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Marco Beverage Systems Ltd

1. 7 IGHT DISPLAY P O LEFT DISPLAY PCB RIGHT DISPLAY POE O 0000 O 1600324 NG dis YELLOW 0 5 420mm 7 ORANGE 0 5 390mm EY d RED 0 5 420mm a 4 WAY RIBBON CABLE BREW LEVEL PROBE HIGH LEVEL PROBE TOW LEVEL PROBE 2301325 Loopy j O PCB DAUGHTER BON CABLE 2301300 J 2301330 akfa oF gt 2004 g Ii H i 1600326 o 1600317 o o 1 Pe MO ES Lb JAR PUMP p pa o o o E JDRVER TN H inar PCB DAUGHTER UN E Ed n oll o 3 m 3 2 amp l Cl WHITE SILICON 2 5 360mm 2 P to o 1600317 o a mm S BROWN FROM AlR PUMP BROWN 0 75 220mm e WHITE SILICON 2 5
2. e The version of software code is indicated when power is applied to the machine for the first time The display PCB LEDs will flash a sequence e g 2 flash pause 6flash indicates software version 2 6 3 Right pump time adjust pot VR2 e turn clockwise to increase brew time on the right hand urn Note that with the current software version the Full brew time is double the Half brew time Current Version 2 6 4 Left pump time adjust pot VRI e turn clockwise to increase brew time on the left urn Note that with the current software version the Full brew time is double the Half brew time Current Version 2 6 5 Live to Dual Timer high voltage 6 Triac switches the left pump 7 Wire to left Pump high voltage 8 Live to Dual Timer high voltage looped to 5 9 Triac switches the right pump 10 Wire to right Pump high voltage n Timer Mode select switches only switch No 1 should be ON for this machine 12 Connector for Right Display PCB right ribbon cable 13 Connector for Right Display PCB middle ribbon cable 14 Connector for Right Display PCB left ribbon cable 15 Connector for Left Display PCB right ribbon cable 16 Connector for Left Display PCB middle ribbon cable 17 Connector for Left Display PCB left ribbon cable 18 Connector for Air Pump Driver PCB Service Manual MAXIBREW 2 TWIN 25 03 08 Page 16 of 31 4 Technical Data 4 5 PCBs 4 5 6 PCB Air Pump Driver 1600319 NOT
3. Note Some of the error sequences will be displayed if there is low water pressure Please check that there is water pressure and that the water stop valve is open before calling your service agent Status Diagnostic light guide No of Water level below elements Normal when Check water pressure if this is OK call service machine first fills agent Temperature sensor failure o c Call service agent 4 Water not heating Call service agent Temperature sensor failure s c Call service agent Check water pressure If this is OK and the Machine not filling machine has not returned to normal operation after 15 min call service agent Service Manual MAXIBREW 2 TWIN 25 03 08 Page 8 of 31 3 BASIC INSTRUCTIONS 3 8 MAINTENANCE Marco machines have been designed to give many years of trouble free service Marco Beverage Systems design manufacture and test to 1809001 2000 standard The only regular maintenance required is occasional de scaling In common with all water boiler manufacturers service calls resulting from limescale are not covered by warranty Fitting a scale reducer is recommended especially in hard water areas This can reduce the build up of scale but may not stop it altogether A service engineer should descale the machine regularly The frequency that descaling is required depends on the local water supply hard water areas need more attention Marco suggest that the machine be descaled every 3 months if
4. PCBs Connector 12 Triac 15 Heater Relay 13 Safety Heater Relay 14 Inlet solenoid Relay 21 Temperature Adjust Pot e To increase temp adjust clockwise to decrease temp adjust anti clockwise Temperature Range Jumper Controls three temperature ranges should be on middle pins Thermistor Connector Daughter PCB Connector low voltage e Connects to Daughter PCBs allows switching of more than one element Relay Heater e Switches the element Relay Heater Safety e Backup relay for element controls the switching should the triac fail 15 Triac e ln parallel with the heater relay Switches the element initially Zero voltage switching e This lengthens the life of relays by removing the arc flash during switching which wears the contacts on the relay Heater Element Tab high voltage Connects to the element Live Mains Tab high voltage Inlet Solenoid Tab high voltage e Connects to the inlet solenoid Live tab spare high voltage Suppressor Relay Inlet Solenoid e Switches the inlet solenoid Fuse Neutral Mains tab high voltage Neutral Mains tab spare high voltage Service Manual MAXIBREW 2 TWIN 25 03 08 Page 15 of 31 4 Technical Data 4 5 PCBs 4 5 3 PCB Dual Timer 1600323 a x ln F4 i COMPONENTS OF DUAL TIMER 1 Connector 4way low voltage e connects to Data 1 O 4way connector on the Brewer PCB see section 4 5 2 2 Microchip
5. an approximate guide for your first brews 220g 240g 8 8 0z for a Half Brew 10 pints 5 7 litres 440g 480g 16 170z for a Full Brew 20 pints 11 4 litres Depending on the coffee grind and roast and on water quality you may have to adjust these quantities to obtain the optimum flavour e Level off the surface of coffee by gently shaking the filter bowl Slide the coffee filter bowl into the guide rails in the brew head and push fully home e Select the correct brew on the relevant control panel e g left control panel if the left urn being used by pressing either the Half Brew switch for a 10 pint brew or the Full Brew switch for a 20 pint brew Press the switch until the amber light illuminates If you make a mistake press the Power switch to turn the machine off Wait 3 seconds and turn back on again Select the correct brew e A half brew should take around 4min30secs 5min30secs A full brew should take around 9 IImin These depend on the set up of the machine factory Note An engineer can set the machine up so that different brew times are available in each urn for different strengths types of coffee e Remove the filter paper with the spent grinds as soon as possible after brewing Note allow time for all the coffee to drain from the filter bowl before removing e A brew can be selected whenever the green Ready to brew lights are illuminated e Left and right brews can run simultaneously although the two brew buttons sh
6. on A brew can now be selected Note Once again the Green Ready to Brew light indicates that the machine is at a safe level and up to temperature but in this case the water has filled to the high probe already so the machine will be full and up to temperature when the light comes on for the first time Unlike the Heat Fill mode the machine will fill with mains water as soon as the water level drops off the high level probe The machine will always be full of water but the drawback is that if operators draw off too much water from the hot water tap the temperature of the beverages can be affected The brew temperature will not drop significantly while brewing even when doing dual brews BUT if a large amount of hot water is used at the same time brew temperatures can be affected because cold mains water replaces the hot water used immediately Service Manual MAXIBREW 2 TWIN 25 03 08 Page 21 of 31 4 Technical Data 4 8 TROUBLESHOOTING DIAGNOSTIC GUIDE The Marco Maxibrew 2 Twin uses an electronic diagnostic system to help determine faults If an error is detected a sequence of flashes is displayed through the POWER light shown in the picture below POWER HALF FULL FACK OA BREW BREW TO BREW 2 FLASH CYCLE BELOW LOW LEVEL Display pattern 2 quick flashes then a short pause repeated Electronic check and action e This indicates that the low level circuit is open i e the probe is not in co
7. sequence is displayed again This cycle is repeated Service Manual MAXIBREW 2 TWIN 25 03 08 Page 23 of 31 Probable causes 1 Mains water pressure problem or the mains water stop valve is closed 2 Inlet solenoid valve failure Action required l Check the mains water supply If it is good wait 5minutes to check that the error cycle is continuing 2 If the mains water supply is good check that the inlet solenoid valve is working 4 Technical Data 4 9 Level Probes The level probes provide much of the control inputs into the PCB and are critical to the operation of the machine The wiring to these should be checked regularly and the probes themselves should be cleaned whenever the machine is serviced There are 3 level probes on the Maxibrew 2 Twin e Low Level Probe e High Level Probe e Brew Level Probe The high and low level probes are are mounted on one assembly on the top right side of the tank The brew level probe is mounted on the top left side of the tank The pictures below show how to remove these assemblies COFFEE AERATOR HALF READY BREW BREW Service Manual MAXIBREW 2 TWIN 25 03 08 Page 24 of 31 4 Technical Data 4 9 Level Probes The Level Probe assemblies are shown in the picture All the probes are mounted above the water line and have stainless steel tabs that hang down to the level required Low and High Level Probe Assembly left in picture e The low level probe has the lon
8. the unit is in a hard water area In soft water environments every 6 months should suffice 3 9 CLEANING Like any cooking utensils the coffee urns of your Maxibrew 2 Twin must be cleaned properly regularly Marco recommend cleaning after each days brewing using a proprietary urn cleansing compound Marco Urn Cleanser Marco Part number 8000240 is available in 800g tubs Instructions are given on each tub Your Maxibrew 2 Twin is supplied with one large urn cleaning brush and one small sight glass cleaning brush to ensure thorough cleaning To clean the sightglass unscrew the small plastic plugs on the top of the sightglass The sightglass is fragile so be careful while cleaning The exterior of these machines may be cleaned with a damp cloth and a light detergent Do not use abrasive cloths or creams as this will spoil the finish of the machine Do not use a water jet or spray Beware of accidentally operating the draw off taps when cleaning the front of the machine 3 10 SAFETY e This appliance must be earthed Risk of flooding The hose supplied with this unit is non toxic food quality tested to 190psi However a hose is not a permanent connection It is therefore advisable to switch off boiler and close the stopcock valve when boiler is not in use e g overnight weekends etc O Risk of scalding Beware of accidentally operating the water drawoff tap especially when cleaning the front of the boiler ALL users of this machin
9. 540mm BROWN 0 75 350mm LUE 0 75 200mm BLACK SILICON 2 5 300mm n BLACK SILICON 2 5 20mm BROWN SILICON 2 5 410mm 1501211 X o LUE 0 75 420mm A i 2 BROWN 0 75 490mm Y Favre o fo lolo fo j 1502000 BLUE from ar pur EARTH STUD ON TANK oohooKo PINK 0 5 280mm LP 120113 TANP E HOLDER S BLUE SILICON 2 5 SOfnm 1501212 EJ v T T 2999 2 E 3333 THERMISTOR E 8 2 E235 ASM 8 ES E E 383 msn 3 8 8 E 2 aa ze 7 E S S n E z z S E m BLUE SILICON 2 5 350mm D 5 LB Pi E E i a 2 2 pH s HERMISTOR 3 3 E B POCK E a BLUE SILICON 2 5 350mm i 3 SUE 3 BLUE SILICON 2 5 320mm ELEMENT FROM PUMP d 1500975 BROWN E PUMP Ei 1501540 FROM PUMP a a BROWN n 3 FROM PUMP PUMP 1501540 3 Exe sro ox asa L EARTH STUD ON BASE S a BLUE ERN a BLUE 0 75 80mm I EARTH MAINS m FROM PUMP a INLET ISOLENOID FLEX IN 1502170 Marco Beverage Systems Description WIRING DIAGRAM Drg No MB2T 001A Tol 10mm Drawn AD ice Change 06 09 05 Model 1000465 MAXIBREW 2 WI 8 4kW 3 PH Part No Scale NTS Date08 06 09 c ice Change 21 09 05 Bend Prog P ch Prog Approv Rev Details Date Page 30 of 31 25 03 08 Service M
10. 600317 e Switches one element only one PCB on 5 6kW Service Manual MAXIBREW 2 TWIN 25 03 08 Page 13 of 31 4 Technical Data 4 5 PCBs PCB Brewer 2004 1600326 E 4 5 2 N N PIE N N N ET N s s e 9 NX wsTIONLNOS 1Z3 SIEDO91 SH3LSAS 39YNINIA Uae COMPONENTS OF PCB BREWER 2004 1 Transformer 2 Power On Off 2way connector low voltage e Looped on this machine power switch controlled through Display PCB and Dual Timer 3 LEDs 5way connector low voltage e Not used on this machine 4 Data 1 O 4way low voltage e Connects to the Dual Timer PCB 5 Earth Tab 6 Mode of Operation selector Heat Fill Continuous Fill e The default position is no jumper or jumper towards the transformer side The default mode is HEAT FILL To change the mode to CONTINUOUS FILL move the jumper so that the two pins furthest away from the transformer are connected Service Manual MAXIBREW 2 TWIN 25 03 08 Page 14 of 31 4 Technical Data 4 5 PCBs 17 18 19 20 21 22 23 24 4 5 2 PCB Brewer 2004 1600326 Water Level 5way connector low voltage e Connects to Low level High level and Brew level probes Microchip e Receives inputs from Data 1 O 4 Mode select jumper 6 Water Level Probes 7 Thermistor 11 Temperature Range Jumper 10 Temp adjust Pot 9 and Power On 2way 2 e Outputs to Data 1 O 4 LEDs 3 Daughter
11. E The PCB Air Pump Driver 1600319 is a PCB Solenoid Driver 1600311 with the suppressor removed If a spare PCB is sent with the suppressor attached use snips to remove the suppressor before attaching the PCB COMPONENTS OF AIR PUMP DRIVER 1600319 1 Connector Ribbon Cable 4way low voltage t NOTE The ribbon cable used to connect the PCB Dual Timer to the PCB Air Pump Driver is wired differently to any other ribbon cable on the Maxibrew 2 Twin The 4way connector is reversed on one end This ribbon is identified by the black insulation strip nnects the PCB Air Pump Driver to the J5 connector on the PCB Dual Timer 2 Live Tab connects to mains live 3 Load Tab connects to Live of Air Pump 4 Triac switches the Air Pump 4 5 5 PCB Daughter 1600317 The PCB Daughter is used to switch an element The triac relay and safety relay used on the PCB Brewer is also used on the PCB Daughter This reduces wear on components 1 Live Tab connects to mains live z MARCO BEVERAGE SYSTEN 2 4way Connector J2 E I DAUGHTER PARI i e connects to next Daughter PCB 3 4way Connector JI e connects Daughter PCB to Brewer PCB 4 Heater Tab connects to element Service Manual MAXIBREW 2 TWIN 25 03 08 Service Manual MAXIBREW 2 TWIN 25 03 08 Page 18 of 31 4 Technical Data 4 5 PCBs 4 5 6 PCB Brewer Display 1600324 NOTE The Left and Right PCB Brewer Displays have the same part number but the Righ
12. anual MAXIBREW 2 TWIN 4 Technical Data 4 14 Spare Parts List Deana PCB Brewer 2004 PCB Timer Dual 2004 PCB Daughter PCB Air Pump Driver PCB Brewer Display Pump Nikkiso Air Pump Valve Inlet Solenoid Thermistor Assembly Element 2 8kW 230V m shape Tam Ballet aie Lamp SW High Level Probe Assembly Low Level Probe Assembly Brew Level Probe Assembly Hot Water Tap with chrome body Coffee Tap with chrome body Tap Assembly Hot Water Tap Assembly Coffee Nut Chromed for Tap Cidip for Tap Sightglass Plastic Rose around Tap Plastic Fascia MB2T Basket Complete MB2 Urn Lid Complete Drip Tray Complete Maxibrew 2 Twin Urn Cleanser 800g Tub Cup Rail Acne Service Manual MAXIBREW 2 TWIN 25 03 08 Page 31 of 31
13. be drawn off In the HEAT FILL mode drawing off Hot Water while brewing Coffee should not affect the quality of the brew The machine naturally gives priority to the coffee The machine will effectively run out of hot water no water will be available out of the hot water tap but brews can still be selected Service Manual MAXIBREW 2 TWIN 25 03 08 Page 20 of 31 4 Technical Data 4 7 OPERATION CONTINUOUS FILL MODE NOTE The standard operation mode for this machine is the Heat Fill cycle The Continuous Fill eycle can be selected by moving the Jumper J12 on the Brewer PCB above the microchip to the position furthest away from the transformer See Section 4 5 2 Turn the water on at the stop valve and switch the power on at the wall connection The sightglass lamps will now illuminate Press the POWER ON button at the front of the machine A red LED next to the button will illuminate and the machine will start to fill Note The machine will not heat until the water has reached the low level probe When the water level is below the low probe the Power LED flashes the diagnostic 2 flash cycle When the low level probe is reached the element is switched on The machine continues to fill until the high level probe is reached This means that the machine is full of cold water at this point The water is heated to the pre set temperature 92 94 5 C The continuous fill cycle is complete when the green Ready to Brew light is
14. cidental misuse by trained personnel If the lock button left hand side control panel is pressed for approximately 6 seconds a red light next to the button will illuminate Both control panels are now locked No buttons are operational when the lock function is enabled The machine will operate as normal i e if the machine is brewing it will continue to brew Once completed another brew cannot be selected until the lock is disabled Note The Ready to Brew lights will still be on but no brew can be selected To disable the lock function hold the lock button for approximately 6 seconds once again 3 6 COFFEE AERATOR The Maxibrew 2 Twin has an air operated agitation system to mix coffee after a brew or after the coffee has been left standing for a period of time Press and hold the Coffee Aerator button right hand side control panel for approximately 10 seconds to mix the coffee in the urns Both urns are aerated when the button is pressed 3 7 TROUBLESHOOTING The Marco Maxibrew 2 Twin uses an electronic diagnostic system to help determine faults If an error is detected a sequence of flashes is displayed through the POWER light This sequence is repeated cycled until 1 The problem is rectified by an engineer or 2 In the case of the 6 flash cycle the machine senses that normal operation has resumed and the flash sequence ceases The number of flashes in a cycle corresponds to the symptom in the table below
15. e When the low level probe is reached the water inlet is stopped and the element is switched on This water is heated to the pre set temperature 92 94 5 C The machine takes in another small body of water while continuing to heat This method of staggered filling heat fill cycle ensures that the temperature in the tank remains within 3 degrees of set temperature This heat fill cycle continues until a the water level reaches the high level probe and b the water temperature reaches the pre set temperature as above Note When the level of water is at a safe height above the low level the green READY TO BREW light illuminates This indicates that the machine has enough water to run a brew and is at the correct temperature The machine is NOT full at this level A brew can be selected but no water is available out of the Hot Water Tap Unless a brew is selected the full quantity of hot water should be available within 15 20 minutes of reaching this level The machine is ready to brew Coffee and up to 20litres of Hot Water is available for immediate draw off when the machine is full and up to temperature There is one large water tank with two urns recessed into it When a brew is selected hot water is pumped from the tank up to a sprayhead and into the filter basket The coffee runs out of the filter basket into the urn Since the water tank surrounds the urn the brewed coffee is kept at temperature The heat fill cycle ensures that t
16. e should be trained and should be aware that the machine dispenses very hot beverages O The utmost care has been taken in the manufacture and testing of this unit Failure to install maintain and or operate this boiler according to the manufacturer s instructions may result in conditions that can cause injury or damage to property If in any doubt about the serviceability of the boiler always contact the manufacturer or your own supplier for advice Service Manual MAXIBREW 2 TWIN 25 03 08 Page 9 of 31 4 Technical Data 4 1 GENERAL DESCRIPTION MAXIBREW 2 TWIN 8 4kW 1000465 i c j Plumbing Dimensions Performance Fittings Pressure Height Height incl Cup Rail Width Depth footprint on counter Depth Depth incl Drip Tray Coffee Output 1 x Half brew 2 x Half brew 1 x Full Brew 2 x Full Brew Maximum Hourly Coffee Output Hot Water Immediate Draw Off Total Recovery rate at 8 4kW MAXIBREW 2 TWIN 5 6kW 1000464 Dimensions Coffee Output 1 x Half brew 2 x Half brew 1 x Full Brew 2 x Full Brew Maximum Hourly Coffee Output Hot Water Immediate Draw Off Total Recovery rate at 5 6kW Service Manual MAXIBREW 2 TWIN 25 03 08 8 4kW 400V 3Phase Neutral c w 1 5m flex 0 75 BSP Food grade inlet hose supplied 5 50 psi 35 345 kPa Up to 6 8 litres 12 pints Up to 13 6 litres 24 pints Up to 13 6 litres 24 pints Up to 27 2 litres 48 pints Up to 91 l
17. gest tab 290mm When in position the bottom of the tab rests in a safe position above the elements e The high level probe has the shortest tab 40mm The Brew Level Probe Assembly right in picture The brew level probe has a 190mm long tab A brew can be selected and will complete safely when the water level has reached this probe A brew cannot be selected below this level Service Manual MAXIBREW 2 TWIN 25 03 08 Page 25 of 31 4 Technical Data 4 10 A A Removing the elements e Drain the machine O remove the top hoseclip off the drain hose loop 1 in picture below O carefully pull the hose off the top elbow O squeeze the silicon hose near the bottom and quickly pull the upper part of the hose out from the machine and place in the drain facility Remove the element assembly clean out door 2 in picture below by unfastening the 8 brass nuts Slide the element assembly through the clean out opening The element assembly consists of three 2 8kW 230V elements attached to the stainless steel clean out door see below The thermistor pocket is welded into the clean out door When reassembling the clean out door element assembly ensure that the red silicon o ring is not damaged and the tank is well sealed Check this carefully while the machine is heating up Service Manual MAXIBREW 2 TWIN 25 03 08 Page 26 of 31 4 Technical Data 4 11 Descaling Procedure To descale the machine thouroughly e Follow t
18. he instructions for removing the elements Attempt to remove as much scale as possible by hand through the clean out door see below Note ensure that internal components are protected if a hose is going to be used to flush the tank Replace the element assembly and switch on the machine e Remove the cup rail and lid of the machine Add a descale solution to the tank through the large sprayhead hose shown below This runs directly into the top of the tank e Wait 20 minutes before draining and flushing the tank again 4 Technical Data 4 12 Coffee Aerator The coffee aerator pump can be accessed by removing the cup rail and lid of the brewer It is located at the back of the machine see below The air flow can be adjusted by rotating the knobs Service Manual MAXIBREW 2 TWIN 25 03 08 Page 27 of 31 4 Technical Data 4 13 Wiring Diagram s Service Manual MAXIBREW 2 TWIN 25 03 08 Page 28 of 31 Ceo ors MLN RIO 9 Description WIRING DIAGRAM Drg No MB2T 002A To 10mm DrawnMH _ Beverage Model 1000464 MAXIBREW 2 TWIN 5 6kW Part No ScaleNTS Date13 03 08 a co 456 sysvems JCC Bernd Prog P ch Prog Approv RevjDetails Date Page 29 of 31 Service Manual MAXIBREW 2 TWIN 25 03 08
19. he temperature in the tank does not drop by more than 3 degrees The machine will only allow small amounts of cold water into the tank while continuing to heat to ensure that the temperature does not drop too low If more hot water is used than the machine can recover approx 0 9l min 5 6kW approx 1 4l min 8 4kW the amount of water in the tank decreases If the full quantity of Hot Water is drawn off the machine will take approximately 15min to recover back up to the high level probe Note brews can still be selected when no Hot Water is available out of the tap This is due to a buffer of hot water beneath the level of the hot water stand pipe inside the tank These should preferably be half brews rather than full brews to ensure shorter recovery times When two brews are running simultaneously the level of the water in the tank does drop slowly because the machine is using water at a quicker rate than it can heat If dual brews are selected at a point where there is no water available at the hot water tap the level of water will drop off the BREW SAFETY LEVEL PROBE If the water level is below this probe a new brew cannot be selected The current brews will be completed but a recovery period will be necessary before brews can be selected or hot water is available After a recovery period up to 15min the machine will be ready to brew once again Note a longer recovery is required before any substantial amount of Hot Water can
20. itres 160pints Heat Fill Mode Up to 20 litres 35 pints when full Continuous Fill Mode 6 litres 10 5 pints recommended max 80 litres hr 141pints hr 5 6kW 230V Single Phase c w 1 5m flex Up to 6 8 litres 12 pints Up to 13 6 litres 24 pints Up to 13 6 litres 24 pints Up to 27 2 litres 48 pints Up to 54 litres 96pints Heat Fill Mode Up to 20 litres 35 pints when full Continuous Fill Mode 5 litres 8 5pints recommended max 50 litres hr 88pints hr Page 10 of 31 4 Technical Data 4 2 EXTERNAL ARRANGEMENT POR Pt Cep Rail Acrylic MB2 Twin 801515 7 Dip y A Past Fascia MB2 1801550 8 CuvedSphshback 2 asker Complete MB2 2300075 9 Piastie Rose MB2T 180560 4 Control Pame e From Panel CCS 5 Coffee Tap 210029 Control Panel Right Son Water Tap 2100275 2 Um Lid 2300350 4 3 ACCESS TO INTERNAL COMPONENTS N w S To access the internal components e Disconnect the machine from the electrical supply e Allow to cool sufficiently e Remove the screw from under each of the Plastic Roses 9 above Slide the roses towards the tap e Remove the Curved Splashback 8 above by pulling out the top edge first e Remove the two screws attaching each side of the front panel to the surround 13 right Slide the front panel down Lever the top of the front panel away fr
21. marco C POURING PERFECTION MAXIBREW 2 TWIN BOILER BREWER SERVICE MANUAL Ireland Tel 01 295 2674 Ireland Fax 01 295 3715 Marco Beverage Systems Ltd 63d Heather Road Sandyford Industrial Estate Dublin 18 UK Tel 0207 274 4577 Republic of Ireland UK Fax 0207 978 8141 CONTENTS PAGE 1 INTRODUCTION 3 2 SAFETY INSTRUCTIONS 4 3 BASIC INSTRUCTIONS 5 3 1 Installation Details 5 3 2 Operation 6 3 3 Brewing Coffee 7 3 4 Hot Water 7 3 5 Lock Function 8 3 6 Coffee Aerator 8 3 7 Troubleshooting 8 3 8 Maintenance 9 3 9 Cleaning 9 3 10 Safety 9 4 TECHNICAL DATA 10 4 1 General Description 10 4 2 External Arrangement 1 4 3 Access to internal components n 4 4 Internal Arrangement 12 4 5 PCBs 13 4 5 1 PCB Layout 13 4 5 2 PCB Brewer 2004 1600326 14 4 5 3 PCB Dual Timer 1600323 16 4 5 4 PCB Air Pump Driver 1600319 17 4 5 5 PCB Daughter 1600317 17 4 5 6 PCB Brewer Display 1600324 18 4 6 Operation Heat Fill Mode 19 4 7 Operation Continuous Fill Mode 20 4 8 Troubleshooting Diagnostic guide 21 4 9 Level Probes 24 4 10 Elements 26 4 11 Descaling procedure 27 4 12 Coffee Aerator 28 4 13 Wiring Diagram 29 4 14 Spare Parts List 31 Service Manual MAXIBREW 2 TWIN 25 03 08 Page 2 of 31 1 INTRODUCTION The information provided in this manual is intended to assist in the installation and maintenance of the Marco Maxibrew 2 Twin Boiler Brewer Please read
22. ns 3 BASIC INSTRUCTIONS This is a copy of the instruction manual that goes out with every unit 3 1 INSTALLATION DETAILS Electrical installation Service Manual MAXIBREW 2 TWIN 25 03 08 Page 4 of 31 e Electrical specificati on O 5 6kW 230V 6 1kW 240V This needs to be connected to a 30A isolator outlet A qualified electrician should do this o 8 4kW 400Vac 3P N E This unit must be connected to a suitable 3 phase power supply This should be done by a qualified electrician e When power is applied to the machine a fluorescent light will come on inside the machine The LEDs on the display PCB will flash a number of times this indicates which version of software code is in the machine Plumbing installation procedure Note Marco recommend that this machine be positioned on a counter with a drainage facility Marco cannot be held responsible for any flood damages e Mains water pressure required limits 5 50psi 35 345kPa e Fita stop Valve on a cold water line and attach a 3 4 BSP male fitting e g 3 4 x 1 2 311 or washing machine type stop valve e Connect straight tailpiece of the inlet hose to the stop valve fitting Make sure that the pre attached sealing washer is fitted e Turn on the water to flush any impurities dust etc from the inlet hose and water pipe Allow several gallons through e Connect right angled tailpiece of the hose to the inlet valve of the boiler again 3 4 BSP Make su
23. ntact with the water e The element is switched OFF at this stage and the inlet is left ON note that if this is a low probe wiring fault the water will stop at the high level probe regardless of the status of the low level e This is a recoverable error i e the machine does not need to be reset when the problem is solved e g if a closed mains water stop valve is the problem opening the valve will allow water into the machine and normal function will resume when the low level probe is reached Probable causes 1 The water level is below the low level probe which is normal when the machine fills for the first time Can be flashing for up to 5 min at start up 2 The low level probe wire is disconnected or there is another wiring fault eg a bad earth return connection between the PCB and the Tank Action required 1 Check that the water pressure is OK and ensure that the stop valve is open 2 Check that the inlet solenoid is working 3 If the water level is above the level of the low probe check the probe circuit wiring 4 Technical Data 4 8 TROUBLESHOOTING DIAGNOSTIC GUIDE 3 FLASH CYCLE THERMISTOR OPEN CIRCUIT Display pattern e 3 quick flashes then a long delay up to 15 seconds repeated Electronic check e This indicates that the Thermistor is measuring such a large resistance that it assumes the thermistor circuit is open Service Manual MAXIBREW 2 TWIN 25 03 08 Page 22 of 31 e The element and inlet val
24. om the plastics Lift the Front Panel away All the internal components are now accessible Service Manual MAXIBREW 2 TWIN 25 03 08 Page 1 of 31 4 Technical Data 4 4 INTERNAL ARRANGEMENT F1 CB Brewer Display Left 1600324 m Mains Cable s Sghgss 7o0 50 fe amp and Lampholder 501212 1501203 8 Tank Overflow Pipe 18 amp Ballast 1501 79 tafe Brew Pump 1501540 19 Low Level and High Level Probe Assembly 6 Elements 1500975 PCB Brewer Display Right 1600324 Service Manual MAXIBREW 2 TWIN 25 03 08 Page 12 of 31 4 Technical Data 4 5 PCBs 4 5 1 PCB Layout INTERNAL PCB LAYOUT 1 PCB Brew Board Twin 2004 Marco part no 1600326 e Controls the heater switching e Switches one element only daughter PCBs switch the other elements e Controls the water inlet switching Controls tank temperature temperature adjustment e Controls water level e Outputs to the Dual Timer PCB e Outputs to the Daughter PCBs 2 PCB Dual Timer Marco part no 1600323 e Controls the brew pump timing e Controls the Display PCBs Buttons and LEDs not shown 1600324 e Controls and Outputs to the Air Pump Driver PCB 3 PCB Air Pump Driver Marco part no 1600319 e Controls the switching of the air pump for the coffee aerator agitator function 4 PCB Daughter Marco part no 1600317 e Switches one element 5 PCB Daughter Marco part no 1
25. ould not be depressed at exactly the same time Press and release one brew button before doing the same on the other side Note Continuous brewing on both sides simultaneously can result in the machine running out of enough hot water to brew coffee This can happen particularly when large quantities of water are drawn off from the hot water tap see next section When the machine does not have enough hot water in reserve for a brew the brew buttons are disabled and the green Ready to Brew lights go off After a few minutes the green Ready to Brew lights will illuminate and a brew can be selected once more 3 4 HOT WATER e When the machine is full up to 35 pints 20litres of water is available for tea etc If all this water is used and no water is available at the hot water tap the machine should be left for a short while to recover Heat fill mode The recovery rate of this machine is approximately 1 6pints 0 9 litres per minute for 5 6kW version and approximately 2 5pints 1 45 litres per minute for 8 4kW Note A brew can still be selected after all the hot water has been drawn off the hot water tap While the machine is brewing however the hot water recovery rate is reduced and the machine will take longer to replenish the hot water supply Service Manual MAXIBREW 2 TWIN 25 03 08 Page 7 of 31 3 BASIC INSTRUCTIONS The Maxibrew 2 Twin has a button lock function to prevent untrained personnel operating the machine or ac
26. re the sealing washer is fitted here also e Turn on water and check for leaks Start up e Check that all installation procedures have been carried out e Turn the water on at the stop valve and switch the power on at the isolator switch The sight glass lamp will illuminate e Switch the machine on by pressing the button associated to the POWER text on the left control panel This button should be held until the red light illuminates The machine will automatically take in water To switch off press the button again Service Manual MAXIBREW 2 TWIN 25 03 08 Page 5 of 31 3 BASIC INSTRUCTIONS 3 2 OPERATION Most boiler brewers will supply water and coffee in abundance If however the hot water is used at a rate quicker than the machine can heat most machines can end up serving cold coffee and water This essentially means that the machine is being used incorrectly and the quality of the end product is directly affected The Marco Maxibrew 2 Twin uses the Heat fill cycle as standard to ensure that only beverages at the correct temperature are served If more hot water is used than the machine can heat it simply runs out of water After a short recovery period more water will be available at the correct temperature Heat fill mode Tea and coffee at the optimum temperature e Water will be taken in until it is a safe level above the elements At this point the water stops and heating begins Once this quantit
27. t PCB needs to be modified on site before it can be installed The Button cap needs to removed off the second button shown below Left Display PCB Right Display PCB COMPONENTS FUNCTIONS OF LEFT PCB BREWER DISPLAY Button Lock function LED Lock function Button Power ON OFF function LED Power ON OFF and Status Diagnostic flash function LED Ready to Brew function Button Left Half Brew function LED Left Half Brew function Button Left Full Brew function LED Left Full Brew function o 0ououwRONM COMPONENTS FUNCTIONS OF RIGHT PCB BREWER DISPLAY 10 Button Coffee Aerator Function 1 LED Not Used 12 Button Not Used Button cap to be removed 13 LED Not Used 14 LED Ready to Brew function 15 Button Right Half Brew function 16 LED Right Half Brew function 17 Button Right Full Brew function 18 LED Right Full Brew function Service Manual MAXIBREW 2 TWIN 25 03 08 Page 19 of 31 4 Technical Data 4 6 OPERATION HEAT FILL MODE Turn the water on at the stop valve and switch the power on at the wall connection The sightglass lamps will now illuminate Press the POWER ON button at the front of the machine A red LED next to the button will illuminate and the machine will start to fill This LED will flash a 2 flash cycle while the water level is below the low probe Note The machine will not heat until the water has reached the low level prob
28. the instructions carefully to prevent accidents and ensure an efficient installation This manual is not a substitute for any safety instructions or technical data affixed to the machine or its packaging All information in this manual is current at the time of publication and is subject to change without notice Only technicians or service providers authorised by Marco should carry out installation and maintenance of these machines Marco accepts no responsibility for any damage or injury caused by incorrect or unreasonable installation and operation Service Manual MAXIBREW 2 TWIN 25 03 08 Page 3 of 31 2 SAFETY INSTRUCTIONS e Read all instructions e To protect against electric shock do not immerse mains cord in water or other liquid To prevent chafing of the cable do not let the mains cord hang over the edge of a table or counter or touch hot surfaces Do not operate any appliance with a damaged cord plugs or after the appliance malfunctions or has been damaged in any manner Switch off at the mains unplug or disconnect from outlet and turn off the water supply when not in use and before cleaning Allow to cool before removing components The use of spares and accessories not recommended by Marco may cause damage and or injuries Do not use outdoors Do not place on or near a hot gas or electric burner Do not use the appliance for anything other than its intended use Save these instructio
29. tor has failed sort circuit e The element and inlet valve are turned OFF when this error is detected e This is a recoverable error When the correct range of resistance is measured normal operation resumes Probable causes 2 The thermistor has failed Action required 2 Replace the thermistor 4 Technical Data 4 8 TROUBLESHOOTING DIAGNOSTIC GUIDE 6 FLASH CYCLE Heat Fill Mode Only NOT FILLING Display pattern e 6 quick flashes then a short pause repeated for approx 2min Then normal function resumes for Imin30secs then flashes for 2min again this eycle is repeated Electronic check e This checks that the inlet solenoid valve is not kept ON for more than Imin30secs when in the heat fill cycle Note this error is only checked once the water level has reached the low level probe and the machine has begun the heat fill cycle e This is a recoverable error In the heat fill cycle even with reasonably low water pressure the inlet solenoid valve usually only stays ON for approx 5 6 seconds If the inlet valve stay ON for more than Imin30secs there is a problem with the inlet valve or the mains water supply After 1min30seconds the 6 flash cycle is displayed for 2min the inlet solenoid valve is turned OFF during this time After this 2min cycle normal operation resumes i e the machine attempts to fill by opening the inlet solenoid valve once more If after Imin30secs no water has come into the machine the 6flash
30. ve are turned OFF when this error is detected e This is a recoverable error When the correct range of resistance is measured normal operation resumes Probable causes 1 The thermistor probe is unplugged from the 4way connector on the PCB or the thermistor has failed open circuit Action required 1 Check that the thermistor is plugged in to the PCB correctly If it is replace the thermistor 4 FLASH CYCLE Heat Fill Mode Only NOT HEATING Display pattern e 4 quick flashes then a short pause repeated Electronic check e This checks that the temperature is increasing when the heater is on e Measures the rate that the temperature increases in a specified time This error is only displayed after 20 mins of the heater being on continuously When the error is detected the element and inlet valve are turned off e This is a non recoverable error The machine needs to be reset when this problem is solved Probable causes 1 All the elements have failed 2 Wiring fault Action required 1 Check that the resistance on the elements If there is a reasonable resistance 15 25Qon the element it probably has not failed so the wiring might be at fault NOTE for this error to be displayed all elements would have to fail 5 FLASH CYCLE THERMISTOR SHORT CIRCUIT Display pattern e 5 quick flashes then a short pause repeated Electronic check e This indicates that the Thermistor is measuring zero resistance lt assumes the thermis
31. y of water is up to temperature another small quantity of cold water is taken in while the heating continues This heat fill cycle maintains the correct temperature in the tank e When the machine has enough water to brew coffee the green Ready to Brew lights illuminate approximately 25 minutes after start up A brew can be selected at this point but the machine is NOT full yet No hot water is available out of the hot water tap After approximately 45 minutes the heaters will shut off The machine is now full up to temperature and water is available from the hot water tap Continuous Fill Mode optional This mode of operation is available as an option but a service engineer is needed to make this change The Continuous fill mode essentially keeps the machine full of water allowing an endless supply of water In this mode the machine will never run out of water but misuse eg filling buckets for cleaning can allow cold water to be served Using hot water at a faster rate than the machine can recover will result in a considerable temperature drop in the beverage Service Manual MAXIBREW 2 TWIN 25 03 08 Page 6 of 31 3 BASIC INSTRUCTIONS 3 3 BREWING COFFEE e Slide out the coffee filter bowl and place a single sheet of filter paper in the bowl e Put the correct amount of ground coffee into the filter paper Your coffee supply company may have pack sizes to suit the brews of your new Maxibrew 2 Twin if not as

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