Marco marco Ecoboiler User manual

Ecoboiler
SERVICE MANUAL
Ireland Tel: [phone]
Ireland Fax: [phone]
Marco Beverage Systems Ltd.
63d Heather Road,
Sandy ord Industrial Estate,
Dublin 18,
Republic o Ireland
UK Tel: [phone]
UK Fax: [phone]

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CONTENTS
PAGE
1. INTRODUCTION 3
2. SAFETY INSTRUCTIONS 4
3. BASIC INSTRUCTIONS 5
3.1. Installation Details 5
3.2. Operation 5
3.3. Temperature Calibration 6
3.4. Time/Volume Dispense Calibration 7
3.5. Troubleshooting 7
3.6. Maintenance 8
3.7. Cleaning 8
3.8. Limescale 8
3.9. Cautions and Sa ety Tips 8
4. TECHNICAL DATA 9
4.1. General Description 9
4.2. External Arrangement 9
4.3. Access to internal components 10
4.4. Internal Arrangement 12
4.5. PCBs 12
4.5.1. PCB Layout 12
4.5.2. PCB Ecoboiler Control – 1600345 13
4.5.3. PCB Ecoboiler Display 5L – 1600348 14
4.5.4. PCB Ecoboiler Display 10L – 1600349 14
4.6. Troubleshooting – Diagnostic guide 15
4.7. Tank Components 16
4.8. Descaling procedure 17
4.9. Wiring Diagram 1000660 Ecoboiler T5 18
4.10. Wiring Diagram 1000661 Ecoboiler T10 19
4.11. Wiring Diagram 1000665 Ecoboiler PB5 20
4.12. Wiring Diagram 1000666 Ecoboiler PB10 21
4.13. Spare Parts List 22

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1. INTRODUCTION
The in ormation provided in this manual is intended to assist in the installation and maintenance o
the Marco Ecoboiler Water boiler. Please read the instructions care ully to prevent accidents and
ensure an e icient installation.
This manual is not a substitute or any sa ety instructions or technical data a ixed to the machine or
its packaging. All in ormation in this manual is current at the time o publication and is subject to
change without notice.
Only technicians or service providers authorised by Marco should carry out installation and
maintenance o these machines.
Marco accepts no responsibility or any damage or injury caused by incorrect or unreasonable
installation and operation.

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2. SAFETY INSTRUCTIONS
• Read all instructions.
• To protect against electric shock do not immerse mains cord in water or other liquid.
• To prevent cha ing o the cable, do not let the mains cord hang over the edge o a table or
counter ; or touch hot sur aces.
• Do not operate any appliance with a damaged cord, plugs, or a ter the appliance mal unctions
or has been damaged in any manner.
• Switch o at the mains (unplug or disconnect rom outlet) and turn o the water supply when
not in use and be ore cleaning. Allow to cool be ore removing components.
• The use o 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 or anything other than its intended use.
• Save these instructions.

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3. BASIC INSTRUCTIONS
3.1. INSTALLATION DETAILS
Electrical installation
• ECO Boiler PB5, PB10, T5, T10 (2.8kW) - A moulded 13A plug is actory itted. A suitable 13A
outlet is all that is required.
Plumbing installation procedure
Note Marco recommend that this machine be positioned on a counter with a drainage acility.
Marco cannot be held responsible or any lood damages.
• Mains water pressure required (limits): 5-50psi (35-345kPa)
• Fit a stop Valve on a cold water line and attach a 3/4" BSP male itting,
(e.g. 3/4" x 1/2" 311 or washing machine type stop valve).
• Connect straight tailpiece o the inlet hose to the stop valve itting. Make sure that the pre-
attached sealing washer is itted.
• Turn on the water to lush any impurities, dust etc rom the inlet hose and water pipe. Allow
several gallons through.
• Connect right-angled tailpiece o the hose to the inlet valve o the boiler (again 3/4" BSP).
Make sure the sealing washer is itted here also.
• Turn on water and check or leaks.
3.2. OPERATION
• Check that all installation procedures have been carried out.
• Ensure water valve is on.
• Plug boiler into 13A socket and press power button on the ront o the machine marked
‘Power’. Re er to Figure 1.
NOTE On a 5L machine the ‘Power’ button light also acts as the “Ready/Status” indicator.
• The “power on” light will glow green and the machine will ill to a sa e level, above the
elements, be ore heating.
• The “Ready/Status” light will cycle two red lashes while the machine is illing to the sa e level.
• A ter this amount o water has heated to about 96ºC the boiler will draw more water in until the
temperature drops by 1 or 2 degrees. The boiler will then heat again. This heat ill cycle
continues until the boiler is ull.
• On a 5L machine, whilst the machine is above the sa e level and illing, the “Ready/Status”
light will glow orange.
• On a 10L machine, whilst the machine is above the sa e level and illing, the “Ready/Status”
light will remain blank.
• The “Ready/Status” light will glow green when the machine is both ull and up to normal
operating temperature.
• The boiler is now ready or use.

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5L Display 10L Display
Figure 1: Machine User Inter ace
NOTE
Because the boiler is electronically controlled no priming is necessary.
The element cannot switch on until a sa e level o water is reached.
3.3. TEMPERATURE CALIBRATION
The Ecoboiler control PCB (1600345) has the ability to have the desired set-point temperature at
whatever setting is required. During manu acture o the PCB it is set to the de ault temperature o
around 80
o
C. During assembly the PCB is then calibrated to give a set point between 95
o
C-96.5
o
C.
I the temperature setting needs to be modi ied on-site please ollow the steps below:
1. To Enter Calibration mode:
a. Turn the machine o at the mains power supply.
b. Then, whilst depressing the tactile switch on the PCB, turn the mains power back on.
c. All available LED’s on the ront panel will now blink continuously.
d. The machine is now in Calibration mode.
2. In Calibration Mode the machine will heat continuously until the tactile switch on the PCB is
pressed or a second time (NB: The tactile switch should be pressed or at least 1 second)
3. Using a thermometer to measure the temperature at the thermistor pocket, the machine should
be allowed to reach the desired set-temperature. (NB: It may be necessary to let the unit cool
down i the desired set point is lower than the units current temperature)
4. At this point the tactile switch on the PCB should be pressed or at least 1 second.
5. Following a correct calibration procedure the tank temperature should be maintained within
3
o
C o the desired set-point temperature.
In the event o an incorrect calibration process the steps below should be ollowed:
6. I the tactile switch is pressed too early and the temperature is set lower than desired, the
tester should simply repeat steps 8-11.
7. I the tactile switch is pressed too late and the set temperature is too high, the tester will need
to wait or the temperature in the tank to cool, or add cool water, and then repeat steps 8-11.
Power
Button
Ready/Status
Indicator
Ecomode
Button

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3.4. TIME/VOLUME DISPENSE CALIBR ATION
1. Open the ront - bottom panel.
2. Make sure that the machine is powered, illed and heated (ready lamp green).
3. Press calibration tactile button on the PCB or a second until status lamp starts blinking red-green.
4. Set new dispense time by pressing dispense button to obtain the required output volume o water.
Button may be pressed several times – all times / volumes will be added together.
5. To con irm and save new value press calibration button on the PCB or a second until the status
lamp stops blinking.
6. Setting dispense time / volume to zero (omit step 4) will make the machine work as “push & hold”
(water dispensed as long as the button is pressed).
3.5. TROUBLESHOOTING
The Ready/Status light signals various errors or problems.
A cycle o red lashes indicates an error. The number o lashes in a cycle corresponds to the
symptom in the table below:
Status/Diagnostic light guide
No of
flashes
Symptom Action required
2 Water level below elements. Normal
when machine irst ills.
Check water pressure , i this is OK then call
service agent.
3 Temperature sensor ailure (o/c) Call service agent
4 Water not heating Call service agent
5 Temperature sensor ailure (s/c) Call service agent
6 Machine not illing
Check water pressure. I OK –
switch machine o
and on again. I problem reoccurs - call service
agent.
Note Some of the error sequences will be displayed if there is low w ater
pressure. Please check that there is water pressure and that the water stop-
valve is open before calling your service agent.
For a more detailed description of error indicators and corrective actions see
section 4.7 of this manual.

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3.6. M AINTENANCE
Marco machines have been designed to give many years o trouble ree service. Marco Beverage
Systems manu acture and test to ISO9002:2000 standard. The only regular maintenance required is
occasional de-scaling.
Descaling Procedure
• Isolate machine rom power supply.
• Isolate machine rom water supply.
• ALLOW TO COOL COMPLETELY!
• Drain water rom machine.
• Remove all lids.
• Remove as much scale as possible by hand, paying particular attention to level probes (White
plastic with steel tab). Be very care ul not to damage any attachments.
• Use ScaleKleen, Marco part No. 8000270 or similar. Follow instructions care ully.
• Thoroughly clean and lush the machine be ore re-use.
• Follow installation and irst time operation instructions
3.7. CLEANING
The exterior o 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 inish o the machine. Do not use a water jet or spray.
Beware o accidentally operating the draw o tap or push button when cleaning the ront o the
machine.
3.8. LIMESCALE
In common with all water boiler manu acturers, service calls resulting rom limescale are not covered
by warranty. Fitting a scale reducer is recommended, especially in hard water areas. This can
reduce the build-up o scale but may not stop it altogether. The requency that descaling is required
depends on the local water supply; hard water areas need more attention. A scale reducer can
reduce the build up o scaling, but may not stop it altogether. Descaling o the machine should ideally
be carried out by quali ied service personnel.
3.9. CAUTIONS AND S AFETY TIPS
• This appliance must be earthed. I the moulded plug supplied is not used then ensure that the
green/yellow cable is connected to a suitable earth.
• Risk o looding. The hose supplied with this unit is non-toxic ood quality tested to 190psi.
However, a hose is not a permanent connection. It is, there ore, advisable to switch o boiler
and close the stopcock valve when boiler is not in use, e.g. overnight, weekends etc.
• Risk o scalding. Beware o accidentally operating the water drawo tap especially when
cleaning the ront o the boiler.
• The utmost care has been taken in the manu acture and testing o this unit. Failure to install,
maintain and / or operate this boiler according to the manu acturer’s instructions may result in
conditions that can cause injury or damage to property. I in any doubt about the serviceability
o the boiler always contact the manu acturer or your own supplier or advice.

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4. Technical Data
4.1. GENERAL DESCRIPTION
ECO Boiler PB5, PB10, T5, T10.
PB5 PB10 T5 T10
Dimensions Height (mm)
Width (mm)
Depth – counter ootprint (mm)
Depth – to ront o Tap (mm)
Depth incl. Drip Tray (mm)
465
210
360
-
460
590
210
360
-
460
465
210
360
470
510
590
210
360
470
510
Per ormance Immediate Draw-O (litres)
Max. Hourly Output (litres/hour)
5
33
10
38
5
33
10
38
Electrical Connection 2.8kW,230V, c/w 1.5m lex and moulded plug -
used (BS1363).
Plumbing Fittings
Pressure
0.75” BSP
Food grade inlet hose supplied
5-50 psi (35-345 kPa)
4.2. EXTERNAL ARRANGEMENT
Outer Lid
Surround
Panel
Tap
Push Button
Front Panel
Top
Front Panel
Bottom
Surround
Panel
Front Panel
Top
Outer Lid
Front Panel
Bottom
Front Panel
Middle - Plastic
Drip Tray
Complete
Drip Tray
Complete
Front Panel
Middle - Plastic

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4.3. ACCESS TO INTERNAL COMPONENTS
To access the tank:
To access the internal components:
Allow to cool. Remove the
outer
lid.
Ensure that the tank is cool,
be ore removing inner lid. To
remove inner lid, undo 4
butter ly nuts
The tank is now accessible
or
cleaning.
Ball Stud/
Spring Clip
locations
Ball Stud
Spring
Clip

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• Disconnect the machine rom the electrical supply.
• Allow to cool su iciently.
• The metal Front Fascia Top and Bottom panels are ixed to the surround with ball studs that
lock into spring clips mounted in the surround panel – re er to picture above.
• To separate the ball studs rom the spring clips insert a lat headed screwdriver at the locations
indicated on the picture and lever apart the ront panels rom the surround.
• To remove the Front Fascia Top panel, a ter seperating the ball stud rom the spring clip,
rotate the top edge o the panel orward and pull the panel in an upwards motion.
• Place the panel to the side o the machine
• To remove the Front Fascia Bottom, a ter seperating the ball stud rom the spring clip, rotate
the bottom edge o panel orwards and pull in a downward motion. This panel is now ree to be
placed out o the way.
• This allows access to most o the internal components and the machine does not need to be
drained or most maintenance or service operations.
• I urther access is required, the plastic Front Fascia Middle panel should be removed by
unscrewing the our cross recessed pan headed screws.
• On Tap versions, the Tap assembly will need to be removed be ore the plastic Front Fascia
Middle can be removed.
• The Tank can be drained by removing the plug rom the end o the drain hose, and draining
into an external drain or a large enough container.
Inlet Solenoid Access
• To access the inlet solenoid, the PCB and PCB bracket need to be removed.
• Unscrew the two crss-recessed pan headed screws holding the bracket in place.

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4.4. INTERNAL ARRANGEMENT
4.5. PCBs
4.5.1. PCB Layout
Internal PCB Layout:
PCB Ecoboiler Control (1600345):
• Controls the heater switching
• Controls the water inlet switching
• Controls tank temperature/temperature adjustment
PCB Ecoboiler Display 5L (1600348) consists o :
• Power On/O button
• Power On LED
• Status/Ready LED
PCB Ecoboiler Display 10L (1600349) consists o :
• Power On/O button
• Power On LED
• Status/Ready LED
• ECO Mode On/O Button
• ECO Mode On LED
High Level Probe Assembly (2300463
)
Low
Level Probe Assembly (2300463)
PCB Ecoboiler
Control (1600345)
Spigot
Element 2. kW 230V
(15009 5)
Valve inlet
Solenoid (1502190)
Overflow Hose
Mid Level Probe Assembly (2300463) –
(10L variants only)
PCB Bracket
Thermal Switch
130Deg (15020 7)

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4.5.2. PCB Ecoboiler Control
COMPONENTS OF PCB ECOBOILER CONTROLLER 2008
1. Dispense Solenoid Tab
2. Inlet Solenoid Tab
3. Neutral Tabs
4. Trans ormer
5. Mains Live In Tab
6. Relays - Heater
• Switch the element
7. Heater Tab
8. On/O 2-way Connector
• Short circuited on this Ecoboiler machines – power switch controlled through the display
PCB
9. LED 5-way Connector
10. Earth Tab
11. Daughter PCB Connector (low voltage)
• Connects to Daughter PCBs – allows switching o more than one element
12. External Connector
13. Thermistor Connector
14. Dip Switch – 3 way
• Allows selection o so tware or speci ic machine
15. Tactile Switch
• For use during calibration procedure (re er to Calibration in Sec 3.3)
16. Water Level – 5-way connector (low voltage)
• Connects to Low level and High level probes. Also connects push button on PB variants.
17. Button Connector – 4-way
18. Data I/O Connector – 4-way
19. Relays – Inlet Solenoid
1
2
3
4
5
7
8 9 10
6 6
11
12
13
16
17
14
18
15
19
19

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4.5.3. PCB Display Ecoboiler 5L (1600348)
1. Power On LED’s
• shows that machine is switched on
2. Status LED’s
• displays Error signals via a lashing RED LED
3. Power On/O switch
4. 5 way connector – to PCB Ecoboiler LED connector
5. 4 way connector – to PCB Ecoboiler BUTTONS connector
4.5.4. PCB Display Ecoboiler 10L (1600349)
1. Power On LED’s
• shows that machine is switched on
2. Power On/O switch
3. Status LED’s
• displays Error signals via a lashing RED LED
4. Eco Mode On LED’s
5. Eco Mode On/O Switch
6. 5 way connector – to PCB Ecoboiler LED connector
7. 4 way connector – to PCB Ecoboiler BUTTONS connector
5
6
2
1
7
4
2
3
5
4
1
3

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4.6.
4.6.4.6.
4.6. TROUBLESHOOTING – DIAGNOSTIC GUIDE
2 FLASH CYCLE – BELOW LOW LEVEL
Display pattern:
• 2 lashes then a short pause - repeated.
Electronic check and action:
• This indicates that the low level circuit is open i.e. the probe is not in contact with the
water.
• The element is switched OFF at this stage and the inlet is le t ON.
(note that i this is a low probe wiring ault, the water will stop at the high level probe
regardless o the status o the low level).
• This is a recoverable error i.e. the machine does not need to be reset when the problem
is solved. (e.g. i a closed mains water stop valve is the problem, opening the valve will
allow water into the machine and normal unction 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 ills or the irst
time. (Can be lashing or up to 2 min at start up)
2. The low level probe wire is disconnected, or there is another wiring ault
(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. I the water level is above the level o the low probe, check the probe circuit wiring
3 FLASH CYCLE – THERMISTOR OPEN CIRCUIT
Display pattern:
• 3 lashes then a short pause - repeated.
Electronic check:
• This indicates that the Thermistor is measuring such a large resistance that it assumes
the thermistor circuit is open.
• The element and inlet valve are turned OFF when this error is detected
• This is a recoverable error. When the correct range o resistance is measured, normal
operation resumes
Probable causes:
1. The thermistor probe is unplugged rom the 4way connector on the PCB or the thermistor has
ailed open circuit.
Action required:
1. Check that the thermistor is plugged in to the PCB correctly. I it is, replace the thermistor.
4 FLASH CYCLE – NOT HEATING
Display pattern:
• 4 lashes then a short pause - repeated.
Electronic check:
• This checks that the temperature is increasing when the heater is on.
• Measures the rate that the temperature increases in a speci ied time. This error is only
displayed a ter 20 mins o the heater being on continuously. When the error is detected,
the element and inlet valve are turned o .
• This is a non recoverable error. The machine needs to be reset when this problem is
solved.
Probable causes:
1. The elements have ailed
2. Wiring ault

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4.6.
4.6.4.6.
4.6. TROUBLESHOOTING – DIAGNOSTIC GUIDE cont
Action required:
1. Check that the resistance on the elements. I there is a reasonable resistance (15-25Ω)on the
element it probably has not ailed, so the wiring might be at ault.
5 FLASH CYCLE – THERMISTOR SHORT CIRCUIT
Display pattern:
• 5 lashes then a short pause - repeated.
Electronic check:
• This indicates that the Thermistor is measuring zero resistance. It assumes the
thermistor has ailed sort circuit.
• The element and inlet valve are turned OFF when this error is detected
• This is a recoverable error. When the correct range o resistance is measured, normal
operation resumes.
Probable causes:
2. The thermistor has ailed.
Action required:
2. Replace the thermistor.
6 FLASH CYCLE – NOT FILLING
Display pattern:
• 6 lashes then a short pause - repeated.
Electronic check:
• This checks that the water in the tank cools when the inlet solenoid valve is switched
on.
• This is a non-recoverable error. This checks that the water in the tank is cooled by when
the inlet solenoid valve is opened. I the water pressure is within the speci ications (5-
50psi), the inlet solenoid should not be on or more than a ew seconds. I this water
temperature has not decreased by the required amount
(1 degree per minute), the inlet solenoid is switched o and the 6 lash cycle is
displayed.
Probable causes:
1. Mains water pressure problem or the mains water stop valve is closed.
2. Inlet solenoid valve ailure.
Action required:
1. Check the mains water supply. (Note: Temporary loss o water pressure can occur in certain
sites – particularly when various machines are plumbed to the same mains water supply.) I
the water supply is ok, reset the machine (switch the machine O and On again). This will
reset the error and i the water supply is ok, the machine will return to normal operation.
NOTE If the water supply is the problem, ensure that this is rectified or this error will re-
occur.
2. I there is no problem with the mains water supply, check that the inlet solenoid valve is
working.

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4.7.
4.7.4.7.
4.7. Tank Components
The tank internals are detailed below. Care should be taken when cleaning inside the tank.
The level probes provide much o the control inputs into the PCB and are critical to the operation o
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 10L Ecoboiler versions and 2 level probes on the 5L versions.
The Ecoboiler T10 tank is shown below – only the low level probe is visible in the picutre.
4. .
4. .4. .
4. . Descaling Procedure
To descale the machine thouroughly:
• Unplug the machine.
• Disconnect rom the water supply.
• Drain as much water rom the tank as possible.
• Remove the lids and allow the machine to cool completely.
• Drain all the water rom the machine.
• Attempt to remove as much scale as possible by hand.
• Reconnect machine and start up once again.
• Add a descale solution ( ollow instructions as given). Flush the machine thouroughly be ore
use
Probe Assembly (2300463) – low position
Outlet on
Tap
Versions
Water inlet
Thermistor Pocket – ensure that this is not
touching the element.
Element (1500985)
Tank Gasket

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4.9.
4.9.4.9.
4.9. Wiring Diagram 1000660 Ecoboiler T5

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4.10.
4.10.4.10.
4.10. Wiring Diagrams 1000661 Ecoboiler T10

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4.11.
4.11.4.11.
4.11. Wiring Diagram 1000665 Ecoboiler PB5