Royal Vendors Merlin IV Building instructions

INTRODUCTION
Introduction
-
Welcome to the MERLIN IV Senice and Parts Manual
It is Rojal Vendors' objectne through this manual to
fmiiliariLc lou nith the MERLIN IV Lending machine
ilre firnil! belie\e that. like our other models. !ou mill
find it to be \en reliable
This Senice and Parts Manual is designed to ease the
programming
of the Vender and to help understand the
Lender as
n ithole Located in this inanual is a helpful
L'ender Component Explanation Section outlining each of
the Vender's major parts There is also a Troubleshooting
Scction at the end of this Manual co\ ering most general
problems
Honeier. if you encounter a problem not
discussed
in either of the aforementioned Sections. it is
,id\ ised that ~ou contact lourRo!al Vendors' senice
rcprcsentnti\ e
IMPORTL4NT NOTE: To sene 10u better. \\e ask you
ha\
e the folloning items a\ ailable before contacting
I
our Ro?a1 Vendors' senice representatir e
A. Your coinpan! 's name
B. Your conipan~'~phone number (area code first)
C. Your first and last name
D. The L%iider( 's) model number
- E. The Vendcr('s)senal number
E The Vender( 's) Control Board re\ ision number (if
concerning a board or programming)
it is also
\en important to hale all of the information
about !our problem a\ ailable 1% hen IOU call
,
GEWRAL CARE AND SAFETY Ne\er plug or
unplug harnessing or connectors
\+ ithout first ternunating
po\\er to the Vender at the wll outlet The Vender's
Control Board
is \en sensiti\e and should be kept in its
'Anti Static Bag
" nhen being stored Keep the Control
Board in
a safe einironment to help ensure that no
damage 1\11] be done Doing this will tninimize an!
problems nhen the Control Board is needed When
touching the electronic boards.
it is adkised to use an
" Anti - Static " Groundingbracelet N hich will ground JOU
to the Vender Aha! s handle the Control Board b! the
edges
make sure not to touch an! components on the
Control Board
(as the! are static sensitive) Any changes
indir idual parts may \old the narrann Please contact
1 our Ro! al Vendors' senrice representatile for more
inforniation
1
1
I
1
affecting the design of the Vender's wiring qstem or
Merlin N Service & Parts Manual 1

TABLE OF CONTENTS
1. General Information ...................................................................................................... 5
..................................... 5
" Merlin IV' Features ............................................................. .....................................
5
Vender Identification
............................................................................................................................................. 6
.............................................................................. 7
Introduction to
" Merlin IV'
-
.............................................................
Crcdit and Replacement Policy ..............................................
2 . Vender Installation ........................................................................................................ 8
Vnpackiiig Tlie Vender .................................................................................................................................................. 8
Voltage Requirements ............................................................................................... ..................................... 8
Placing Tlie Vender
On Location ............................................................................................................................... 8
L'cnder Power Cord Note ...........................................................
....................................... 8
Loading Instructions
.......................................................................................................................................... 9
3 .
Vender Component Explanation ................................................................................. 11
Lender Control Board (IncludingPinouts) ................................................................................................... 11
LED Displa! (Digital Displavj ......................................................................................................................... 16
Lou Lb!tage Transformer ....................................................................................................................... 17
Deli\ sc Chiire Sensor (Including Adjustmentj .................................................................................................. 18
Door Snitch ................................................................................................................................................. 19
Vend Motors .............................................................................................................................
Refriger;rtion System .....................................................................................................................
C 01 II Mechanism ( Changer ) ......................................................................................................................
4 . Vender Programming .................................................................................................. 25
The Necessil\ Of Correct Programming ........................................................................................................... 25
Prcii1t!tlo11< To Take When Working With The Control Board .................................................................................. 25
Introdiiction To Programming ................................................................................................................ 25
\leilu Le\ CIS ....................................................................................................................
Sen lie hlenll .................. ........................................................................................................ 27
Eror (errors)Mode
...................................................................................................................... 27
CPO (coinpayout) Mode ...................................................................................................... 27
tllFL . (coin tube fill) Mode .............................................................................................................. 28
tESt (colunintest \-end)Mode ..........................................................................................
PASS (passuord)Mode .................................................................................................................... 28
rtn (return to sales) Mode .............................................................................................................................. 28
Pass\\ord Protected Menu .................................................................................................................................... 29
CASH (cash counter) Mode
................................................................................................................................ 29
SALE (sale counter) Mode
.................................................................................................................................. 29
diFc (discounted differential cash counter)Mode ....................
PriC(selection price) Mode ......................................................
StoS (space to sales) Mode ................................................................................................
SdEP (set \.ending depth ) Mode ...............................................
StCL (set timer controlled selections) Mode .............................
tiifi (time and timer settings) Mode ..........................................
FriG (refrigeration parameters) Mode ................................................................................................................. 37
PAS (ExternalMenu password setting) Mode
..................................................................................................... 39
LAnG (international language setting) Mode ..................................................................................................... 39
ECO (exact change mode)
................................................................................................................................... 40
v
dSAL (discounted sale counter) Mode .......................................
SdiS (discounted selection price) Mode ........................................................
Con (configurations) Mode .................................................................................................................................. 33
.................
................
Merlin IV Service & Parts Manual
3

TABLE OF CONTENTS CONTINUED
External Menu (accessible while in the “greeting” mode) ............................................ .............................. 40
SALE (sale counter) Mode ..................................................................................... .............................. 40
rtn (return to sales) Mode ....................................................................................... .............................. 41
Eror (errors)Mode ................................................................................................................................. 41
-
5. Vend Cycle ................................................................................................................... 42
Establishing Credit ................................ .......................................................................................
Valid Selection ........................ ..................................................................................................
..........................................................................................
..................................................................................
....................................................................................................
Resetting Sold Out Selections ..................................................................................................................................... 43
6. Vender Maintenance ................................................................................................... 44
General Maintenance ................................ ....................................................................................................... 44
Using TheVender’s Error Code System ..................................................................................................................... 45
Error Codes ............................................... ........................................................................................................ 15
Troubleshooting ......................................... ................................................................ 46
Coin Acceptance .................................. ............................................................................................ 46
Bill Acceptance .................................. ................................................................... 17
Vending Problems
............................... ................................................................. 18
Miscellaneous Problems ............................................ ................................................................. 19
Refrigeration Problems ............................................ ........................................................................... 50
Electronic Refrigeration Troubleshooting Flow Chart ...................................................................................... 5 2
7. Exploded Views and Part Numbers ........................................................................... 54
Port Assembly -
Inner Door Assembly ................................
Refrigeration System Assembly ..............
Evaporator Fan Motor Assembly ..............
Vend Mechanism Assembly .....................
Door Assembly. Front .............................................................
..
Control Board and Winng .......................................................................................................................................... 54
............................................................................................................................................................. 56
.................................................................................................. 58
ssemblies ........................................................................................ 60
........................................................................................................ 62
................................................................................................... 64
.................................................................................................. 66
................................................. 70
Main Door Hinge, T
- Handle And Door L
Miscellaneous Assemblies
..........................................
Door Assembly. Rear ..................................................
Select Panel Assembly, Front ......................................
Select Panel Assembly. Rear
RVMC/RVCDVandal Resistant Door (CDC)Front
.......................................
..................... 76
................................. 78
........................................ 80
..................................................... 82
.............................................................. 86
Door Assembly Rear. Dr Pepper Vision
4 ..................................................................................................... 88
Coin Insert Assembly Front, Dr Pepper
Vi ..................................................................................................... 90
CI Rear and Button Panel Assembly. Dr Pepper Vision 4 .......................................................................................... 92
Changer VaultAssembly, Dr Pepper Vision 4 ............................................................................................................. 94
.................................................................................................... 96
.................................................................................................... 98
...................................................
RVMC/RVCDVandal Resistant Door (CDC)Rear ...........................................
RVMCRVCD CenterDoor Changer Vault .............................
Port Assembly. Dr Pepper Vision 4 .............................
Door Assembly Front, Dr Pepper Vision 4 .................
Flat Horizontal Display, Door Front . , _.
Flat Horizontal Display. Door Rear
Flat Horizontal Display. Select Panel
...................................................................................................................... 100
Appendix A: Factory Standard Space To Sales Settings ............................................ 102
*Note: VenderWireDiagram located in rear of Manual
4
Merlin IVService & PartsManual

SECTION I : GENERAL INFORMATION
Merlinw
- General Information
INTRODUCTION TO " MERLIN IV "
The hlERLIN IV bottle and can lender is capable of
1 ending most packages It uses a Control Board to
in,inage I ending operations This Control Board must
be programmed correctl? for the Vender to operate
properl! Through the Vender's electronic Control
Board
\oil nil1 find better space to sales allocations
\\ hich \t ill increase profits through fener sold out
selections ,ind less loading frequent?
Through 2IPRLIN IV s flcxibilih loti will profit b\
iicing the hlulti-Pricing and Spacc to Sales features As
\oii nil1 we later in the Maii~ial.there are other fca-
tlircs such
built iii timer or b\ ming an optional on'off kc\
s\\ itch I il\c moqt electronic equipment the Control
Ro,ird hns thc ,ibilih In control most iterns 111 the
\ending nixhiin: It manages the operation of the
the abilih
to control lending b\ usiiig a
MERLIN IV FEATURES
Field proven. reliable impact deli\ en sensor detects
the lend to cancel vend cycle.
0
Patented learning mode for quick vending.
4 " Direct drile" DC i end motor in each column
driles each column's \end rotor
No lend mechanism adjustments are necessary to
change from 1201 cans
to 1607 or 2007 bottles
All that
is needed is to change the depth setting in
the programming and product retainers / rear
spacers
User friendl? menu st?le programming
Refrigeration
SJ sten1and el en the lighting n stem nith
xi optional kit MERLIN IV utilires high torque 21 jolt
DC \ end motors resting has proLen these Leiid motors
to be \en strong and reliable
\lERLlh IV s prograniiiiirig is done " Menu St\le" nith
thc inenus consisting of Main Items' and Sub-Items "
Fiyire 1 I 15 good ewmple of liov thc iiieriii s\ stem
\\orb
. Hand Held Computer (HHC)
and data
retrielal
Rcal time clock I calendar to control " built-in " timer
(can displa! time
on LED)
MERLIN IV supports Multi - Drop Bus Coin Meclia-
nisnis. bill r alidators and card readers
v
Allou s programmable space to sales Custom or
Factor? settings
Tlic 1- Lael (as shonn) is the Passnord Protected
hlenu (Main Menu) Pressing the " ENTER " button at
-
Capable of setting full escrou to vend (elen if a
column
lams)
External menu allo\+ s access to sales (\end) counts
and error information
'in item on this menii nil1 allou access to this Mode s
Sub-hknu (sho\\n as the 2IdLael) Pressing the
E".TER button at an itern on this Sub - Menu nil1
~icccss '1 second Sub-Menu (sho\in <is the 3d Lelcl) In
sonic caw there mar be nioic hels
You can only acccss nieiiii items from the
menu
yon arc 111. Just as the " ENTER "
button takes yxi into each le\.el. the
"HOhIE" bntlon takes you back to
prel ious menu le\.els each time ou press
it. The
menu system is explaincd in
grcater detail in Section 5. Vender
Programming: Menu Levels.
I
2E Level 3F Level
Figure 1. I
Merlin IVService & Parts Manual 5

SECTION 1 : GENERAL INFORMATION
Both total (historical) and indnidual (resettable)
\end and cash counters The jecond initial
(I;) represents the !ear that the
Vender
1) as produced
MERLIN IV can displa? the sale (1 end) and cash
totals (historical)
on the LED upoii opening the
Vender's main door for easy access
VENDER IDENTIFICATION
Your MERLIN IV x ending machine can be easil!
identified b! taking note of the following three items
I
2
i
Vender Serial Plate - mounted on the c\terior left
side
of the Vender door.
Refrigeration Serial Plate
- mounted oil the "bich
plate " of the refngeration unit. and
Control Chip Rex
ision Number - iiioiintcd 011 the
right side
of the Control Board
A
= 198X D = 1991 G = 1904 J = 1997
B = 1089 E = 1992 H = 1995 K = 1998
C = 1900 F = 1991 I
= 1900 L = 1999
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 hich plate It loohs
similar
to the Serial Plate shonii in Figure 1 2 mitli the
e\ceptioii that the model number specified is the refrig-
cratiaii unit model (as rho\\n bclou ) There is currentl)
one niodel in nsc
Model Compressor Sire Usage
80f )O iv
Super 1 3 .\I1 MERLIN 1V
Hoi-sepon cr \knders
VENDER SERIAL PLATE
TheVender's Main Serial Plate (shoun III Figure 1 2 i 1s
located 011 the evterlor left '1'' of the 'cnder's lllaln door
and has the following iiLforrnation
CONTROL CHIP VERSION NUMBER
The Control i hip krsion Number is printed on a white
dcL211 located to the to top right of tlre main chip of the
Controi Hoard Thi' nuniber is e\treniel? important
- Vender model number
- Vender serial number
- Anips required b! Vender
- Unit charge of R131A
- Refrigeration design pressures
TheVender
's model number contains tv o important
pieces of information the machine hpe (such as
RVCDE. Ro! a1 Vendors ('old Driilk Electronic) and
the Vender model number (such as 650-10 capacit? of
650 1,iehe ounce cans / 10 selections)
TheVender's serial number contains three important
pieces
of information the Production Run Number
(such as 1782). the Vender Number from nithin the
run (such as
00 15 1 ). and a date code (snch a5 BK )
The first initial (B) represents the quarter of the \car
the Vender was produced
A
= January. February. March
B =April, May, June
C = July, August. September
D = October, November, December
\\hen c~lliiig tor sen ice programming help. or for
rtiatclung a replacement Control Board Srv frp 2 2
]I MODEL RVCDE650-1 Q
I
1 Keameylvllle, WV 25430 USA
AMPS R134a
12 5.250~
SERIAL NUMBER
1382BK - 001 51
DESIGN PRESSURES 300 HS/156LS 115V/60HZ/IPH
LISTED REFRIGERATED VENDING MACHINE 66E9
SUITABLE FOR OUTDOOR USE
Figure 1.2
6
Merlin IVService & PartsManual

SECTION 1 : GENERAL INFORMATION
Creditand
ReplacementPolicy
CREDITS OR REPLACEMENTS WILL BE ISSUED
DURES ARE FOLLOWED:
ON WARRANTY ITEMS IF TKE PROPER PROCE-
1
Rol a1 Vendors ui11 pa) shipping charges on all parts
co\ ered undcr this narranh. vhen transportation has
bccn made the most economical
\%a) (\\ithin the
continental
US regular ground UPS) An ARS
(4utliorixdReturn Senice)stick \\ill be sent vith
all varranh parts This method of shipping is
preferred for returning parts to Ro?al Vendors
2 Credits will on11 be issued to \+arranh parts that
ha\ c been ordered in ad\ ance. not for parts ordered
as stock (NO EXCEPTIONS)
3
When ordering marranh parts in ad\ ance. please
ha\ e the full Vender ,' Unit Serial Number
4. A cop! of the Packing Slip. correct Serial Nuniber.
snd complete Return Material Tag (provided nith
part i are required for sending back parts. Please
coniplete
the Return Material Tag. keeping the tvhite
cop! for !our records and sending the yelloiv tag
brick \\it11 the attached part. Makc sure you ha\z
\our conipan? .s name. address. phone number. serial
nunibcr. and model number along \vith a brief
explanation of the probicm.
5 If the item returned is not uiider \\arrant). it nil1 be
seiit bach to J ou at >ourexpense or It \\ill be
scrapped
6
All vnrrant\ parts should be properl) nrapped and
packed
secureh to a\oid further damage Refrigera-
tion iinits that are returned from the field and ha\e
been tapped into. tampered ~1111. not packaged
propcrl) or ha\ e had the serial plate remoLed nil1
\old the narranh
7
If parts are not returned \\ithin 15 norking dals. the
in\ oice nil1 be due in full
I
Merlin IV Service & Parts Manual
7

SECTION 2. VENDER INSTALLATION
Vender Installation
UNPACK THE VENDER
VOLTAGE REQUIREMENTS
The Vender is designed to operate at a 1 oltage of 1 15
jolts. 60 Iicrt7 It requires a iiiiiiiniiini of 15 amp senice
The senice outlet
\oltagc must not exeed 129 VAC or
~ fall belon 101 VAC The Vender has a three prong three
\\ire. grounding cord Tlie Vender must be plugged into a
I grounded electrical outlet to protect the customer from an
' electrical shock If qou are not sure \our outlet IS
1 properlq grounded. ha\ e it checbed b\ d qualified
Umrapthe Vender and reiiio\ e an! padding Chech for
signs of damage at the time of deli\ eq If the Vender is
damaged. contact the carrier imniedidtelq The carner
mill instruct qou as to the procedure for filing a claim
The Vender ke!
s are located in the coin return cup Mahe
sure to remole the stretch - \\rap if the Vender will be
stored in direct sunlight
so the stretch - \\rap nil1 not melt
to the Vender and decals or fade the Vender s paint
electrician
~ When q ou plug in tlie Vender q ou should obsen c the
I folloning
PLACING THE VENDER ON LOCATION
Separate each skid section b? inserting a clan hammer.
cron - bar. or similar de\ ice into the slot of each section
to brcak apart Tilt the Vender slightl! to rciiio\ e the
separated pieces When placing the Vcndcr
011 location.
allon for a minimuin of four inches (4' ) of space at the
rear of the Vender This
will ensure proper \ entilation of
tlie Refrigeration
Sqstem Leiel tlie Vender bq ~id~usting
the four le\ eling legs on the bottoiu corims of the Vender
The Vender is le\ el If the main door reniaiiis stationaq
it hen opened to different positions The four le\ eling
legs must be in contact \\ith the floor This
is imperati\ c
for proper drainage of e\ aporator frost
1 Tlie florescent lights displa!ing the Vcndcr sign nil1
come on
, 2 The refrigeration compressor nil1 start to run after
1 i The LED displa? vi11 liglit
I
appro~irnatelq 5 - 7 nunutcs 01 /th the (loor closed^
~ VENDER POWER CORD NOTE
Evtensioii cords are not recoimnended. unless the! are
~ authorized before use bq a certified electrician
8
Merlin IVService & Parts Manual

SECTION 2. VENDER INSTALLATION
Loading Instructions
SPACER & RETAINER LOCATIONS
Package Tj pe Front Rear
10 01 Straight Wall (Glass) 12 10
10
01 Can (2 - deep)
3 3
12
01 Can (2 - deep) 2 2
10 OL Can
9 9
10 O/ Liptoil (Glass) 10 8
20 oz Peps1 Suirl (Plastic) 7 5
20 01 Straight Wall (Plastic) 9 5
20 01 All Sport (Plastic) 8 J
20 o/ Venfinc (Glass) 8 6
20 o/ Dr Pepper (Prop )
20 oz Gntorade 6* 6
See Ser Bulletin 159
Notes:
1.
Due to different package hpes of the
slinie product. the spacer and retainer
settings
ma! ~aq See Figire 2 1for
proper setup
When loading bottles. load caps to front
111 the front columns and caps to the rear
111 the rear columns See Figure 2 1
For packages not listed abo\e. use
Figure 2
1 for reference
Packages taller than
5 19 " mi11 on14
\end single depth and packages smaller
than
5 19 " \+illTend double depth
2.
3.
1.
Figure 2.0
Merlin IV Service & Parts Manual
9

SECTION 2. VENDER INSTALLATION
Figure
Rear Spacer
112” Max.
Front Retainers should be placed
as close to the package as
possible without making contact
while still maintaining a clearance
of 118” to 112”.
atorade Package
Front Retainers for Gatorade
be set in front
of the bottle.
2. I FRONT
should
10
Merlin NService & Parts Manual

SECTION 3. VENDER COMPONENT EXPLANATION
Vender Component
Explanation
VENDER CONTROL BOARD
(Including Pinouts)
Your MERLIN IV Vender is equipped with a Main
Control Board which is responsible for most Vender
operations. In most Venders (non
- CDC). it is located in
the upper section of the Select Panel inside the Vender's
main door. The Control Board is protected
by a cover.
Remo\ing this cover will expose the Control Board in its
en!iret>. along Lvith all of the Control Board's lviring
connections.
- IDENTIFICATION The MERLIN IV Control Board
cdii easil! be identified b> noting the identification
number pnnted on a small mhite decal on the Control
Board
s e - prom chip The Control Board's identification
number is a necessit3
M hen ordering parts for 1 our
Vender and \then contacting a Ro?al Vendors'
sen ice
reprcsentatn e The Control Board identification decal is
sho\\n iii Vender Identification' of Section 1
OPERATION REOUIREMENTS The Control Board
requires appro\iinatel?
24 lolts AC from the lo\$ loltage
transformer (described later in this Section) This nil1
allou the Control Board to function and to suppl>poner
to all the Vender's components listed below
OPERATION Upon receil ing the appropriate \ oltage
from the transformer. the Control Board
n ill issue
information to some components. receike information
from some components. and communicate both ~\aqs
\\ith some components
The Control Board issues instructions ( and/or
voltage) to:
LED Display
Vend Motor (only when vend motor is to run)
Refrigeration Relay (for use with Electronic
Refrigeration Control)
The Control Board receives information (and or
voltage) from:
Select Switches (logic level)
Door Switch (logic level)
Delivery Chute Sensor
Temperature Sensor (for use with Electronic
Refrigeration Control)
The Control Board communicates both ways with:
Coin Mechanism
Bill Validator (optional)
Debit Card Reader (optional)
Hand Held Computer (optional)
CONTROL BOARD PINOUTS: The MERLIN
IV
Control Board has several electrical pinouts, a set - up
mode button.
a delivery sensor adjustment trimpot, a
delivery sensor adjustment indicator lamp. and various
other electronic components (all
of which have desig -
nated position codes). The following section outlines all
the Control Board's pinouts by showing for each:
The pinout position code as found on the Control
Board (Esample: P15).
The nanie/purpose of the pinout (Example: 24 volt
power connection),
A paragraph describing in detail the pinouts purpose
and its function. and
A table describing the pin number. wire number. and
function of each position
The word key refers to the small plastic insert plugged
into a position of the connector. The purpose of the key
is to pre\.ent connecting the harnessing backwards or
upside
- down. The " keyedposition " is a blank position
within the pinout (nopin) in which a key is inserted.
Some pinouts may have several blank positions with a
key plugged into one or more of the positions. You can
use the key to determine which end of the pinout is Pin
1.
Merlin IV Service & Parts Manual 1 1

SECTION 3. VENDER COMPONENT EXPLANATION
/- Contra' Board
Figure 2.2
MERLIN IV CONTROL BOARD
Standard LED Displa) Interface (Position P1) The four
(1) wire harnesses connecting to this pinout tra\ el from
the Vender's LED to the Control Board It allons the
Control Board to send pomer to and conimunicate \\ith
the LED If this harness is cut or disconnected. the LED
will go blank If this harness is pinched. jou ma? see
" broken segments " on the LED with \arious segments of
the display lit
:rol Ch
Pins
!te Dec
PIN WIRE FUNCTION
NUMBER COLOR
1 YELLOW DISPLAY 5 VOLT DC
2 GREEN DISPLAY CLOCK
3 BROWN DISPLAY DATA
1 RED DISPLAY 5 VOLT DC
POWER
RETURN TO COMMON
1 2
Merlin IV Service & Parts Manual

SECTION 3. VENDER COMPQNENT EXPLANATION
\lulti-Drop Bus (Position P3) The file (5) nire serial
limiess coiinecting to this pinout pro\ ides poner and
coiiiiiiiiiiic~itionsto and from the Control Board for the
C 0111 hleclianisin. the optional 24 \ 011 Bill Validator.
'ind or the optioiial Debit Card Reader If this harness is
cut pinched. or disconnected. > 011 n 111 iioticeabl! lose
pol\ er to the Coin Mechanism
-
I
1
PIN
NU3IBER
1
,
1
WIRE
COLOR
WHITE
BROWN
KEY
R1,ACK
RED
ClKF E N
BLUE
FUNCTION
MDB 35 VOLTS DC
UNREGULATED
MDB
15 VOLTS DC
RETURN TO COMMON
KEY
L-MC RECEIVE/
VDB TRANSMIT
VMC TRANSMIT
MDB RECEIVE
VMC bfDB COM\ION
NOT USED
Dcli\en Sensor (PositionPl) The hto (2) nire harness
cciiiicctiiig to this pinout is a Era?. shielded cable
Ii,irness It sliotild ne\ er be cut. pinched. or spliced
This harncss is formed into the iinpact sensor (mounted
bc!ieaili tlic cei:ter of the delneg cliute) It tralels
!hrougli the bottom of tlie Vender's main door to the
Control Board
PIN WIRE FUNCTION
\\t17MBER COLOR
i \WC COMMON (2 5DC) I
2 RED DROP SENSOR OUTPUT #1
> BLACK DROP SENSOR OUTPUT #2 ,
4
VMC COMMON
RETURN TO GROUND
RETURN TO GROUND
Selection Si\itclies
(Position P7) The wiring harness
connecting to this pinout carries a logic lexel (ground)
signal froin Pin # 1 1 of the Control Boardto tlie common
position of each Select Snitch Upon actnation. the
Select S\\itch
xi111 alloii the logic le\el signal to tralel
back to tlie Control Board This nil1 tell the Control
Board a particular snitch
is act11ated
PIN WIRE FUNCTION
NUMBER COLOR
1 WHITE SELECTION SWITCH $9
2 YELLOW SELECTION SWITCH #8
7 ORANGE SELECTION SWITCH #7
-1 GREEN SELECTION SWITCH #C
5 BLUE SELECTION SWITCH #5
6 BROWN SELECTION SWITCH #4
7 PURPLE SELECTION SWITCH #3
8 GREY SELECTION SWITCH #2
9 BLACK SELECTlON SWITCH #1
10 KEY KEY
I1 RED SELECTION SWITCH
!2 SELECTION SWITCH #I2
13 SELECTION SWITCH dl 1
COMMON
14 PINK SELECTION SWITCH #10
Merlin IV Service & Parts Manual 1 3

SECTION 3. VENDER COMPONENT EXPLANATION
Vend Motors (Position PSI The fourteen (14) wire
harness connecting to this pinout pro\ ides cominon
po\+erfrom the Control Board to each \end motor
There is one \\ire in this harness for each \end motor to
provide each motor \\ith 24 volts DC. \\hen a selection
is
made Be sure that this harness is proper11 grounded
PIN
NUMBER
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
WIRE
COLOR
GREEN/YELLOW
BLACK
BLUEMITE
BROWNWHITE
ORANGE/WHITE
KEY
YELLOWiWHITE
RED/WHITE
GREEN/WHITE
BLUE
BROWN
ORANGE
YELLOW
RED
GREEN
FUNCTION
GROUND
VEND MOTOR
COMMON
(Source)
VEND MOTOR
# 12
VEND MOTOR
# 11
VEND MOTOR
# 10
PP
VEND MOTOR #9
VEND MOTOR #8
VEND MOTOR #7
VEND MOTOR #6
VEND MOTOR #5
VEND MOTOR #4
VEND MOTOR #3
VEND MOTOR #2
VEND MOTOR #1
Features Connection (Position P9) The iring harness
connectingto this pinout travels from the Vender's door
s~itchthrough the bottom of the Vender's main door and
to the Control Board Pinout
P9 is also used for the
optional " free Lend"and " no tend " ke! smitch kits
PIN WIRE FUNCTION
NUMBER COLOR
1 WHITE FEATURE PLUG/
2 KEY
3 (OPTIONAL) FREE VEND
4 (OPTIONAL) NO VEND
SWITCH COMMON
SWITCH INPUT
(VEND DISABLE)
INPUT
5 (OPTIONAL) OPTION SWITCH
INPUT
6 PURPLE DOOR SWITCH
INPUT
DEX UCS Connection
(Position P101: The three (3)
n.ire harness connecting to this pinout comes from the
Hand Held Computer jack. located inside the Vender's
main door (near the Control Board). The Hand Held
Computer (HHC) plugs into thisjack to read and write
information from the Vender's Control Board.
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 FUNCTION
NUMBER COLOR
1 RED VMC TRANSMIT/DEX
2 KEY
3 WHITE VMC RECEIVE/
RECEIVE DATA (TIP)
DEX TRANSMIT DATA
(RING)
1 GREEN DEX COMMON
DEX UCS Connection
(Position P11) The three (3)
\\ire harness connecting to this pinout conies froin the
evternal Hand Held Computer lack located on top of the
welded port assembl) The Hand Held Computer plugs
directl? into thisjach \\bile the Vender's main door is
closed to read information from the Vender's Control
Board Information cannot be nntten to the Vender's
Control Board unless the Vender's door s\+itchis in the
" door open " position If the HHC does not operate
properl). check the harness for bad connections at the
solderjoints Also check to ensure
the insulator at the
jack
is not cracked from 01 er tightening
PIN WIRE FUNCTION
NUMBER COLOR
1 RED VMC TRANSMIT/
2
KEY
3 WHITE VMC RECEIVE/
DEX RECEIVE DATA (TIP)
DEX TRANSMIT DATA
(RING)
4 GREEN DEX COMMON
14 Merlin ZV Service & Parts Manual

SECTION 3. VENDER COMPONENT EXPLANATION
Priiiian Teinaerature Sensor (Position P12) The
u iring harness coiiiiecting to this piaout Ira\ els from the
Temperature Sensor to the Control Board The Tempera -
ture Seiisor is niouiited on the rear tank abole the
e\ aporator f'in This hariiess is molded into the Tem-
perature Sensor and should lie\ er be cut. pinched. or
spliced together if cut
If the harness is cut. pinched. or
iniproperl) grounded. the seiisor rnaj gir e the Control
Board false temperature readings Refrigeration actn
it\
I< based 011 the signal reported to the Control Board from
this seiisor
(Pin 2)
PIN WIRE FUNCTION
NlJMBER COLOR
1 RED TEMP SENSOR 5 VOLT
i KEY KEY
7 LiWITE TEMP SENSOR. SIGNAL
-1 BLACK TEMP SENSOR 5 VOLT
DC SUPPLY
3
RETURN TO COMM
Au\;i!im Temperature Sensor (Position P13) This
piriout nid\ be a\ ailable in the fuhlre. but as of this
Sen ice hlatiual printing it is not a\ ailable
PIN WIRE FUNCTION
NIJMBER COLOR
1
2
1
KEY
Emironmental Controls (Position P14) The winng
harness connecting this pinout po\\ers the Refrigeration
Relaj (to poner the refrigeration unit) It is also respon -
sible for ponering an) optional relaqs. such as the
Refrigeration Heater Relaj. ELaporator Fan Relaj.
Illumination (sign lighting) Relaj. and a 21 Tolt DC
counter It poners each relaj and counter bj pro1iding
a
constant 24 1 olts DC to each relaj from Pin 1 Upon
actnation. the Control Board \+illremain neutral for each
relat or counter from either Pin
2. 3. 4
6 or 7
PIN
NUMBER
x
7
6
WIRE
COLOR
2x6
KEY
2 x4
2x3
2x2
2x 1
FUNCTION
21 VOLT REGULATED DC
IMPULSE COUNTER
FLUORESCENT LIGHT
RELAY
FAN RELAY
OUT
FAN RELAY
COMPRESSOR RELAY
HEATER RELAY
21 VDC
24 Volt AC Power In (PositionPlS):The two (2) wire
harness connecting this pinout come from the Low
Voltage Transformer. It is imperative the correct harness
be coniiected
to this pinout. If this harness is not
connected (or
if pon.er is lost to this connection). you
n
- ill noticeably lose all Vender functions (except main
door lighting) including power to your LED display.
Poner to your Coin Mechanism will not accept coins.
Power to your Refrigeration System (compressor and
condenser fan motor
also will not run). With this
connector. the wire harness can be in either position and
the Control Board will not be affected.
PIN WIRE FUNCTION
NUMBER COLOR
1 21 VOLT AC
2 NEUTRAL
Merlin IV Service & PartsManual 1 5

SECTION 3. VENDER COMPONENT EXPLANATION
LED Display
(Digital Display)
Your MERLIN IV Vender is equipped nit11 a IOU ~oltage
LED display receibing \ oltage inforination from the
Main Control Board The LED is a \ CQ important
communication link beheenthe Vender aiid the custonier
or operator
IDENTIFICATION The LED displa?
is an electronic
component consisting of
a four (1) digit displa!. a
correct change indicator lamp. and a sold out indicator
lamp TheLED snaps into place
on the inside of the
Vender's main door abo\e the T
- handle assenibl! (inthe
coin insert)
I OPERATION REOUIREWNTS The LED displa!
must recene fibe (5) bolts DC for it to operate properl!
This toltage can be read nith a \oltage meter at the LED
connector
'Pl" beheen Pin 1 (5 VDC) and Pin 4 (5
\DC return to common) If nothing is rad. tlierl mid
bet\+cenPin 1 (5 VDC) and chassis door ground
OPERATION In thc Sales Mode (iimndoor closd)
the LED is used to displa! a greeting (Emiiplc ICE
COLD). credit inforination, and sold
- out iirformdtion In
addition.
it I S optional to displa! the 1 crid price. the tinie
of day. and the temperature (in either Fahrenheit or
Celsius) While
in the Senice Mode (Vciidcr's main door
open),the displa) gibes the operator the
abilit), to
manual11 program the Vender nitliout using the HHC
Upon opening the Vender's man door. the displa? nil1
gn e the operator helpful error codcs and el en sales and
cash counters (this must be programmed In Configura
-
tions Mode)
Since
it is possible for the Vender to fxinctioii without the
LED displaq.
it is recommended price decals be used to
indicate to the customer the bend price
TESTING
THE LED DISPLAY If iipon am\ Ing at a
Vender ~ounotice that the LED displa! is not lit. check
to ensure that the Vender
IS plugged in Tp poaering the
Vender doi\n and back up
TA pressiiig the Control
Board's
" modebutton " plus check all connections aiid
1% iring
1
Check the Coin Mechanism to see if it \$ill accept
coins (routethe coin?
to the coin niechanisni tubes
or the Vender's cash bou
) If so tg to I end a
product If it x ends fine. iiiore than likel! the LED
displa!. or the LED lead.
is bad
2.
If the Coin Mechanism does not accept coins. the
nest step to make
is to be sure the Control Board has
the abilit!.
to power the LED by checking the
transformcr. Check xoltage at the Vender's "two (2) -
;\.a?" 21 AC poncr connection positiori " PI 5"
on the Vkrtder's controller. It should read approsi -
iiiatcly 24 \.olts AC. If not. then check the Vendcr's
transformer (asdescribed under .'Lo\\ Voltage
Transformor" in this Section).
7
If 21 1 olts AC is registered during Step 2 then !ou
\\an? to measure boltage at the LED coiinector
(position
"Pl") on the Contlol Board across Pins 1
and 4 on the rear of the LED lead (ensure the LED
lead attached to the pinout
has a good coniiect~oii)
You should read appro\lmatel\ file (5) xolts DC If
approvniatel) fi~ c (3) x olts DC 1 oltage is not
registered. renioxe the LED lead and measlire the
xoltage dlrectl? from the Control Board's Pins 1 and
4 If the appropriate \ oltage is still not read replace
the Control Board
1
If approuimatel? fi\ e (5) \ olts DC is registered
check the ioltage at the other end of the LED lead
(\$here it coiiiiects to the LED Displa)) In the same
fashion as abobe If appropriate koltage is not
registering. replace LED lead If
\ oltage is correct
replace LED Displa)
1 6
Merlin IV Service & PartsManual

SECTION 3. VENDER COMPONENT EXPLANATION
Low Voltage
Note: A\ferlin IT* 1 knders made before run 1476 use an
rtilernalfuse rri the transfornier
1 Check the po\\er going into the transformer at the
coniiected red andblack \+ires It should register
110 Lolts AC If not. ~OU need to check all wiring
leading up to this point froiii the bottom of the
Vender's main door The transformer ma? not be the
problem
You may ha\ e a broken wire or a bad
connection
Transformer
(Run 1476 and after will have a fuse
between the transformer and the
ControlBoard)
The MERLIN IVVender uses a IOU \oltage (75 VA)
transfornier u hrch reduces 110 T olts AC (con\eiitional
joltage)to 21 loltsAC to power the Vender s Control
Board The traiisformer
is a major contributor to the
Vender
5 operation Without the transformer. the Control
Bo'ird cannot fiiiiction
~________~___ LOCATION OF TRANSFORMER In a CDC (Center
Door Changer) \kiider tlie transformer is located belou
[lie Contiol Board Thc fiisr: 1s fastcncd to the Changer
Plug Bracket
1:) a noii-CDC Veiider. the traiisforiiier and
fuse are located at thc top of the itiaiii door
QPERATION Thc transformer has a three (3) amp
c\teriial fiasc on a sccondan circuit to protect the
Control Board arld thc Coin Mechanism If the trans
-
foriiier fiise blou s. ! 011 ]\ 111 lose pol\ er to thc Control
Board. noticeabh
losing pover to the LED Displa\. and
also losing pouer to tlie Coin Mechaiiism (Coin Mecha-
nisni it 111 not accept coins and Bill Validator ill not
accept
a bill) If \oil ha\e a probleni similar to this.
foilon the procedures listed belon
OPERATION REOUTKEMENTS The transformer
operates b? recen
irig 1 l01 oltsAC from the Vender
(black and red \\ires) It transforms the 110 lolts AC
into
21 \ olts AC 1% hich IS what the Control Board
requires for
its operation
CHECK THE TRANSFORMER AND
FUSE If upon
arming at a Vender the LED displa? 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 e\ternal fiise for
1 ma1damage Check
for continuity across the fuse nith
a Loltage meter or
similar de\ ice If defectire. replace the external fuse
2.
If 110 lolts is registered during Step 1. ~OU nant to
measure
\ oltage at the other end of the transformer
The two
(2) pin connector at the Control Board
connected to position P
15 should register approxi -
mately 21 I olts AC at this end of the harness If so.
check the Control Board. the transformer is good
7
If 110 \olts is registered during Step I and 21 \olts
AC is not registered during Step 2. \ou probabl?
ha\ e a bad transformer Unplug the Vender and
transformer coiiiiections at the transformer
(1 10 \olt
side) Unplug the transformer from the Control
Board and remo\e
it from the Vender s main door b?
locating the side of the transformer that has t\+o (2)
" built - in " \\ires going into the plastic housing
Merlin IV Service & Parts Manual 1 7

SECTION 3. VENDER COMPONENT EXPLANATION
Delivery Chute
Sensor
(Including Adjustment)
The MERLIN IV Vender is equipped mith a Deli\ eg
Chute Sensor responsible for reporting to the Control
Board the impact of product
(on the delirer?,chute)
during a vend c~cle This allom
s the Control Board to
cancel credit and terminate power to the \end motor
to
end the c~cle
IDENTIFICATION The sensor is ceiitrall~located
beneath the delneq chute (tra?)nith
t\$o (2) 1/8"
aluminum pop rix e!s It has a built - in harness that tra\cls
from the sensor through the bottom of the Vender's main
door and up
to the Vender's Control Board At the
Control Board.
li connects to position P1(louer right
corner of
the Control Board)
OPERATION REOUIREMENTS The Deli\ ep Chute
Sensor
is a coil generating a small signal upon impact
The sensor can be adjusted. or fine tuned. b! using the
adjustment trimpot screu located abo\c the Deli\
er?,
Chute Sensor Connection
OPEKATION: The DeliL.cn. Chute Sensor
is responsible
for sensing the impact of the vended product and
reporting it to the Control Board immediately upon
impact. The Sensor Adjustment Indicator Lamp (located
above the Sensor Harness Connection
on the Control
Board) can be used to \isually determine if the Delivery
Chute Sensor's sensitivity is correct. This can be done
either during a stand
- by coiidition or during a vend clcle.
as long as the Control Board is powered with
21 volts
from the transformer. The indicator lamp should iiot be
lit during stand
- by. but should quickly blink upon impact
on the delivery chute. This indicates the Delivery Chute
Sensor
is proper11 adjusted and it's telling the Control
Board it has detected impact. If the indicator lamp does
not light, impact was not detected. If the indicator lamp
is constantly lit, or fades on and
off frequently. the
Deliver) Chute Sensor is detecting noise or \ibratioii
from the Vender.
ADJUSTMENT: Located below the Sensor Connector
is
the Sensor Adjustment Trimpot. which includes an
adjustment screw. The trimpot is used to adjust and fine
tune the sensor. It is capable of turning both clockwise
and counter - clockwise. Located directly above the
trimpot is the Sensor Adjustment LED Indicator Light.
The indicator light is mainly used
to aid inadjusting the
sensor but can also be used
to test its operation during
product impact
1
Turn the adjustment screw clocknise until the
indicator light comes on
2. Turn the screw counter-clockmise until the light just
goes out,
3
Continue to turn the sue\\ counter-clock\%iset\\o
(2) full turns.
For Multiple Vending from all columns. make sure the
sensor
is adjusted to the Factor?,specifications as listed
abo\ e Neut. turn the adlustmeiit screw clock\\ise l/l
turn to increase sensitix it) Test \end all columns If
still Multiple Vending. turn the adjustment sere\+ an
additional
1/1 turn clocknise
For Dq Vending from all columns. make sure the sensor
is adjusted 10 the Facton specifications as listed abole
Next. turn the adpsiincnt scrt':\ csunrer-ciock\\ise 114
turn to decrease sensitikit? Test 1 end all ColuIniis If
still
Dr?, Vending. turn the adjustment scren an addi -
tional 111 turn counter-clock\% ise
TESTING THE DELIVERY CHUTE SENSOR Make
sure the Vender
is plugged in and the Controller has
polier (theLED displaq on the front of the Vender ~111 be
lit and the Coin Mechanism nil1 accept coins) The
Sensor Indicator Lanip \%illblink upon impact on the
delileg chute Lightl? tap the chute with a tool. or lour
fist. to simulate a can drop
1 Locate the Sensor Adjustment Indicator Lamp oii the
louer nght corner of the Vender's Control Board
Under normal conditions (asin stand-b?). the lamp
should be
off
2 Test the sensor by hitting the center of the deheq
chute while natching the Coiitrol Board's Sensor
Adlustment Indicator Lamp The light should blink
solidlj upon impact If not. turn the sensor adjust -
ment screu clocknise in l/J turn increments (to
increase the sensitn
15) and test after each turn If
the indicator lamp still does not light. turn the
adjustment
sere\% clockmise for inany turns If the
indicator lamp does not light. change the sensor
(assuming the Control Board has poner and
is
working)
3 If the Sensor Adjustment Indicator Lamp lights
properly during Step
2. change the Control Board.
1 8
Merlin NService & Parts Manual

SECTION 3. VENDER COMPONENT EXPLANATION
Door Switch
Tlie Vender's door smitch is mounted on tlie lo\\er right
edge of tlie Vender's cooling compartiiient (under the
Vend Mechanism) It is responsible for reporting to the
Control Board vheii
the door is opened (Senice Mode)
aiid nhen it is closed (Sales Mode) The door s\\itch has
d feu other responsibilities \thich are listed belon
Resets any pre\.ious sold - outs.
Actimtes sales and SeniceModes.
Sequences LED displa! test upon door closure.
Resets credit to a Lero state.
After prograniniiing.
will allow you to return to the
Sales Mode.
Resets iiidi\.idual counters (depending oii Configura -
tion j!.
*
IDENTIFICATION: TheVender's door switch
is nhite in
color and is a " three - pole snitch " (thethree positions:
co~iiiiioii. normall! open. and normally closed). Tlie door
sv itch has ;I ~vo-uire.. harness connecting to the
options comcction (position PO) oftheVender's Control
Board
OPERATION REQLrIREMENTS The \%nder'sdoor
suitch rcquircs ;i loit le\el (ground) signal froni the
Control Board (common position) IIpon actnation. the
door
sv itch I\ 111 return the lo\\ le\ el signal to the Control
Hoard This
i\ill alto\\ the Control Board to constnntl!
iuoiiitoi the door snitch. thus ackriowlcdgiiig the door s
condition (either opened or closed)
-___ OPERATION
The u hite oiretralels from Pin 1 of the
options coiiiiectioii
P9 of the Vender's Control Board to
the coiiiiiion position of
the Veiider's door suitch This
ire
is responsible for caqingthe ground signal to the
S\I itch
When the door
is opened. the door witch pops out The
signal traels from the coinnioii position through the
door svitch out of the normalh closed position and
through
the blach \\ire bach to the option's coniiection of
the Control Board This produces the Open Door Mode
The same result ma! be acliieLed b! remo\ing the t\\o
(2) \\ires from the door snitch and connecting them
together During the Senice Mode. the displal will
shon an! Vender Error Codes If no errors are present
the display will
shov . none " and relert to a greeting
When the Vender
s main door is closed. the signal will
tmel through the door s\+itchfrom the common
position. out of the norinall! open positioii
(1% here there
is not currentl! connected a wire) This breaks the
circuit to the Control Board and produce the Sales
Mode This mode can also be acliieled b!
removing one
(or both) of the \+ires from the snitch and lealing them
disconnected Dunng tlie Sales Mode. the LED displaj
\\ill shov a greeting and possibly Larious other optional
inforination
TESTING THE DOOR SWITCH Make sureVendcr's
main door
is closed and the Vender is plugged in Make
sure there
is poner to the Control Board. the LED is lit.
and the Changer will accept coins
I.
Take note of the LED display and what it is showing
with tlie door closed. At this time.
you should be
seeing
a greeting (Example: ICE COLD) andor
possibl?. tlie price, time. temperature. or " Use Coin
Onl!". Open the Vender's niain door and take note
of \\hat the LED display shows. It should either
shon any error codes (see Section 6. Error Codes)
or flash '-none" aiid go into its greeting (and all
optional information to be shown in the Sales
Mode)
2 If the Sales and Senice displa! s arejust the
opposite. check the
nirc connections at the door
switch (theblack wire
ma! be on the normall! open
position instead of the normall! closed position)
and at the Control Board (Lerifq
nit11 \%iring
diagram)
3
If the LED displaj does not change upon opening or
closing the Vender's main door. remo\e the h+o
\\ires from the door snitch The displal should go
into a Senice Mode Short the \\ires together to
simulate
a Sales Mode If this \\arks. replace the
door snitch
If the LED displa! still does not change after Step
2.
the white and black \\ires niaj be either shorted
together (causing
a constant SeniceMode) or cut
(causing
a constant Senice Mode) somewhere
bet\\een the door snitch and the Control Board If
no problems are found. the Control Board may be at
fault
1
Merlin NService & PartsManual
19

SECTION 3. VENDER COMPONENT EXPLANATION
nism and the Control Board for continuih and bad
connections If continuit? and connections are
correct. tlie Vender's Control Board ma? be bad
Coin Mechanism
(Changer)
~ TESTING THE COIN CHANGER If the Coin Mecha -
1 nism does not accept coins. make sure tlie Vender is
1 plugged in and the LED displa) is lit
'Our MERLIN Iv Vender
" Multi - DropBus " (also knonn as MDB) Coin Mechd-
nisin It is mounted to the changer access door nith
three Phillips head screws, or is mounted in the center
on a CDC Vender
"lth a 24 "lt
1
Check to ensure tlie coin changer is plugged in
Neut. chech the Pouer Indicator Lamp located
beneath the Coin Acceptor (near the Changer Setting
Snitches) If
it is on, replace the Coin Mechaiiisin
~
IDENTIFICATION " Multi - Drop Bus " is the connection
of one or more devices, such
as a coin mechanism. bill
T. alidator, or debit card reader. through one central
coInmunicatioii link to the Controller This hpe of
communication pro\ ides more information in the form
of coin mechanism and bill \ alidator error codes With
MERLIN IV, the line
of communication is a serial
changer harness connected to position
P3 of the
Vender's Control Board
,
OPERATION REQUIREMENTS The Control Board
provides the Coin Mechanism nith
a iioiiiiiidl 34 \olt DC
from Pin
1 of the Multi - Drop Bus connection (P3)
Pin 2 of this connection is the 24 - 35 VDC return to
common
1
OPERATION: The Coin Mechanism determines tlie
validity and value of each coin that is inserted into the
Vender and sends the coin information to the Vender's
Control Board. The Coin Mechanism continuously
informs the Controller
of the level of the coins in the
coin tubes to be used for change. All change tube status
and creht information is accumulated in the Vender's
Control Board. At this point, the Vender's Control
Board
is responsible for lighting the Correct Change
Indicator Lamp in case the changer does not have change
to payback, the Coin Mechanism is disconnected. or the
changer harness is cut or disconnected.
With the
MERLN IVVender, the prices are set through
the Vender's Control Board via programming, not
through the Changer. The Control Board
is in charge of
initiating coin payout. Change is paid out through the
three
(3) DC operated solenoid slides, when payback is
required. Coin payout can also be done by using the
Control Board's CPO Mode. If further Coin Mechanism
information is required, refer to your separate Operation
and Service Manual for your type of Coin Mechanism,
or contact your local Coin Mechanism representative.
20
Merlin IVService & Parts Manual