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Merlin IV Plus - Royal Vendors, Inc.

1. TORG WHINEL WHIRED WHTIGRN BLUE 0 0060 6 REAR FRONT COLUMNS COLUMNS 5 0 O KON ORANGE YELLOW RED GREEN E TES SOME MODELS MAY HAVE THE 10 COLUMN E MECHANISM CONFIGURATION THE WIRE PE E COLORS SHOWN NEXT TO THE MOTORS REPRESENT Mm THE LEAD WIRES BLACK IS ALWAYS THE COMMON WIRE 3 BLACK E a Ty BEK La rm Jg RED RED MULTI DROP BUS fi ut I E 3 CHANGER VALIDATOR a m Of fe Hi HI HTI 3 uu m n J uu EE CO N HEATER RELAY e 8 BLACK 3 R a AE E es aM 41 RED a t E g E D E L De De a TR TA DA T a OO O0 IEC L fi m 220 VOLT ul RANSFORMER N fp o rue BED 8 5 8 miell en co 1 0 KVA 2 au 3 422 9 Oo S LIEK ax ge m rT TT SZ SS E El BAK 5 Li Li ic 8 a Y BARN 7 Wel EN RED y RED 3 E 3 al 3 En g 24 E a oc E oc JE Eet ET pe e E zle ER i z CHUTE SENSOR ai o lt p s ee M TEMPERATURE c ef Te SENSOR LU El El verwe ZS D 3 Ziv 3 Ko SLT i BIK E 3 2 2 12 22 E GR EVAPORATOR 3 153 a gt FAN RELAY i x ENI NE gt nn uu no nn e s a d
2. 3 BLACK 3 a UA BOON 7 E RED RED tz z 111 EVAPORATOR EN amp g EN FAN MOTOR oc De ON E co COMPRESSOR 3 BLACK 8 FAN MOTOR El SACK BIA E PLUG CAP RED 1 i A RED STs 3 een DCH 123 S za Ge a PLUG CAP T T SIEL appe cp gt PUG o FA COMPRESSOR FI E ST 9 4 corah erar UJE URPLE En PLUS BROWN D WE y BLACK DO PLUG CAP REFRIGERATION MATO su MAIN WIRING Ra RD DOOR YELLOW 5 YELLOW HARNESS HH ORANGE i ORANGE SWITCH sni zd nm BROWN BROWN zlilE swe gt Z mut BACK Fie E WHTIGRN gt WHTIGRN u WHTRED WHTRED N WHTNEL WHTIYEL BROWN TI WHTIORG h M WHTIORG sm BA v WATBRN o y WHTERN s muj WHTELU E Z u n a HE p pu 110v RED z Li D N PURPLE Y pc 4 4 AC N A sa BLACK poja ET 1 Merlin IV Plus Operation and Service Manual 71 Section 10 Programming Flowchart LLOZ vO 4 9H pue 8 00LZ29 x 1 ats 49MOJ dud UVA I 4emoj pue 8 001429 y I 4euBiu pue LL 00129 Gaubiy pue 6 00L29 a hes uns TIV Jor Hy oua RS ss EET IE an OJO ood aba 01198 SI ZO 4 sulajj NUSN euondo L 0438S si ZO 41 uu nusp 8211125 EUISIUI UM avs NUSN leul9 jxg 1eufiu pue 2 00 L29 SUOISIN8H piomssed jnoyjim JIBPUIMOJJ GBuruwe1501dg UMN Merlin IV Plus Ope
3. Defective harness between coin mechanism and control board Defective coin mechanism Defective control board 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 Merlin IV Plus Operation and Service Manual 33 Section 6 Vender Troubleshooting TROUBLE POSSIBLE CAUSE CORRECTIVE PROCEDURE BILL ACCEPTANCE Validator will not pull Make sure that the validator harnessing is Replace defective or wrong validator in a bill correct for the style of validator being used harness and that it is plugged in properly Acceptance disabled by coin mechanism Make sure changer is plugged in accepts or bad harnessing validator status light is coins and the tubes are full of coins on Changer harnessing not properly Repair or replace faulty harnessing connected If validator accepts replace changer and Replace defective validator If problem test persists replace control board Validator pulls in the Defective wrong cut or miswired Make sure the validator harnessing is bill but won t establish validator harnessing correct for the style of validator being used credit and it is plugged in wired properly Defective validator Replace validator and test Defective control board Replace control bo
4. Press select button and watch LED reset vend switch etc Signal from switch via N O terminal e Door switch e Check with ohm meter Updates door status to control board open closed 2 Depress switch check to see 1f LED resets 3 Check wires at switch for correct positions Vend Motor Harness See Figure 7 6 e Options switches e Vend motor power supply 24 VDC from pin 14 at 1 Allow free vend no vend etc position P8 2 5 VDC on pins 6 and pin for option switch see Neutral side is closed cycles vend motor wiring diagram f vend motors to right do not vend check black wire 24 VDC from last working vend motor e If one single motor does not work check neutral Sh 4 VDC GREEN YELLOW GROUND c BLACK 24 VDC DE WHITE BLUE COLUMN 12 ja 13 WHITE BROWN COLUMN 11 ee WHITE ORANGE COLUMN 10 mm 11 11 WHITE YELLOW COLUMN 9 WHITE RED COLUMN 8 ele le VVHITE 7 GREEN COLUMN 7 717 BLUE COLUMN 6 B 5 4 3 WHITE YELLOW ORANGE GREEN BLUE BROWN COLUMN 5 ORANGE COLUMN 4 FREJ 4 YELLOW COLUMN 3 3 RED COLUMN 2 212 GREEN COLUMN 1 Figure 7 6 Vend motor harness BROWN PURPLE GREY BLACK ovjejnlolalpluolj vij o o l oj o 5 o w o o RED WHITE GREEN WHITE BLUE L NOILOATAS Z NOILOATAS ei NOILOd T3S 8
5. Royal Vendors Inc Merlin IV Plus Operation and Service Manual Manufactured by Royal Vendors Inc 426 Industrial Boulevard Kearneysville WV 25430 2776 USA Telephone 1 304 728 7056 e Fax 1 304 725 4016 technicalinquiry royalvendors com parts royalvendors com www royalvendors com Royal Vendors Inc 426 Industrial Boulevard Kearneysville WV 25430 2776 USA Customer Service 1 304 728 7056 Fax 1 304 725 4016 E mail technicalinquiry royalvendors com parts royalvendors com Website www royalvendors com Table of Contents Safety Information sr e ve ER 5 SECTION 1 General Information and Setup 7 a poo NOT A M H 7 Unpacking the Vender and Installing It On Location esses gt POU NO NS Gana inate i T7 Voltage Requirements and Vender s Power Cord tete o ns so sos nse siste se Ee Ee EE 8 Vender Identification MR v n CEDERE 8 SECTION 2 Vender Component Explanation oo nana nana ee ee ee ee ee even eee mee sete sene nenen e eee rere pene RR EER 9 Vender Control Board including PINOUIS aie iare dh ed Ee aai 9 Low Voltage IRAN eL NN ENTE 12 Vend Mechanism e EE 12 Delivery EE 13 Refrigeration SY SUSI dee ra v 13 BEES Ee GE Ed Aa Ne GE AE GE a rer 15 SECTION 3 Vender Programming ccccccccccccccnoncnnnnnnnnnnnnanann cnn nn cnn cnn RR RR RR RARR RR RR RR EER RR RR RR RR RE EER 16 Int
6. ITEM NO 1 NOOB WD Note Fluorescent tubes are not available for purchase from Royal Vendors 54 s oy Ge b A Section 8 Parts Catalogue Lighting Assemblies ITEM NO 1 an KON OO JO COLD DRINK ADA MODELS 650 AND 768 DESCRIPTION PART NO Lamp Bracket Top Model obt 381511 z Model 768 e aia tun dL RR Reds 382508 Lamp Socket Top spring loaded sss 842512 Fluorescent TUBE nes ttc See note below Lamp Socket Bottom tat 842513 Lamp Bracket Bottom Model 650 ssss 381512 Model 68 riusci mete ee ula ee EE 382502 Bottom Lamp Panel rte penne k s 378516 Bottom Lamp Bracket an 378538 EI 838053 Harness Lower Lamp sese 842754 Upper Lamp needs erbe nee tiri D c 842755 Note Fluorescent tubes are not available for purchase from Royal Vendors E SO 1 amp E E COLD DRINK DR PEPPER ADA MODEL 542 DESCRIPTION PART NO E Lamp Panel Narrow Cold Dk 380501 ae EB t 376505 Lamp Bracket Magnum Left amp Right Dr Pepper Right 380507 Lamp Bracket Dr Pepper Left onhy ee ee Re Ge Re 380506 Lamp Socket Top spring loaded sss 842512 Fluorescent Tube iii See note below Lamp Socket Bottom static esses 842513 Sy A E 838053 K A Merl
7. Vender 12 column 385710 s 195 Vender 12 column ie c eran ii 386710 12 Vender 10 Colby EE 387710 2 Backspacer Assembly Airflow 79 Vender nn 261720 PAP TTE 262750 3 Backplate Airflow Stack 79 Vender aaa aaa aaa aaa eee eee eee eke eee eee enen enen enen ee tee tete sensns sna ee ee ee 261711 A Wde Gl 332704 CG Narrow Vender cetero ege ke OE Ee EES Ee 264732 4 Product Retainer Left 79 Vender etit ee tr rU e e E d a e dk a ENEE 810093 oa aso EE RR OE 810095 5 Product Retamer Right 79 Vender eet PD edd RR ARR Ee 810092 Ge EE 810094 6 FunnekAngle AIFTIOW ia ED ber e den ed di cadet ua 810243 7 Ee eg 803035 8 ROIO ani e de eae 813027 9 Vend le GE RR EE RR EE OE ER IE N 839031 10 Rod Relaifier sine EE 256714 11 OGEN 310 32 CIO ER ER e AE RE E901011 12 Product Eunnel t iron EE cada 332702 13 SETI DAIMO BEE E902004 Hitch Pin Clip some venders may have Dis 906023 14 ect EE KO RE OE EE RE 811026 Front Rotor Bearing BE 915156 Rear Rotor Bear BEE 915222 Front Rotor Assembly incl rotor front rotor bearing and motor 332730 Rear Rotor Assembly incl rotor rear rotor bearing and motor 332740 Anti bridging Spacer d LTE 815392 Antibridaing Spacer TEE 815393 e Antistriction Sheet Re A e e A E Re RA Se tua ena dah Ka e 915197 e Rubber Retainer Strip AE AE EE RE OE OR RE ARE 915217 Rear Can Retainer Anti tilt Spring
8. board sign lighting are lit If not check power at transformer Coin mechanism harness to control board Repair or replace changer harness is cut or disconnected Short in coin mechanism 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 and the coin return lever is in the proper position Acceptor is dirty or foreign matter is in the Check to ensure that the coin path mechanism s acceptor is clean Defective control board No acceptance or Coin return lever rejects a percentage of good coins Coin changer is improperly tuned if Contact coin changer manufacturer tunable Defective control board Replace the control board and test Erratic or no credit Acceptor coin Replace coin mechanism acceptor and mechanism test No credit Defective harness between coin Check harness for cut wires or wrong mechanism and control board connections If defective replace it No credit Defective control board Replace control board and test Accepts coins but gives erratic no credit Changer will not pay out coins Check harness for cuts or wrong connections If defective replace it
9. into a direct power source wall outlet or extension cord If it does not run replace the refrigeration unit Master control disabled Check FrG setting in the refrigeration control mode FriG to make sure it is set to 1 If it is set to 0 change it to 1 Cut in cut out not set properly Check cut in and cut out settings If set incorrectly reprogram them Temperature sensor not reading correctly Test the temperature sensor by setting the temperature to be displayed on the LED and measuring the actual inside cabinet temperature with a thermometer or by opening closing door to see if the temperature changes Replace if defective Short in wiring harness from control board Unplug one of the two wires coming from to refrigeration relay 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 Defective refrigeration relay Test the relay by making sure all connections are made for the refrigeration unit the refrigeration relay and the control board Next go into FriG mode Scroll to rELY press senter and go to CnPr Press senter change it to On and press enter again If the unit does not come on replace the relay 36 Merlin IV Plus Operation and Service Manual Section 6 Vender Troubleshooting TROUBLE POSSIBLE CAUSE CORRECTIVE PRO
10. 2nd ofj time for selections SC 2 OFF 2nd on time for selections SC 3 On 3rd off time for selections SC 3 OFF 3rd on time for selections dScn On off time for discounting dSen OFF on time for discounting FriG On off time for refrigeration FriG OFF on time for refrigeration LEI On Ist off time for illumination LEI OFF Ist on time for illumination Lt 2 On 2nd off time for illumination Lt 2 OFF 2nd on time for illumination Lt 3 On 3rd off time for illumination Lt 3 1 OFF 3rd on time for illumination To set On and OFF times for the timer press lt enter gt upon reaching the desired timer setting mode 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 up or lt down gt will change the hour of this particular setting Pressing lt enter gt will lock in the hour setting and the minutes will begin to flash which indicates that the minutes can now be changed Pressing up or down will change the minutes of this setting Pressing exit at any time during this operation will lock in the changes and bring the controller back to the timer setting mode followed by the time set for that particular mode Exa
11. GROUNDING PRIOR TO INSTALLATION IN ORDER TO REDUCE THE RISK OF ELECTRICAL SHOCK AND FIRE Safety Information Section Il 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 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 PERSONNEL SHOULD ACCOMPLISH SERVICING WITH POWER ON SUCH SERVICE BY UNQUALIFIED INDIVIDUALS CAN BE DANGEROUS 2 LIGHTING CIRCUITS CAN BE HAZARDOUS ALWAYS DISCONNECT FROM POWER SUPPLY BEFORE REPLACING A BULB OR SERVICING THE VENDER IN THAT AREA 3 NEVER USE A HOSE PRESSURE WASHER OR ANY CLEANING METHOD THAT COULD WET ELECTRICAL COMPONENTS SEE CLEANING SECTION OF MANUAL FOR SUGGESTED CLEANING METHODS IF WATER CONTAMINATION OF ELECTRICAL COMPONENTS IS SUSPECTED USE QUAL
12. Manual Section 7 Training Guide LED Harness See Figure 7 2 Chute Sensor See Figure 7 4 e Supplies 5 VDC to LED Position P4 on control board e Check for 5 VDC across position PI pins 1 and 4 e Low voltage 5 mV 500 n Seconds impact sensor e Ohm out harness Voltage returned from chute sensor signaling control board to cancel credit and reset Trimpot R19 on control board is used to increase or Multi Drop Bus MDB Harness See Figure 7 3 decrease sensitivity e Supplies 24 VDC to changer validator and or card reader from position P3 pins 1 and 6 e Data transmitted and received by control board e Confirm with changer LED on payout works Multiple harnesses may be connected in series for more peripherals check all harnesses WHITE 24 VDC BROWN NEUTRAL BLACK RX RED TX GREEN NEUTRAL TVAIHdiuid SUN Figure 7 3 MDB harness CHUTE SENSOR lt m m E O Gi lt g O D oo as m m2 Sg 5 8 gt 2 ES m O E mi o gt E lzisjejsiej Figure 7 2 LED harness Figure 7 4 Chute sensor harness Merlin IV Plus Operation and Service Manual 39 Section 7 Training Guide Select Switch Harness See Figure 7 5 Door Switch Options Harness See Figure 7 7 e Supplies 5 VDC to select switches from position P7 e Supplies 5 VDC from position P9 to door switch pins pin 11 and 6 and to options harnesses free vend switch no
13. 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 power source before servicing Only fully trained service technicians should service vender when vender has power Remove any product before moving a vender Use appropriate 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 precautions 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 grounding 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
14. SE OE GE EE Ee DO DES N De ee ee Ee ie 369524 Wide Vender Dr Pepper see ee ee ana 374508 Narrow Vender Gold Drink EDS e FE V REPE Ee GO RED pel Ge Ge Ee DS Ge DERE RR EO Re PEUT ede 380508 NETOS 376503 atch Roller Bracke teenin apo 010516 Anti theft ET 378521 Motion Detector COVE EE 385516 Keps Nut 8 32 eee id pd N a a ii E905001 SEENEN E901011 Sems Screw S822xv1T eee ee enen e te eren tete teren tete tere eee tete tere E901002 Burst openi E ie EE 912003 Merlin IV Plus Operation and Service Manual Section 8 Parts Catalogue Port Assembly Live Display ITEM NO DESCRIPTION PART NO 1 Delivery Port Weld Assembly 384520 2 Port Brace Wide Vendel siii 369524 3 Latch Roller Bracket 010516 4 Anti tlieft Plate tana adria 384505 5 Port Bottom Plate duan doke aea axe LER edax TEN Te a Ru ee cda Rev ee ies 384507 6 Bottle StOP ras da 384506 7 Sems Screw 8 32 x 1 2 nana E901002 8 sessi M 912003 9 Carriage Bolt 1 4 20 x IT E901007 1 Keps Nut 1 4 20 2 iia E905002 Merlin IV Plus Operation and Service Manual 57 58 Section 8 Parts Catalogue Security Plate Assembly Cold Drink Live Display 385540 Merlin IV Plus Operation and Service Manual ITEM NO CO Oo JO om KON Section 8 Parts Catalogue Security Plate Assembly Cold Drink Live Display 38554
15. Usage All Merlin IV Merlin IV Plus Operation and Service Manual Section 2 Vender Component Explanation Vender Component Explanation Vender Control Board including pinouts The control board is responsible for most vender operations In most vender s it is located in the upper left corner of the inside of the door The control board is protected by a cover Removing this cover will expose the control board along with all wiring connections to the board 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 EEPROM chip 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 information to some components receive information from some components and communicate both ways with some components Thecontrol board issues instructions and or voltage to Display Vend motors Refrigeration relay The control board receives information and or voltage from Select switches logic level Door switch logic level Delivery chute sensor Temperature sensor e The control board communicates both ways wit
16. and 1 enabled When the desired status is displayed pressing exit will save that status and return the controller to the Cn X display i Single price multi price This option is used to toggle between the single price and multi price modes In the single price mode one price will be used for all selections In the multi price mode each selection may be set to a different price If X 0 single pricing is used If X 1 multi pricing is used e C2 Optional menu enable This option is used to enable the optional menu which contains several more mode options than available in the standard service menu If this configuration is set to 0 all optional menu items will be disabled If X 0 the optional menu items will not appear If X 1 the optional menu items will appear 21 Section 3 Vender Programming CH Open door totals This option is used to turn on the display of the total machine sales and total machine cash values in the open door mode If X 0 only error codes or nonE are displayed If X 1 sales and cash totals will be displayed and Eror or nonE will replace the error codes when the door is opened C5 Door switch reset This option is used to allow the door switch to reset all resettable MIS resettable cash and sales counts etc If X 0 all resettable MIS registers are reset only when the CF command is received from the hand held device
17. be set to 0 If X 1 the controller is set for Tier 2 operation RETURN TO SALES If lt enter gt is pressed at the rtn prompt the controller will return to the open door mode Note This item will only appear at this point in the menu if C2 is set to 0 23 Section 3 Vender Programming Optional Menu Items Note The following items will only appear in the menu if C2 is set to 1 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 light will be lit EXACT CHANGE VALUE MODE If lt enter gt is pressed when the display shows ECO the display will show the exact change value Pressing lt up gt or lt down gt allows you to adjust the value Pressing lt exit gt will save the currently displayed value and return the controller to the ECO display From ECO press up to proceed to the next prompt CPO Po If lt enter gt is pressed at the CPO prompt the controller will enter the coin payout mode by displaying the lowest coin value that can be paid out Pressing lt up gt will increase the display to show the next highest coin value pressing lt down gt will decrease the display to show the next lowest coin value or wrap around Pressing lt enter gt when a particular coin value is displayed will pay out the displayed coin type at half second intervals until the bu
18. control board to each vend motor There is 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 grounded PIN WIRE COLOR FUNCTION 1 GREEN VEND MOTOR 1 2 RED VEND MOTOR 2 3 YELLOW VEND MOTOR 3 4 ORANGE VEND MOTOR 4 2 BROWN VEND MOTOR 5 6 BLUE VEND MOTOR 6 7 GREEN WHITE VEND MOTOR 7 8 RED WHITE VEND MOTOR 8 9 YELLOW WHITE VEND MOTOR 9 10 KEY 11 ORANGE WHITE VEND MOTOR 10 12 BROWN WHITE VEND MOTOR 11 13 BLUE WHITE VEND MOTOR 12 14 BLACK COMMON 15 GREEN YELLOW NEUTRAL 16 NOT USED 17 NOT USED Merlin IV Plus Operation and Service Manual Section 2 Vender Component Explanation OPTIONS 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 COLOR FUNCTION 1 WHITE DOOR SWITCH COMMON 2 KEY 3 OPTIONAL FREE VEND INPUT 4 OPTIONAL NO VEND INPUT 5 OPTIONAL OPT SWITCH INPUT 6 PURPLE DOOR SWITCH INPUT HHC 1 Position P10 The three wire harness connecting to this pinout comes from the Hand Held Computer HHC jack located inside the vender s main door near the control board The HHC plugs into this jack to read and write information from the vender s control board If the HHC is not o
19. ee den dre did 803031 Coin Return Lever ie RR dh de N 369570 Coin Plate Bushing Retainer nan 378533 Keps Nut DM E905001 KepsNuUT 174 WE E905002 Bottom Validator Filler Plate Weld Assembly 381523 Display Plate Gasket eee eene eee vene nennen teen ee ee ee tee eter 829067 Display Plate Assembly LED 4 character not part of Security Plate Assembly includes the following five items aa aaa anen enen eventet 378598 LED Display EE 836012 SLED RE 916032 LED WIMKOW EE 815121 LED Display Shroud aaa nana 929031 LED Display Cover 4 character Display 378541 Merlin IV Plus Operation and Service Manual Section 8 Parts Catalogue Sign Cold Drink 1 Dr Pepper Door N Ss ITEM NO DESCRIPTION PART NO 1 SON See note below 2 Selection Button includes items 3 4 and Di 816152 6 Switch Retainer Ont uide eee eh rre ri traho nte n ERR e eA ha Tob A Nee ed ed M ka 357513 7 Witch Retaane REA 357512 8 Selection SWIG DEE 835001 9 Keps Nut 28 32 eerie iode tese eie e iden eegene ud P s odda E905001 Note Please call Royal Vendors Service Parts Department for all sign part numbers Merlin IV Plus Operation and Service Manual 61 62 Section 8 Parts Catalogue Inner Door Assembly Merlin IV Plus Operation and Service Manual ITEM NO 1 Section 8 Parts Catalogue Inner Door Assembly DESCRIPTION ROYAL NO Inner D
20. if that relay is currently off or the word On if that relay is currently on Pressing up or down 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 TELY mode is exited all relays will return to the state they were in prior to entering the rELY mode NOTE In this feature the user has the ability to continuously turn the compressor on and off Be aware that quickly restarting the compressor may result in serious damage to the compressor Merlin IV Plus Operation and Service Manual Section 3 Vender Programming PASSVVORD PREVIEVV MODE On the Merlin IV Plus vender the total historical and individual sales counts can be accessed externally as well as the error mode by entering the external password Neither the sales counts nor the errors can be cleared externally The Password Preview Mode allows the external password to be changed If lt enter gt is pressed at the PAS prompt the controller will display the external password preview mode The first digit of the number will be flashing Pressing lt up gt or down will adjust the currently flashing digit up or down Pressing lt enter gt will save the currently flashing digit and cause the next digit of the password
21. individual wire for the motor attempted and the common neutral wire A selection must be made and the LED should be displaying as if a vend is in process scrolling down 24 VDC should be registered If not replace control board Merlin IV Plus Operation and Service Manual 35 Section 6 Vender Troubleshooting TROUBLE POSSIBLE CAUSE CORRECTIVE PROCEDURE REFRIGERATION PROBLEMS Refrigeration unit runs J Cut out temperature not properly set Check cut out setting in the FriG mode constantly Correct if necessary Temperature sensor not reading correctly Test the temperature sensor by setting the temperature to be displayed on the LED and measuring the actual inside cabinet temperature with a thermometer or by opening closing door to see if the temperature changes Replace if defective Short in wiring harness from control board Unplug one of the two wires coming from to refrigeration relay 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 Refrigeration relay contacts welded Unplug one of the two wires with pink together connectors coming from the control board to power the relay If the unit continues to run replace the relay Refrigeration unit will Defective refrigeration unit Unplug the refrigeration unit from the top not run of the main wiring harness and plug it
22. minute setting for the corresponding day value and will return to the prompt for that day Pressing exit again will return the controller to the dAY prompt Pressing exit one more time will return the controller to the Strt prompt 27 Section 3 Vender Programming StoP If lt enter gt 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 the controller 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 up 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
23. necessi enema SEENEN shi dna te th kene ER Rek See Gog 378517 slk lee EE 380502 Coin BOX EE 815347 Display Plate Decal tren acte gr n O O 831855 Display Plate Assembly EE 385560 Latch Pocket Plate mc i bre A ce e Nt a 380505 Keps Nut EE E905001 Harness COVER urticaria da 378542 Merlin IV Plus Operation and Service Manual 47 Section 8 Parts Catalogue Dr Pepper Door Assembly Rear Merlin IV Plus Operation and Service Manual 48 ITEM NO 1 Section 8 Parts Catalogue Dr Pepper Door Assembly Rear DESCRIPTION PART NO Door Weld Assembly Dr Pepper Wide Vender 27 374510 Wide Vender EE 375510 INarrow Vender E 376510 Security Plate Assembly Dr Pepper kana aaa ese see Ee Ee LAE Ed ee ee Ee Ke SS Ee Ke SE Ed ee ee nai nnn dt 374530 Seed re Die Ee TEE 010518 Narrow Vender eret N ER EE EN 258504 Vandal Panel FRIGHT 2 deeglech ada bs ses et 011501 SD OE NE EO EE EE 010519 Control Board HOUSING DT 261570 Coin Box Housing Panel Assembly ese ee ee ee ee nana 378596 eler de e Lu te e Le 213503 Changer Door Assembly Dr Pepper ees tinni a 374550 Selection Panel Strap Weld Assembly iii AA nennen EER AS AD ER d bank d d aa 378592 Validator Vault Dr Pepper II Innen nnn nnn tet er ee ner eee ee sins 374503 Coin Cup Assembly Dr POPPER asian A dd eeu a pa da ENN 374580 Com Cup Plate RE ER OE EE EE 378595 Com Cup Plate Decal Dr Peppet sasie ESE eorr trae ei ge eed xe EE
24. pressing up or lt down gt will increase or decrease the minutes value Pressing exit will save the hour and minute setting for the corresponding day value and will return the controller to the prompt for that day Pressing exit again will return the controller to the dAY prompt Pressing exit one more time will return the controller to the StoP prompt dEG If lt enter gt 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 C if the controller is currently in Celsius mode Pressing up or down will toggle X between F and C Pressing exit at this point will save the displayed temperature mode and return the controller to the dEG prompt SEEP If lt enter gt is pressed at the SetP prompt the controller will display the current set point temperature setting xx F or xx C depending on the degree dEG mode setting The cold set point default is 35 F 2 C Pressing up or 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 exit at this point will save the displayed temperature and return the controller to SetP 28 Star If lt enter gt is pressed at the Stor prompt the controller will display the current storage for energy conse
25. set and saved all individual selection prices will be set to that value Pressing lt exit gt while a selection is displayed will return the controller to the Pric prompt without saving Use up to proceed to the next prompt StoS If single price mode is enabled only the single price can be adjusted In single price mode SPri will be displayed after pressing lt enter gt at the Pric prompt If enter is pressed at SPri the display will show the current price Pressing up or down will increase or decrease this price When the desired price is on the display press exit to save that price and return to the SPri prompt then press exit to return to the Pric prompt Press up to proceed to the next prompt StoS 19 Section 3 Vender Programming SPACE TO SALES PROGRAMMING MODE The space to sales mode is used to determine which column s will vend for each selection If lt enter gt is pressed at the StS prompt the controller will enter the space to sales mode by displaying CStS if a custom space to sales configuration is currently used or OPtX where X is the current option selected Using up or lt down gt will cycle through the available space to sales options and CStS After setting space to sales and returning to the StoS prompt use Sup to proceed to the next prompt SdEP There are two different types of settin
26. up or down will toggle X between 1 enabled and 0 disabled Pressing exit will save the displayed setting and return the controller to the Enb prompt Skrt 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 lt exit gt 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 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 flashing and cause the minutes to flash indicating that they can be modified At this point pressing up or lt down gt will increase or decrease the minutes value Pressing exit will save the hour and
27. 0 DESCRIPTION PART NO Security Plate Weld Assembly teret De EE Eg GE ER Eg SS EE eg SEE eg ay ed de de dd e du 385530 Tehandle ASSemlbly RE tt 812428 Com Return Bushing me er EE ene ei o 803059 Comm Return Buttons hehe 803031 diete ek Ere GR EE EE EE E901037 Keps Nut 114202 citar E905002 Col Retum Lever Assembly cce RE e Pe ro ar ea de A 369570 Coin Chute Assemibly EE RE Rede RE SR i ee I DIS tees 369580 Thandie TEE 337583 OCI OW 310 32 EEN E901011 ENK UE E905001 Com Plato jeme hh 815651 Eet ee E TEE 303145 Coin Plate Bushing Retainef coria 378533 Top Validator Filler Plate V A ec si a EEN 381522 Display Plate Assembly LED 4 character not part of Security Plate Assembly includes the following five emis carr sli 378598 LED DISpIAV ES 836012 Ee MR AE ER EE 916032 s LED VVINdOW ME EA EE RE OE Ut mU rt vdaja 815121 LED Display Shroud ett eerte reb eret o a kt eu E RO 929031 LED Display Cover 4 character Display aaa aaa nanen ne eee eve eee ze zene emen 378541 Merlin IV Plus Operation and Service Manual 59 ITEM NO 00 JO om KON mk 0 60 Section 8 Parts Catalogue Security Plate Assembly Dr Pepper 374530 DESCRIPTION PART NO Security Plate Weld Assembly Dr Pepper nena 374520 T handle Assembly Dr Pepper nsien dd lio 812440 Coin Chute Assembly Dr Pepper eee e eee teve ete eter tete tete tee eee nn enne 374540 Coin Return BUSING coi A i 803059 Goin Return Button eo
28. 256004 e Gondensor Shroud EE 095401 NOTE This part is not available individually It must be ordered as an assembly Merlin IV Plus Operation and Service Manual 69 70 Section 9 VViring Diagram BLUE YEL LAMP YEL RED WH pa LAMP t YEL RED D LAMP g BLUE YEL s LAMP E PLUG CAP 8 BLUE 3 g BLUE
29. 9 rH 012554 Port MM a OE EN 815249 Package STOP ss M 273508 Merlin IV Plus Operation and Service Manual 45 Section 8 Parts Catalogue Cold Drink Door Assembly Rear Merlin IV Plus Operation and Service Manual 46 ITEM NO 1 Section 8 Parts Catalogue Cold Drink Door Assembly Rear DESCRIPTION PART NO Door Weld Assembly Cold Drink Wide Vender 2 385510 Wide Vend r c 386510 INarrow Vender E 387510 Security Plate Assembly tete ena EES 385540 Rain Guard Wide Vender acosan aia daa 010518 neus m 258504 Vandal Panel Right 23 eter ette n er mese dea de A da lai 011501 iun 010519 Control Board HOUSING DEET 261570 Coin Box Housing Panel Assembly 385591 Coin Box Housing CDC s did vids dd ee edi t Dee tr er e rv edt a Duce rre rc 273503 Changer Door Assembly 2 tret i h R L n 385570 Selection Panel Strap Weld Assembly eed de Se EE KA ioi i 378592 Coin Cup Weld Assembly rcr eroi ce reped duda iced ED ge een Ge ee RE Ee 385590 Colt Cup DOOM eee detectar a a rci a nat cedes deu murs Ee dd us 385512 Coin Cup Plate Weld Assembly ccce entente ae 385580 Com Cup Plate De CT saiiOS 831856 Door ed ie LI UU LT m 835019 Transformer Assembly EE AI e RR Na 842147 Fuse Holder Assembly SE triti nib did 842219 A as 838053 Lamp Guard Wide Vender SE EE BERE BE
30. BLACK RED a RED WHITE VEL SSe BALLAST VEL BLUE jg BLUE YEL RED 5 5 RED YEL 4 4 YEL Y n ware 3 3 lf BLACK lt Jr ag rit Bax FER HIS Nee z sue SLEEVE LAMP CAP PLUG TP ni AE ST LAMP EE a 9 EC RNG 12 amp yt EC 8 Cs BLACK N cf POWER d RED 5 INTERUPT e ELECTRONIC nus ar Sel sf d P su BLACK Es E E Spo so om I 33 UIE prom BALLAST z Sja n nim j sel Lu ok Bae 2121 ue l E Sr um s a NM o4 1 TP TT A L J D L 3 wl Z 9 z zu E 3 E y E gj l In PA o EEEEEEEEFEEEEE ER EE O er E 5 8 8 82198 3 z PO 1 2 3 4 5 6 nl 234 BROWN 1 2 3 4 8 6 7 8 9 10 1 0 19 W is KEY 2v WHITE See 5 oc BROWN ER x ac BA en a Z RED LED BROWN e EC DISPLAY ev av reo BLACK _ O P10 O wO O BES Av TE reo EB d AS MET g Mi E 2 REDI BRON 7 CERA g Z 2 E GREEN O El Pa DN E a De VELLON D 2 D Dc z Dc pi D Pia is M 13 12 11 10 9 8 7 6 5 4 3 2 1 4 3 2 1 P12 Na SEE KA o m zi ul SI el Bl al SBEEEEEFEEELEELE O sele CEEEEE gja gj 2227828 O a ZS 6 BEE 4h Cp PLUG zi Gro ze Fe IMPULSE De FT COUNTER zo Fa M z g z j al 5 i E 5 4 8 3 E x 2 3 8 E E d E E El L 1 L L L 1 L 1 jd L H j no SS SS SS ss 22 SS 22 SS 22 SS SS SS LI SE U q U q U U U U q Lej z LA DS oa N co lt LO co co o eS LT ED HI 2 DB o o o o o o o o o o o o Bg eja BIS eja gg gg gg eja aje gg da a SIS Be Ble 8g BB 28 SIS ge SIS 22 SR a L L POS
31. CEDURE MISCELLANEOUS PROBLEMS LED not vvorking No povver to control board LED harness Display shows SOLd Door switch wiring improperly connected OUt immediately cut or pinched Control board upon pressing a selection column full of product and sold out not clearing Merlin IV Plus Operation and Service Manual Check for 24 VAC at control board s main power connection coming from the transformer If no power replace transformer Check the LED harness for pinches cuts or backed out wires If any found replace harness Check for 5 VDC on pins 1 and 4 of the harness at the LED If power is present replace the LED Check for cuts on the two 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 main door and at the control board s connection If no problems found check door switch Check the door switch for defects stuck shut etc If defects found replace the door switch Check the control board by shorting across the two pins for the door switch wiring white and purple wires If the sold out condition is still not cleared replace the control board 37 Section 7 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 co
32. Code System The Merlin IV Plus has a built in error code diagnostic system that vvill help in troubleshooting and solving problems This system is best used in conjunction vvith the follovving section Troubleshooting These errors are not a replacement for knowledge of the vender or its operation but they will lead in the general direction of the problem Most vender parts are independent of one another so most problems can be confined to the item in question such as an LED coin changer or select switch the harnessing connecting it to the control board or the control board itself See Section 3 Vender Programming for detailed instructions on how to use and access the vender s error codes Note It is recommended the error codes be cleared after correcting any problem s to prevent confusion and unnecessary work in the future MAIN DETAILED ERROR CORRECTIVE ACTION door door switch no detailed error Check and or replace the door switch or door switch harnessing SS01 thru SS10 selection switch closed CHAr CC changer communication IC niet chute blocked t changer tube jam CrCH changer ROM checksum CSF invalid changer scale factor nJ acceptor coin jam Check for blockage or dirty sensor in acceptor LA low acceptance rate Consult changer manufacturer bUAL bC bill validator communications Check bill validator harness connections bFUL bill validator cash box full Remove bills from cash box biLL bill valid
33. HHC If X 1 all resettable MIS registers are reset when the door switch is sensed as open and at least one of the resettable MIS registers has been read 1 e individual cash and sales counts t Cheat mode This option is used to prevent vending with insufficient change to pay back correct change after a purchase If disabled and the correct change cannot be paid back the vend is aborted and the deposited credit is returned if possible If X 7 0 the cheat mode is disabled If X 1 the cheat mode is enabled C1 Bill acceptance This option is used to allow higher order bills to be accepted without the risk of cheating the customer If enabled a bill is not accepted unless the controller verifies that it has enough change to cover the bill s value plus any accumulated credit If X 0 high order bill acceptance is disabled If X 1 high order bill acceptance is enabled CB Forced vend attempt This option prevents the machine from becoming a change maker When this mode is enabled escrow of coins is allowed until any of the following three events occurs 1 Any bill is inserted into the bill acceptor 2 Any cash box coin is inserted into the changer or 3 The maximum vend price is reached Once any of these conditions are met any accumulated credit must be used toward a vend attempt and coins will not be dispensed for credit in response to an escrow request Ifa sold out selection or if a valid selection
34. IFIED ELECTRICAL TESTING EQUIPMENT AND TEST METHODS TO ASSURE THAT VENDER IS NOT A HAZARD BEFORE APPLYING POWER FOR ANY REASON 6 Merlin IV Plus Operation and Service Manual Section 1 General Information and Setup Merlin IV Plus Vender General Information Introduction This manual contains installation operation and service instructions for the Royal Vendors Merlin IV Plus Vender This manual also contains a parts catalog and electrical schematic for the Merlin IV Plus The Merlin IV is a microprocessor controlled vender that permits pricing per selection from 0 00 to 99 95 The Merlin IV provides electronic space to sales programmability and it will collect store and transfer MIS data fields to a hand held computer HHC or on line device through a DEX port Unpacking the Vender and Installing It On Location Unwrap the Vender Unwrap the vender and remove the padding Check for any signs of damage If the vender is damaged contact the carrier immediately They will instruct you on the procedure for filing a claim If the vender is being stored remove the plastic stretch wrap cardboard cover and styrofoam cushioning first The plastic stretch wrap and styrofoam cushioning can adhere to the exterior of the vender over an extended period of time damaging the vender s finish Note The vender 5 keys are located in the coin cup Remove the Shipping Skid Separate split each section of the shipping skid by
35. ITION CONNECTION NAME H rE H PI LED DISPLAY E erlin iring Diagram E P4 CHUTE SENSOR P7 SELECT SWITCHES N P VEND MOTORS miki SE PS OPTIONSIFEATURES M e TN BARDANE INDUSTRIAL PARK Pi PRIMARY DEXJUCS Pit SECONDARY DEXJUCS 426 INDUSTRIAL BLVD E NOTES 1 SOME MODELS MAY HAVE THIS TYPE OF SELECT SWITCH VENDAS KEARNEYSVILLE WV 25430 e USA P ZAVOLTAC 2 SOME MODELS MAY HAVE FEWER s1 CONTROLLER MODE BUTTON SELECT SWITCHES sk E 3 SOLID COLORS CAN BE SUBSTITVED 1 304 728 7056 len SENSOR AMUSTMENTLED FOR STRIPED WIRES INDICATED RA SENSOR ADJUSTMENT TRIMPOT Merlin IV Plus Operation and Service Manual Section 9 VViring Diagram
36. NOILOATAS 6 NOILOATAS WHITE NEUTRAL BLACK No KEY FREE VEND SWITCH DOOR SWITCH WOO ONO OINOI ONO ege pi WOO ONO pd Msi EE N EG Gau OWO9 ONI OL NOILO3T3S eem ANI ONO SHTES IPURPLE 5 VDC DOOR SWITCH V BROWN O com Figure 7 5 Select switch harness Figure 7 7 Door switch options harness 40 Merlin IV Plus Operation and Service Manual Section 7 Training Guide DEX 1 UCS Harness See Figure 7 8 Environmental Control Refrigeration Harness See Located at positions P10 Internal and P11 External Computer access point Internal read write anytime standard item e External read anytime can only write when door switch is open optional item e Temperature Sensor Harness See Figure 7 9 e Supplies 5 VDC to temperature sensor from position P12 pins 1 and 4 5 VDC from pins 1 and 4 e 5 VDC return resistance across pins 1 and 2 e Setto display temperature on LED compare to ther mometer e Temperature sensor mounted on rear of cabinet 353318 3143318 INTERNAL EXTERNAL OPTIONAL Figure 7 8 DEX UCS harness REFRIGERATION RELAY Figure 7 10 Environmental control harness Merlin IV Plus Operation and Service Manual Figure 7 10 Supplies 24 VDC to refrigeration relay from position P14 pins 1 and 3 Check for 24 VDC in relay test mode Harn
37. ODE 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 up 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 exit is pressed anytime during this operation the controller will return to the CArd display Press the up button to proceed to the next prompt toKn 18 TOKEN COUNTER DISPLAY MODE If lt enter gt 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 exit is pressed anytime during this operation the controller will return to the toKn display Press the up button to proceed to the next prom
38. Price Label Strip TOP issie EEN EE 218512 14 Price Label Strip Bottoril ER EE RE cda dh sht dd SCENE eg 218538 15 Foam SUID dei A A Pe A A ee ei eg 829051 16 TOOL FOZI2 X EE E901054 17 POK SPAC EE 815248 18 Port e 815249 19 Coin Cup Weld Assembly ce eruere eek en eine ee Pd e e e Y ug nea 385590 20 SCIEN 30 32 oo AE EE ht eed ceste didus E901011 21 Display Plate Assembly trt ctt ttt vd 385560 22 Display Plate Gasket EE 829065 Note Please call Royal Vendors Service Parts Department for all sign part numbers Merlin IV Plus Operation and Service Manual 51 Section 8 Parts Catalogue Live Display Door Assembly Rear Merlin IV Plus Operation and Service Manual 52 2200 JO Om BON AO Merlin IV Plus Operation and Service Manual Section 8 Parts Catalogue Live Display Door Assembly Rear ITEM NO DESCRIPTION PART NO Changer Door Assembly iste HEERSER RE GE ee eg EE eg t hd 385570 Coin Box Housing Panel Assembly 385591 Coin Box HOUSING E 273503 Bottom Inner Door Hinge ES RE EG DRE ES 010543 Display Backs RE EE EE Ee 278505 Selection Panel Strap Weld Assembly 378592 SOW 110 92 E E901011 Latch Pocket Plate onec de 380505 Control Board HousingASsembly 2 d t term do 261570 lug 842676 Filter Mouriting Bracket doctr oret etr Colette n e er n c ne eins 381531 53 od
39. SE ee Ke 831918 Door SMILE can KA N OE er 835019 Transformer Assembly TEE 842147 Fuse Holder Assembly irit EE Ped Patente de De RA ty e SX ht he 842219 CLIE OT EE hd 838053 Lamp Guard Dr Pepper Wide Vender nennen 374509 INartow Vender uere edere eine dd de Mna edu bx dea toad eves 376504 COMBO qe 815347 Changer Guard Dr Peppel cett tr oet rtt ht 374515 Keps NO E905001 Lateh Pocket Plate ut etre tt etes detenta RE xe bI A nte exi eden ee 380505 ao OE OE EE RO AE OE N 378542 Merlin IV Plus Operation and Service Manual 49 50 Section 8 Parts Catalogue Live Display Door Assembly Front Merlin IV Plus Operation and Service Manual Section 8 Parts Catalogue Live Display Door Assembly Front ITEM NO DESCRIPTION PART NO 1 Door Weld Assembly 2 Live Display de ettet t reo e ed GR RE RAS Gee RERO CO YR 384510 2 Security Plate Assembly x re rer rere Rer EE EUR po dor 385540 3 Port Assembly Live Display See exploded view elsewhere in Parts Catalogue 4 Coin Cup Plate Weld Assembly coincide 385580 5 Vandal Panel del AE EE OE EO vg V EE RE d trate 011501 6 Button Panel EE 218532 7 Display Product Holder and rcc dae cee ENEE c 023107 8 Sce M See note below 9 Trim 10 iieri 815364 11 Lamp Panel TOP EE 278506 12 Lamp Panel Bottom x ett eet quede quesos sr edis dea Rx o Rue debi 278507 13
40. al 34 VDC bill validator and or the optional debit card reader If this harness is cut pinched or disconnected you will noticeably lose power to these items PIN WIRE COLOR FUNCTION 1 WHITE 24 VDC 2 BROWN NEUTRAL 3 BLUE 4 BLACK RECEIVE 5 RED TRANSMIT 6 GREEN COMMON 7 NOT USED CHUTE Position P4 The harness connecting to this pinout is a grey shielded cable harness This harness is formed into the delivery impact sensor mounted beneath the center of the delivery chute It should never be cut pinched or spliced PIN WIRE COLOR FUNCTION NOT USED NOT USED 2 5 VDC NEUTRAL RETURN NOT USED NOT USED DNnBWN ra 10 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 WIRE COLOR FUNCTION 1 WHITE SELECTION 9 2 YELLOW SELECTION 8 3 ORANGE SELECTION 7 4 GREEN SELECTION 6 5 BLUE SELECTION 5 6 BROWN SELECTION 4 7 PURPLE SELECTION 3 8 GREY SELECTION 2 9 BLACK SELECTION 1 10 KEY 11 RED COMMON 12 NOT USED 13 NOT USED 14 NOT USED 15 NOT USED 16 NOT USED VEND MOTORS Position P8 The fourteen wire harness connecting to this pinout provides common power from the
41. an additional 1 4 turn counterclockwise until proper adjustment is made Note The minimum recommended setting for the chute sensor is 1 4 turn counterclockwise from the indicator light The maximum setting is two 2 turns If the sensor requires a setting outside the recommended 1 4 2 turn range the sensor should be replaced Merlin IV Plus Operation and Service Manual Refrigeration System The vender s refrigeration system 1s responsible for the cooling of the cabinet and the products loaded within it The refrigeration system comes as a completely sealed unit and should never be cut or tapped into or the warranty will be voided Operation Requirements The refrigeration system requires 115 volts AC from the main wiring harness for it to operate The main wiring harness will get its voltage for the unit from the refrigeration relay Refrigeration Components The refrigeration system is a sealed system Described in this section are explanations of the refrigeration system s major components 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 refrigeration relay Condenser The condenser is located beneath outside the cooling com
42. and packed securely to avoid further damage Parts that are returned from the field and have been tapped into tampered with not packaged properly or have had the serial plate or label removed will void the warranty 7 If parts are not returned within 15 working days the invoice will be due in full Royal Vendors Publication ROYAL 833102 Rev 01 January 2013 Printed in the United States of America
43. any liquid refrigerant which did not vaporize before it reaches the compressor Refrigeration Relay The refrigeration relay is located in the lower left section of the vender s cabinet near the main wiring harness 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 VDC and a 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 115 VAC travels from the refrigeration relay to the main wiring harness for the refrigeration unit Condensor Fan Motor Direction of b gt Refrigerant Flow Merlin IV Plus Operation and Service Manual Section 2 Vender Component Explanation Refrigeration Cycle Ballast 1 The rising temperature in the cooling compartment is reported to the control board through the temperature sensor The ballast acts as a transformer to convert conventional mE voltage 115 VAC to a higher voltage required to energize 2 The control board registers the current temperature inside the vender s fluorescent lights upwards of 600 VAC The the vender s cabinet When it rises equal to or above the ballast is located inside the vender s door To remove the pre programmed eut n temperature the control board will ballast from the door use a Phillips scr
44. ard and test Validator takes a bill Validator switch settings if any Refer to validator s service manual or but is not erasing validator representative credit Defective validator interface harness Refer to validator s service manual or validator representative Defective validator Replace validator and test Defective control board Replace control board and test Validator takes a bill Control board s configurations not set Access the vender s configurations mode and allows payback of properly and check the C8 forced attempt coins without making setting a selection VENDING PROBLEMS Multiple vending If from all selections delivery sensor cut Set vender s delivery sensor by turning the not properly grounded disconnected or adjustment screw improperly set 1 Clockwise until the indicator lights 2 Counterclockwise until it goes out and 3 Counterclockwise one and a half turns If no progress is made by adjusting replace the sensor Control board sending power to motor Check power at vend motor during when not supposed to multiple vend 24 VDC If power is present the control board is at fault Mechanical error Check the vend motor to ensure the gearing within it is OK 34 Merlin IV Plus Operation and Service Manual Section 6 Vender Troubleshooting TROUBLE POSSIBLE CAUSE CORRECTIVE PROCEDURE VVrong product Misloaded vender Ensure all products vvithin each column vending upon are the same selectio
45. at 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 damaging 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 conceivable 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 recommended maintenance procedures If you have any questions please contact the Technical Service Department at 1 304 728 7056 Merlin IV Plus Operation and Service Manual Safety Regulations
46. ate Vender Identification Vender Serial Plate The vender s main serial plate shown in Figure 1 2 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 e Unit charge of R134a and e Refrigeration design pressures The vender s model number contains three important pieces of information the machine type such as RVMC Royal Vendors Magnum Curve the vender model number such as 650 capacity of 650 cans and the number of selections such as 10 How to read the serial number The first 4 numbers represent the year the vender was produced The fifth and sixth numbers represent the number of the week within that year the vender was produced The first letter represents the style of the vender e The second letter represents the location where the vender was built and The last five numbers represent the number of the vender built within 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 looks similar to the vender serial plate shown in Figure 1 2 with the exception that the model number specified is the refrigeration unit model number One refrigeration unit model is used on the Merlin IV Model 8000W Compressor size Super 1 3 HP
47. ator motor bJ bil jam brCH bill acceptor ROM checksum error bOPn bill validator cash box open bS bill validator sensor bSF invalid bill acceptor scale factor rC card reader communications error rSF invalid card reader scale factor CrXY other card reader error CoLd sensing temperature 3 F 1 5 C below cut out Check for a welded contact in refrigeration relay or shorted wire from board to refrigeration relay CnPr not cooling within 30 minutes of cut in Check FrG in programming and check all wiring connections from board to refrigeration unit ACLo less than 95 VAC from outlet for greater than Check voltage at wall outlet during the peak of the load 30 minutes with all units if any others are present in circuit running 32 Merlin IV Plus Operation and Service Manual Section 6 Vender Troubleshooting Troubleshooting Use the following section to troubleshoot the Merlin IV Plus vender in the event there is a problem in one of the following areas power acceptance coin or bill vending or refrigeration Listed below are the problems that are most likely to be encountered If the Merlin IV Plus displays a problem not listed here please contact a Royal Vendors service representative TROUBLE POSSIBLE CAUSE CORRECTIVE PROCEDURE COIN ACCEPTANCE Coin mechanism will No power to vender s main door lights Check to make sure the LED and the not accept coins not lit or no power to transformer control
48. d see PAS in the Optional Menu Items section Note Sales counters cannot be reset and error codes can not be cleared in the External Menu MODE If lt enter gt is pressed at the SALE prompt the controller will enter the vend count display mode by displaying SALE XXXX XXXX where the X s will represent total number of all paid vends over the life of the vender s control board If the sales amount is less than five digits long the upper four digit set is not displayed Using up or down will cycle through each selection as SLNN XXXX I XXXX where the N s represent the appropriate selection number and the X s represent the vend count for that selection If exit is pressed at any time during this operation the controller will return to the code level Press the up button to proceed to the next prompt Eror ENS This mode was designed to help diagnose vender problems If lt enter gt is pressed at the Eror prompt the controller will enter the error display mode If no errors have occurred since the last error reset the display will show nonE If an error has been detected since the last error reset the display will show the first summary error code that has occurred such as UEnd which would indicate a vend error Pressing lt up gt or lt down gt will allow you to cycle through all of the summary error codes that are present Pressing lt en
49. dirt or foreign materials Clean dirt and debris from the condenser and evaporator coils vvith a small light bristled brush vacuum cleaner or compressed air This vvill help to ensure an extended unit life Control Board The vender s control board should always be enclosed by its cover to protect it Routine cleaning is not necessary but if desired the controller s area may be blown out with compressed air What to Lubricate Inner Door Gasket The door gasket comes from the factory pre lubricated but should be lubricated periodically with a silicone based 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 Latch Strike Nut The latch strike nut should be lubricated as needed Refrigeration Unit The refrigeration unit is a sealed system that does not require any lubrication Also the condenser and evaporator fan motors do not require any lubrication Anti friction Sheets The anti friction sheets should be lubricated with a thin layer of food grade silicone The sheets should be kept clean and free of debris and they should not be peeling Merlin IV Plus Operation and Service Manual Preventive Maintenance Vender Leveling Make sure that the vender is level when placed on site If the vender is not properly leveled it can begin t
50. djust the time for daylight savings If X 1 the controller will adjust the time for daylight savings Using lt up gt or lt down gt will toggle the value of X If exit is pressed at this point the currently displayed value of X will be saved and the controller will return to the dLt prompt When enabled the controller will advance the system time forward one hour at 2 00 AM on the first Sunday of April It will back up the system time one hour at 2 00 AM of the last Sunday of October Merlin IV Plus Operation and Service Manual REFRIGERATION CONTROL MODE If lt enter gt is pressed at the FriG prompt the controller will enter the refrigeration control mode Using up or down will cycle through the various refrigeration control settings Enb Strt StoP dEG SEtP Stor dSP and TELY If exit is pressed the controller will return to the FriG prompt Press lt up gt to proceed to the next prompt PAS Enb If lt enter gt is pressed at Enb the controller will display EnbX X will be flashing 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 programmed time blocks If X 0 the energy conservation mode will be disabled and the machine will function as normal Pressing
51. e dle Cea EG en Ud 29 Return to A AR SEE BEE Re GER SE ED 29 External OR ER 29 c cassum oo SE 29 Error Codes NO M 29 Return Ne Ec me t PE 29 SECTION eks ie C ica 30 SECTION 5 Vender MainteNaNCE as mii 31 SECTION 6 Vender Troubleshooting nene nene non n nn nene nese nese nese tete eee eee eee mese 32 Using the Verder s Error Code ys Misuri dha Oo EE n kabel Oe ce sinas ove Ee EE RUE 32 leese OO CE shat a vere e o o 33 SECTION 7 Training GUIdE Ga nnne 38 SECTIONS Paris e US aa e ae S ee ona 42 SECTION 9 ler Wl E mew 70 SECTION 10 Programming Flowchart aa da ca gas d KEER d S d EER EE 12 CREDIT AND REPLACEMENT POLIC Y jau venin id nd Back Cover Safety Information Safety Information Royal Vendors Commitment to Safety Royal Vendors is committed to safety vvith 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 potentially dangerous areas and to provide basic safety guidelines for proper upkeep The service manual contains various warnings th
52. e the vend price has been achieved the control board enable a vend from any selection Valid Selection The control board constantly sends a logic level signal to the common position of each select switch When a selection is made the switch closes This allows the low voltage signal to travel from the switch s common position through the switch and out its normally open position 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 a product Product Delivery As the product drops the vibration from the impact allows the delivery sensor to send a low voltage signal to the vender s control board indicating that a product has been vended After the control board receives the sensor s signal it will take into account how the vender is programmed set depth and will act accordingly If set for double depth and the first package has just vended the control board will kill all power to the vend motor at the exact same time that a product drop is registered this avoids a multiple vend of the next product to the rear of the cab
53. elections to turn off by 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 in order for the timer or key switch to operate The timer or key switch will control any selections set to 1 Selections set to 0 vvill function normally If lt enter gt is pressed at the StCL prompt the display will show ALLX or tY X depending on whether the ALL setting is being used or an individual selection is being accessed Y represents the individual selection number and X represents the status of ALL or the individual selection 1 if enabled or 0 if disabled The X character will be flashing Using up or down will toggle X between 0 and 1 When the desired setting is on the display pressing lt exit gt will save that setting and return the controller to the selection level If ALLX is being used all selections will be set to this value If lt exit gt is pressed at the selection level the controller will return to the StCL prompt Use up to proceed to the next prompt tinE mua If lt enter gt is pressed at the tinE prompt the controller will enter the time setting mode by displaying YEAr Using up or down will cycle through all available time setting options If exit is pressed at any time during this level of the operation the controlle
54. ess also used for connections to evaporator fan relay heater relay and light relay Allows relay to energize and close contacts to complete 110 VAC hot circuit GROUND SHIELD N 1 0 BLACK NEUTRAL TEMPERATURE SENSOR WHITE TEMP SIGNAL RED 5 VDC 41 Section 8 Parts Catalogue Control Board and VViring L E D DISPLAY e TO SELECT NY Switches N TO COIN CHANGER VALIDATOR etc TO IN LINE FILTER 42 Merlin IV Plus Operation and Service Manual ITEM NO 1 an ko 11 12 13 14 15 16 Section 8 Parts Catalogue Control Board and Wiring DESCRIPTION PART NO Control BOANG ME 836182 LED Display HarnesSi si Mi edie Dee tee e tt anaes se 842081 LED Harness Dr Pepper ec nisin dh de e dri 842326 Serial Changer Hammes iia 842079 Delivery Sensor includes harness Piezo emm emnes 210121 Select Switch Harness Pepsi Cola 10 Gelee 842190 Select Switch Harness Live Display Vender nns 842192 Select Switch Harness Dr Pepper Vender ane 842201 Main Door Harness vend motor 1 door switch wiring 842169 Cabinet Harness 12 Column Mechanism Wide 842230 Cabinet Harness 10 Column Mechanism Narrow ne 842231 Merlin IV Harness 117V Lines sa Ret e ete desee ee a rn b ped RH ees vina 842151 Internal DEX e lun 842099 Temperature Sensor includes NarneSs aa aaa aaa ee e
55. ewdriver to remove complete the circuit to the refrigeration relay to energize the scerews that mount the ballist ta th door chassis its coil 3 The refrigeration relay coil closes the contact between the common and normally open positions allowing 115 WARNING Before removing the ballast volts to travel to the main wiring harness to start the tray remove power from the vender by compressor unplugging the main power cord from the 4 The compressor circulates refrigerant throughout AC voltage source wall outlet the system by pulling low pressure refrigerant vapor from the evaporator coil compressing it and forcing it into the condenser The condenser aided by the Note Power to the ballast is controlled by a relay which condenser fan motor removes heat from the refrigerant is in turn controlled by the logic of the vender control as it flows through the condenser and releases it to the board See SECTION 3 VENDER PROGRAMMING for outside environment The dropping of the refrigerant temperature changes the vapor to liquid 5 The evaporator coil allows the liquid refrigerant to absorb heat from the cooling compartment as it evaporates in the coil 6 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 repo
56. gs available e Factory Standard Space to Sales There are eight factory preset settings from which to choose These settings depend on how C12 Configuration 12 is set for 12 or 10 columns e Custom Space to Sales Allows you to custom configure any column to any selection 20 C5E5 Custom Space to sales If lt enter gt is pressed at the CStS prompt the controller will enter the custom space to sales option Upon entry into this routine the display will show SLXX followed by the current cell assignments for selection XX If SLXX is flashing and not followed by a column number there are no columns assigned to selection XX Using up or lt down gt will cycle through all the available selections and their associated column assignments Pressing lt enter gt at the SLXX prompt will allow the assignment of columns to selection XX The display will show CoN where N is the column number If CoN if flashing the column is assigned to the current selection if CoN is steady not flashing the column is not assigned to the current selection Using up or down will allow you to cycle through all the columns Pressing lt enter gt when CoN is displayed will cause the column to flash if not already assigned or not flash if it is already assigned If exit is pressed the display will return to the SLXX prompt Once all space to sales assignments have been comple
57. h Coin mechanism Bill validator optional Card reader optional Hand held computer optional Merlin IV Plus Operation and Service Manual CONTROL BOARD PINOUTS The Merlin IV control board has several electrical pinouts a setup mode button a delivery sensor adjustment trimpot a delivery sensor adjustment indicator lamp and various other electronic components all of which have designated position codes The following section outlines all the control board s pinouts 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 Precautions to take when working with the 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 to 200 volts is enough to create problems within the circuitry of the electronics I
58. h setting If lt enter gt is pressed the day setting will flash Up or down can now be used to set the day Pressing lt enter gt again will cause the month setting to flash again Pressing exit in this mode will save the displayed month and day settings and return the controller to the time selection level hour If lt enter gt is pressed at the hour prompt the current time is displayed in a 24 hour format The left two digits of the display show the current hour and the right two digits show the current minutes The hour setting will be flashing Pressing up or down at this point will increase or decrease the hour setting If lt enter gt is pressed the minute setting will flash Up or down can now be used to set the minutes Pressing lt enter gt at this point will cause the hour setting to flash again Pressing exit in this mode will save the displayed hour and minutes setting and return the controller to the time selection level SEkd If lt enter gt is pressed at the SEtd prompt the current day of the week is shown Pressing lt up gt or lt down gt will cycle through all days When the desired day is selected press lt exit gt to save the displayed day setting and return the controller to the time selection level SEOP If lt enter gt is pressed at the StOP prompt the display will alternately show CLOC StOP If lt enter gt is pressed at this point the system cl
59. howing SALE XXXX XXXX where the X s will represent the total number of all free vends over the life of the vender s control board Using up or lt down gt will cycle through each selection as SLNN XXXX XXXX where the N s represent the appropriate selection number The individual selection counts are resettable If exit is pressed the controller will return to the SALE prompt Press up to proceed to the next prompt CoSt If lt enter gt is pressed at the CoSt prompt the controller will enter the free vend equivalent cost display mode by displaying SLNN XX XX where the N s represent the appropriate selection number 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 the controller will return to the CoSt prompt Press lt exit gt again to return to the FrEE prompt ENS This mode was designed to help diagnose vender problems If lt enter gt is pressed at the Eror prompt the controller will enter the error display mode If no errors have occurred since the last error reset the display will show nonE If an error has been detected since the last error reset the display will show the first summary error code that has occurred such as UEnd which would indicate a vend erro
60. impot is used to adjust and fine tune the sensor It is capable of turning both clockwise and counterclockwise Located adjacent to 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 Turnthe adjustment screw clockwise until the indicator light comes on 2 Turn the screw counterclockwise until the light just goes out 3 Continue to turn the screw counterclockwise one 1 full turn Note Slight adjustments may be needed outside the factory set one turn Turning the adjustment screw clockwise makes the sensor more sensitive and counterclockwise 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 columns 1 and 4 and 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 cancelled credit with no product delivery from all columns make sure the sensor is adjusted to the factory specifications as listed above Next turn the adjustment screw counterclockwise 1 4 turn to decrease sensitivity Test vend all columns If still dry vending turn the adjustment screw
61. in IV Plus Operation and Service Manual Section 8 Parts Catalogue Lighting Assemblies lt a Q DR PEPPER ADA MODELS 650 AND 768 LG _ ITEM NO DESCRIPTION PART NO 9 B 1 Lamp Bracket Top Model obt 381511 le 3 z Model 768 EEN 382508 2 Lamp Socket Top spring loaded A 842223 JA 3 Fluorescent Tube un eer rte nn See note below Y 4 Lamp Socket Bottom static seeks se se kes iso Anek AE BA2224 5 Lamp Bracket Bottom Model 650 ee ee ee ee ee 381544 Model Kiss OR EE 382507 6 Bottom Lamp Panel Dr Pepper ese sees ee ee zere Re Re AG 374517 4 7 Ballast aro tad a a a eiiis 838053 oder Harness Lower Lamp 842754 5 Upper Lamp cuina 842755 SCH Note Fluorescent tubes are not available for purchase from Royal Vendors LIVE DISPLAY MODELS ITEM NO DESCRIPTION PART NO 1 Lamp Panel Top 218506 2 Lamp Panel Bottom 278507 3 Lampholder iiiter terere 842011 4 E EEN 838031 5 Fluorescent Tube See note below Ballast Assembly Live Display 2 bulb 122529 Note Fluorescent tubes are not available for purchase from Royal Vendors Merlin IV Plus Operation and Service Manual 55 Section 8 Parts Catalogue Port Assembly Cold Drink Dr Pepper Door ITEM NO 1 CO ONOG AO 56 DESCRIPTION PART NO Port Body Weld ASSOMDIY ennemi DANENA rr 378540 PortBrace Wide Vender Gold Drift EE
62. inet As the next package vends the control board will cycle the vend motor to pick up another load of product This allows a quick vend less than three seconds for the next customer 30 Vend Cycle Note The control board will go through a Learning Mode It will be reset either on power down up or a door opening closing This allows the vender s 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 package has vended How it works The controller will notice the first long timed out vend cycle during the Learning Mode From this the controller will know the 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 setting of the selection 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 10 to 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 3 The sensor is out of adjustment and does not detect the product drop or 4 If any selec
63. inserting a claw hammer crowbar or similar device into the slot of each section to break it apart Tilt the vender slightly to remove the separated pieces See Figure 1 1 Remove the Door Block After opening the vender s door locate the wooden shipping block at the bottom right under the door Lift the block straight up to remove it Merlin IV Plus Operation and Service Manual Place the Vender on Location When placing on location allow for a minimum of 4 10 cm of space at the back of the vender This will ensure proper ventilation of the refrigeration system To level the vender close and latch the vender s door Using a spirit level adjust the four leveling legs until the top of the vender is level left to right and front to back Make sure all leveling legs are in contact with the floor Program the Vender All programming of the vender is done in the Service Mode For programming instructions see the section entitled Vender Programming later in this book Figure 1 1 Removing the shipping skid Specifications 202 cm 183 cm 183 em Empty Weight 648 Ibs 620 Ibs 550 Ibs 294kg 281kg 249kg Operating Voltage Amperage Refrigerant Charge R134a 6 5 oz 0 18 kg Steel cabinet steel rack Capacity 768 cans 650 cans 542 cans 12 oz 12 oz 12 oz 115 VAC 60 Hz Section 1 General Information and Setup Voltage Requirements and Vender s Power Cord The vender is designed
64. lus Operation and Service Manual Section 8 Parts Catalogue Cabinet Assembly ITEM NO DESCRIPTION PART NO 1 Cabinet Weld Assembly ctt e trea ede ceu er etude tt e codd SN bd de ds 257260 2 Right Column CU 257350 3 Verid Mechanism SUP DOME esouguer 058001 4 Product Chute Tie Bracket aaa 010017 5 Product Chute Assembly iss es EE GE DE lit aida id 256070 6 Harness Splash Shield eee eee eee tete tentene Ee Re ee ee ee 385002 7 Left Vandal Panel 12 m 142022 8 Hinge TOD Pi RE EE ME RR EE NE 810075 9 Bottom Hinge Weld Assembly ceret ederet ttt etd ati a Lo b etd dd 256082 10 Temperature Sensor Mounting Bracket Cp 286002 11 Temperatule Sets OI cse exse A ene ed eura dedi e RR ee Pe vee 822030 12 Temperature Sensor Bracket 810085 13 Evaporator Fan Housing Assembly 2 221 ses i trit eg Ie se Ve E ttd c t Rd d d x ee ged C Y 256035 14 RE MONS E EE EE X E803002 15 Vend Mechanism Assembly Wide 27 385710 uA A UTERETUR 386710 Eu EN ER 387710 16 Latch Strike Mounting Plate Weld Assembly ee ee sss emen 385010 17 Lateh Strike Assembly i s editae dhe cede ude ani e ve EN 378010 18 Door Switch ActlVator EE AE Rodas 231009 Merlin IV Plus Operation and Service Manual 65 Section 8 Parts Catalogue Vend Mechanism Assembly Merlin IV Plus Operation and Service Manual Section 8 Parts Catalogue Vend Mechanism Assembly ITEM NO DESCRIPTION ROYAL NO 1 Vend Mechanism Assembly 72
65. mple SC 1 On 0900 Merlin IV Plus Operation and Service Manual Section 3 Vender Programming At this point up or lt down gt will cycle through all timer setting modes listed previously From this level pressing exit will return the display to the day of the week Pressing exit again will return the display to dAY Press lt up gt to proceed to StOP Note If certain selections are being set to go off and come back on at a programmed time first enter into SC 1 On to set the first off time for selections Then program the first return on time for selections by entering into SC 1 OFF For the timer to be able to control the selections those selections must be set to I in the StCL mode dt If lt enter gt is pressed at the dSt prompt the display will show dStX where the X will be flashing If X 0 this indicates that the current time is not being displayed in place of the POS message in sales mode If X 1 the time is being displayed in sales mode Using up or lt down gt will toggle the value of X If exit is pressed at this point the currently displayed value of X will be saved and the controller will return to the dSt prompt dt If lt enter gt is pressed at the dLt prompt the display will show dLtX where the X will be flashing If X 0 this indicates that the controller will not a
66. mponent repair replace component test to confirm fix e Identify source path or load e Distinguish between software and hardware Repair the problem not the symptom Simple circuit e Power supply source example control board e Line path example display harness e Device load example LED display e Failure of any one results in service call e Skill required is systematical logical process of elimi nation 1 Do I have power 2 Can the power get to where I want it 3 Does the device work e Confirm through use of volt ohm meter e Understand the impact of software on hardware Testto confirm repair e Low voltage circuits are affected by harness connec tions insulation line noise polarity and ground e The meter is not an option when checking low voltage circuits 38 Component Highlights Control board e Brains of vender Controls all vending operations e See Chapter 2 Vender Component Explanation for full explanations of control board pinouts and functions Power Supply See Figure 7 1 e Supplies 24 VAC 10 to control board e Only AC voltage at control board e Check for primary voltage to transformer at lamp bal last harness e Check for secondary voltage across position P15 pins 1 and 2 e Secondary is protected by a 3 amp fuse e Ohm out fuse holder w 2 m c n m TRANSFORMER Figure 7 1 Povver supply Merlin IV Plus Operation and Service
67. n without affecting the control board PIN WIRE COLOR FUNCTION 1 RED 24 VOLTS AC 2 BLACK NEUTRAL MODE SVVITCH Position P16 This pinout is not currently used 12 Low Voltage Transformer The Merlin IV Vender uses a low voltage transformer which reduces 115 volts AC conventional voltage to 24 volts AC 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 The transformer is located in the top of the vender s door behind the top bulkhead WARNING Before working on or near the transformer remove power from the vender by unplugging the main power cord from the AC voltage source CHECK THE TRANSFORMER AND FUSE If upon arriving at the vender the LED display is not lit and the coin changer does not take coins or pay out coins make sure the vender is plugged in Next check the transformer s external 3 amp fuse for visual damage Check for continuity across the fuse with a voltage meter or similar device If defective replace the external fuse 1 Check the power going into the transformer at the connected red and black wires It should register 115 volts AC If not check voltage coming out of the main wiring harness 2 If115 volts is registered in Step 1 measure voltage at the other end of the transformer The two 2 pin connector leading to the control board should register app
68. n Space to sales not properly set Enter space to sales Make sure the columns are set correctly according to the buttons Miswired motor Check wiring at each vend motor at the vend motor connection in the bottom of the door and at the control board vend motor connection Miswired selection button Check the wiring at each selection switch and at the selection switch harness connection at the control board No vend upon Delivery sensor Check to see if the delivery sensor selection dry vend adjustment LED is constantly on no refund If so turn the adjustment screw counterclockwise until the adjustment LED goes off Cuts or pinches in delivery sensor harness Replace defective sensor adjustment LED constantly on Defective control board Unplug the sensor connection from the control board If the adjustment LED light stays on replace the control board No vend from some Selection switch Make sure the LED acknowledges but not all columns each selection switch If not check the allows refund or selection switch Trace the selection second choice switch harness all the way up to the control board Replace if necessary Wiring from motor connection on control Check wiring all the way from the control board all the way to the vend motor of the board to the vend motor for cuts pinches defective column or backed out wires Control board Measure voltage at vend motor s connection on the control board Measure it on the
69. ne en 822030 Temperature Sensor Mounting Bracket below chute assembly 286002 Relay Harness Refrigeration Door Side nennen 842236 Evaporator Fan Door Side 842281 Relay Harness Refrigeration Cabinet Side 842237 Evaporator Fan Cabinet Side e tete eterik eke ke kek eee eee e near nnns 842623 Refrigeration Relay tatc O v 836130 Transformer Assembly pass vid 842147 Merlin IV Harness Transformer and Fuse to Board 842210 Fusebox ASS MDIV er E Ee 842219 LED Display e rekah AM Re 836012 MDB Reen E 842116 Merlin IV Plus Operation and Service Manual 43 44 Section 8 Parts Catalogue Cold Drink Dr Pepper Door Assemblies Front Merlin IV Plus Operation and Service Manual ITEM NO 1 2 3 Section 8 Parts Catalogue Cold Drink Dr Pepper Door Assemblies Front DESCRIPTION PART NO elitso 815248 Sign Assembly eor ER rente Ern RE Ere te Ep See exploded view elsewhere in Parts Catalogue Trim All Wide Vender e 013580 s Wide Vender 9 iei OR EA AR EE RE 012597 Narrow Vender EE Top Bottom only Wide Vender 72 79 012553 Top Bottom only Narrow Vender 727 et bte ee i bnt eee da 040811 Left only A OE AE EE NA UN ER ES 142502 s ketoni FQ e RE OE EE EAA 141553 aene Am 013507 Right ONY 7
70. nto this routine the display will show CO 1 indicating that a test vend from column 1 may be initiated Up or down can be pressed to cycle through the available columns Activation of lt enter gt at a displayed column will initiate a test vend on that column Vends made while in this routine will not be added to the SALE mode totals If exit is pressed at any time when CONN is displayed the controller will return to the tESt prompt Press up to proceed to the next prompt Pric Note Test vends will not affect cash or sale counters PRICE SETTING MODE Pot If lt enter gt is pressed at the Pric prompt the controller will enter the selection price setting mode If multiple prices are enabled at C1 in configurations mode the controller will display ALL for the universal selection price If lt up gt is pressed the controller will display P 1 for the price of selection 1 The current set price for selection 1 will alternate with the P 1 display Using up or down will cycle through each individual selection price If lt enter gt is pressed at P XX where XX represents the selection number the display will show the current price for the displayed selection Use up or lt down gt to increase or decrease the price When the desired price is on the display use lt exit gt to save that price and return to the P XX display If the ALL price is
71. o accumulate standing water which over a period of time may begin to freeze and will eventually freeze the evaporator Another problem that may occur from an unleveled vender will be improper vending which would include but not be limited to product not vending from column product vending slow from column product not sliding or rolling down to the delivery port or product jamming Lighting System The lighting system contains high voltage Power MUST be disconnected when working with or around this portion of the vender Light bulbs should be replaced whenever one or more of the bulb ends are blackened or discolored or when the lights are flickering or are not lit and it has been determined that the ballast is good Replace these bulbs as soon as it is determined they are bad If it is decided not to use the lighting system the ballast MUST be unplugged DO NOT remove the bulbs and leave the ballast plugged in Doing so can cause the ballast to generate a very high amount of electrical noise which can cause problems for or permanently damage electronic components Product Chute Bottles or cans should never be placed under the product chute Bottles can prevent air flow and may hinder the proper performance of the chute sensor WARNING ELECTRIC SHOCK DANGER Power MUST be disconnected when working with or around the lighting system 31 Section 6 Vender Troubleshooting Vender Troubleshooting Using the Vender s Error
72. ock will be shut off the display will show OFF for approximately 1 2 second and then the display will return to the StOP prompt If exit is pressed at the CLOC SOP prompt the controller will return to the StOP prompt without turning off the system clock To restart the system clock use the hour feature to reset the current time When the current time is reset the battery will be turned on automatically 26 dP If lt enter gt is pressed at the dAY prompt the controller will enter the time range programming function to allow the timer on off times to be set for each day of the week The display will show ALL From this point there are two different options ALL to allow the timer to function at the same time settings every day of the week and individual day settings for using different time blocks for different days Pressing lt up gt or down will cycle through ALL and each day of the week If enter is pressed either at ALL or an individual day the controller will enter into that particular day The display will show SC 1 On then the currently set off time as listed below If lt up gt or down is pressed at this level the display will cycle to all other available timer setting modes SETTING MODE PROGRAM MEANING SC I On Ist off time for selections SC 1 1 OFF Ist on time for selections SC 2 On
73. ode is disabled C6 0 then both bill acceptance checking and bill escrow should be enabled C7 amp C10 1 This is the only way to ensure the customer will never be cheated Cii Error code display This option is used to set the controller to restrict error code displays When set to 1 only certain sets of error codes will be shown If X 0 all error codes will be displayed If X 1 only certain error codes are displayed Cte Column quantity This configuration is used to set the controller for 12 column operation models 768 and 650 or 10 column operation model 542 It is imperative that this configuration be set correctly for the vender model If X 0 the controller is set for 12 columns If X 1 the controller is set for 10 columns C H ENERGY STARO Tier Setting ENERGY STAR is a government led program to promote energy efficient products All venders built for use in the USA and Canada since April 2004 are ENERGY STAR compliant Beginning with serial numbers 200724 and after these venders are now ENERGY STAR Tier 2 compliant which denotes even greater energy efficiency Tier 2 compliant venders can be identified by the placement of the temperature sensor In older venders the temperature sensor was mounted on the rear cabinet wall behind the evaporator fan On Tier 2 compliant venders the temperature sensor is mounted in front of the evaporator directly below the chute assembly Merlin IV Pl
74. oor Assembly Wide Vender Cold Drink 1 Live Display 72 378610 Wide Vender Dr Pepper 2 aci A Re HRS ices equa ters e ee des bee 374610 Wide Vender Cold Drink Live Display 79 ee ee ER EA AR nennen AA Ge 379610 Wide Vender Dr Pepper 7 9 nein aie taie et epe aia OE EE iai 375610 Narrow Vender Cold Drink Live Display 72 essin ei tnnt 380610 Narrow Vender Dr Pepper 72 enc ie ee leh iei nra tu nd dh n n SEE REGS ndere d gea dead NAG der ona 376610 Door Gasket Wide Vender 12 nvidia 815032 Wide Vender WEE 815033 Narrow Vender Plain ii ivre ee or do ori d e een e a d e e a ate a be ee 815219 Bushing Inner Door WINGS za cei it OO EE OR e HE ER dat 815026 Top Inner Door hinge VAL nece EE EE e or reti ote aaa 010520 Keps Nut 910 32 EE E905001 Screw Self drillitig with ES EE nri Ph net o n EE N E902001 gea mL E908002 Cable Clamp EE E916004 Port Door Rod WIde i a aer ten a a ete dun e Eee ha EO a OR Pre e d aaa 811028 Burst Open Kalon ER TE N EE E a a 812002 Inner DOOR ao OE AO OR OE AE EE Eo AR ER 815192 Frame Inner Dor ananasi a en e ee ek SE edge eG e tid reg 815191 Elastic Stop Nut Assembly 26 32 sse ener ener ennt E905006 Seirat d Screw 1 4 20 X EE E901003 Bottom Inner Door TAINS ien iti RE ER Hen atia 010543 Merlin IV Plus Operation and Service Manual 63 64 Section 8 Parts Catalogue Cabinet Assembly Merlin IV P
75. or improperly grounded the sensor may give the control board false temperature readings Refrigeration activity 1s based on the signal reported to the control board from this sensor PIN WIRE COLOR FUNCTION 1 RED 5 VDC POWER 2 WHITE TEMP SENSOR SIGNAL 3 KEY 4 BLACK RETURN TO COMMON 11 Section 2 Vender Component Explanation ENV CONTROLS Position P14 The vviring harness connecting this pinout povvers the refrigeration relay to power the refrigeration unit It is also responsible for powering any optional relays such as the heater relay evaporator fan relay light 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 pins 2 3 4 6 or 7 PIN WIRE COLOR FUNCTION 1 2X1 24 VDC 2 2X2 HEATER RELAY 3 2X3 COMPRESSOR RELAY 4 2X4 FAN RELAY 5 KEY 6 2X6 LIGHT RELAY 7 IMPULSE COUNTER 8 24 VDC 24 VAC Position P15 The two wire harness connecting to this pinout comes from the transformer It is imperative the correct harness be connected to this pinout If this harness is not connected or if power is lost to the connection the vender will noticeably lose all functions including power to the LED display The coin mechanism will not accept coins and the refrigeration system will not run With this connector the wires can be in either positio
76. partment next to the compressor It can be seen from the front with the door open The condenser 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 start winding and 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 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 13 Section 2 Vender Component Explanation 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 vvhile the compressor operates Evaporator Coil The evapora
77. perating properly check this harness for bad connections at the solder joints Also check to ensure the insulator is not cracked from over tightening PIN WIRE COLOR FUNCTION 1 RED VMC RECEIVE DEX TRANSMIT DATA ring 2 KEY 3 WHITE VMC TRANSMIT DEX RECEIVE DATA tip 4 GREEN DEX COMMON sleeve Merlin IV Plus Operation and Service Manual HHC 2 Position P11 The three wire harness connecting to this pinout comes from the external Hand Held Computer HHC jack located on top of the port assembly The HHC 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 is not operating properly check this harness for bad connections at the solder joints Also check to ensure the insulator is not cracked from over tightening PIN WIRE COLOR FUNCTION 1 RED VMC RECEIVE DEX TRANSMIT DATA ring 2 KEY 3 WHITE VMC TRANSMIT DEX RECEIVE DATA tip 4 GREEN DEX COMMON sleeve TEMP SENSOR Position P12 The wiring harness connecting to this pinout travels from the temperature sensor to the control board The temperature sensor is mounted below the product chute in the vender s cabinet This harness is moulded into the temperature sensor and should never be cut pinched or spliced together if cut If the harness is cut pinched
78. presents the number of the selection and X represents the current column depth setting of the selection X will be 2 if set to double depth mode cans or other small packages or 1 if set to single depth mode most bottles and other long packages Using up or lt down gt will alternate X between 2 and 1 When the desired setting is on the display pressing exit will save that setting and return to the selection level If the ALL setting is used all individual selections will be set to this depth From the selection level press lt exit gt to return to the SdEP prompt Use up to proceed to the next prompt Con Merlin IV Plus Operation and Service Manual CONFIGURATIONS MODE ra If lt enter gt is pressed at the Con prompt the controller will enter the configurations mode by displaying Cn X where n is the configuration number and X is the current status Using up or down will cycle through all available configuration options If exit is pressed at any time during this operation the controller will return to the Con prompt From the Con prompt use lt up gt to proceed to the next prompt rtn if C2 is set to 0 or ECO if C2 is set to 1 If enter is pressed the display will flash X the current status Pressing up or lt down gt will cause the flashing status to toggle between 0 disabled
79. pt FrEE MODE The Free Vend Accounting Mode is used to track cash counts sales counts and cost of all free vends If lt enter gt is pressed at the FrEE prompt the controller will enter the first of three sub menus CASH If exit is pressed at any time during this operation the controller will return to the code level Press the lt up gt button to proceed to the next prompt Eror FREE VEND ACCOUNTING If lt enter gt is pressed at the CASH prompt the controller will enter the non resettable cash value display mode by showing CASH XXXX XX XX where the X s will represent the total equivalent value of all free vends over the life of the vender s control board A decimal point will be displayed in the appropriate position with the lower four digits If the cash amount is less than five digits long the upper four digit set is not displayed Using up or lt down gt will cycle through each selection as CANN XXXX XX XX where the N s represent the appropriate selection number The individual selection counts are resettable If exit is pressed the controller will return to the CASH prompt Press up to proceed to the next prompt SALE Merlin IV Plus Operation and Service Manual Section 3 Vender Programming If lt enter gt is pressed at the SALE prompt the controller will enter the non resettable free vend count display mode by s
80. r Pressing up or down will allow you to cycle through all of the summary error codes that are present Pressing lt enter gt at the displayed summary error code will allow you to view the detailed error codes beneath the summary error heading For a list of possible error codes refer to Section 6 Vender Troubleshooting Pressing up or down at this point will allow you to cycle through all of the detailed error codes that are present beneath the summary error code If the exit button is pressed anytime during this operation the controller will return to the Eror prompt Press the up button to proceed to the next prompt tESt ERROR CODE DISPLAY MODE If up or lt down gt is pressed and held for two seconds during the display of any detailed error code that error will be cleared If other errors exist that fall under the currently accessed detail type the next error would be displayed If no other errors of the current type exist the next error summary code will be displayed or nonE will be displayed if no other errors exist Merlin IV Plus Operation and Service Manual TEST VEND MODES rz This mode will test the control board s ability to distribute 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 board s coin acceptance credit payout circuit Upon entry i
81. r will return to the tinE prompt From the tinE prompt use lt up gt to proceed to the next prompt FriG TIME SETTING MODE The following options can be selected in tinE e YEAr current year e dAtE current date month day hour current time hours minutes e SEtd current day of week e StOP turn real time clock on off e dAY timer settings e dSt display current time e dLt daylight savings time enable disable NOTE The StOP feature is used to conserve the control board 5 built in lithium battery when the board is placed in storage for long periods of time The shelf life of the battery is about three years with the clock turned on or about ten years with the clock turned off 25 Section 3 Vender Programming HERF If lt enter gt is pressed at the YEAr prompt the current year is displayed and will be flashing Pressing up or lt down gt at this point will increase or decrease the year setting Pressing exit at this point will save the displayed year setting and return the controller to the time selection level date If lt enter gt is pressed at the dAtE prompt the current date is displayed The left two digits of the display show the current month and the right two digits show the current day The month setting will be flashing Pressing up or lt down gt at this point will increase or decrease the mont
82. ration and Service Manual 72 Merlin IV Plus Operation and Service Manual 73 CREDIT AND REPLACEMENT POLICY Credits or replacements will be issued on warranty items if the proper procedures 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 Example within the continental USA regular ground UPS An A R S Authorized Return Service sticker will be sent with all warranty parts This method of shipping is preferred for returning parts to Royal 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 refrigeration unit and or control board serial numbers 4 Acopy of the Packing Slip the correct serial number and complete Return Material Tag provided with part are required for sending back parts Please fill out the Return Material Tag completely keeping the white copy for your records and sending the yellow tag back with the attached part Make sure you have your company name address phone number serial number and model number along with a brief explanation of the problem 5 fthe item returned is not under warranty it will be sent back to you at your expense along with a US 10 00 handling fee or it will be scrapped 6 All warranty parts should be properly wrapped
83. roduction to Four button Proga nm ini cae oa te dcr nates quie e Er Eben ac de de cutie ei ko 16 ui en 16 MENTES AA e m 17 Internal Service Menu EE 17 Cash Counter Display Mode LASA asociada daria 14 Sale Counter Display Mode SALE teta en incen d 18 Card Counter Display Mode EFid is sees inde dite hd ske ennt pras hd 18 Token Counter Display Mode Kah E 18 Free Vend Accounting Mode FEE cda Kuk de korea Se sudo ed 18 Error Code Display Mode Eror ecu ia Aa 19 Test Vend Modes BESE ae cti aii ada 19 Pri e Setting MOJO Pri Es CC 19 Space to Sales Programming Mode GES 20 Selection Depth Setting Mode BilEP orante n tarn aln dl c RE N EE nine 21 Configurations Mode Eon 21 Return to sales e EE 24 Optional Menu NOTE anni is 24 Exact Change Value Mode ECD ier pai ii 24 Coin Pay Out Mode N EE OE aa do iones 24 Tube EM Mode OR ion IA N ee en Ee EE ed 24 Recycler Pay Out Mode PIE esse Winkie se RE een es de Ee da reve ob 24 Discounted sale Counter Mode ASH sesse ss nd heqe d ii 24 Differential Cash Counter Mode eli EL sesse sales esse Eed nantes sense es GR dete 26 Set Discount Pricing Mode 5d 5 zav pni A A A ee dace 26 Set Timer Control Mode SELL suis as teret ee dose Se ge ke Fede gs i 25 BI SUG E 25 Refrigeration Control Mode Fock ZI Table of Contents continued Password Preview Mode PA liceo 29 Language Selection Mode Hb Ee a nas strane deutet anda
84. roximately 24 volts AC If so check the control board the transformer is good 3 If115 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 unplug the connections at the transformer 115 volt side Then unplug the transformer from the control board and from the connector at the fuse box Remove the transformer from the door Replace it with a new transformer Vend Mechanism Assembly The vend rack assembly located in the cooling compartment of the vender is composed of twelve product columns six located in the front columns one through six and six in the rear columns seven through twelve Both front and rear columns are double depth columns that can be adjusted to single depth to accommodate packages other than 12 ounce cans Different package types cannot be mixed within the same column Merlin IV Plus Operation and Service Manual Section 2 Vender Component Explanation Located in the bottom of each column is a single 12 volt DC vend motor This motor is attached to a rotor on which the product rests when in a normal ready position When the control board sends power to the vend motor the rotor rotates to drop a package and deliver it to the customer Delivery Chute Sensor ADJUSTMENT Located near the control board s chute sensor connector at position R126 is the sensor adjustment trimpot which includes an adjustment screw The tr
85. rts this to the vender s control board 7 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 information on energizing this relay through the service menu for troubleshooting purposes Testing the Refrigeration System 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 the unit still does not operate a problem exists within the sealed unit 2 Ifthe sealed unit runs when plugged into an external power source the problem more than likely lies between the control board the refrigeration relay and the main wiring harness WARNING ELECTROCUTION HAZARD When plugging the refrigeration unit directly into a wall outlet or other external electrical source the refrigeration unit MUST remain in the vender for proper grounding If the unit is removed from the vender an electrocution hazard exists Merlin IV Plus Operation and Service Manual 15 Section 3 Vender Programming Vender Programming Introduction to Programming It is very important that your vender is programmed properly All programming of the vender options is done in the Service Mode To enter the Service Mode open the vender door and press and release the service mode button that is located on the control board The first three selection svvi
86. rvation mode temperature setting xx F or xx C depending on the degree dEG mode setting The default storage temperature is 60 F 14 C Pressing up or lt down gt will adjust the temperature value by 1 0 5 C The storage temperature can be adjusted from 45 F through 75 F Pressing exit at this point will save the displayed temperature and return the controller to Stor d5P If lt enter gt 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 or 1 if the controller is currently displaying the cabinet temperature in addition to the POS message Pressing up or down will toggle X between 0 and 1 Pressing exit at this point will save the currently displayed setting and return the controller to the dSP prompt rELY If lt enter gt is pressed at the rELY prompt the controller will enter the relay test mode by displaying Fan If exit is pressed in this mode the user will return to the rELY prompt Using up or down will toggle between the following submodes FAN evaporator fan relay Ly EE machine light control relay Her heater kit relay e CnPr compressor relay If lt enter gt is pressed at any of these prompts the controller will alternately flash the prompt and the word OFF
87. s dispensed in this mode are counted in the MIS manual dispense mode counters Pressing lt exit gt while a bill value is displayed will return the controller to the rPO prompt Use lt up gt to proceed to the next prompt dSAL MODE This mode is very similar to the Sale Counter Display Mode It permits manual extraction of the amount of product dispensed through the vender during the discounted sales periods up to 99 999 999 This mode consists of a non resettable total count and individual counts per selection which are resettable depending upon the proper configuration setting DISCOUNTED SALE COUNTER If lt enter gt is pressed at the dSAL prompt the controller will enter the non resettable discount vend display mode by displaying SALE XXXX XXXX where the X s will represent total number of all discounted vends over the life of the vender s control board If the discount sales amount is less than five digits long the upper four digit set is not displayed Using lt up gt or lt down gt will cycle through each selection as SLNN XXXX XXXX where the N s represent the appropriate selection number and the X s represent the resettable discount vend count for that selection If exit is pressed at any time during this operation the controller will return to the dSAL prompt Press the up button to proceed to the next prompt diFC CLEARING INDIVIDUAL COUNTERS If
88. sists of various items or modes such as Price Setting Mode or Space to Sales Programming Mode There are two menus 1 INTERNAL Service MENU This menu is available only with the vender s door open It is accessed upon pressing the control board s mode button 2 EXTERNAL MENU This menu is available by entering the proper external password with the vender s door closed See Password Preview Mode in the following section From this menu cash sales counts and vender errors can be read but not cleared Note Programming flowchart located in rear of manual Internal Service Menu Opening the vender s main door and pressing the control board s service mode button will allow entry into the Internal Service Menu This section outlines all the menu items CASH COUNTER DISPLAY If lt enter gt is pressed at the CASH prompt the controller will enter the non resettable cash display mode by displaying CASH XXXX XX XX where the X s will represent total cash over the life of the vender s control board A decimal point will be displayed in the appropriate position with the lower four digits If the cash amount is less than five digits long the upper four digit set is not displayed Using lt up gt or lt down gt will cycle through each selection as CANN XXXX XX XX where the N s represent the appropriate selection number and the X s represent the resettable cash count for that selec
89. t is advised when storing the electronics that they be kept in anti static bags even if the electronics are thought to be defective If a control board is thought to be defective and is really not it soon will be after being charged with ESD The ideal prevention against ESD is to use anti static conductive wrist straps which earth you to the machine before touching the electronic boards If it is not possible to use these at least earth 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 Section 2 Vender Component Explanation Merlin IV Control Board DISPLAY Position P1 The four wire harness connecting to this pinout travels from the vender s LED to the control board It allows the control board to send power to and communicate with the LED If this harness is cut or disconnected the LED will go blank If this harness is pinched broken segments may be seen on the LED with various segments of the display lit PIN WIRE COLOR FUNCTION 1 YELLOW 5 VDC POWER 2 GREEN CLOCK 3 BROWN DATA 4 RED COMMON 5 KEY 6 FUTURE USE 7 FUTURE USE HS TEMP SENSOR Position P2 These pinouts are not currently used on the Merlin IV MDB Position P3 The five wire serial harness connecting to this pinout provides power and communications to and from the control board for the coin mechanism the option
90. tches are used to navigate through the service routines as follows Button Meaning Usage 1 UP Increase next up 2 DOWN Decrease previous down 3 tap ENTER Enter accept save 3 hold EXIT Exit cancel home The controller will automatically return to the Sales Mode if e No response from the selection switches is received for approximately five minutes e The service mode button is pressed a second time The Return to Sales mode is activated or e The door is actually closed If credit exists the credit amount will be displayed after returning to the Sales Mode 16 Button Schemes The following illustrations show the button schemes for all Merlin IV Plus venders Live Display RVDVE 650 10 Buttons are counted from right to left top to bottom as shown below Figure 3 1 Live Display vender buttons Merlin IV Plus Operation and Service Manual Section 3 Vender Programming All other Merlin IV Plus models On all other Merlin IV Plus models buttons are counted from left to right top to bottom as shown below Note Some models may have more or fewer buttons than this illustration Figure 3 2 All other Merlin IV Plus vender buttons Merlin IV Plus Operation and Service Manual Menu System When programming you must first use the programming buttons listed above to maneuver through menus and sub menus before you will be allowed to accomplish your task Each menu con
91. ted press lt exit gt to return to the CStS display Press lt exit gt again to return to the StoS prompt NOTE Selection pricing must be aligned with the space to sales assignments DPE Options When one of the options OPtX is on the display and lt enter gt is pressed the display will begin displaying the space to sales assignments for that configuration The display will show SLXX where the X s represent the selection number followed by either a blank display indicating that no columns are assigned to that selection or a sequence of numbers that represent the columns that are currently assigned to that selection After each selection has been shown the display will return to StoS From StoS press Sup to proceed to the next prompt SdEP Merlin IV Plus Operation and Service Manual Section 3 Vender Programming SELECTION DEPTH SETTING MODE If lt enter gt is pressed at the SdEP prompt the controller will enter the by selection column depth setting mode by displaying ALL Using up or down will allow you to cycle through the individual selections This is the selection level If exit is pressed at any time during this operation the controller will return to the SdEP prompt If lt enter gt is pressed the display will show ALL or NN X depending on whether the ALL mode is being used or an individual selection is being accessed NN re
92. ter gt at the displayed summary error code will allow you to view the detailed error codes beneath the summary error heading For a list of possible error codes refer to Section 6 Vender Troubleshooting Pressing up or down at this point will allow you to cycle through all of the detailed error codes that are present beneath the summary error code If the exit button is pressed anytime during this operation the controller will return to the Eror prompt Press the lt up gt button to proceed to the next prompt rtn SALE COUNTER DISPLAY ERROR CODE DISPLAY MODE RETURN TO SALES If lt enter gt is pressed at the rtn prompt the controller will return to the sales mode 29 Section 4 Vend Cycle Stand By Condition In a stand by condition the vender will show the greeting the vend price if set for a single price or if all prices are set the same and a choice of other optional features on the LED display Ifa select button is pressed prior to reaching the vend price establishing a credit the display will show the price for that selection This will indicate to the customer that more money is needed for that selection Establishing Credit As coins are inserted 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 Onc
93. that becomes sold out is made this option will be overridden and an escrow will be honored If X 0 forced vend attempt is disabled If X 1 forced vend attempt is enabled Note that forced vend attempt has no effect on the card reader Once a card is inserted it can always be returned to the customer via the escrow lever on the changer or return button on the card reader C9 Multi vend This option will allow multiple purchases without re entering coins If enabled instead of immediately returning the change after a vend the credit will remain on the display to be used for another selection An escrow request will be honored at any time This option will take precedence over the forced vend option after the first vend has been completed If X 0 multi vend is disabled If X 1 multi vend is enabled Merlin IV Plus Operation and Service Manual Section 3 Vender Programming ram LiD Bill escrow This option will allow escrowing of bills If enabled and the current bill value inserted takes the accumulated credit over the maximum price the bill will be held in the escrow position If the rule is disabled bills will always go to the cash box If X 0 bill escrow is disabled bill sent to cashbox If X 1 bill escrow is enabled Conflicting Options In order to avoid conflicts between options and potential cheating of customers it is recommended that the following rule be followed If the cheat m
94. the Configurations Mode is set to allow the individual counters to be reset the individual counters will be reset upon reading at least one of them and closing the vender s main door Merlin IV Plus Operation and Service Manual Section 3 Vender Programming DIFFERENTIAL CASH COUNTER MODE This mode is comparable to the Cash Counter Display Mode It permits monitoring of the difference betyveen discounted prices and regular prices This mode consists only of a non resettable total count If enter is pressed at the diFC prompt the controller will enter the non resettable cash display mode by displaying CASH YXXX 1 XX XX where the X s will represent total discounted value of all discounted vends over the life of the vender s control board If product is sold for less than the normal vend price Y will be a negative sign if product is sold for greater than the normal vend price Y will be a blank A decimal point will be displayed in the appropriate position with the lower four digits If the discount amount is less than five digits long the upper four digit set is not displayed If exit is pressed at any time during this operation the controller will return to the diFC prompt Press the up button to proceed to the next prompt SdiS SET DISCOUNT PRICING MODE This mode is used to set discount prices for each selection This mode works in conjunction with the built in
95. timer in the tinE mode Before entering into the tinE mode all selections to be discounted should be set to 1 in the StCL mode Then the time the discounted selections are to be activated should be set by using dSCn located under dAY in the tinE mode If lt enter gt is pressed at the SdiS prompt the controller will enter the discount price setting mode The display will alternately flash ALL and the last discount price set for all selections If lt up gt is pressed the controller will alternately display P1 and the discount price of selection 1 Using up or down will allow the controller to cycle through each available individual discount price This is the selection level If exit is pressed at any time at this level the controller will return to the SdiS prompt Use lt up gt to proceed to the next prompt StCL If lt enter gt is pressed at the selection level the display will continuously show the current discount price for the displayed selection Using up or lt down gt will increase or decrease the discount price When the desired discount price is on the display press lt exit gt to save that price and return to the selection level If the ALL discount price is set all individual discount prices will be set to this value Merlin IV Plus Operation and Service Manual SET TIMER CONTROL MODE SEEL This mode is used to choose which s
96. tion If exit is pressed at any time during this operation the controller will return to the code level Press the up button to proceed to the next prompt SALE CLEARING INDIVIDUAL COUNTERS If the Configurations Mode is set to allow the individual counters to be reset the individual counters will be reset upon reading at least one of them and closing the vender s main door 17 Section 3 Vender Programming SALE COUNTER DISPLAY MODE If lt enter gt is pressed at the SALE prompt the controller will enter the non resettable vend count display mode by displaying SALE X XXX XXXX where the X s will represent total number of all paid vends over the life of the vender s control board If the sales amount is less than five digits long the upper four digit set is not displayed Using up or down will cycle through each selection as SLNN XXXX XXXX where the N s represent the appropriate selection number and the X s represent the resettable vend count for that selection If exit is pressed at any time during this operation the controller will return to the code level Press the lt up gt button to proceed to the next prompt CArd CLEARING INDIVIDUAL COUNTERS If the Configurations Mode is set to allow the individual counters to be reset the individual counters will be reset upon reading at least one of them and closing the vender s main door CARD COUNTER DISPLAY M
97. tion does not have a column assigned to it it will read SOLd OUt The digital display will indicate SOLd OUt This signals to the customer to make another selection or push the coin return lever for a full refund If set for forced attempt the customer must make an initial selection If the 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 product 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 indicate a vend is in progress It will automatically show SOLd OUt upon pressing the select button after reaching a vend price Merlin IV Plus Operation and Service Manual Section 5 Vender Maintenance Vender Maintenance VVhat to Clean VVARNING Electrical and electronic components should NEVER be subjected to vvater Do not use hoses or pressure vvashers to clean the interior of the vender Cabinet and Vend Mechanism Steam clean as required Never use petroleum cleaners Condenser and Evaporator Coils For efficient operation the condenser and evaporator coils must be kept clear of any
98. to begin flashing All digits may be modified in this manner Pressing exit at any point in the procedure will save the currently displayed password and return the controller to the PAS prompt Use up to proceed to the next prompt LAnG Note Password digits correspond to the selection switches If a digit is set to 0 zero it will not be possible to enter the external password LANGUAGE SELECTION MODE The Merlin IV Plus vender has the ability to display vending messages ICE COLd SOLd Out etc in any of several preset languages The available languages are listed below If lt enter gt is pressed at the LANG prompt the controller will display the current language setting Pressing up or down will sequence through the available languages e Eno English e FrEn French e SPAn Spanish e HEbr Hebrew e GEr German e USE Custom Pressing exit at any point in the procedure will save the currently displayed language setting and return the controller to the LAnG prompt Use up to proceed to the next prompt rtn Note Custom language is present only if custom language has been uploaded using DEX mode RETURN TO SALES If lt enter gt is pressed at the rtn prompt the controller will return to the open door Merlin IV Plus Operation and Service Manual External Menu Access the External Menu by entering your 4 digit password when the main door is close
99. to operate at a voltage of 115 volts AC 60 Hertz It requires the minimum of a 15 amp service and it should be on a dedicated circuit The service outlet voltage must not exceed 129 VAC or fall below 103 VAC The vender has a three wire grounding cord The vender must be plugged into a grounded electrical outlet to protect customers from electrical shock If the outlet is not equipped with a grounded socket have one installed by a qualified electrician Do not use an extension cord unless it has been authorized by a certified electrician Extension cords are not recommended After plugging the vender s power cord into the AC voltage source the following should be observed 1 The fluorescent bulbs will illuminate if the door is closed 2 Therefrigeration compressor will start to run after approximately 5 7 minutes with the door closed 3 The evaporator fan will run and 4 The display will light The control board is equipped with a battery back up for use in the event of a power loss The battery is used to retain important programming information such as space to sales prices etc so that it will not be erased if power is lost or the vender is unplugged MODEL RVMC 650 10 ROYAL MA Kearneysville WV 25430 USA SERIAL NUMBER 201126FA00001 9 AMPS R134a 5 25 oz DESIGN PRESSURES 300 HS 156LS 115V 60HZ 1PH LISTED REFRIGERATED VENDING MACHINE 66E9 SUITABLE FOR OUTDOOR USE Figure 1 2 Vender serial pl
100. tor coil is located in the cooling compartment As lovy 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 Capillary Tube The capillary tube is located in the refrigerant line between the condenser and evaporator coils 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 passes through the evaporator coil Drier The drier is located in the refrigerant line between the capillary tube and condenser It traps and removes moisture from the refrigeration system while allowing oil and refrigerant to pass through the system REFRIGERATION SYSTEM pes SS ccu Capillary EVAPORATOR Tube 1 n 1 1 lt Evaporator Fan Motor 1 I 1 I 1 1 1 1 1 I 1 1 1 1 1 1 1 Y Suction Accumulator COMPRESSOR Figure 2 1 Refrigeration system flow 14 Accumulator The accumulator is located in the refrigerant line between the evaporator coil and the compressor The accumulator traps
101. tton is released All coins dispensed in this mode are counted in the MIS tube counts and the manual dispense mode counters Pressing lt exit gt while a coin value is displayed will return the controller to the CPO prompt Use lt up gt to proceed to the next prompt tUFL Ma If lt enter gt is pressed at the tUFL prompt the controller will enter the coin tube fill mode In this mode you are allowed to deposit any coin that is routed to a tube This provides total accountability The tube inventory level for the deposited coin will be displayed after the coin is accepted If a tube full status is detected that coin will no longer be accepted During this entire operation MIS tube counts and manual fill mode counters will be updated accordingly If exit is pressed at any time during this operation the controller will return to the tUFL prompt Use lt up gt to proceed to the next prompt rPO COIN PAYOUT MODE TUBE FILL MODE 24 RECYCLER PAY OUT MODE n If lt enter gt is pressed at the rPO prompt the controller will enter the bill payout mode by displaying the lowest bill value that can be paid out Pressing lt up gt will increase the display to show the next higher bill value if any pressing down will decrease the display to show the next lower bill value or wrap around Pressing lt enter gt when a particular bill value is displayed will pay out the displayed bill type All bill
102. uie de ER a iria dd tdt 810054 Merlin IV Plus Operation and Service Manual 67 Section 8 Parts Catalogue Refrigeration Assembly AX AE VC VAS AC VN Sp OPTIONAL Merlin IV Plus Operation and Service Manual 68 Section 8 Parts Catalogue Refrigeration Assembly ITEM NO DESCRIPTION ROYAL NO 1 Heat Exchange rondiri lus R 210425 2 BIET 824005 3 COndenser EE AE EO EE EE RAINER 820007 4 Condenser Fani MOLOF eet e dd Ar e Ad 839010 Condenser Fan blade 810014 Condenser Fan Motor Bracket utin kd ENEE 810006 5 SEFENV EA dl EE EE Padus EE dede x E kao za e xa 901006 6 13t HP Capacitor Start CompreSSOF ett t ete sas rd o eee P VE Re TERRENO ede 819028 7 Compressor Relay 1 3 H P Tecumseh Only aaa sesse ese ese ee ee ee never eee emen 822042 8 Compressor Overload 1 31 H P Tecumseh Only 822010 9 Compressor Led socie n Na SEE NOTE 10 Grommets e Lull 916015 11 Grommets el e EE 815017 12 Clip COMPLE SO A a n v aN 914002 13 lu e EET 822001 14 D NONV a 902004 15 Evaporator Fan Shroud Assembly Airflow Wide 256035 Evaporator Fan Shroud Assembly Wide prior to 200422 256080 Evaporator Fan Shroud Assembly Airflow NaFFOW aaa nana aaa ee ne eee ee eee er z eee ever eve teren een 264030 Evaporator Fan Shroud Assembly Narrow prior to 200422 258070 16 Evaporat r e 820002 17 Refrigeration System Merlin IV 1734 HP 256420 e See ege E
103. us Operation and Service Manual The features of ENERGY STAR Tier 2 compliant venders are Normal Mode Energy Saving When the main door is closed and the door switch is made the controller will count the number of refrigeration cycles When this number equals a stored counter the refrigeration unit will convert from a pull down mode in which the evaporator fun runs continuously to a normal mode in which the evaporator fan runs only when the compressor is on Defrost Mode The defrost feature is a 30 minute period in which the compressor is shut off and the evaporator fan is allowed to run The defrost feature is initiated by a timer The factory default is three hours but this setting may be adjusted in the Refrigeration Control Mode from 3 to 24 hours IT IS IMPERATIVE THAT CONFIGURATION 11 BE SET CORRECTLY Possible problems due to incorrect setting of this configuration include e TIER 1 Ifa Tier 1 compliant or non Energy Star vender s controller is set for Tier 2 operation the refrigeration unit could short cycle eventually shutting off the unit completely TIER2 Ifa Tier 2 compliant vender s controller is set for Tier 1 operation the refrigeration unit could freeze up and shut down A PULL error will be shown in the vender s error codes This configuration should be set as follows If X 0 the controller is set for Tier 1 operation NOTE All venders built for use outside the USA and Canada should

Merlin IV Plus - Royal Vendors, Inc.

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