Marco Uber Boiler User manual

SERVICE MANUAL
Model: Uber Boiler
1000680 #1000681
Marco Beverage Systems Limited.
63d Heather Road,
Sandyford Industrial Estate,
Dublin 18.
Marco Beverage Systems Limited.
Shire House, Strixton Manor,
Strixton, Wellingborough, Northants,
NN29 7PA
Ireland Tel: [phone]
Ireland Fax: [phone]
email: [email protected]
www.marco.ie
UK Tel: [phone]
UK Fax: [phone]
email: [e-mail]
www.marco-bev.co.uk

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Service manual April 2017 Uber boiler
CONTENTS
1- INSTALLATION:
1.1 Unit Installation Information
1.1.1 Safety Instructions
1.1.2 Installation Details
1.1.3 Cleaning
1.1.4 Limescale
1.1.5 Precautions
1.1.6 Installation Template
2- OPERATION
2.1 Principle of Operation
2.1.1 Simplified Operation
2.1.2 First Operation
2.2 Display and Controls
2.3 Operation Modes
2.3.1 Prime Mode
2.3.2 Boost Mode
2.4 User Setup
3 - SERVICE
3.1 Service Setup
3.1.1 Delta Values
3.2 Uber Boiler Calibration Instructions
3.2.1 Weighing scale calibration instructions
3.3 Uber Boiler Internal Plumbing
3.3.1 Flow Rate Adjustment
3.3.2 Temperature Calibration
3.4 Uber Boiler Pump Replacement
3.5 Display Board Replacement
3.5.1 Disconnecting The Machine
3.5.2 Removal/Replacement of Display Board Bracket

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Service manual April 2017 Uber boiler
3 - SERVICE (cont’d)
3.6 Uber Boiler Load Cell Replacement
3.6.1 Attaching Loadcell to Tile
3.6.2 Fixing Support Platform to Loadcell
3.6.3 Platform Adjustment Screws
3.6.4 Font Dial Replacement
3.7 Font to Tile Installation Instructions
3.7.1 Aligning the Font on the Tile
3.7.2 Connecting the Font Tubing
3.8 Water Level Probes Installation
4 - TECHNICAL
4.1 Uber Boiler Functional Diagram
4.2 Spare Parts Diagrams
4.3 Electrical Schematic

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Service manual April 2017 Uber boiler
1.1 UNIT INSTALLATION INFORMATION
1.1.1 Safety:
•Risk of scalding. Beware of accidentally operating the water drawoff dial or push
buttons especially when cleaning. If the dial is left in the ON position (shown later)
then pressing boost will cause water to flow immediately from the font.
•This appliance must be earthed. If the plug supplied is not used then ensure that
the green/yellow cable is connected to a suitable earth.
•Risk of flooding –inlet hose. 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.
•Risk of flooding –overflow hose. Water spilling in the scale platform area will run
down a waste tube which should be plumbed –this is not intended to be used as a
dedicated drain facility. If a waste bucket is used it risks overfilling.
•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.
•Children should be supervised to ensure that they do not play with the appliance
•In the event any wires are damaged, such wires can only be replaced by experts
or professional afterservice staff from the manufacturer, afterservice department or
similiar function departments.
1.1.2 Installation Details:
Electrical installation:
•Electrical specification: 2.8kW-230V-50Hz
•The electrical power supply must be connected in accordance with the applicable
regulations of the country of installation.
Plumbing installation procedure:
•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 fitting, (e.g. 3/4" x
1/2" 311 or washing machine type stop valve).
•For US versions use 3/8” NPT male fitting.
•Connect straight tailpiece of the hose to the stop valve fitting. Make sure that the pre-
attached sealing washer is fitted.
•Turn on the water to flush any impurities, dust etc from the inlet hose and water pipe.
Allow several gallons through.
•Connect right-angled tailpiece of the hose to the inlet valve of the boiler (3/4" BSP).
Make sure the sealing washer is fitted here also.
•Turn on water and check for leaks.

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Service manual April 2017 Uber boiler
1.1.3 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.
NB: To avoid the possibility of accidentally operating the Font Dial or buttons when cleaning
the front of the machine, switch the unit off using the switch at the bottom of the unit.
1.1.4 Limescale:
In common with all water boiler manufacturers, service calls resulting from limescale are not
covered by warranty. Fitting a scale reducer or in-line filter is recommended, especially in
hard water areas. This can reduce the build-up of scale but may not stop it altogether. The
frequency that descaling is required depends on the local water supply; hard water areas
need more attention. Descaling of the machine should ideally be carried out by qualified
service personnel.
Descaling Instructions
Descale agents/solution should be added to the Tank via the large tube as shown in photo
below. Follow the descale agent instuctions.
➢Bring the Uber Boiler up to temperature and allow to fill and heat until Prime Ready
Full is shown on the screen.
➢Turn off the water supply to the Uber Boiler.
➢Mix a concentrated descale solution for a 6 litre tank, according to the instructions on
the descaler container.
➢Press the Boost button and dispense water equal to the volume of the concentrated
descale solution.
➢Add the concentrated descale solution via the descale hose on the front of the tank
and continue to follow usage instructions on the descaler container.
➢Allow the descale solution to recirculate in Boost mode two or three times during the
recommended descale time, normally 30 minutes.
➢Drain the descale solution from the tank using the drain hose.
➢Turn the water on and thoroughly flush the tank, taking care to use Boost mode to
flush the pump and font plumbing, also.
➢Operate Uber Boiler as normal.

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Service manual April 2017 Uber boiler
1.1.5 Precautions:
•NEVER lift or lower the unit by holding the font!–use the upper wide tile or lift from the
base.
•The unit requires a counter thick enough to support the weight of the machine when
full, when full it could be up to 30kg in total.
•Never overload the scale platform with a force greater than 9kg.
•Ensure the flow control dial is in the OFF position as shown below.
•Check the dimensions shown for the counter cutout and the upper tile. Leave
adequate clearance on your counter top and check the space below the
counter/cabinet to ensure there is enough room.
•Cut out the counter top to be 410x195mm. This dimension includes
clearance/tolerance space for the lower part of the machine (the actual machine is
approx 405x190mm). The full dimensions are shown on the following page.
•Hold the machine by the tile and slowly lower it down into the cutout. It is advisable to
wear thick work gloves. A second person may be needed to hold the machine at the
bottom. Be careful not to trap fingers under the tile as it is lowered.
•The weight of the machine when filled should be enough to ensure it does not move.
If further fixing is required, silicone can be used to stick the tile to the counter.
However, it is advisable to leave the machine free to be taken out for servicing.
Off
On
The Font Dial operates
anticlockwise to begin the flow of
water.

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Service manual April 2017 Uber boiler
1.1.6 Installation Template:

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Service manual April 2017 Uber boiler
Uber Boiler –Front View

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Service manual April 2017 Uber boiler
Uber Boiler –Top View

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Service manual April 2017 Uber boiler
Uber Boiler –Side View

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Service manual April 2017 Uber boiler
2.PRINCIPLE OF OPERATION
•The Uber Boiler is designed to be a highly accurate hot water delivery system. This
temperature accuracy is achieved by several features;
oIn stand-by the water is maintained at a set temperature [Prime Mode] This is
controlled via a thermistor in the tank
oIn [Boost Mode] the hot water is circulated through the FONT (to reduce any
temperature loss)
▪a second thermisor located in the FONT is now used to control the
temperature of the water and therefore ensure the accuracy of the
delivered water
▪a specialised software algorithm APLogicTM is used to control the
temperature within +/- 0.2ºC,
2.1.1 Simplified Operation:
1. The unit is preset to a Prime Temperature at the factory (this may be changed
by the user). This is the stand-by mode and the temperature is displayed on
the display panel as Tank Temp.
2. The user presses the Boost button and holds this button down until the desired
set temperature is displayed on the display panel.
3. The Uber Boiler will now ramp the tank temperature from the Prime setting up
to the Set Temp while recirculating the water through the Font.
4. When the set temperature is reached the user will rotate the Font Dial
counterclockwise to start the flow of water.
5. To select another set temperature the user should press the Prime button –
return the unit to the Prime Mode –and repeat step 2 to the new temperature.
6. If a user has several brews/volumes to dispense they should remain in boost
mode where possible, otherwise the tank will refill with cold water when you
return to Prime and will take approx 2min to heat each 1Litre of water. If you
have several brews in a row at different temperatures it is best practice to do
your colder brew first and then heat up while still in Boost, as you cannot cool
down in boost mode.
2.1.2 First Operation:
•Check that all installation procedures have been carried out
•Ensure water valve is on
•Ensure Font Dispense Knob is in the Off position
•Plug boiler into 13A socket and operate the Power Switch –located on the bottom of
the boiler
•See Photo 1 for location and name of each feature
•The boiler will take in water to the middle level probe and commence heating. The
display will show : PRIME FILL and the TANK TEMP: will show the temperature of the
water in the tank.
•Once the temperature reaches the set point, the boiler will continue filling the tank in
short bursts to maintain constant temperature. The display will show PRIME READY
at this stage and the BOOST button will be enabled.
•Once the water level in the tank has reached the high level probe (full) the heater will
turn off and display will show PRIME READY FULL
•The boiler is now ready for use

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Service manual April 2017 Uber boiler
•Use of the Time and Weigh Features:
oTime : 00:00 –when the Timer Button is pressed the display will indicate time
elapsed in minutes : seconds. This can be used to indicate the brewing time.
Pressing the button once quickly will pause the current time which can be
restarted again. Pressing the button for more than 2 seconds resets the Timer
display to zero.
oWeight : 0000 –this is in grams. Pressing the Weigh button will reset the
weighing scale. The brewing vessel can be placed on the scale/drip tray and
the display will show its weight. Pressing the Weight button again will “zero”
(tare) the scale so that when the coffee grind is added to the basket, its weight
can be displayed. This is to help control the Coffee / Water ratio. 1ml of water
weights approx 1gram.
o9kg is the max allowable weight on the scales. DO NOT OVERLOAD
Weighing scale /
platform
Prime
Timer
Weigh
Boost
Display

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Service manual April 2017 Uber boiler
2.2 THE DISPLAY AND CONTROLS
The Display screen contains 4 lines of information:
1. First line on the display shows status message:
Status
Description
PRIME FILL
Tank is filling, not heating until reaches the middle level probe.
Boost button disabled.
PRIME HEAT
Tank is heating, not filling until temperature in the tank reaches
“Prime temp”. Boost button disabled.
PRIME READY
Tank is heating and refilling. Temperature is maintained around
“Prime temp” value. Boost button is operational and puts machine into
BOOST mode. Tank is not full yet.
PRIME READY
FULL
Tank is heated up to the “Prime temp” and reheats once the
temperature falls 0.5°C below “Prime temp”. Boost button is
operational and puts machine into BOOST mode. Tank is full.
EMPTYING THE
TANK
Pump is running allowing to dump all water from the tank through the
font. Inlet disabled. Option triggered by pressing PRIME button for
more than 5 seconds. Press PRIME again to quit.
BOOST TEMP:
xx.x °C
Machine in BOOST mode. Water inlet disabled.
Shows the target temperature set by pressing and holding BOOST
button. Machine heats up to the set temperature and maintains it
within ±0.2 °C. Press PRIME button to go back to PRIME mode.
LOW TANK
LEVEL !
Machine in BOOST mode –Tank Level is below 2 litres.
Only when in LARGE TANK Mode (Service Set up Menu #8)
Communication
error!
Display board lost communication with boiler PCB (can not receive
serial data about temperature and level probes). All actions cancelled.
Whenever communication is restored, machine will go back to PRIME
FILL mode.
---
Top water level probe covered while low level not. Check low level
probe for scale. Boost button disabled.
Tank thermistor err!
Tank thermistor disconnected or short circuited. Boost button
disabled.
Font thermistor err!
Font thermistor disconnected or short circuited. Boost button
disabled.

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Service manual April 2017 Uber boiler
2. The second line shows the live readout of:
•Tank temperature in PRIME mode,
•Font temperature in BOOST mode.
3. Third line shows the timer
•Clicking TIMER button turns on and off the timer clock.
•Pressing it for longer than 2 seconds resets it and turns it off.
4. Fourth line shows measured weight, scaled in grams.
•Numbers above 9999 can NOT be displayed –“----“ will be shown instead.
•Negative numbers will be shown with minus sign (down to -9999).
•Pressing WEIGH button will reset scale to zero.
•Please note that the max weight for the load cell is 4kg and any loads higher than 9kg
may destroy it.
NOTE: Because the boiler is electronically controlled, no priming is necessary.
The element cannot switch on until a safe level of water is reached.
WARNING: ALWAYS ENSURE THE DIAL IS SET TO OFF BEFORE PRESSING BOOST
OR HOT WATER WILL
FLOW IMMEDIATELY.
Off
On
The Font Dial operates anticlockwise
to begin the flow of water.

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Service manual April 2017 Uber boiler
2.3 OPERATION MODES
2.3.1 Prime Mode:
After turning on or pressing PRIME button the machine goes into Prime Mode.
This is a stand-by mode when the water is prepared for final dispense.
The tank will fill to the middle level probe (PRIME FILL) and heat up (PRIME HEAT) to the
preset temperature (Prime temp in calibration). Once the temperature gets above (Prime
temp - 1°C) the display will show PRIME READY message and the BOOST button will be
enabled. From this moment machine will be taking water in short bursts until it fills all the
tank (heat fill cycle) and the message PRIME READY FULL will appear.
NOTE: The user may use water even before the tank is full. The amount of water available
will be in the range between 2 and 6 litres.
Prime Mode logic is based on thermostatic principal –the water accuracy is around ±2°C
from the set point.
Prime Mode
status
Description
BOOST
button
PRIME FILL
Tank fills to the top probe; heater off.
disabled
PRIME HEAT
Tank heats up to the preset Prime temp
disabled
PRIME READY
Tank temperature above (Prime temp - 1°C).
The tank is still being filled (heat fill cycle).
enabled
PRIME READY
FULL
Heat fill cycle finished. Tank is full.
enabled
To Empty the Tank.
In the Prime Mode the tank maybe emptied by Pressing and Holding the PRIME button for
>5 seconds. This will switch on the Pump –Using the Dial on the FONT the tank may be
emptied. To exit this mode press the PRIME button.
Note: LARGE TANK setting will empty approx. 8 Litres.
2.3.2 Boost Mode:
In Boost Mode the user sets the desired temperature. This is done by pressing BOOST to
turn on the pump and then repeatedly pressing the BOOST button to increase the SET
TEMP (shown on the screen) in 0.1°C steps (holding down the button will quickly cycle it
upwards). The set-up temperature range is between Prime temp and Max temp.
After setting up the machine, it will start to heat to the desired temperature and will maintain
it within ±0.2°C. The SET TEMP may be increased at any time by pressing the BOOST
button. Pressing PRIME button will make the machine go back to Prime Mode and reset the
SET TEMP back to Prime temp. The machine will refill when in Prime mode and so take time
to heat back up again.
The Boost Mode is based on the Advanced Proportional Logic (APLogic™) control algorithm
that controls the heating rate to avoid temperature overshoots..

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Service manual April 2017 Uber boiler
2.4 USER SETUP (software ver 1.10)
To change the Prime Temperature setting and the Temperature Unit it is necessary to
access the User Setup menu.
To enter User Setup press all four buttons on the front tile and then release them. While
pressed the screen will show USER SETUP message in its first line.
Buttons on the left hand side change calibration option (up/down): See options below
Buttons on right hand side adjust the calibrated value (up/down, press longer to repeat).
Screen view
Options 1 –2
Description
Default
value
Sets temperature at which the element
clicks off in prime mode. The turning-on
temperature is 0.5 degree below this point.
(89.0
for 2L)
(90.0
for 6L)
Sets temperature measurement units
(Celcius / Fahrenheit)
Celcius
Press TIME button to accept all the settings
–they will be stored in the non-volatile
memory. To cancel and come back to the
previous settings –turn the machine off and
on again.

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Service manual April 2017 Uber boiler
3.1 SERVICE SETUP (software ver 1.10)
The following information is for Calibration purposes and should not be required for normal
use conditions.
To enter calibration mode press all four buttons on the front tile at the same time and hold
them until SERVICE SETUP message will appear on the first line of the screen (approx. 5
seconds).
Buttons on the left hand side change calibration option (up/down): See options below
Buttons on right hand side adjust the calibrated value (up/down, press longer to repeat).
Screen view
Options 1 –10
Description
Default
value
Sets offset value for tank temperature sensor.
The offset is the difference between absolute
temperature and a measured one.
It is factory set using calibrated instruments.
TEMP shows live readout from tank sensor with the
applied offset.
0.0
Sets offset value for font temperature sensor.
The offset is the difference between absolute
temperature and a measured one.
It is factory set using calibrated instruments.
TEMP shows live readout from font sensor with the
applied offset.
0.0
Sets maximum temperature at which the element
can be switched on. Both sensors (tank and font)
are monitored, if any reading is above set value, the
element switches off.
97.5
Sets heating delta factor. This number tells the
software how many energized seconds it will take to
heat up the tank by one degree. This number is
proportional to the size of the tank and inversely
proportional to the power of the element. Setting
value too high will make the machine overshoot too
much; setting too low will make the process of
reaching the set temperature slower. This value
must be altered for different tank sizes and different
voltages (see next page for info & table)
(8.0
for 2L)
(13.0
for 6L)
@230V
Sets the time for which the inlet opens every time
the machine needs water. It minimises temperature
fluctuations. The value should be picked to allow
0.5°C cooling after water intake and depends on the
tank size and element power. This is a factory
setting and should only be changed by trained
personnel.
3.0

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Service manual April 2017 Uber boiler
Sets dead time (measured in seconds from the
beginning of every heating cycle in BOOST mode)
when software waits for the tank sensor to record
temperature change. Value depends on element
time constant and placement of the thermistor.
Setting the value too high will make temperature
swing too much in BOOST mode; setting too low
will make machine overshoot too much.
00:12
(for
both 2L
&6L,)
Sets BOOST mode time-out. Timer starts at the
beginning of the BOOST mode. Machine goes back
to PRIME mode after that time to avoid unit being
left in Boost Mode for too long.
06:00
This sets the tank volume (switching between 2
probes). LARGE is a ~6L drawoff and SMALL is a
~2L drawoff. In SMALL/2L mode the temperature
increases faster (e.g. to boost from 90 to 96C will
be quicker ). There is no difference in recovery
rates, i.e. if you take off 1Litre of water in either
mode it takes ~2min for it to heat back to 90C.
A 2L setting is typically used when you require
lower brew volumes and more varied temperatures
between brews.
-
Calibrates weighing scale. 1kg weight is needed.
Do NOT press any of the right hand side buttons
if you don’t have any reference weight! TIMER
button sets scale to zero; BOOST button sets new
value for 1kg.
To recalibrate the scale:
-empty the weighing platform,
-press TIMER button (reset scale to 0),
-place 1kg calibration weight,
-press BOOST button (set new value for 1kg)
WEIGHT shows live readout of the weight.
Press TIME button to accept all the settings –they
will be stored in the non-volatile memory. To cancel
and come back to the previous settings –turn the
machine off and on again.
-

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Service manual April 2017 Uber boiler
3.1.1 Delta Values:[Step 5 in Uber Boiler Calibration]
.
The default Delta value is based on a 230V power supply and a Large/6L tank volume
setting. Varying voltages & volumes require the Delta value to be changed to ensure optimal
operation of the machine. The following are optimal settings for different voltages & tank
sizes.
Tank size: SMALL
Tank size: LARGE
Voltage
Delta Value
Delta Value
230V –240V
6.0
13.0 (default)
208V
7.3
15.9
200V
8.0
17.2

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Service manual April 2017 Uber boiler
3.2 UBER BOILER CALIBRATION INSTRUCTIONS
Initial Setup & Weighing Scale Calibration:
Plumb in and turn on the machine, when the machine is turned on the Version number will
be shown on the screen (e.g. 1.8).
Enter calibration mode by pressing down all 4 buttons at the same time. Enter your settings
as shown on the calibration sheet, some will already be set by default .
1. Tank Temp Offset: This will be set later
2. Font Temp Offset: This will be set later
3. Prime Temp: 90°C (this is your tank standby temp)
4. Max Temp: 97.5°C
5. Delta Value: 13.0 (this will change to 8.0 if a customer requests a preset 2L tank or if
they are operating at a different voltage it will be a different value –see R&D)
6. Inlet Time: 00:03
7. Dead Time: 00:12
8. Boost Timeout: 06:00
9. Weighing Scale: A calibration should be performed if a New load cell is fitted or if
the scale is reading incorrectly. Please see Section 3.2.1 Weighing scale calibration.
10.Tank Size: LARGE (this is 6L, it could be set to small if a customer requests it
preset.)
11.Save & Exit: Once settings are correct press Time to save.
3.2.1 WEIGHTING SCALE CALIBRATION INSTRUCTIONS
•Enter Service set-up by pressing all 4 buttons for 6 secs
•Scroll the menu using the left hand buttons. Prime = up
•Scroll to Menu 9 weight
•Select top right hand button “Time” to zero scales
•Place the 1kg weight on the centre of the scales and press bottom right button “boost”
to enter the weight.
•To save press bottom left button and scroll to the words “Save and Enter” appear.
•Press “Timer” button, top right to Exit
•The load cell is now calibrated and ready for use.
NOTE: If you do not have a 1 kg weight use a scales to measure a weight of 1kg jug
containing water. Accuracy of scales plus or minus 1gram