temperature the Control Board will complete the circuit to the Refrigeration Relay to energize its coil 3 The Refrigeration Relay coil closes the contact between the common and normally open positions allowing 110 volts to travel to the main wiring harness to start the Compressor passes through the Evaporator Coil Drier The Drier is located in the refrigerant POWER FLOW TO REFRIGERATION SYSTEM Control Board line between the Capillary Tube and Con denser It traps and removes moisture from the Refrigeration System while allowing oil and refrigerant to pass through the system Accumulator The Accumulator is located in the refrigerant line between the Evaporator Coil and Compressor The Accumulator traps any liquid refrigerant which did not vaporize before it reached the Compressor Refrigeration Relay The Refrigeration Relay to compressor amp condenser fan motor to wall outlet Black 110 VAC NUM White neutral e ise Groun Main Wiring Harness circuits for evap fan motor and door power eliminated for clarity is located in the lower sect
129. rom pressing down will take you to tinE Pressing up will take you to PAS Cut In Function Cuti If lt enter gt is pressed when the display shows Cuti the Controller will enter the Cut In Setting FriG function and the display will show the current Cut In Temperature Setting Factory setting 41 F Pressing lt up gt or lt down gt allows you to change the Cut In Setting The setting can be adjusted between 39 F to 45 F 4 C to 7 C Pressing lt exit gt anytime during this process will save any change and returns you to the beginning of the Cuti FriG function where the display shows Cuti From Cuti pressing down will take you to Pressing up will take you to Cuto Cut Out Function Cuto If lt enter gt is pressed when the display shows Cuto the Controller will enter the Cut Out Setting FriG function The display will show the current Cut Out Temperature Setting Factory setting 29 F Pressing up or down will allow you to change the Cut Out Setting The setting can be adjusted between 24 F to 34 F 4 C to 1 C Pressing exit anytime during this process will save any change and returns you to the beginning of the Cuto FriG function where the display shows Cuto From Cuto pressing down will take you to Cuti Pressing up will take you to dEG Select Degree Function dEG
130. rrent language being used Pressing lt up gt or lt down gt allows you to change the language to one of the follow ing EnGL English Language HEbr Hebrew Language FrEn French Language GEr German Language SPAn Spanish Language Pressing lt home gt anytime during this process saves any change and returns you to the LAnG display From LAnG pressing down will take you to PAS Pressing up will take you to rtn ma Return to Sales Greeting Mode rtn This mode is used to exit the Service Menu and return to the Sales Mode where the display flashes the greeting ICE COLD or PEPSI COLA along with any other display options OPERATION If enter is pressed when the display shows rtn the Controller will revert to the Sales Mode and the greeting will be displayed From pressing down will take you to LAnG Pressing up will take you to CASH SECTION 3 VENDER PROGRAMMING External Menu By entering the correct four digit password when Vender Is in stand by condition display is showing the greeting a credit is not established and the Vender is not set for free vend you will access the External Menu This menu consists of three 3 menu items previously discussed in the Internal Menu The External Menu is designed to give you access to a few features such as total and individual per selection vend counts Vender error diagnostics and a clearing feature for indivi
131. s for each selection This mode works in conjunction with the built in timer in the tinE Mode Before entering tinE Mode you must set the selections to 1 in StCL Mode After the StCL Mode you may set the discounted price for each desired selection Then set the time you wish the discounted selection to be activated by using the dScn settings in the tinE Mode under the day function OPERATION If lt enter gt is pressed when the display shows SdiS the Controller will enter the Discount Price Setting Mode The display will flash ALL for all selections and flash the last discount price value that ALL was set at This is referred to as the selection level If lt enter gt is pressed at this point the display will steadily show the discount value for all selections Press up to increase the discount price value in 05 incre ments or down to lower it in 05 increments If home is pressed after adjusting the price your new discount price will be saved and the display will return to the selection level You may now set a few all or different individual discount prices if desired If up or down is SECTION 3 VENDER PROGRAMMING pressed when the display flashes ALL for all selec tions then flashes the last discount price value that ALL was set at the display will cycle through the individual discount price settings for each selection The display will show the selection number follo
132. sedet te 835012 13 SWITCH clo EROR 815018 14 Keps 0 CERES 905018 15 Button Assembly cence 815025 16 Transformer Assembly 842147 17 Transformer 010063 18 Self Tapping Screw 8 32x3 8 901002 19 Slimline u a peo peii edes 838002 Splash Guard protect sel 815303 NOTE 1 There are various parts Please specify model and serial number at the time of order Merlin IV Service amp Parts Manual 71 SECTION 7 EXPLODED VIEWS AND PART NUMBERS RVMC RVCD Vandal Resistant Door CDC Front LD 2A235 034 003RV 72 Merlin IV Service amp Parts Manual SECTION 7 EXPLODED VIEWS AND PART NUMBERS RVMC RVCD Vandal Resistant Door CDC Front ITEM DESCRIPTION PART NUMBER 1 C D C Door Weld Assembly 79 Wide UHR 198522 C D C Door Weld Assembly 72 Wide UHR 195536 79 Wide Cold Drink 1533 amp 229510 72 Wide Cold Drink 1533 amp 230510 2 Assembly i fette 010593 3
133. setting the Control Board will enter the ALL Setting Mode The display will steadily show ALL and flash the current StCL setting Pressing up lt down gt allows you to change the flashing setting between 0 and 1 Pressing lt enter gt saves any change and returns you to the selection level where the display steadily shows StCL and the new setting At this time you will be able to cycle through each selection to set individual settings If completely done pressing lt home gt from the selection level display shows ALL and current setting will return you to the display Individual Setting If up or down is pressed when the display shows ALL and the current setting the Controller will cycle through each selection showing the selection number and the current setting for that selection Example If the display shows t 3 1 for selection 3 the timer 1s set to on If enter is pressed while the display is showing an individual selection timer setting the current setting for that selection will start flashing Pressing up or down allows you to change the flashing timer setting between 0 and 1 Pressing enter saves any change and returns you to the selection level At this time you will be able to cycle through each selection to set other individual Timer Controlled Selection Settings Pressing home from the selection level will return you to the StCL display
134. sor Voltage returned from chute sensor signaling control board to cancel credit and reset Trimpot R19 on control board is used to increase or decrease sensitivity WHITE 24 VDC BROWN NEUTRAL BLACK RX RED TX GREEN NEUTRAL TyH3HdlY3d SON Figure 6 3 MDB Harness CHUTE SENSOR GROUND O Figure 6 4 Chute Sensor Harness Merlin IV Service amp Parts Manual 45 SECTION 6 TRAINING GUIDE Select Switch Harness See Figure 6 5 Supplies 5 VDC to select switches from position P7 pin 11 Press select button and watch LED reset Signal from switch via N O terminal Check with ohm meter Vend Motor Harness See Figure 6 6 Vend motor power supply 24 VDC from pin 14 at position P8 e Neutral side is closed cycles vend motor If vend motors to right do not vend check black wire 24 VDC from last working vend motor Ifone single motor does not work check neutral WHITE YELLOW ORANGE GREEN BLUE BROWN PURPLE GREY BLACK RED WHITE GREEN WHITE BLUE OL NOILOdT3S LL NOILO3T3S 2 02135 NOILO3T3S Y NOILO3T3S 5 NOILO3T3S 9 NOILO3T3S 4 NOILO3T3S 6 NOILO3 T3S ONO ES ONO WOO ON INO9 ONI WOO ON WOO ON ONO ON WOO ON ONO NOI ON NOS ON WOJ ONO NOD ON OO ON
135. sulation line noise polarity and ground meter is not an option when checking low voltage circuits 44 Merlin IV Service amp Parts Manual Component Highlights Control board Brains of vender Controls all vending operations Chapter 2 Vender Component Explanation for full explanations of control board pinouts and functions Power Supply See Figure 6 1 Supplies 24 VAC 10 to control board Only AC voltage at control board Check for primary voltage to transformer at lamp ballast harness Check for secondary voltage across position P15 pins I and 2 Secondary is protected by a 3 amp fuse Ohm out fuse holder w gt c O m TRANSFORMER Figure 6 1 Power Supply SECTION 6 TRAINING GUIDE LED Harness See Figure 6 2 Supplies 5 VDC to LED Check for 5 VDC across position P1 pins 1 and 4 Ohm out harness Multi Drop Bus MDB Harness See Figure 6 3 Supplies 24 VDC to changer validator and or card reader from position P3 pins 1 and 6 Data transmitted and received by control board Confirm with changer LED on payout works Multiple harnesses may be connected in series for more peripherals check all harnesses 9 MOTISA 40019 TVHLNAIN Figure 6 2 LED Harness Chute Sensor See Figure 6 4 Position P4 on control board Low voltage 5 mV 500 uSeconds impact sen
136. the cooling compartment as it evapo rates in the coil The falling temperature in the cooling compartment is caused by the continual circulation of refrigerant through the system removing heat from the cooling compartment and transporting it to the outside environment As the temperature drops the temperature sensor reports this to the Vender s Main Control Board When the temperature drops below the preset cut out temperature the Control Board will disable the Refrigeration Relay This will break the Refrigeration Relay Switch connec tion shown in Fig 2 3 as CR1 1 thus canceling power to the refrigeration unit REFRIGERATION COMPONENTS The Refrigeration System is a sealed system Cutting or tapping into it will void all the manufacturer s warranty Described in this section are explanations of the Refrigeration System s major components Cooling Compartment The Cooling Compartment is the sealed area of the Vender holding the product for deliv ery This area 1s designed to allow free flowing air to circulate throughout the product Compressor The Compressor is a hermetically sealed unit located beneath outside the cooling compartment The Compressor is a pump driven by the Compressor motor which draws low pressure vapor refrigerant from the Evaporator Coil compresses it and forces it into the Condenser under high pressure The motor is started and controlled by the temperature control Condenser The Condenser is
137. to use You may also decrease the number of the Vender selections Example Your Vender has a total of ten 10 select buttons on the front panel If you wish you may program the controller to only use eight 8 seven 7 or six 6 selections or even less This is done by assigning all additional columns to one of the popular selections being used A benefit of doing this is you will be allowed to allocate the extra columns to a faster moving flavor Space to Sales Mode will come factory set for your type of Vender Upon entering the Space to Sales Mode two different types of settings are available Factory Standard Space To Sales There are eight 8 factory preset settings from which to choose These settings depend on how the Con 12 Mode is set for 12 or 10 columns see Appendix A in the rear of the Manual Custom Space To Sales Allows you to custom configure any column to any selection OPERATION If enter is pressed when the display shows StoS the Controller will enter the Space to Sales Setting Mode The Control Board will always enter at the current Space to Sales Setting If your Vender is pro grammed for custom Space to Sales or if programmed with a Hand Held Computer you will enter at CStS If up or down is pressed at this point you will be allowed to cycle through all Space to Sales Settings Factory Standard Space To Sales Pressing lt enter gt at any Factory Standard Opt
138. u 902004 31 Control Board Cover niece a EE dat 141903 32 Control Board u 836134 33 PG Board Spacer eterne def 916027 Merlin IV Service amp Parts Manual 95 PROGRAMMING FLOWCHARTS 70 4 pue 8 001 29 uv es ung 1 pue 8 001279 I pue 6 00129 rip 1 15 Have HaosHeiasHinou au or 1085 Sps abu 01195 SI ZO suu 1l 1 1 NUS N 1 uu avs 1 pue 7 001479 uoisi eH paomssed 1nouylIMm JJEYSMO 4 96 Merlin IV Service amp Parts Manual PROGRAMMING FLOWCHARTS Sps Sa ver EnA HSVO psomssed I I 1810 jH 139 Haan Huvds uss Hloua Houvd1 I Favo 2109 109 AH I l nuoy y o21A49S AH os Hasr Hoar HonoHanoH ou jes UNS avs de ti Tv 10 Lap Hsr Have HaosHeiasHinou Havel fava IPu49 X3 A 2 001 29 UOISINAH SS Vd 910Jeq Jeadde V 1236 Ilim 4suejse ue Aq Sula 1 001 9 UOISH Y o OL Aq 195 puomssed or
139. u u deti tte ede 842147 Merlin IV Harness Transformer and Fuse to 842210 Fusebox Assembly eie dente detecte de eie quic 842219 15 LED DiS Play I 836012 16 MDB Harness o D usu m eee S n Heec eee edens 842116 Control board housing eme emen nnne 261570 Merlin IV Service amp Parts Manual 49 SECTION 7 EXPLODED VIEWS AND PART NUMBERS Port Assembly 50 Merlin IV Service amp Parts Manual SECTION 7 EXPLODED VIEWS AND PART NUMBERS Port Assembly ITEM DESCRIPTION PART NUMBER 1 Can Stop Mec IEEE 010508 Can Stop Wide Port aient reiten tcr ecrit ocn e nep ener REPE de dese 273508 2 POrt Trim c inm e ect 815019 Port Trim Wide 2 24044440 815249 3 SIN Lese nd SEE NOTE 1 Poit SpaCer Mer 815020 Port Sp cer Wide ekle tate be 815248 5 Port Body W A Merlin IV Narrow Venders 273510 Wide Port WA CDC sh intente tease pd to ebd e ELE Ge added 303510 Wide Port W A 305510 6 Anti Theft Plate Non CDC Wide u 305501 CDC WIide 2 aa an a stt 303503 7 BolE 1 4 20 can uu ds
140. ua ed a 908002 6 Screw 8 32X3 87 eis cece 901011 7 Rod Retainer s e attesten 256714 8 R tor Rodeo ssh T 803035 9 Vend Motor Merlin IV Black s m 839031 1618 and Before 839029 10 Rotor Merlin IV i citet feo ord aa 815305 11 Front Rotor Bearirig cerit ettet tereti s 915156 12 Rear Rotor Bearing lt 2 22 pM DE 915222 13 Product Retainer Left 79 810093 Product Retainer Left 72 Vender eenen 810095 14 Product Retainer Right 79 Vender 810092 Product Retainer Right 72 Vender sse 810094 15 Backspacer Assembly 79 256730 Backspacer Assembly 72 257730 16 Funnel Angle cei teen deeem Rak A 256719 17 Rotor Assembly Front Column 256740 18 Rotor Assembly Rear 256750 19 Anti friction Sheet nea ne ode da sus 915197 20 Gan Eunnel 256712 Rear Can Retainer anti tilt Spring eee 256717 Merlin IV Service amp Parts Manual 63 SECTION 7 EXPLODED VIE
141. unts will be preceded by the count type CL cash level and can be displayed in one 1 or two 2 sets of four 4 digits Examples for both types of cash counters are Count Type Actual Count 1 Display 2 Display 3 Display Total Cash 56 789 10 CASH 567 89 10 Count Selection 6 789 10 CL number 67 89 10 Cash Count OPERATION If enter is pressed when the display shows CASH the Controller will enter the Cash Counter Mode The display will flash CASH and the total amount of cash taken into the Vender This can be shown in two 2 sets of four 4 digits see Example 1 above Using up or down will cycle through individual selection cash counts for each The display will flash individual selection counts as shown in Example 2 above If home is pressed anytime during this operation the Controller will return to the CASH display From CASH pressing down will take you to Pressing up will take you to SALE CLEARING INDIVIDUAL COUNTERS Ifthe Configura tions Mode is set to allow the individual counters to be reset the individual counters will reset upon reading at least one of them and closing the Vender s main door actuating the Vender s door switch EN Sale Counter Mode SALE This mode is very similar to the Cash Counter Mode The Sale Counter Mode allows you to manually extract the amount of product vended from your Vender up to 99 999 999 vends The
142. vable ways in which service might be done Consequently Royal cannot predict all of the possible dangerous results These outlined safety precautions are the basis for an effective safety program Use these safety measures along with the service bulletins helpful hints and product specification sheets when installing or servicing Royal equipment We recommend that persons servicing our equipment maintain a similar commitment to safety Only personnel properly trained should have access to the interior of the vender This will minimize the potential dangers that are inherent in electrical and mechanical devices Royal has no control over the vender once it leaves the premises It is the owner or lessor s responsibility to maintain the vender in a safe condition See installation insert located in the coin box of a new vender for proper installation procedures and refer to the service manual for recom mended maintenance procedures If you have any questions please contact the Technical Services Depart ment at 1 800 931 9214 4 Merlin IV Service amp Parts Manual SAF ETY REGULATIONS Read the safety segment before installation or service Test for proper grounding before installing to reduce the risk of electrical shock and fire Turn off or disconnect power cord from wall outlet before servicing Only fully trained service technicians should service vender when vender has power Remove any product before moving a vender Use appropriat
143. wed by the discount price for that selection Example If selection one Is set at fifty cents the display will flash P 1 followed by 50 Pressing lt enter gt while an individual selection is being displayed will cause the display to steadily show the discounted vend price for that selec tion to allow a change to it Press up to increase the discount price value in the same fashion as above or down to lower it Pressing home after adjusting a price will save that price and return you to the selection level Pressing home while at the selection level will return you to the SdiS display From 5415 pressing down will take you to diFc Pressing up will take you to StCL Set Timer Controlled E Selections Mode StCL This mode is used to choose the selections to turn off either using the built in timer or with the optional key switch kit This mode must be set to enable one or all of the selections for the timer or the key switch to operate The timer or key switch will control any selections set to 1 Selections set to 0 will function normally OPERATION If lt enter gt is pressed when the display shows StCL the Control Board will enter the Set Timer Controlled Selections Mode at the selection level and the display will show ALL From this point two types of settings are possible ALL Setting If enter is pressed when the display shows ALL and the current
144. will return to the toKn display From toKn pressing down will take you to CArd Pressing up will take you to FrEE Merlin IV Service amp Parts Manual 21 SECTION 3 VENDER PROGRAMMING Free Vend Accounting FrEE mg 67100 10 and higher only This mode is used to track cash counts sale counts and cost of all free vends If enter is pressed at the FrEE prompt the controller will enter the first of three sub menus CASH Pressing up at FrEE prompt will take you to the next prompt Eror If enter is pressed at the CASH prompt the control ler will enter the cash value display mode by displaying CASH XXXX XX XX where the X s represent the equivalent free vend cash value received over machine life A decimal will be displayed in the appropri ate position with the lower 4 digits no decimal will be used with the upper 4 digits If the cash amount is less than 5 digits long the upper byte is not displayed Using up or down will cycle through each selection as SLN XXXX XX XX where N will indicate the selection number and the X s represent the resettable value of free vends If exit is pressed anytime during this operation the controller will return to the FrEE prompt If enter is pressed at the SALE prompt the controller will enter the free vend counter display mode by display ing SALE XXXX
145. xceed 129 VAC or fall below 103 VAC The Vender has a three prong three wire grounding cord The Vender must be plugged into a grounded electrical outlet to protect the customer from an electrical shock If you are not sure your outlet 1s properly grounded have it checked by a qualified electrician When you plug in the Vender you should observe the following 1 The florescent lights displaying the Vender sign will come on 2 Therefrigeration compressor will start to run after approximately 5 7 minutes with the door closed 3 The LED display will light VENDER POWER CORD NOTE Extension cords are not recommended unless they are authorized before use by a certified electrician SECTION 2 VENDER COMPONENT EXPLANATION Vender Component Explanation VENDER CONTROL BOARD Including Pinouts Your MERLIN IV Vender is equipped with a Main Control Board which is responsible for most Vender operations In most Venders it is located in the upper section of the Select Panel inside the Vender s main door The Control Board is protected by a cover Removing this cover will expose the Control Board in its entirety along with all of the Control Board s wiring connections IDENTIFICATION The MERLIN IV Control Board can easily be identified by noting the identification number printed on a small white decal on the Control Board s e prom chip The Control Board s identification number is a necessity when ordering
146. y test mode switch is open optional item Harness also used for connections to evaporator fan relay heater relay and light relay Allows relay to energize and close contacts to Temperature Sensor Harness See Figure 6 9 complete 110 VAC hot circuit Supplies 5 VDC to temperature sensor from position P12 pins I and 4 5 VDC from pins I and 4 e 5 VDC return resistance across pins and 2 Setto display temperature on LED compare to thermometer Temperature sensor mounted on rear of cabinet GROUND SHIELD udi En 7 3A331S BLACK NEUTRAL WHITE TEMP SIGNAL RED 5 VDC TEMPERATURE SENSOR 3 3319 3A331S MOVIE NMOS INTERNAL EXTERNAL OPTIONAL Figure 6 8 DEX UCS Harness Figure 6 9 Temperature Sensor Harness REFRIGERATION Figure 6 10 Environmental Control Harness Merlin IV Service amp Parts Manual 47 SECTION 7 EXPLODED VIEWS AND PART NUMBERS Control Board and Wiring L E D ec TO SELECT NY SWITCHES gt VEND p MOTORS amp T DOOR SWITCH C 3 5 ae I D A235 083 003RV 48 Merlin IV Service amp Parts Manual SECTION 7 EXPLODED VIEWS AND PART NUMBERS Control Board and Wiring ITEM DESCRIPTION PART NUMBER Control Board ea eet Gah ee Ged ei 836134 2 LED Display Harness 842081 LED Harness Dr
147. you to hour Pressing lt up gt will take you to dAY Day Function dAY If enter is pressed when the display shows dAY the Controller will enter the tinE function to allow you to set the timer on off times for each day of the week The display will show ALL From this point you have two different options the All Day Timer Setting will enable you to set all days the same in which the timer operates such as ALL of the price mode and Individual Day Timer Settings will give you the option to set all the timer operations different daily Pressing lt up gt or down allows you to cycle from ALL to each day ofthe week If enter is pressed either at ALL or a week day the Controller will enter into that particu lar day The display will show SC 1 then On and then the current first Off time for selections as listed below From here on this will be referred to as the Timer Setting Mode Viewing Only Level If up or down is pressed at the Timer Setting Mode Viewing Only Level the display will cycle to all other available Timer Setting Modes SETTING MODE PROGRAM MEANING SC 1 On 1 OFF time for selections SC 1 Off 1 ON time for selections SC 2 On 244 OFF time for selections SC 2 Off 2 ON time for selections 5 3 3 OFF time for selections SC 3 3 ON time for selections dSen
148. your changes and bring you back to where the display shows the Timer Setting Mode and the time set for that mode Timer Setting Mode Viewing Only Level At this point up or down allows you to access all Timer Setting Modes listed earlier From this Timer Setting Mode Viewing Only Level pressing home again will return you to the day of the week level Press lt home gt again to return to the display of dAY From dAY pressing down will take you to StOP Pressing up will take you to dSt Note If you are setting certain selections to go off and come back on at a programmed time you must first enter SC 1 On to set the first off time for selections When done programming the first off time you must then program the first return on time for the selections by entering into SC 1 Off and programming your return on time For the timer to be able to control the selections you must set the selections to be controlled in the StCL Mode of the Password Protected Menu Display Time Function dSt If enter is pressed at this display the Controller will enter the Display Time Setting Mode and the display will show dSt while flashing the current setting Pressing up or down allows you to change the flashing setting back and forth between 0 and 1 If set to 1 the time of day will be displayed on the LED during the greeting If set to 0 the time will not be displayed during the gre

Service/Parts Manual - D and S Vending Inc.

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