Seaga VC4000 Service Manual
OPERATION & SERVICE MANUAL
VC4000 Series
MDB-120 Controller
67196-2 Software
120 Volts, 60 HZ
230 Volts, 50 HZ
Seaga Manufacturing, Inc. 700 Seaga Drive, Freeport IL 61032 USA
Phone: 815-297-9500 Fax: 815-297-1700
www.vendtronics.com www.seagamfg.com
A Member of the
Family of Companies.
Table of Contents
SECTION 1 – SPECIFICATIONS
Physical characteristics
Environment
Health safety protection
Electrical and Refrigeration Characteristics
4
4
4
4
Location
Power supply connection
SECTION 3 – INITIAL SETUP
Vending
Health and Safety Range
Temperature Settings
Defrost Delay
Refrigeration System
Condensing unit
Evaporator
Temperature Display
Refrigeration Control system
Defrost System
System Control
Door Switch monitoring
Idle Condition
Coin Acceptance
First Bill Acceptance
Additional Bill Acceptance
DEX / UCS Data Retrieval
Vending Selection
Loading Product
SECTION 5 – PROGRAMMING
The Service Mode of Operation
Flow Chart
Diagnose
Error Codes
Motor
Count
Config
Account
Hist Sales
Hist Count
Res Sales
Res Count
Rdr Sales
SECTION 2 - INSTALLATION
SECTION 4 – OPERATION
5
5
6
6
6
6
7
7
7
7
8
8
8
9
9
9
9
10
10
11-12
12
13
14
15
16-17
18
18
18
18
18
18
18
18
19
1 VC4000
Set Range
Set Range
Range Cash
Range Vends
Clear
Coin
Payout
Tube Fill
Uncon Accp
Exact Change
Test
Test Vend
Test Relay
Serv / Contr
Price
Items
Options
Bill Escrow
Force Vend
Max Change
Value
Multi Vend
Free Prod
Promo Vend
Default
Model
Messages
Options
POS / AUX
POS
Language
AUX
Time / Date
Shutdown
Temperature
Degree
Sensor 1
Sensor 2
Set Point
Delta
Health
Defrost
Discount
Auto reinstate
Table of Contents
19
SECTION 5 – PROGRAMMING
Menu 2
Menu 3
19
19
19
19
20
20
20
20
21
22
22
23
24
25
25
26
26
26
26
26
27
27
28
29
29-31
31
32
33
33
34
34
35
36-37
37
37
37
37
38
38
39
40-41
42-43
44
2 VC4000
Table of Contents
Can / Bottle
Optic
Refrigeration Interface Diagram
Electrical Diagram 115 Vac
Trim Diagram/Parts List
Service Door Diagram/Parts List
SECTION 8 MAINTENANCE
SECTION 8 TROUBLESHOOTING
APPENDIX 1 MESSAGES
APPENDIX 2 DEX / UCS RECORD SUBSET
SECTION 6 DIAGRAMS
45
46
47
48
50
48
51-52
53
54-55
56-57
58
48
3 VC4000
SECTION 1 SPECIFICATIONS
PHYSICAL CHARACTERISTICS
• Height: 72 in. / 183 cm.
• Width: 48 in. / 122 cm.
• Depth: 32 in. / 81 cm.
• Weight: 875 lb. / 397 kg
• Construction: Heavy Gauge Steel
• Finish: Powder Coated Paint
• Number of Trays: 5 / 6
• Maximum Selections: 50 / 60
• Maximum Capacity: varies with size of product
ENVIRONMENT
• Operating Ambient Temperature: 50°F to 100°F
• Location Environment: Indoors only
HEALTH AND SAFETY PROTECTION (Vending of products is disabled)
• Activation Temperature:
Refrigerated: +41°F or higher if more than 15 minutes
None None
ELECTRICAL AND REFRIGERATION REQUIREMENTS
Power Requirements 110 / 120 Vac, 60Hz
Amperage Rating 16
Control Transformer ½ Amp fuse
Lamp Transformer 2 Amp fuse
Compressor 1/2 hp Hermetic
Refrigerant Charge 1 lb 10 oz R404a
Evaporator Forced air, Elec. Defrost
4 VC4000
SECTION 2 INSTALLATION
LOCATION
Upon receipt of the unit, inspect for any shipping damage and report directly to the
carrier. A damage report will be necessary before contacting the factory. Allow the unit to set at
room temperature for at least 24 hrs. before operation. The unit should be stored or transported
vertical at all times. When relocating the unit, it should not be tipped at extreme angles. If the
unit is relocated, it is strongly recommended that a similar 24 hr. non-operating period be
observed. If the unit was in an operating mode prior to relocation, the inside of the refrigerated
compartment should be allowed to rise to room temperature and completely dry out before
placing back into service.
The back of the unit must be located at least 6 inches from any obstruction to ensure
proper airflow in the compressor area. The system requires air to be induced from underneath the
base of the unit, through the condensing coil, and expelled out the back of the vending machine.
POWER SUPPLY CONNECTION
CAUTION: DO NOT USE AN EXTENSION CORD
The 110 / 120 Vac unit requires an independent 20-amp earth grounded circuit.
To insure safe operation of the VC4000, the power supply must be a properly grounded
and a polarized outlet must be used. Before plugging the VC4000 into the outlet, test the outlet to
confirm it will meet the VC4000 power requirements. If the power requirements are not met,
contact a Licensed Electrician and have any necessary corrections made. After connecting to the
wall outlet, open the Service Panel and turn the main power switch on. The display on the front
panel should become active after approximately 20 seconds.
5 VC4000
SECTION 3 INITIAL SETUP
Upon placement of the machine on location, the following programming should be setup
to insure proper operation of the VC4000. Please verify the unit has reached the desired
temperature settings before loading product.
The temperature may be viewed at any time by pressing the “0” button on the keypad.
VENDING
Vending operations, such as, setting prices, changing the message on the front display,
handling bills, coins, credit, making change, and operating vend motors should be tested before
loading product into the machine.
(Refer to Section 5 for programming instructions)
HEALTH AND SAFETY RANGE
The function of this system is to provide additional user protection by disabling vending
operations, “PLEASE CALL SERVICE” will be displayed if the air temperature inside the
refrigerated space rises above the selected setting for a preset period of time.
Proper Health and Safety settings must be set for proper operation.
Refrigerated: +41°F or higher if more than 15 minutes
None: None:
A magnetic switch is located at the top of the glass door that will provide an additional 60
minutes whenever the service door is opened, an additional 15 minutes will also be provided
whenever a defrost cycle occurs.
TEMPERATURE SETTINGS
Temperature settings can be programmed for Degrees Fahrenheit or Degrees Celsius. The
Set Point can be programmed to maintain a desired temperature. A minimum 35°C delta is
recommended to prevent short cycling and extend the life of the Compressor.
The temperature may be viewed at any time by pressing the “0” button on the keypad.
DEFROST DELAY
This option is only necessary if the customer would like the machine to defrost at a
specific time. This option allows the user to set the starting point for the first defrost cycle. When
a power loss to the Control Board has occurred, 12 hours of operation will be resumed from the
moment power was restored, before defrosting.
6 VC4000
SECTION 4 OPERATION
REFRIGERATION SYSTEM
The system is comprised of an Evaporator, Condensing Unit, and Electronic Control
System. The refrigeration system will shut down whenever the glass door is opened. The System
Control Board regulates all refrigeration functions; the temperatures can be adjusted by entering
the service mode and inputting the desired set point and delta temperature settings. In the event
of a Control Board failure, the Refrigeration system will run continuously, and will not cycle off
until the Control Board is repaired or replaced.
The Evaporator removes heat from the air in a refrigerated space and transfers the heat to
the liquid Refrigerant. The liquid Refrigerant evaporates and is pumped out by the Compressor
through the larger diameter tubing. The Compressor pumps the low-pressure vapor into the
Condensing Coil where it gets rid of the heat and condenses into a high-pressure liquid. The
high-pressure liquid travels through the smaller diameter tubing to the Evaporator.
The temperature can be viewed at any time by pressing the “0” symbol on the keypad.
CONDENSING UNIT
The VC4000 uses a 1/2 hp Danfoss Condensing Unit. It is located on the base of the
cabinet and can be accessed from the front of the unit. It consists of a Compressor, Condensing
Coil, Fan, Liquid Receiver, Starting Relay, Start Capacitor, Run capacitor, and a Thermal
Overload Protection Device. Two service ports are provided for a Qualified Service Technician
to diagnose and repair the Refrigeration System.
EVAPORATOR
The VC4000 uses a low Temperature, Forced Air, and Electric Defrost Evaporator. Each
consists of an Evaporating Coil, Evaporator Fan, and a Heating Element. They are located inside
each of the refrigerated spaces at the top
TEMPERATURE DISPLAY
The temperature sensor readings can be displayed by pressing “0” in the sales mode of
operation.
7 VC4000
SECTION 4 OPERATION
REFRIGERATION CONTROL SYSTEM
The following sequence describes a typical Refrigeration Control cycle.
Upon initial power up, both compartments will begin to cool down.
1. The air temperature inside the refrigerated space cools down to the Cutout setting.
2. The Control Board receives a signal form the Temperature Sensor.
3. The Control Board energizes a 24Vdc Refrigeration Relay and opens the Normally Closed
Contacts.
4. The Compressor shuts off, Evaporator Fans continue to run.
5. The system remains off until the air temperature inside the refrigerated space warms up to the
Cut-In setting.
6. The Control Board receives a signal From the Temperature Sensor.
7. The Control Board de-energizes the Refrigeration Relay and closes the Normally Closed
Contacts.
8. The Compressor starts up and the cycle is repeated until the unit goes into defrost.
DEFROST SYSTEM
The Control Board controls the timing of the defrost cycle. The Control Board will
simultaneously energize a Defrost Relay, and the Refrigeration relays. When the Defrost Relay is
energized, the Normally Closed Contacts open and shut off the Compressor and Evaporator fans,
the Normally Open Contacts close and turn the Defrost Heaters on. The electric defrost is
automatic and will be initiated every 12 hours. The on time will be approximately 21 minutes.
During this period the compressor and evaporator fans are turned off. Whenever power to the
Control Board is removed, the Refrigeration will run for a full 12 hrs. before a defrost period
begins. The Defrost Start Time, duration, and period can be programmed from within the service
mode of operation.
SYSTEM CONTROL
The MDB-120 Selection System Control Board controls the message on the front
Display, Bill Acceptor, Coin Changer, Accumulation and Display of Escrow, Issuing Change
Payments, Keypad Selection, Vending of product, Price Settings, Health Safety, and
Refrigeration Control Functions.
The Sales Mode is the normal mode of operation. The controller will always default to
the sales mode under the absence of other inputs.
8 VC4000
SECTION 4 OPERATION
DOOR SWITCH MONITORING
Both of the door switches will be monitored at all times, if an open to close transition is
detected then all health safety related errors, timers, and sold out errors will be reset.
If either glass door is opened the refrigeration system will be switched off. If this open state
exceeds 30 minutes then a DOOR OPEN ERROR message will be continuously scrolled
across the display and the refrigeration system will be reactivated.
To protect the compressor from encountering overpressure situations due to opening and closing
the door repetitively, the controller will not re-activate the refrigeration system for a period of 90
seconds from the initial opening of the glass door.
IDLE CONDITION
The controller will monitor all present MDB peripherals for customer input while waiting
for a keypad generated interruption. If no action is taken, then the programmable Point of Sales
message will be scrolled on the display provided there are sufficient coins in the coin changer. If
an adequate quantity is not detected, the “PLEASE INSERT EXACT MONEY” message will be
displayed. When credit has been established, the amount of credit will be displayed, otherwise
the controller will continue as above until a vend sequence is initiated or a Coin Return request is
made. If a Coin Return request is received and the Force Vend feature is disabled, the deposited
credit will be returned in a “like coin” fashion.
COIN ACCEPTANCE
The controller will allow acceptance of all coins as long as the accumulated credit is
equal to or less than the maximum price of any selection in the current configuration. When
Multivend is active then this maximum value increases to 3 times the highest priced selection in
the machine. Coin acceptance will be disabled during all vends, while coins are being paid out,
and while in the service mode of operation, and if card reader credit is established.
FIRST BILL ACCEPTANCE
The first bill will be accepted if the quarter tube is above the low indicator or if the dime
and nickel tubes are both above the low indicators. When accumulated credit is greater than or
equal to the maximum price, additional bill acceptance will be prevented. When multivend is
active then this maximum value increases to 3 times the highest priced selection in the machine.
If the bill acceptor offers escrow and acceptance is disabled because of the maximum price, the
last bill inserted will be kept in the escrow position, otherwise the bill will go straight into the
bill stacker. If the bill acceptor does not offer escrow, or bill escrow is disabled, the bill will go
straight to the bill stacker. The bill will be accepted if the coin tubes total cash amount is
greater than or equal to the established credit plus the additional bill value. If credit is
established from a card reader, no bills will be accepted.
9 VC4000
SECTION 4 OPERATION
ADDITIONAL BILL ACCEPTANCE
Additional bills will be accepted if the dime and quarter tubes are both above the low
indicators. If the accumulated credit is greater than or equal to the maximum price, additional bill
acceptance will be disabled. When multivend is active then this maximum value increases to 3
times the highest priced selection in the machine. If the bill acceptor offers escrow, and
acceptance is disabled because of the maximum price, the last bill inserted will be kept in the
escrow position. If the bill acceptor does not offer escrow, or bill escrow is disabled, the bill will
go straight to the bill stacker and the bill acceptor will be disabled after the second bill has been
sent to the stacker.
DEX / UCS Data Retrieval
DEX / UCS data retrieval is only allowed in the sales mode of operation. The retrieval
device initializes the data retrieval after it has been properly connected to the DEX port. Refer to
page 73 for the available DEX fields.
10 VC4000
SECTION 4 OPERATION
VENDING SELECTION
The controller responds to keypad selections from two possible sources. One source is
the 120 Select controller's own keypad and the other source is a selection received from an MDB
USD peripheral by the 120 Select Controller.
Following reception of any keypad selection, the controller will then calculate a checksum of the
MIS and pricing information. The resulting checksum will then be compared to the previous
checksum calculated when the controller last changed a MIS or price location.
If the two checksums are different, the vend will not be allowed. This same checksum error will
cause the controller to return any deposited credit in a "like coin" fashion.
If the two check sums are identical, then the selection's character, number, and price will be
displayed while additional checks on the selection are made in the following order.
1) Passes Health and Safety rules
2) Item is not in Shutdown range of the 'Timed Shut Down Intervals' feature
3) Item is in the configuration and it does not contain a bad motor
4) Deposited credit is greater than or equal to the price of the selection
If the selection fails any of these checks then the vending attempt will be aborted. The
controller will continue to display the selection's character, number, and price for a period of 1
second. This is followed with three beeps from the speaker along with the one-time scroll of a
failure dependent message.
• If the item failed the shutdown check then this scrolled message will be "VENDING
OPERATION TO RESUME AT hh.mm”. The deposited money will be automatically
returned to the customer.
• If check #4 failed then this message will be "PLEASE INSERT MORE MONEY".
• For the other failures, "MAKE ALTERNATE SELECTION" will be the message. The
credit or the point of sales message (if no credit has been established) will be displayed
again following the message.
If the selection has passed all of the previous checks, the controller will determine if the
exact amount of change can be paid to the customer.
The vending sequence will be halted if the controller determines that exact change cannot
be returned. The controller will return the deposited credit in "like coin" fashion. The controller
will issue three beep tones along with one scroll of the PLEASE INSERT EXACT MONEY"
message and then return to the idle condition of the sales mode. If a Promotional item (in
response to purchase of another item) failed to vend, the vend is considered good. The failed
motor is flagged and displayed in service mode.
If all previous checks have passed then a vend of the selection will be attempted.
11 VC4000
SECTION 4 OPERATION
A successful vend results in a display of the amount of change while it is returned using a
"least coins" algorithm. If the correct change is returned, the "THANK YOU" message will be
displayed for 0.8 seconds, followed by the idle condition of the sales mode. If for some reason
the exact amount of change cannot be returned, as much as possible will be paid out and the
remaining amount will be retained as credit toward another vend. An item price of $0.00 is
allowed as a valid vend while in the sales mode of operation.
When a vend fails, the controller will beep three times while the "MAKE ALTERNATE
SELECTION" message is scrolled one time. This will be followed by the amount of accumulated
credit. When the force vend feature is enabled, faulty vends will result in an override of the
force vend feature. Force vend will stay overridden until the customer has attempted to escrow
the credit or vended another product.
For those failed vend attempts of motors connected to the 120 Select controller, if the
motor is not allowed to complete a full cycle, or if after twelve seconds the motor has not yet
returned to a home position, the vend will be considered a failure.
A bad motor is defined as:
1) A motor location requiring more than 12 seconds before detecting a home position signal
2) An electrically open motor circuit at the time the controller first attempts to vend the
motor.
If a configured motor not in the auto reinstate range has been detected as being bad due to
the detection of an open circuit, that motor can not be vended until it is cleared by performing a
successful free vend from within the service mode of operation.
When the optics mode is enabled and auto reinstate is inactive for the particular selection
but the optical sensor detects no product. In this case, the controller will flag the item with a
sold out error (VMC 9) in addition to a long vend error (VMC 2). The controller will also
prevent further attempts to vend the particular selection until the selection's sold out error status
is cleared.
LOADING PRODUCT
Product should be loaded behind the push mechanism as shown below. A display product should
be loaded in front of the push mechanism. The driver chain should be examined regularly to
insure that it is in the correct position to perform a vend.
Vendible Product
Push Mechanism
Drive Chain
Display Product
12 VC4000
SECTION 5 PROGRAMMING
THE SERVICE MODE OF OPERATIONS
To enter the Service Mode press the red button located on the controller board. The
controller automatically returns to the sales mode if no input from the keypad is received in
approximately 25 seconds, or if the button is pressed a second time within this period. If credit
exists upon entering the service mode, it will be restored when the sales mode is re-established.
At the time of initial entry into and final exit from the service mode, the controller will
briefly power all currently configured motors to determine if an open circuit condition exists.
Any configured motor that exhibits an open circuit during this process will be immediately
removed from the vending machine configuration. This means that a motor previously tagged
bad in the sales mode due to an open circuit condition, and presently found to have an open
circuit condition upon entry to the service mode, will not be flagged as bad in the diagnostics
service mode menu.
For the remainder of the programming section the following commands will be used in place of
keypad buttons
5 keypad buttons will be used to navigate the service menu
A = SCROLL UP
B = ENTER
C = SCROLL DOWN
D = SAVE
E = EXIT / CANCEL
A 1 2
B 3
C 5
D 7
E 9
4
6
8
0
F G H
J K L
13 VC4000
SECTION 5 PROGRAMMING
14 VC4000
SECTION 5 PROGRAMMING
DIAGNOSE
The Diagnostics menu item displays the current status of the controller and peripherals.
Pressing “ENTER” after the user has navigated to the menu item labeled DIAGNOSE starts
this function. Upon entry the status of the controller and each of the peripherals will be checked.
The order of checking is the Vending Machine Controller, the Changer, the bill Validator, and
the card reader. The display will show in that order "VMC", "CHANGER", "VALIDATOR",
and "READER". If no problems are encountered with the individual device then the name of the
device will be followed by "OK". If problems are encountered then the device name will be
followed by an error code.
In the case of the Vending Machine Controller, it's possible that a sequence of error codes
could follow the "VMC" display if multiple errors are found with that device. The diagnostics
for the VMC will include an error code if any motor in the configuration has been flagged as
bad. In addition, the error code for the bad motor will indicate why.
A definition of all possible error codes is shown in the table below. This function may
be exited at any time by pressing the "CANCEL" button.
ERROR CODE ERROR DESCRIPTION
VMC 1
VMC 2
VMC 4 NOVRAM checksum error. The display would read "VMC 4"
VMC 5
VMC 6
VMC 7 The door is still open after 30 minutes "VMC 7".
VMC 8 Eyes on the activated optical sensor are blocked.
VMC 9
CHANGER 3
VALIDATOR 7
READER 8
Too little motor current (under 20mA).
For an example, the display will show "VMC A1 1"
Too much time to complete vend (12 seconds).
For an example, the display will show "VMC C2 2"
Health & safety error on temperature sensor 1.
The display would read "VMC 5".
Health & safety error on temperature sensor 2.
The display would read "VMC 6".
Selection was not detected by optical sensor and, as such, is
considered sold out. ).
For an example, the display will show "VMC A1 9"
Loss of changer communications or no changer.
The display would show "CHANGER 3".
Loss of bill validator communications or no bill validator.
The display would read "VALIDATOR 7"
Loss of card reader communications or no card reader.
The display would read "READER 8"
15 VC4000
SECTION 5 PROGRAMMING
ERROR CODES
Enter the service mode by pressing the red button on the controller, a beep will be issued
to recognize the transition and “DIAGNOSE” will be displayed until a function key is pressed.
Press the letter “B” to enter the diagnostics menu. The diagnostics routine will present various
error codes relating to the nature of a fault condition
VMC 1
If any previously configured selection motor has become disconnected, the Control Board
will display VMC 1 after entering the Diagnostics Mode. A successful Test Vend of the selection
will clear this Error.
VMC 2
If any selection becomes jammed, turns too slow, or the home switch on the motor does
detect the home position, the Control Board will display a VMC 2. A successful Test Vend of the
selection will clear this Error.
VMC 4
A NOVRAM checksum error indicates that "some" configuration information has
changed erroneously. Configuration information consists of prices and all option settings
including health safety and temperature settings. When the error occurs, the controller does not
know what information changed, just that "some" information changed. It could be a single
location or all locations. Your customer must go in and manually check all settings to insure the
controller will function, as they want it to. This error will be cleared upon exiting the Service
Mode of Operation. Power surges are the most likely cause of a VMC 4 message
VMC 5
A VMC 5 Error indicates that Sensor 1 air temperature in the refrigerated space has risen
above the Health and Safety setting selected by the user. All vending functions within a selected
range of rows will be disabled and “MAKE ALTERNATE SELECTION” will be displayed. If
all rows are designated in the range, “PLEASE CALL SERVICE “will be displayed. This Error
will be cleared upon exiting the Service Mode of operation.
• Frozen Foods: +0°F or higher if more than 15 minutes
• Slack Frozen: +15°F or higher if more than 15 minutes
• Cold: +41°F or higher if more than 15 minutes
• None: None
VMC 6
A VMC 6 Error indicates that Sensor 2 air temperature has risen above the Health and
Safety setting; The VC4000 does not utilize a 2-sensor mode of operation and must be disabled.
16 VC4000
SECTION 5 PROGRAMMING
VMC 7
A VMC 7 error indicates that the reset switch at the top of the glass door has remained
open for more than 30 minutes. This error will be cleared upon exiting the service mode of
operations.
VMC 8
A VMC 8 error indicates that the optical sensor is blocked, the lens is dirty, faulty sensor,
or the connector on header P8 is disconnected. This error cannot be cleared until the problem is
resolved.
VMC 9
A VMC 9 error indicates that the optical sensor did not detect product. These errors will
be automatically cleared by either opening and closing the glass door or exiting the service
mode.
CHANGER 3
If the Coin Changer becomes disconnected from the Control Board, (i.e. Broken wire,
Faulty Control Board, or Faulty Coin Changer) CHANGER 3 will be displayed. This Error
cannot be cleared until the source of the problem is repaired. If the VC4000 uses a Debit Card
Reader without a Coin Changer or Bill Acceptor, CHANGER 3 will always be present and
cannot be cleared, this is normal
VALIDATOR 7
If the Bill Validator becomes disconnected from the Control Board, (i.e. Broken wire,
Faulty Control Board, or Faulty Bill Validator) VALIDATOR 7 will be displayed. This Error
cannot be cleared until the source of the problem is repaired. If the VC4000 uses a Debit Card
Reader without a Coin Changer or Bill Acceptor, VALIDATOR 7 will always be present and
cannot be cleared, this is normal
READER 8
If the Card Reader becomes disconnected from the Control Board, (i.e. Broken wire,
Faulty Control Board, or Card Reader) READER 8 will be displayed. This Error cannot be
cleared until the source of the problem is repaired. If the VC4000 does not use a Debit Card
Reader, READER 8 will always be present and cannot be cleared, this is normal
17 VC4000
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