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Rancilio Silvia PID Kit Manual
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Rancilio Silvia PID Kit Manual

Rancilio Silvia PID Kit Manual

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Silvia PID Kit
Copyright © 2006, 2007, 2008 MLG Properties, LLC
All rights reserved

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Summary of Contents for Rancilio Silvia PID Kit

  • Page 1 Silvia PID Kit Copyright © 2006, 2007, 2008 MLG Properties, LLC All rights reserved...
  • Page 2 This kit is intended to be installed in properly functioning, properly maintained Rancilio Silvia espresso makers of the type depicted in these instructions. It is intended to be installed by qualified technicians or other individuals with significant experience with electrical and electronic equipment.
  • Page 3 Silvia PID Installation Guide Silvia PID Kit Parts List – Watlow 96 kits Wiring Size Color Length Terminal Terminal Purpose 13” #8 ring ins. male QD full high voltage leads to SSR (blue) ins. (blue) black 48” female QD full...

  • Page 4: Tools Required

    Silvia PID Installation Guide Tools Required Tool Used for: Comments • Screws that fasten Silvia’s enclosure Philips head screwdriver panels • Wiring terminals on 1/16 DIN size (medium size tip) digital controllers • Screw used in cable clamp assembly • Screw terminals on some SSR’s •...
  • Page 5 Silvia PID Installation Guide Part A Version 2.04 Part A – New Wiring Inside Silvia’s Enclosure Step A1 – Unplug Silvia Turn off Silvia and UNPLUG from main power. Make sure that the brew, hot water, and steam switches are in OFF position as well. Move the plug away from any outlet, wrap it in plastic, or whatever else it takes to make sure there is absolutely no chance of Silvia being plugged in again while you are working.
  • Page 6 Silvia PID Installation Guide Part A Version 2.04 Set aside the backsplash. Place the screws in a safe place (a little plastic Jello Snack Pack cup is perfect for this job). Copyright © 2006, 2008 MLG Properties, LLC Page A-2...
  • Page 7 Silvia PID Installation Guide Part A Version 2.04 Step A4 – Mount the SSR Locate the 4 mm screw that is sticking through the black metal wall behind the back splash (this is the end of the screw that secures the main power cable on the other side of the black metal wall).
  • Page 8 Silvia PID Installation Guide Part A Version 2.04 Step A5 – Remove top panel Put Silvia back in a normal, upright position. Remove the four (4) screws that secure the top panel (so-called cup warmer) in place, being careful not to scratch the stainless steel.
  • Page 9 Silvia PID Installation Guide Part A Version 2.04 Step A6 – Reality check This would be a swell time to a) check and make sure once again that Silvia is unplugged, and b) go back and read the Disclaimer. If, after reviewing this guide, re-reading the Disclaimer, examining the internal wiring of Silvia, or for any other reason you find yourself uncomfortable with proceeding, please take advantage of our return policy.
  • Page 10 Silvia PID Installation Guide Part A Version 2.04 Locate and loosen (do not remove) the single screw at the very back of the U-shaped enclosure panel that fastens the panel to the black metal base. After you have loosened this screw, carefully work the back panel free. You will probably have to spread the “U”...
  • Page 11 Silvia PID Installation Guide Part A Version 2.04 Step A9 – Disconnect wires from brew thermostat Go back around to the front of Silvia, look down at the mess of wires, and locate the “brew thermostat” on the top of the boiler. There are two thermostats on the top of the boiler (a third, on the side of the boiler, must not be disturbed).
  • Page 12 Silvia PID Installation Guide Part A Version 2.04 Once you have located the brew thermostat, carefully work loose the two spade “quick disconnect” electrical connections, as shown in the following pictures. Patience is rewarded in this operation. Gentle side to side wiggling, along with a slight pulling force away from the thermostat, will usually free these connectors.
  • Page 13 Silvia PID Installation Guide Part A Version 2.04 Step A10 – Install power leads to SSR Locate the two (2) power leads to the SSR. These are heavy (14 AWG) red wires. On one end of each lead wire is a blue partially insulated ring terminal.
  • Page 14 Silvia PID Installation Guide Part A Version 2.04 Once you have located the SSR power lead wires, fasten the ring terminal ends to terminals 1 and 2 (the AC side) of the SSR. (Polarity is not important so it doesn’t matter which wire is connected to terminal 1 and which to terminal 2).
  • Page 15 Silvia PID Installation Guide Part A Version 2.04 You may find that your Silvia’s insulators are yellow and fragile: be very careful to not damage them. If they are damaged, you will need to replace them because leaving an uninsulated high voltage connector, or conductor, exposed is bad. If it were to come in contact with any of Silvia’s metal, and you are lucky, then you will blow a circuit breaker.
  • Page 16 Silvia PID Installation Guide Part A Version 2.04 A word about routing the SSR power leads: as the photo immediately above shows, it is best to route the SSR leads (the new red wires) up from below. That way, the factory female connectors can remain in about the same orientation as when they were connected to the thermostat.
  • Page 17 Silvia PID Installation Guide Part A Version 2.04 Fasten the red wire to the positive (+) terminal of the SSR (normally terminal no. 3). Fasten the white wire to the negative terminal (-), which is normally terminal no. 4. Please confirm the location of the + and – terminals by looking at the label on the actual SSR in your kit (from time to time, kits will contain different SSR’s).
  • Page 18 Silvia PID Installation Guide Part A Version 2.04 Step A12 – Install protective cover on SSR Locate the clear plastic protective SSR cover provided with your kit. Study the orientation of the holes in the cover and compare closely with the locations of the screws on the SSR.
  • Page 19 Silvia PID Installation Guide Part A Version 2.04 Step A13 – Install splitters on main power switch Locate the main power switch for Silvia. The top terminals on the back of this switch are going to be used to provide switched high voltage power for the digital controller. In the photo below, the spade connectors for the red and black wires are the ones we will be using (the yellow wire is for the switch lamp and will not be disturbed).
  • Page 20 Silvia PID Installation Guide Part A Version 2.04 Copyright © 2006, 2008 MLG Properties, LLC Page A-16...
  • Page 21 Silvia PID Installation Guide Part A Version 2.04 Once you have removed the wires, the spade terminals should be exposed as shown above. Locate the spade connection splitters in your kit, and carefully install one on each of the two exposed spade terminals. These splitters are easily bent, so take it easy! A little push from your flat bladed screwdriver (see photo below) can be helpful to get these splitters fully seated on the spade connector.
  • Page 22 Silvia PID Installation Guide Part A Version 2.04 Once you have both splitters fully seated on the spade terminals, you should reinstall Silvia’s main power wires (the ones you removed a few minutes ago). Be sure to get them back on the same side they came from. Slide them carefully onto the lower half of the new splitters you just installed.
  • Page 23 Silvia PID Installation Guide Part A Version 2.04 Note: Some users have suggested a simpler way to install the splitters: 1. Remove the original wire connections from the tabs (as directed above). 2. Install the splitters into the now-open female connectors on the ends of the original wires 3.
  • Page 24 Silvia PID Installation Guide Part A Version 2.04 Connect the push-on connectors onto the newly installed splitters as shown in photos below. Copyright © 2006, 2008 MLG Properties, LLC Page A-20...
  • Page 25 Silvia PID Installation Guide Part A Version 2.04 Pull the free ends of these wires toward the rear of the machine (right next to the low voltage DC control wires installed in previous step). Note: Some of our kits use controllers for which the polarity of the power supply wires is important.
  • Page 26 Silvia PID Installation Guide Part A Version 2.04 A short discussion of thermocouple placement: it is theoretically possible to locate your thermocouple just about anywhere on the surface of the boiler. We recommend, however, that you closely follow these instructions and mount the thermocouple where shown.
  • Page 27 Silvia PID Installation Guide Part A Version 2.04 Place a small amount of white thermal paste (included in your kit) where the thermocouple will be in contact with the top of the boiler. This will improve the response of the thermocouple. You may place the grease directly on the boiler (see photos below), on the thermocouple’s ring, or on both.
  • Page 28 Silvia PID Installation Guide Part A Version 2.04 Be sure to mount the thermocouple ring below the clamp bracket so that the thermocouple is tightly against the brass boiler surface. Once the thermocouple has been fastened, route it behind the boiler and out the back of the machine, with the other 4 new wires you have already installed, as shown below (thermocouple is the brown wire in picture).
  • Page 29 Silvia PID Installation Guide Part A Version 2.04 Note that the red/white DC control wires, the black power supply wires, and the brown thermocouple wire are all routed out of the boiler compartment below the steam supply tube. Eventually, all of these new wires, along with a green ground wire, will be wire- tied to Silvia’s main power cable.
  • Page 30 Silvia PID Installation Guide Part A Version 2.04 Locate the green grounding wire including with your kit (it will have a push-on type connector on one end, and a ring terminal on the other). Copyright © 2006, 2008 MLG Properties, LLC Page A-26...
  • Page 31 Silvia PID Installation Guide Part A Version 2.04 Finally, reconnect the original Silvia grounding wire, along with your new grounding wire, to the splitter you just installed. (Note: if your kit includes a steam control package it should be installed now. Please refer to Part S of this guide for instructions).
  • Page 32 Silvia PID Installation Guide Part A Version 2.04 Step A17 – Route new wires out of Silvia In preparation for routing the wires, locate the 2 smaller rubber grommets, along with the cable clamp and associated screw, washers, and nut, in your kit. Carefully work these grommets into place in 2 of the holes in Silvia’s base.
  • Page 33 Silvia PID Installation Guide Part A Version 2.04 If you have a steam control package with your kit (only available for selected controllers), you will have two (2) yellow control wires in addition to the wires described above. There will also be an additional rubber grommet provided with the steam package.
  • Page 34 Silvia PID Installation Guide Part B Version 96-2.04 Part B – Installing the Digital Controller Properly installing the digital controller into its enclosure, and connecting your new wiring, can be challenging because of the tight spaces in which you will be working. If you follow these instructions, it will be easier, but will still require patience.
  • Page 35 Silvia PID Installation Guide Part B Version 96-2.04 Make sure you have the bottom cover oriented correctly – the countersunk holes should be on the bottom, or outside. Pass the wires from the side with the countersunk holes to the side without the countersunk holes. Step B3 –...
  • Page 36 Silvia PID Installation Guide Part B Version 96-2.04 Step B5 – Connect wires to controller The next step is to connect the remaining wires to the back of your controller. It is a little simpler to do this before the controller is inserted into the enclosure. Note that the photos and instructions on this page depict a kit that includes a steam control package in addition to the basic PID kit.
  • Page 37 Silvia PID Installation Guide Part B Version 96-2.04 Step B6 – Mount controller in enclosure Once you are satisfied that your wiring is properly connected and is securely fastened, carefully slide the controller through the enclosure opening. Be very careful to position the wires in such a way that they do not bind or get cut in the opening as the controller is inserted.
  • Page 38 Silvia PID Installation Guide Part B Version 96-2.04 Step B7 – Clamp wires and install covers Next, perform a trial fit of the bottom cover (the one with the wires running through the grommet). At this time you may find it necessary, or desirable, to adjust the amount of wire passing through the grommet.
  • Page 39 Silvia PID Installation Guide Part B Version 96-2.04 Step B8 – If you need to remove the collar Once the collar has been locked tightly into place, removing it requires disengaging the toothed gripping mechanism. Generally, disengaging the teeth can be accomplished by sliding a thin sheet of cardboard or plastic (credit card thickness) between the collar and the controller body.
  • Page 40 Silvia PID Installation Guide Part B Version 96-2.04 to see exactly where you want the enclosure to be located on Silvia’s side. (We recommend that you position the vertical leg of the L on the black iron frame so that it blends in as much as possible).
  • Page 41 Silvia PID Installation Guide Part B Version 96-2.04 Step B10 – Tidy up the wiring At this point, the enclosure should be mounted on the side of Silvia and you should have a fair amount of excess wire between the bottom of the enclosure and the pump compartment (the wires in your kit are intentionally a little long).
  • Page 42 Silvia PID Installation Guide Part B Version 96-2.04 Once you have the internal wiring secured, insert the wires into the black split loom cable sheath provided. Starting at the bottom of the controller, insert wires through the split in the sheath, working your way towards the grommets where the wires enter the bottom of Silvia.
  • Page 43 Silvia PID Installation Guide Part B Version 96-2.04 Locate the 2 large black wire ties provided in your kit. The ties should be routed between the black acrylic L-bracket and the iron frame of Silvia. Before tightening the ties, push the cable loom up and compress it tightly against the underside of the enclosure (against the rubber grommet).
  • Page 44 (30 minutes or more is ideal). This will help the group head, the portafilter, and the rest of Silvia’s brew system to fully heat up. At this point, you are done and can follow Rancilio’s instructions for brewing espresso. Enjoy! Page B-11 Copyright ©...
  • Page 45 Silvia PID Installation Guide Part B Version 96-2.04 Step B14 – Troubleshooting common problems Problem Possible Causes Corrective Action 1. The temperature Thermocouple wires are Connect red thermocouple wire to negative reading on the digital reversed at controller. terminal, blue wire to positive terminal. controller is going down instead of up.
  • Page 46 Silvia PID Installation Guide Part C Version 96-2.04 Part C – Using Your Digital Controller General Your controller will come pre-set to 228F (or 109C), which is a good average set point, near sea level, for many espresso blends with Silvia. You may easily adjust this set point. Your controller will also be pre-programmed and pre-tuned for use on Silvia.

  • Page 47: Changing The Set Point

    Silvia PID Installation Guide Part C Version 96-2.04 visual indication of the action of the PID. When Silvia is very near the chosen set point, the controller will apply power for only a small fraction of each second. Because of the sophisticated PID algorithm built into the digital controller, you should see very little “overshoot”...
  • Page 48 Silvia PID Installation Guide Part C Version 96-2.04 You will notice that, while in steam mode, Silvia’s ready light will remain lit until the temperature reaches a certain point, usually between 285F and 300F. At this point, the steam thermostat switches off the heating element (and the ready light) and allows the boiler to begin a cooling cycle.
  • Page 49 Silvia PID Installation Guide Steam Package Silvia PID Kit Parts List for Optional Watlow 96 / Fuji PXR3 Steam Control Package Wiring (incl. connectors) Size Color Length Terminal Terminal Purpose brown 14” female QD female QD 1 ea high voltage lead to relay full ins.
  • Page 50 Silvia PID Installation Guide Part S Version 96-1.01 Part S – Install Steam Control Package Step S1 – Install relay At this point, you should have already installed all of the wiring required for a basic PID installation. You should have completed steps A1 through A16. Your machine should still be unplugged, and you should not have completed the step of running your wires through the base of the machine in the pump compartment.
  • Page 51 Silvia PID Installation Guide Part S Version 96-1.01 This is a stainless steel screw and it has two washers under the head. Since the screw is not magnetic, you will probably need to use needle nose pliers to remove it once loosened.
  • Page 52 Silvia PID Installation Guide Part S Version 96-1.01 When all five (5) screws that secure the front cover have been removed, very carefully and gradually pull the cover towards you. Do not remove the wires connected to the switches. Take your time, and reposition the connected wires as necessary to allow the cover to be pulled out a short distance.
  • Page 53 Silvia PID Installation Guide Part S Version 96-1.01 The view in the photo below is looking down from above. Connect the brown wire from the relay coil to this empty tab on the steam switch by pushing it onto the tab. See photos below: Copyright ©...
  • Page 54 Silvia PID Installation Guide Part S Version 96-1.01 This is the “hot” side of the steam switch, as indicated by the black wires connected to the tab immediately below the empty tab. Polarity of these wires is important to the proper function of the coil in the relay.
  • Page 55 Silvia PID Installation Guide Part S Version 96-1.01 Once the cover has been positioned as shown above, look at the steam switch again from the rear (see photo below). Once you have located the steam switch again, look for the tab where a gray wire with white insulator is connected to the steam switch.
  • Page 56 Silvia PID Installation Guide Part S Version 96-1.01 Gently pull this gray wire loose from the tab on the back of the steam switch. Replace the gray wire with the new purple wire whose other end is connected to the relay coil.
  • Page 57 Silvia PID Installation Guide Part S Version 96-1.01 Step S4 – Connect cap wire Locate the short red “cap” wire in your steam package. It will have a blue, fully insulated male quick disconnect terminal on one end, and a crimped white cap on the other. Connect the blue male disconnect to the gray wire that was removed from the steam switch in the previous step.
  • Page 58 Silvia PID Installation Guide Part S Version 96-1.01 Next, locate the steam thermostat on the top of the boiler. This thermostat will be immediately to the right of the brew thermostat. Following the same procedure as the brew thermostat, remove both connectors from the steam thermostat. See photo below. Finally, connect the jumper to the two connectors that were just removed from the steam thermostat.
  • Page 59 Silvia PID Installation Guide Part S Version 96-1.01 Use the same careful method of connecting this jumper to the white connectors as you followed when re-wiring the brew thermostat. WARNING: Under no circumstances should you leave any bare wire or any portion of the metal connectors exposed in this location.
  • Page 60 Silvia PID Installation Guide Part S Version 96-1.01 Next, reinstall the stainless steel screw through the bottom panel of the front enclosure and into the brew group. The lock washer goes on first, followed by the smooth washer. This is usually a rather challenging operation because of the location of this screw and the fact that the magnetic tip on your screwdriver will not attract the screw.