Marco Qwikbrew 2 Twin User manual

Qwikbrew 2
Service Manual
Marco Beverage Systems Ltd.
63d Heather Road,
Sandyford Industrial Estate,
Dublin 18,
Republic of Ireland
Ireland Tel: [phone]
Ireland Fax: [phone]
UK Tel: [phone]
UK Tel: [phone]

Service Manual 1000379 Qwikbrew 2 01-10-12Page 2 of 37
Contents
Page
1. Introduction 3
2. Safety instructions 4
3. General description 5
4. Installation 8
5. Start Up 9
6. Operation 9
Brewing Coffee 10
Hot water 10
Lock function 11
7. Hygiene 11
8. Technical Data 12
Access to Internal Components 12
PCBs 12
PCB Brewer Display 12
PCB Timer Single 2002 15
PCB Brew Board 2002 16
Probes 19
Element 20
De-scaling the tank 20
Pipework and Sprayhead 22
9. Wiring Diagrams 24
10. Amendments 27
11. Spare Parts List 35

Service Manual 1000379 Qwikbrew 2 01-10-12Page 3 of 37
1. INTRODUCTION
The information provided in this manual is intended to assist in the installation and
maintenance of the Marco Qwikbrew 2 Boiler Brewer. Please read 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 1000379 Qwikbrew 2 01-10-12Page 4 of 37
2. SAFETY INSTRUCTIONS
1. Read all instructions.
2. To protect against electric shock do not immerse cord and plugs in water or
other liquid.
3. Do not let cord hang over edge of table or counter; or touch hot surfaces.
4. Switch off at mains (unplug from outlet) and turn off water supply when not in
use and before cleaning. Allow to cool before putting on or taking off parts.
5. Do not operate any appliance with a damaged cord, plugs, or after the
appliance malfunctions or has been damaged in any manner.
6. The use of spares and accessories not recommended by Marco may cause
damage and/or injuries.
7. Do not use outdoors. Do not place on or near a hot gas or electric burner.
8. Close supervision is necessary when the appliance is used by or near children.
9. Do not use the appliance for anything other than its intended use.
10. Save these instructions.

Service Manual 1000379 Qwikbrew 2 01-10-12Page 5 of 37
3. GENERAL DESCRIPTION
Qwikbrew 2 –2.8kW
Performance
Coffee output: Half Brew
Full Brew
Hot Water: Immediate Draw Off
Total Recovery at 2.8kW:
Up to 3.4 litres (6 pints)
Up to 6.8litres (12 pints)
5.5 litres (10pints)
0.48litres/min (0.85pints/min)
Electrical
Connection
230V 2.8kW
c/w 1.5m flex + 13A plug
Plumbing
Fittings
Pressure
0.75” BSP
Food grade inlet hose supplied
5-50 psi (35-345 kPa)
Dimensions
Height
Height incl. Cup Rail
Width
Depth
Depth incl. Drip Tray
705mm
775mm
365mm
440mm
575mm

Service Manual 1000379 Qwikbrew 2 01-10-12Page 6 of 37
Fig.1 - General Arrangement
Description
Description
1. Cup Rail - 1801510
9. PCB Brew Display (switches) - 1600324
2. Label Header Marco - 1900690
10. Tap Coffee - 2100295
3. Basket complete - 2300085
11. Tap Hot Water - 2100275
4. Urn Lid - 2300350
12. Curved Panel
5. Plastic Body - 1801480
13. Drip Tray Complete (255mmX186mm)- 2300299
6. Plastic Service Face - 1801490
7. Label Face - 1900700
8. Label Controls - 1900710
1
2
5
3
4
7
9
6
8
10
11
12
13

Service Manual 1000379 Qwikbrew 2 01-10-12Page 7 of 37
Fig.2 - Internal Arrangement
Description and Part Number
Description and Part Number
14. Probe Brew Level - 2301310
22. Pump Nikkiso - 1501540
15. Probe High Level - 2301300
23. Tee Plastic Overflow - 1801250
16. Probe Low Level - 2301320
24. Inlet Solenoid Valve –1502190 (1502170 see amendments/part list)
17. Sight Glass - 1700260
25. Element 2.8kW 230V –1500975
18. Lamp Ballast –1501211
26. Thermistor Assembly - 1600691
19. Lamp –1501213
27. PCB Brew Board –1600321 (1600326 –see amendments/parts list)
20. Lampholder - 1501212
28. PCB Timer –1600322 (1600323 –see amendments)
21. Drain Valve - 2100100
14
15
16
17
18
19
20
21
23
22
24
25
26
27
28

Service Manual 1000379 Qwikbrew 2 01-10-12Page 8 of 37
4. INSTALLATION
Plumbing:
1. Fit a stop valve on a cold water line and attach a ¾” BSP male fitting
(e.g. ¾” x ½” 311 or washing machine type stop valve).
2. Connect straight tailpiece of the hose to the stop valve fitting. Make sure that pre-
attached sealing washer is secure.
3. Connect right angled tail piece of the hose to the inlet valve of the boiler
(again ¾” BSP).
Make sure pre-attached sealing washer is also secure here - see Figure 3.
4. Turn on water supply and check fittings have sealed.
5. A hose is not a permanent connection so it is advisable to close the stop when not
in use.
Electrical:
A moulded 13A plug is factory fitted. A suitable 13A outlet is all that is required.
Fig.3 –Plumbing and Electrical Connections

Service Manual 1000379 Qwikbrew 2 01-10-12Page 9 of 37
5. START UP
Turn the water on at the stop valve and switch the power on at the plug. Press the
POWER ON button at the front of the machine. A red light 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 low-level probe is reached the element is switched on this water is heated to the
pre-set temperature (93 –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.
This may take up to 1 hour.
Note: When the level of water is at a safe height above the low level, the green
READY TO BREW light illuminates. The machine is not full at this level. A brew
can be selected, but no hot water is available. Unless a brew is selected, the full
quantity of hot water should be available within 25minutes of reaching this level.
6. OPERATION
The machine is ready to brew Coffee and 10 pints of Hot Water is available for
immediate draw-off when the machine is full and up to temperature.
The machine has one large water tank, with an urn recessed into it. When a brew is
selected, hot water is pumped from the tank up to the 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 machine works on a heat fill cycle which means that the 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 (0.48l/min), the amount of water
in the tank decreases. If the full quantity of Hot Water is drawn off, the machine will take
approximately 25min to recover back up to the high level probe.
Note: a brew 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. This should preferably be a half brew rather than a full brew to ensure
shorter recovery times. Drawing off Hot Water while brewing Coffee should not
affect the quality of the brew.
When the level has dropped to a point where a brew cannot be completed, the ready to
brew light goes out and a brew cannot be selected. A 3rd level sensor probe, the ‘Brew
Level Probe’ controls this level. After a recovery period (up to 20min), the machine will
be ready to brew once again. Note: a longer recovery is required before any substantial
amount of Hot Water can be drawn off.

Service Manual 1000379 Qwikbrew 2 01-10-12Page 10 of 37
Brewing Coffee:
Slide out the coffee filter basket and place a single sheet of filter paper inside
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 Qwikbrew 2; if not,
as an approximate guide for your first brews:
Try about: 110g-130g (4-4½oz) for a 5 pint brew (2.85 litres)
220g-260g (8-9oz) for a 10 pint brew (5.7 litres)
Depending on the coffee grind and roast, and on water quality, you may have to
adjust these quantities to obtain the optimum flavour. Level off the surface of
coffee by gently shaking the filter basket. See Figures 4 and 5.
Slide the coffee filter basket into the guide rails in the brew head and push fully
home.
Select the correct brew on the front panel by pressing either the Half Brew button
for a 5 pint brew or the Full Brew button for a 10 pint brew. Press the button 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.
A half brew should take around 4-5min. A full brew should take around 8-10min.
These depend on the set up of the machine (factory).
As soon as possible after brewing –remove the filter paper with the spent grinds.
Note: allow time for all the coffee to drain from the filter basket before
removing.
A brew can be selected any time the green ‘Ready to brew’ light is illuminated.
Fig.4 –Filter Basket Fig.5 –prepared
Hot Water:
10 pints of water is available as an immediate draw-off when the machine is full;
after this no water is available until the ‘heat fill cycle’ has recovered. This is to
ensure that any water drawn off is at the correct temperature.

Service Manual 1000379 Qwikbrew 2 01-10-12Page 11 of 37
Lock Function (see figure 6)
This is to prevent untrained personnel operating the machine, or accidental misuse by
trained personnel. If the lock button is pressed for approx. 5 seconds, a red light next to
the button will illuminate. At this point the rest of the control board is locked. The
machine will operate as normal,
i.e. If it is brewing –it will continue to brew. Once completed another brew cannot be
selected, until the lock is disabled.
NOTE: The ‘Ready to Brew’ light will still be illuminated, but no brew will be able
to be selected.
To disable the lock –hold the lock button for 5 seconds once again.
This is a particularly useful function in a self-service environment.
Fig.6 –Display
7. HYGIENE
Like any cooking utensils, the coffee-holding urn of your Qwikbrew 2 must be cleaned
properly, regularly.
MARCO recommend cleaning after each day's brewing using a proprietary urn-
cleansing compound. MARCO URN CLEANSER is available in 1kg tubs for this
purpose. Full instructions are given on each tub.
A large Urn cleaning brush and a small sight-glass cleaning brush are supplied to assist
in thorough cleaning.

Service Manual 1000379 Qwikbrew 2 01-10-12Page 12 of 37
8. TECHNICAL DATA
Maintenance should be carried out by Marco approved technicians only.
Access to internal components:
The Qwikbrew 2 has been designed with ease of service in mind. All the components
(PCB’s, inlet solenoid, probes, pump and element) are accessible from the front of the
machine. See figure 2 on page 7.
Switch off and unplug machine.
Remove the two mounting screws positioned in the plastic service panel (near the tap
spigots - see Figure 7). Pull the bottom of the plastic service panel away from the curved
steel panel. Push the service panel down towards the counter, to release the tongue (top
edge), from the plastic body. Gently lift away from the taps (the display board is still
connected to the machine! See figure 8)
Remove curved steel panel by levering the top edge out first.
PCBs: (also see amendments)
Figure 9 shows the PCBs and their connections.
Three PCBs control the functions of the Qwikbrew 2.
1. Main control board (1600321 - P.C.B. Brew Board 2002)
2. Timer board (1600322 - P.C.B. Timer Single 2002)
3. Display controls (1600324 –P.C.B. Brewer Display Board 2002)
P.C.B. Brewer Display Board –1600324
This PCB consists of four black buttons, five LEDs and three 4-way connectors which
connect to the timer board (PCB Timer Single 2002 –1600322).
The board is screwed into brass inserts mounted in the plastic service panel. These screws
should be M4 x 6mm s/s.
Note: Some early models have M3 mounting screws.
When attaching the board to the plastic, ensure that all buttons move freely within the
locating holes in the plastic. If they are sticking at all, unscrew slightly and reposition
before tightening again.
Note that the ribbon cables are unmarked and care should be taken to connect them
correctly.
Ribbon Connections:
1. Display Top (Between Lock [SW1] /Power [SW2]) Timer Board J1
2. Display Middle (between Power [SW2]/Half brew [SW3])Timer Board J2
3. Display Bottom (between Half brew [SW3]/Full brew [SW4])Timer Board J3
(See Figure 10)

Service Manual 1000379 Qwikbrew 2 01-10-12Page 13 of 37
Fig.7 –Plastic Service Panel
Fig.8 –Plastic Service Panel Removed
Plastic Service Panel
Mounting Screws

Service Manual 1000379 Qwikbrew 2 01-10-12Page 14 of 37
Fig.9 –PCB connections
Fig.10 –Display PCB connections

Service Manual 1000379 Qwikbrew 2 01-10-12Page 15 of 37
P.C.B. Timer Single 2002 –1600322
Figure 11 shows a close up of the timer board.
This timer developed in 2002 is a simple timer/pump driver, which uses information
supplied by the Brew Board (1600321) to control brewing function.
Ribbon Connection:
1. Timer Board J6 Brew Board DATA I/O
The switching is done using a line driver (triac based - zero voltage switching). This
component operates off the neutral from the pump.
Note: The pump has a live wire connected permanently. The switching is done on
the return/neutral side.
Adjusting Brew Times:
The pot on the timer board adjusts the half brew time. The full brew time is always
double the half brew time. The half brew range is currently set at approx: 3 minutes to 6
minutes. Adjusting clockwise –increases half brew time.
Adjusting anti-clockwise –decreases half brew time.
Note: the first batch of machines (serial no. 08022211 –08022230) requires that the
timer board be reset for changes to take effect. Once the pot has been turned, the
machine needs to be switched off and switched on again for the new settings to be
saved. The brew times will not change until the machine has been reset.
Machines with serial numbers outside of this range DO NOT need to be reset. The
change will automatically be detected before a brew commences.
Fig.11 –Timer PCB
P.C.B. Brew Board 2002 –1600321 (NOTE: also see amendments)
Connector J1
To Display PCB top
Connector J2
To Display PCB
middle
Connector J3
To Display PCB
bottom
Microchip
Software:SM5023-..
matches Brew PCB code
SM5022-..
Connector J5
(not used)
Connector J6
To PCB Brew Board
Data I/O
Time Adjust Pot
Neutra from PCB
Brew Board
From Pump Neutral
(black/white)

Service Manual 1000379 Qwikbrew 2 01-10-12Page 16 of 37
This is a modification to the EZT boiler PCB.
The software code on this PCB (SM1078-05 or SM5022-..) enables it to be used in
this brewer or any other standard Marco Boiler –EZT 400/700, Comet2,
Aquarius 15, 3/30,6/30,6/45. The jumper J12 (6below) selects either boiler or brewer
mode.
Fig.12 –PCB Brew Board 2002
9
7
5
11
8
6
10
12
15
16
17
19
18
23
24
22
21
20
13
14
2
1
3
4

Service Manual 1000379 Qwikbrew 2 01-10-12Page 17 of 37
Components of PCB Brew Board 2002 (fig. 12):
1. Transformer
2. Power On/Off –2way connector
olooped on this machine
3. LEDs - 5way connector
onot used on this machine
4. Data I/O –4way
oconnects to timer PCB J6
5. Earth Tab
6. Mode of Operation Jumper
to be positioned closest to the transformer for Boiler mode
to be positioned furthest away from transformer for Brewer mode
7. Water Level –5way connector
connects to Low level, High level and Brew level probes.
9. Temperature Adjust Pot
oto increase temp –adjust clockwise
oto decrease temp –adjust anti-clockwise
10. Temperature Range Jumper
ocontrols three temperature ranges
oshould be on the middle pins for boiler/brewer operation
11. Thermistor Connector
12. Daughter PCB Connector
oused in 5.6kW machines
13. Relay - Heater Safety
obackup relay for element
14. Relay –Heater
oswitches the element
16. Heater/Element Tab
17. Live Tab
18. Inlet Solenoid Tab
19. Live tab - spare
20. Suppressor
21. Relay –Inlet Solenoid
oswitches the inlet solenoid
22. Fuse
23. Neutral tab
24. Neutral tab –spare
8. Microchip –version number
The software code on this microchip is very important. Part no, 1600321
should have the software code SM5022-.. The Timer PCB should have
software code SM5023-.. These two PCBs are matched. Subsequent
modifications have been made to the PCBs and care should be taken that
the Timer and Brewer PCB are matched together. (See amendments)
15. Triac
controls the switching of relays at zero voltage.
this lengthens the life of relays, by removing the arc (flash) during switching
which wears the contacts on the relay.

Service Manual 1000379 Qwikbrew 2 01-10-12Page 18 of 37
General Operation - PCB Brew Board 2002 (software vers. SM5022-..) -1600321
When the machine is switched on, the PCB checks what state the machine is in, by
checking probe levels and temperature.
If the low level probe is uncovered, the machine will take in mains water until this probe
is in contact with the water.
At this level, the element is switched on and this body of water is heated to the preset
temperature (temp adjust pot), approx 93.5-96C.
More mains water is taken in (heating does not stop) until the temperature sensor senses
a drop of 1-2 degrees. The machine stops taking in water and allows time for this water to
reach preset temperature. This is the Heat-Fill cycle.
This cycle will continue until the high level probe is reached.
If the water level drops off the high level probe, this cycle is repeated.
By using this method, the water in the tank remains between favourable temperature
limits. However, this does mean that the machine can run out of hot water.
Note: old versions of the Qwikbrew did not work on the heat fill system, and the
level of the water remained at the high level probe regardless of temperature.
In between the low level and high level is a 3rd level probe –‘the brew level probe’.
There is 12-13 pints of water between this level and the low level. A brew of coffee can
be started at any point above this level.
A normal full brew is approx. 11 pints of water –so this is a safe level, even in a situation
of mains pressure drop. In normal circumstances approx. 6 pints of water is taken in and
recovered during a full brew. Therefore, there should always be at least 7 pints of water
above the low level cut off.
Approximately 15mm (2 pints) above the Brew level probe is the Hot Water Draw off
limit. This is the level in the tank at which the Hot Water tap runs out of water.
A brew can still be selected at this point.
Drawing off water at any time should not affect the brewing system.

Service Manual 1000379 Qwikbrew 2 01-10-12Page 19 of 37
Probes:
As mentioned earlier, there are 3 probes (low level, high level and brew level) on the
Qwikbrew 2, the positions of which are shown in figure 2.
Figures 13 and 14 show how the probes are removed.
Note: Tank does not have to be drained to remove any probes.
The probes and bracket are sealed against the wall of the tank with 2 M6 nuts that screw
onto studs welded to the tank.
Remove these nuts and pull the probe assembly out.
Fig.13- remove nuts Fig.14 –remove probe
Low Level Probe assembly - 2301320 (see figure 15)
The low level probe is mounted on the sight glass side of the machine, and is connected to
the Brew Board PCB with a yellow wire.
High Level Probe assembly - 2301300 (see figure 15)
The high level probe is mounted in the top centre of the tank, and is connected to the
Brew Board PCB with an orange wire.
Brew Level Probe assembly - 2301310 (see figure 15)
The brew level probe is mounted on the tank near to timer PCB, and is connected to the
Brew Board PCB with a red wire.
Fig.15- probe assemblies
Low Level Probe Assembly
2301320
High Level Probe Assembly
2301300
Brew Level Probe Assembly
2301310

Service Manual 1000379 Qwikbrew 2 01-10-12Page 20 of 37
Element:
Figures 16 and 17 show the two types of element used on the Qwikbrew 2. The element
shown in figure 16 is used on the first batches of the machine. This is either a 2.8kW
220V or a 2.8kW 240V depending on whether the machine is in Ireland or the UK.
Since the European standard voltage is 230V, we are in the process of changing our
elements to suit this.
Figure 17 shows the element to be used on new batches of the Qwikbrew 2. This shape of
element has a great advantage.
Fig.16
Fig.17
Replacing the Element:
Switch off the machine and remove the plug from the socket. Drain the tank
using the drain valve at the front of the machine (see figure 18).
Unscrew the 8 M6 nuts that clamp the clean out door against the tank wall.
Pull clean out door back and check element. If element is of the type in fig. 16,
remove element nuts on the front of the clean out door. Remove clean out
door. (If element is of type in figure 17, pull the assembly straight out of the
tank.)
Not the position of the red silicone o-ring - remove and discard. Remove
element by sliding one leg out at a time (see figures 21 and 22).
Replace in reverse order. Use a new red silicone O-ring (1800770). Do not
over-tighten M6 nuts. Check that the clean out door is sealed at temperature
before leaving site.