Marco MAXIBREW 2 User manual

MAXIBREW 2 TWIN BOILER-BREWER
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 Fax: [phone]

Service Manual MAXIBREW 2 TWIN 25-03-08 Page 2 of 31
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 11
4.3. Access to internal components 11
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 3 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 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 4 of 31
2. SAFETY INSTRUCTIONS:
Read all instructions.
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 instructions.
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 5 of 31
Electrical specification:
o5.6kW/230V, 6.1kW/240V This needs to be connected to a 30A isolator outlet. A qualified
electrician should do this.
o8.4kW/400Vac/3P+N+E This unit must be connected to a suitable 3-phase power supply. This
should be done by a qualified electrician.
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.
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).
Connect straight tailpiece of the inlet 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 (again 3/4" BSP). Make sure
the sealing washer is fitted here also.
Turn on water and check for leaks.
Start-up:
Check that all installation procedures have been carried out.
Turn the water on at the stop valve and switch the power on at the isolator switch. The sight-glass
lamp will illuminate.
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 6 of 31
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 (e.g.
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.
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):
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 quantity 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.
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.

Service Manual MAXIBREW 2 TWIN 25-03-08 Page 7 of 31
3. BASIC INSTRUCTIONS:
3.3. BREWING COFFEE:
Slide out the coffee filter bowl and place a single sheet of filter paper in the bowl.
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 an approximate guide for your
first brews:
220g-240g (8-8½oz) for a Half Brew (10 pints [5.7 litres])
440g-480g (16-17oz) 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.
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.
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.
A half brew should take around 4min30secs-5min30secs. A full brew should take around 9-11min.
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.
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.
A brew can be selected whenever the green ‘Ready to brew’ lights are illuminated.
Left and right brews can run simultaneously (although the two brew buttons should 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:
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 (1.45litres) 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 8 of 31
3. BASIC INSTRUCTIONS:
3.5 LOCK FUNCTION:
The Maxibrew 2 Twin has a button lock function to prevent untrained personnel operating the machine, or
accidental 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:
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
flashes
Symptom
Action required
2
Water level below elements. Normal when
machine first fills.
Check water pressure, if this is OK - call service
agent.
3
Temperature sensor failure (o/c)
Call service agent
4
Water not heating
Call service agent
5
Temperature sensor failure (s/c)
Call service agent
6
Machine not filling
Check water pressure. If this is OK and the
machine has not returned to normal operation
after 15 min –call service agent

Service Manual MAXIBREW 2 TWIN 25-03-08 Page 9 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 ISO9001:2000 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 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:
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.
Risk of scalding. Beware of accidentally operating the water drawoff tap especially when cleaning the
front of the boiler. ALL users of this machine should be trained and should be aware that the machine
dispenses very hot beverages.
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 10 of 31
4. Technical Data:
4.1. GENERAL DESCRIPTION:
MAXIBREW 2 TWIN - 8.4kW 1000465
Electrical
Connection
8.4kW,400V (3Phase+Neutral)
c/w 1.5m flex
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 (footprint on counter)
Depth
Depth incl. Drip Tray
816mm
855mm
762mm
480mm
590mm
630mm
Performance
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:
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 litres(160pints)
Heat Fill Mode:
Up to 20 litres (35 pints)when full.
Continuous Fill Mode:
6 litres (10.5pints) recommended max.
80 litres/hr (141pints/hr)
MAXIBREW 2 TWIN –5.6kW 1000464
Electrical
Connection
5.6kW,230V (Single Phase)
c/w 1.5m flex
Plumbing
As above
Dimensions
As above
Performance
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:
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)