Marco AQUARIUS FC/T User manual

SPARE PARTS DIAGRAM FOR
First Choice Group
Blakeney Way, Kingswood Lakeside
Cannock, Staffs, WS11 8LD
TEL: [phone] FAX: [phone]
Email: [email protected]
Web: www.firstchoice-cs.co.uk
Water Boiler
AQUARIUS FC/T

AQUARIUS FC/T
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 1000112 Aquarius FC-T 04-10-06.doc Page 2 of 18
CONTENTS
Page
1. Introduction 3
2. Safety instructions 4
3. General description 5
4. Installation 7
5. Start-up and Operation 8
6. Routine Maintenance 9
7. Technical Data 10
Base of Machine 10
Inside Machine 11
Probes 12
PCBs 13
PCB Components 14
PCB Functionality 15
Trouble shooting 16
8. Wiring diagram 17
9. Spare Parts list 18

Service Manual 1000112 Aquarius FC-T 04-10-06.doc Page 3 of 18
1. INTRODUCTION
The information provided in this manual is intended to assist in the installation and
maintenance of the Aquarius FC/T boiler manufactured by Marco Beverage Systems.
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 correct 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 1000112 Aquarius FC-T 04-10-06.doc Page 4 of 18
2. SAFETY INSTRUCTIONS
1. Read all the instructions.
2. To protect against electric shock do not immerse the cord and plugs in water
or other liquid.
3. Do not let the cord hang over edge of table or counter; or touch hot surfaces.
4. Switch off at the mains (unplug from outlet) and turn off the water supply (if
applicable) when not in use and before cleaning. Allow the machine to cool
before removing any components.
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.

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3. GENERAL DESCRIPTION
Performance
Minimum Immediate Draw Off
(filling a bucket in one single go with no
incoming water)
Total Heating Rate at 2.8kW
Maximum Hourly Output
Water Temperature
8.75 litres
0.46litres/min 28litres/hour
37litres
95-96.5˚C
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
Width
Body Depth
Depth from Back to Front of Tap
Depth incl. Drip Tray
Maximum Cup Height (on driptray)
Maximum Cup Height (no driptray)
585 mm
190 mm
290 mm
405mm
425 mm
157mm
183mm

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EXTERNAL ARRANGEMENT
Description and Part No.
Description and Part No.
1. Power On/Off Switch - 1501216
5. Element 2.8kW 230V - 1500985
2. LED Tri-colour - 1501214
6. Thermistor Pocket
3. Rating Plate
7. Low Level Probe 360mm 2300477
4. Water Inlet
8. High Level Probe 40mm 2300463
6
1
2
3
4
6
5
7
8

Service Manual 1000112 Aquarius FC-T 04-10-06.doc Page 7 of 18
4. INSTALLATION
The Aquarius FC/T is a automatic fill (plumbed in) unit.
Standard Automatic Fill (plumbed in) machine 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. Direct the hose
through the clearance provided at the back of the boiler.
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 valve when
not in use.
6. A moulded 13A plug is factory fitted. Plug the machine in to a suitable 13A outlet.
6

Service Manual 1000112 Aquarius FC-T 04-10-06.doc Page 8 of 18
5. START-UP AND OPERATION
Start up and basic operation:
Turn the water on at the stop valve.
Switch the machine on by pressing the Power On/Off switch at the back of the
machine. The LED (small light above the tap) should be Red. This indicates that the
water level in the tank is below the low level probe. The machine should 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 switches on and the LED changes
from Red to Amber. The water is heated to approximately 1°C below the pre-set
temperature (around 95°C) at which point the machine takes in more cold water, while
continuing to heat. When this incoming cold water causes a temperature drop of
approximately 2°C, the machine shuts off the water inlet. Heating should continue
throughout. When the temperature reaches approximately 96°C once again, more water
is taken in. 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/or
b) the water temperature reaches the pre-set temperature (approx 96°C).
At this point the LED changes from Amber to Green. This may take 25-30 minutes.
This cycle is known as the ‘first fill cycle’. Whenever the machine is unplugged and
plugged in again, or switched off and on, this routine is activated.
The level of water in the tank drops during dispensing. When the water drops below
the high level probe, mains water is taken into the machine until the temperature of the
water drops by approx 3C or the high level is reached again. The element switches on
and the water is heated to the set-point temperature once again.
When the water level drops below the tap spigot, water will not be able available the
machine should be allowed to recover at this point. If the water level drops off the low
level probe the LED colour changes to red, this could happen if there is no water
supply and the water has evaporated so much that it has dropped off the low level
probe.
If the machine is started from empty it is not possible to draw off cold water due to the
heat fill cycle operation. The low level probe is below the water draw off tap spigot.
While the machine is filling for the first time hot water may be drawn off while the
LED is amber. Due to the heat fill cycle this water should be within the correct
temperature range. BUT- If the machine is turned off with water in it and allowed to
cool, then cold water may be drawn off when it is turned back on. The amber light will
indicate heating but since it is above the low level probe cold water may be available.
In this case water should not be drawn off until the light turns green (full and up to
temperature).

Service Manual 1000112 Aquarius FC-T 04-10-06.doc Page 9 of 18
6. ROUTINE MAINTENANCE
Descaling the tank:
Use the tap to drain the machine until no more water is dispensing. Unplug the
machine and leave to cool.
Isolate machine from water supply. Remove the 3 lids and pour the remainder of the
water out of the machine, by turning the unit upside down over a sink.
Try to remove as much loose scale by hand. Be careful not to damage the element or
probes.
Ensure that the plug and cord are dry before reconnecting the power to the machine.
Fill the tank with water.
Allow the machine to reach temperature. Add the contents of a descale sachet. Use
ScaleKleen, Marco part No. 8000270 or similar.
Leave for 10 minutes to allow the descaler to dissolve the lime.
Use the tap to empty the boiler. Unplug the machine and let it cool.
Empty the remainder of the water into the sink. Flush the tank thoroughly with clean
water. Ensure that the plug and cord are dry before reconnecting.
Cleaning:
The outside surfaces of this unit should be cleaned using a non-abrasive cloth and warm water
only.

Service Manual 1000112 Aquarius FC-T 04-10-06.doc Page 10 of 18
7. TECHNICAL DATA
Base of Machine:
Description and Part Number
Description and Part Number
1. M4 S/S Screw (remove for access to front)
5. Switch On/Off 1501216
2. Strain Relief Bush (for cord) - 1801200
6. Hose Clip Type-F 1800540
3. Plug Moulded 13A Cord - 1501480
7. Feet Nylon 1800191
4. Valve Inlet Solenoid 1502170
8. Service Plate (remove for access)
7
1
2
3
4
5
6
7
8

Service Manual 1000112 Aquarius FC-T 04-10-06.doc Page 11 of 18
Inside Machine:
Description and Part Number
Description and Part Number
1. PCB InCup Dispenser –1600312
5. Thermistor Assembly 1600691
2. LED Tri-Colour 1501214
6. Element 2.8kW 230V –1500985
3. Chromed Nut 1401170
7. Valve Inlet Solenoid 1502170
4. Circlip for Spigot 1400550
8. Tap 2100279
1
2
3
4
5
6
7
8

Service Manual 1000112 Aquarius FC-T 04-10-06.doc Page 12 of 18
Probes:
Fig 12 Probe Assemblies - High Level (left) and Low Level (right)
High-Level Assembly 40mm - 2301463
Low-Level Assembly 360mm -2300477
1. O-ring for probe - 1800780
6. O-ring for probe - 1800780
2. Insulator PTFE for Probe - 1800970
7. Insulator PTFE for Probe - 1800970
3. Screw M4x35mm S/S - 1401750
8. Screw M4x35mm S/S - 1401750
4. Locknut ¼”BSP brass - 1401000
9. Locknut ¼”BSP brass - 1401000
5. Probe Plate 40mm - 1800971
10. Probe Plate 360mm - 1800968
11. Screw Selftap S/S - 1401810
12. Probe Bobbin White PTFE - 1800979
10
4
3
2
1
6
7
11
8
5
12
9

Service Manual 1000112 Aquarius FC-T 04-10-06.doc Page 13 of 18
PCB
PCB In-Cup dispenser - 1600312
Note: This is a modification to the standard EZT controller, which is found on most
Marco water boilers with manual tap dispense (e.g EZT 105/110/400/700, Aquarius
15/30/45).
The machine will only function properly with an INCUP PCB.
PCB In-Cup dispenser
9
7
11
8
6
10
12
15
16
17
19
18
23
24
22
21
20
13
14
2
1
3
4
5
Note: The two boards appear identical, except for the label
on the microchip:
Standard boiler (tap dispense): EZT SM-1078-04
Aquarius FC/T: INCUP

Service Manual 1000112 Aquarius FC-T 04-10-06.doc Page 14 of 18
Components of PCB In-Cup Dispenser
1. Transformer
2. Power On/Off –2way connector (low voltage)
connects to the Power On/Off switch at the back of the machine
3. LEDs - 5way connector (low voltage)
connects to the tri-colour LED
4. Data I/O –4way (low voltage)
connects to the Solenoid Driver PCB on Push Button machines (Not used on
Aquarius FC/T)
5. Earth Tab
6. Mode of Operation Jumper Pins
For default automatic fill the jumper connector must be positioned over the two
pins nearest to the transformer or the jumper can be removed completely. To
switch to manual fill mode the jumper must be placed on the 2 pins furthest from
the transformer, as shown in the wiring diagram. The machine must undergo a full
rest, powered down at the mains, before the switch from auto-manual or manual-
auto fill is achieved.
7. Water Level –5way connector (low voltage)
connects to Low level and High level probes.
9. Temperature Adjust Pot
to increase temp –adjust clockwise; to decrease temp adjust anti-clockwise
10. Temperature Range Jumper
controls three temperature ranges –can be on middle or outer pins.
11. Thermistor Connector
12. Daughter PCB Connector (low voltage) –not used on this machine
13. Relay - Heater
switches the element.
14. Relay - Heater Safety
backup relay for element –controls the switching should the triac fail.
16. Heater/Element Tab (high voltage)
connects to the element
17. Live Tab (high voltage)
18. Inlet Solenoid Tab (high voltage)
connects to the inlet solenoid
19. Live tab –spare (high voltage)
20. Suppressor
21. Relay –Inlet Solenoid
switches the inlet solenoid
22. Fuse
23. Neutral tab (high voltage)
24. Neutral tab –spare (high voltage)
8. Microchip –the label indicates the functionality of the machine.
Note: Only a chip with the In-Cup label will be suitable for this machine.
15. Triac
in parallel with the heater relay. Switches the element initially.
this lengthens the life of relays, by removing the arc (flash) during switching
which wears the contacts on the relay.

Service Manual 1000112 Aquarius FC-T 04-10-06.doc Page 15 of 18
PCB Functionality / Machine Operation
All functionality of the PCBs is controlled through the microchip on the In-Cup Dispenser
The Software uses 3 inputs to control 3 outputs:
Inputs: Low level probe sensor
High Level probe sensor
Temperature Sensor (thermistor)
Outputs: Inlet Solenoid
Element
Tri-Colour LED
When the PCB is switched on ‘heat-fill’ functionality is used. This is as follows:
When the machine is switched on, water is taken in until the low level probe is
reached. The LED on the front panel reflects this –when the water is below the low
level, the LED is red and changes to amber once the low level probe is reached and
heating begins.
The water is heated up to 1.5ºC below the set point temperature (SPT), which can
be adjusted using the temperature adjust pot on the In-Cup Dispenser PCB. More
water is taken into the machine (heating continues) at this point, until the
temperature drops to approx 3ºC below SPT. The water inlet is switched off and
heating continues –attempting to reach SPT. Once again before SPT is reached,
water is taken in until the water temperature drops to 3ºC below SPT. The water
inlet solenoid is turned off again while heating continues.
This ‘staggered filling’ continues until the high level probe is reached. At this point
the water inlet function is disabled and the water is finally heated to the set point
temperature. When SPT is reached the LED changes colour to Green. This
indicates that the machine is full and ready for use. When the machine is switched
on for the first time or is switched off and on at any time, this cycle (first fill) is
activated.
When dispensing is underway water drops off the high level probe. Water will be
taken in and will stop when the temperature goes out of range. When full, the
machine has a minimum drawoff of 8.75litres, this means there is 8.75litres
between the high level probe and the tap. However the machine has a recovery rate
of 0.46 litres per minute, so if filling 250ml cups 8.75l will fill 35cups. This would
take several minutes and in this time more cold water will be drawn in and heated
so the actual immediate drawoff is dependent on how long it takes to draw off the
water. e.g. if you take 5 minutes to fill 35 cups, it should have recovered 2.3 litres
(5x0.46) in that time.
Error indicator
A flashing Red LED indicates a problem with the thermistor assembly. The PCB is either
reading an infinite resistance or no resistance. This could mean that the thermistor has failed or
has been disconnected from the PCB. A short circuit failure is shown with rapid flashes of the
LED, an open circuit failure or disconnection is displayed as a slow flash. If there is
uncertainty about which is a slow flash or a rapid flash, this can be checked when the front
panel is removed. Disconnect the thermistor assembly from the PCB and check if there is a
change in frequency.

Service Manual 1000112 Aquarius FC-T 04-10-06.doc Page 16 of 18
Troubleshooting
No
Fault description
Probable cause
Action required
1
LED is RED. Machine
not heating.
Machine is empty/low on water
Wait for machine to fill with water.
Water pressure is low or water main is shut
off.
Check and confirm –customer.
Low-level probe is disconnected or a wiring
fault to the probe.
Check and repair - Engineer
Machine is in the wrong mode. Machine set to
manual fill mode.
Ensure that the mode select jumper on
the PCB is in the correct position for
automatic fill. 2 Pins nearest
transformer.
Inlet solenoid failure
Replace - Engineer
Low-Level probe extension completely scaled
up (unlikely).
De-scale tank and probes –customer.
If the water level is below the high level probe
–the wiring to the probes may be reversed.
Check the wiring - Engineer
Earth wire not connected to the tank body.
Earth wire or crimp faulty.
Check and repair or replace –Engineer.
2
LED is RED. Machine is
heating.
LED should be Amber. Green light in LED has
failed. (Red light is on when empty and
heating. No light on when it should be green,
dispense is functional.)
Check wiring/crimps to LED.
Replace LED
PCB failure –chip placed incorrectly, bent leg.
Track damage, dry solder.
Replace PCB - Engineer
3
LED is AMBER.
Machine heating but not
changing to green
Takes up to 30min to heat a full tank.
Wait 30min - customer
Thermistor out of pocket. Machine eventually
boils water off to low level. RED LED comes
on.
Switch off unit –customer
Secure thermistor into pocket –Engineer
4
LED is AMBER.
Machine not heating
Element disconnected. Element failure.
Check and replace - Engineer
PCB failure. Triac and safety relay.
Replace PCB- Engineer
5
LED is GREEN. No
water available
Water has dropped below the spigot level and
needs more water to be added
Wait for water to recover
0.46litres per minute
LED should be Amber. Red light in LED has
failed (No light will be on when empty. Green
light will be on when heating.)
Check wiring/crimps to LED. Replace
LED -Engineer
6
LED is green. Machine
only dispenses a small
amount before LED is
RED again.
If the tank is full of water –the low level and
high level probes are reversed.
Reverse the wiring on the probes -
Engineer
7
LED flashes Red
Slow flash - thermistor failed open circuit.
Disconnected from PCB
Replace or reconnect - Engineer
Quick flash –thermistor failed short circuit.
Replace.
12
Machine flooding –does
not stop at high-level
probe. LED is RED.
High-Level and Low-Level probe extension
BOTH completely scaled up (unlikely).
De-scale tank and probes –customer.
13
Machine flooding –does
not stop at high-level
probe. LED is AMBER
or GREEN.
Mains pressure very high. Burst of water
when machine is turned on first thing in the
morning, causes machine to overflow.
Water stop valve should be closed
slightly –customer/Engineer
High-level probe scaled up.
De-scale –customer.
High-level probe disconnected or wiring fault
to high-level probe.
Check crimps and wiring to high level
probe. Check 5-way connector on PCB.

Service Manual 1000112 Aquarius FC-T 04-10-06.doc Page 17 of 18
8. AQUARIUS FC/T WIRING DIAGRAM

Service Manual 1000112 Aquarius FC-T 04-10-06.doc Page 18 of 18
9. Aquarius FC/T Spare Parts List
PART NO.
DESCRIPTION
1401170
CHROMED NUT FOR TAP
1400550
CIRCLIP FOR TAP SPIGOT
1500985
ELEMENT 2.8kW 230V
1800191
FEET NYLON
1800370
GROMMET FOR TAP
1800620
HOSE SILICONE 12mm IDx17mm OD
- FOR WATER INLET SOLENOID
1800520
HOSE ½” PVC - FOR OVERFLOW
1800540
HOSE CLIP PLASTIC 18.2mm TYPE F
FOR INLET SOLENOID
1800550
HOSE CLIP PLASTIC 20.2mm TYPE G
FOR INLET TIT AND OVERFLOW PIPE
1800970
INSULATOR PTFE PROBE (PROBE BODY)
1501214
LED TRICOLOUR
1401000
LOCKNUT 1/4" BSP BRASS
1401150
NUT BRASS M6
1401280
NUT S/S M6
1800780
O-RING FOR PROBE
1600312
PCB IN-CUP DISPENSER
1801230
PILLAR SUPPORT PCB
1501480
PLUG MOULDED 13A CORD
1800979
PROBE BOBBIN WHITE PTFE LOW LEVEL
1800964
PROBE PLATE 245mm LOW LEVEL
1800971
PROBE PLATE 40mm HIGH LEVEL
2300477
PROBE COMPLETE ASSEMBLY 360mm LOW LEVEL
2301463
PROBE COMPLETE ASSEMBLY 40mm HIGH LEVEL
1401760
SCREW M4X10mm S/S
1401750
SCREW M4X35mm S/S FOR PROBE
1801200
STRAIN RELIEF BUSH (FOR ELECTRICAL CORD)
1501216
SWITCH - POWER ON/OFF
2100279
TAP - BLACK HOT WATER
1600691
THERMISTOR ASSEMBLY
1502170
VALVE INLET SOLENOID 90 DEG
1800690
WATER INLET HOSE WHITE