I just purchased a used Vesuvius that was manufactured in 05/2020, but only used by the previous owner “three times.” (It shows that it only has 26 lever operations on the menu screen)

When I first turned it on, nothing happened and I received the Fillingup Timeout error with the red screen and triangle.

I cycled the main rocker switch and jiggled the water level sensor tube and that seemed to get the pump started as I heard it pump and could see it drawing water out of the reservoir.

Once the machine got to temperature, I was able to operate the steam wand and the hot water tap. However when I pulled up on the lever to operate the grouphead, water just trickled out and eventually stopped altogether. Couldn’t hear the pump run or anything and definitely wasn’t getting and pressure or flow.

When I opened up the machine, the pump was extremely hot to the touch which I assume is not normal.

Can’t determine whether I have a pump problem, a water level sensor problem, or an overheating problem. Can anyone help me?

I filled it with distilled water, previous owner had it direct plumbed (bottom direct plumb rocker switch is in the correct position for reservoir and the plug is in place)

Here is a link to the machine in operation:

Thanks,

Chris

    Welcome to the forum.

    Interestingly the pump ran to fill the steam (service) boiler, but didn’t run when you lifted the lever. Oh just a side note, don’t leave the group lever up too long or it will lower the level of water in the brew boiler as it steams/dribbles out. This might not be a great thing for the heating element.

    Two simple tests you can do.

    1. Bring the machine up to temp with the service boiler on and when it’s up to temp (set it to 125C), draw a mug of water, does the pump run to fill the boiler, if not draw another mug of water.
    2. Look at the back of the group lever, is it actually pushing in the roller pin that actuates the microswitch behind the panel. If you don’t think it is…push this switch in manually, does the pump run?

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      DavecUK

      Thanks! It’s a great forum and I’ve learned alot searching and reading up on things, however hadn’t found anyone with a similar issue to what I’m having.

      1. I brought the machine up to temp and was able to dispense hot water, but it turns mostly to steam and does not activate the pump to fill the boiler. I tried it a couple times and it didn’t run the pump.
      2. Yes, the group lever is engaging the switch and the pump does not run.

      Here is a video after the machine is up to temp and nothing happening

        OK, turn off the steam boiler and keep it off!

        fought70 I cycled the main rocker switch and jiggled the water level sensor tube and that seemed to get the pump started as I heard it pump and could see it drawing water out of the reservoir.

        This would indicate the pump is working, so the housing getting hot could be a red herring e.g. not faulty? I don’t notice any low water warning on the display and as far as I am aware the tanked plumbed switch only routes the mains water into the internal tank and stops a short time after the level sensor tells it it’s full. So I don’t think it’s a faulty rocker switch.

        A few more tests, before you contact ACS for a final diagnosis and link them to this thread:

        • Remove the wire to the autofill probe, does the pump run (if the pump runs replace the wire quickly)
        • You said the motor housing was hot, is it hot without the service boiler on

        If the first test doesn’t run the pump it could be:

        • Loose wire/connector on the main board which fires the transformer for the pump
        • fuse failed on the main board preventing the pump from running, but this could be due to a fault elsewhere e.g. pump drive unit/on main board SSR, don’t just replace the fuse.
        • bad connection to pump from transformer

        Do my test and if the pump still doesn’t run contact ACS for further guidance and support…but link them to this post @Paolo_Cortese, have a look at this.

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            DavecUK

            To answer your questions: no the pump does not run if I unplug the wire to the fill sensor and yes the pump is still hot even with the service boiler off.

            I had already emailed Paolo with M&V at the same time I posted in this forum. He said that the sound in the video is not the pump and said the pump might be frozen from being direct plumbed and sitting so long without use by the previous owner.

            He told me to remove the pump and open it to free up the gears/magnet.

            I was able to remove and disassemble the pump. I spun the two gears and they moved freely. I removed the magnet from the shaft and reinstalled. The magnet was also able to spin freely by hand.

            I reassembled everything and reinstalled the pump. I turned on the machine and after two minutes, I received the same error message and red screen (“FillingUp Time-out”)

            The pump is still very hot to the touch (this is before either of the boilers even begin to heat up)- the heat is originating from the square magnetic portion of the pump motor.

            Do I have a bad magnet?

                Here is a video of the disassembled pump- turning the gears and magnet freely by hand:

                And here is a video of the pump ‘running’ very weakly. It does create a little bit of vacuum, but seems like it should be much stronger, correct? This is what makes me think I have the bad magnet that I’ve read is a common problem with the Vesuvius… thoughts?

                  magnet is the cheapest thing to try, the drive unit is expensive.

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                  fought70 I’ve read is a common problem with the Vesuvius… thoughts?

                  Oh just thought I would add it’s not a common problem with the Vesuvius, it’s a possible problem with all machines from all manufacturers using that pump from 4 or 5 years ago as Fluid O Tech (FOT) the manufacture had a batch of bad magnets. They are cobalt samarium magnets and loose their magnetism gradually on exposure to air. They are "potted so this doesn’t happen, but a batch had bad potting and gradually failed over time.

                  There was no way for machine manufacturers to know, or FOT, so they simply let the bad magnets work through the system and gave free magnets to manufacturers for that period. I don’t know if FOT still gives the magnets free to manufacturers, but of course you would still have to pay P&P.

                  I have a very early Vesuvius, but fortunately my magnet was “potted” correctly, so never had a problem.

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                      DavecUK My impression was that the faulty magnets were installed on the FOT before 2020 on the older Vesuvius machines (pre-2020) and quite a few of forum members replaced the magnets with new ones sent by Paolo.
                      Or do we still encounter some odd FOT gear pumps suffering from the issue?

                      Current setup: ACS Vesuvius, Nuova Simonelli Mythos One. Past experience, Nuova Simonelli Apia 1 gr., San Remo Capri 1 gr., Bezzera BZ 35e, Fracino Heavenly. Anfim Super Lusso.

                      Contact me at: john_yossarian11@yahoo.com

                          John_Yossarian thanks for the reply! My manufacture date says 05/20 and I’m wondering if the problem is just surfacing due to the extremely limited use in the last 4 years (26 lever pulls on the dashboard)

                          I’ve seen new pumps on eBay for $300, but I think I’d like to try the magnet replacement first- just not sure where to buy one from. Any ideas?

                              John_Yossarian My impression was that the faulty magnets were installed on the FOT before 2020 on the older Vesuvius machines (pre-2020) and quite a few of forum members replaced the magnets with new ones sent by Paolo.
                              Or do we still encounter some odd FOT gear pumps suffering from the issue?

                              Probably all worked their way through the system now, but this machine is from 2020 and there “may” have been a few around, or it may not be the magnet at all.

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                                fought70 I guess Paolo should be best positioned to advise. In case it is a magnet issue.

                                Current setup: ACS Vesuvius, Nuova Simonelli Mythos One. Past experience, Nuova Simonelli Apia 1 gr., San Remo Capri 1 gr., Bezzera BZ 35e, Fracino Heavenly. Anfim Super Lusso.

                                Contact me at: john_yossarian11@yahoo.com

                                  I just heard from Paolo (he is in Hong Kong), he believes the problem is the pump itself.

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                                    7 days later

                                    DavecUK

                                    Okay thanks Dave! I had sent several follow-up emails to Paolo and have not received any replies or assistance from m&v since he initially responded. I decided to take a chance and order a new FG304 pump off eBay for $300. It’s arriving today. Wish me luck! (I do find it odd that the company is not responding or offering any assistance at all.- I’ve received more help from you on this free forum! Thank you!)

                                        fought70 (I do find it odd that the company is not responding or offering any assistance at all.- I’ve received more help from you on this free forum! Thank you!)

                                        I think it’s odd as well, unless you are e-mailing Paolo? You should always e-mail Maria, not Paolo. Maria will always follow things up as she is not trying to run the company as well.

                                        Maria is at sales@mevsrl.net

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                                          7 days later

                                          I was emailing the Paolo and Maria.

                                          My resolution ended up being this: I purchased a new FG304 pump on eBay for $300. Swapped it out and everything works great!

                                          Now I just need to dive into this forum to figure how to get things dialed in! So overwhelming!