Well now I'm pissed off... the install was pretty straightforward, but the results were a little disappointing to say the least...
(Disclaimer - these are not instructions - do not do this if you have no electronics training. Electricity + water = death. You're on your own. Don't come running to me if you kill yourself)
Anyway, first thing to do is read the instructions, then read them again. They are pretty good, with a couple of exceptions which I'll cover below.
First, wire up the relay as described in the instructions...
Anyone who's ever built a PC will be familiar with this...
Apply thermal paste to relay..
Mount on back of machine
Now the fun part - replacing the thermostat. This is mounted at the bottom of the boiler. Easy to remove - nearly impossible to replace...
It's that little black thing. Remove the connectors. Use a 17mm spanner - it's not that tight - once it's loose, you can ease it off with your fingers. When it falls on the bottom of the machine, fish it out with a long nose pliers, magnet on a string or a trained mouse.
Replacing with the temperature sensor is the hardest part of the install. You need to thread it into a hole that you can't see. I used a little of the thermal compound in it even though it wasn't in the instructions. The original thermostat had some on so I figured it's probably a good idea.
Try it a few times. Swear. Try it again. Swear like a docker. Apologise to your girlfriend. Agree it's not the kind of language that an unborn should hear in the womb. Hug. Tell her you love her. Take a deep breath.
BRAINWAVE! use and elastic band to wrap around wire loom and attach other end to the steam wand. Now you have room to work!
With a great deal of patience and care, thread sensor into hole you can't see, turning half a turn at a time. Make sure to keep sensor leads tied up, and keep wire bundle turning too - it's really delicate and I'm sure it's easy to break off wires.
Slowly slowly catchy monkey!
Tighten this hand tight. Breath a sigh of relief. Hard part is now over. Yay!
Now - Wiring
Groovy piggyback connectors so you don't have to splice anything. One goes on to the middle connector of the power switch (forgot to take photo). Notice how the 2 thick red wires from the relay are now connected to the thermostat connectors?? Yes - I forgot a step.
Other one goes to brown wire on power socket on back of machine.
Max just can't stay awake without espresso. He turns his nose up at instant (good boy!)
Wire up PID as per instructions
Smoke test. Behold! It lives!!
Tidy up cables and and use cable ties for strain relief.
Reconnect earth connection to chassis. This is NOT in the instructions and is SUPER important.
Mounted with supplied 3M pad
Now for the down side...
I swich it on. The temp rises, hits 100 degrees. Keeps rising. Weird - soem kind of self test??? Temp hits 150 degrees and thermostat kicks in, light goes off. Temp drops to 125, light turns on. Temp hits 150 again. Not good.
Swearing starts again, but by this time girlfriend is in bed and can't hear.
I double check wiring. All seems fine.
I check the resistance on the sensor - fine.
I check voltages on the PID. As temperature passes 100, voltage to relay drops from 6.5 V to 5.5 V. Surely that not enough to close the realy... So I do some digging and find a data sheet for the relay, and sure enough it need voltage to drop past 1.5V to turn off. PID is FUBAR...
Now auberins.com want me to return PID at my own cost before they will replace, and I can't return my machine to original without replacing the thermostat (noooooooo!!!!)
So I had to dig out my old school stove top espresso pot this morning. Considering it cost me €10 on a trip to rome a couple of years ago, and allowign for the lack of crema, it makes really tasty coffee. Dare I say it, better than an unmodded Gaggia.
Have I been wastiing my money??