Pro 500 PID: Static Relay Upgrade Kit Install

This guide covers installing the static relay upgrade kit for the Profitec Pro 500 PID espresso machine. Upgrading your relay helps improve reliability. This process involves opening the machine, repositioning wiring, installing the new relay, and reassembling your espresso machine.

Technical Skills

This installation requires basic electrical and mechanical skills. You'll need to handle small wiring connections and understand basic safety procedures related to electrical appliances.

Tools Needed

• Adjustable wrench or pliers

• Allen wrench (included with kit)

Associated Parts

• Static Relay Upgrade Kit (includes static relay with adhesive tape, nut and bolt, Allen wrenches, wire ties, and extension wire)

1. Intro & Required Tools (00:04)
2. Removing Reservoir Housing (01:02)
3. Disconnecting Sensor Wires (01:46)
4. Removing Old Static Relay (02:05)
5. Extending and Re-routing Wires (02:53)
6. Installing New Static Relay (05:01)
7. Connecting Wires to Relay (06:10)
8. Securing Wiring with Wire Ties (07:05)
9. Reinstalling Reservoir Holder (07:53)

Step-by-Step Instructions

1. Preparation and Safety

• Ensure your machine is unplugged and cooled down before beginning.

2. Removing the Housing

• Remove the housing from your Profitec Pro 500 PID.
  [Refer to separate instructions provided with the kit if needed.]

3. Removing the Reservoir Housing

• Remove screws securing the reservoir housing. (Consider marking screw locations with a Sharpie for ease of reassembly.)

• Disconnect wires from the reservoir sensor:

  • Remove one wire from the top connection.

  • Remove the other wire from the bottom connection.

4. Removing Old Static Relay

• Locate the existing static relay (near the control box).

• Use the provided Allen wrench to remove the relay mounting screw.

• Disconnect the four wires from the existing relay.

• Fully remove the old static relay from the machine.

5. Wire Preparation

• Identify the four wires (brown, blue, gray, and black).

• Extend the brown wire using the provided extension wire (male to female).

• Cut existing wire ties to free wiring for repositioning.

• Route wires (brown with extension, black wire from high-limit, gray, and blue wires) to the opposite side of the machine where the new static relay will be installed.

6. Installing the New Static Relay

• Prepare the static relay with provided double-sided heat transfer tape.

• Insert the provided nut and bolt into the relay (one side open, one side closed; nut on the back side).

• Remove the tape cover and carefully position the relay inside the machine against the side wall, aligning the bolt into the pre-drilled hole.

• Press firmly to secure it in place.

• Tighten the bolt (avoid over tightening due to the lock washer).

7. Connecting Wires to New Relay

• Connect the wires in the following sequence:

  • Blue wire → Terminal #1

  • Gray wire → Terminal #2

  • Red (brown extended wire) → Terminal #3

  • Black wire → Terminal #4

• Confirm all connections are secure.

8. Securing Wires

• Use provided wire ties to neatly organize and secure wiring.

9. Reassemble Reservoir Holder

• Reattach the reservoir housing, and reconnect the sensor wires (order doesn't matter).

• Secure reservoir holder screws using your markings as a guide.

10. Final Checks and Startup

• Inspect all connections carefully.

• Replace the outer housing and ensure all screws and fittings are secure.

• Once reassembled, plug in the machine and test operation.

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⚠️ Important Safety Notice

Always ensure the machine is unplugged before starting repairs or modifications. Incorrect connections or handling of electrical components may lead to damage or injury. If unsure, seek professional assistance.