There still seems to be power to the Pre, but no illumination on the off/on switch and it doesn't heat. The boiler was 2/3rds full when the light went out, (the II setting after 12 minutes). Can't find anything that I can identify as a reset, fuse or fusible link. Did this portent the death of the heating element?

Sounds like what happened to mine a couple of weeks ago. Turns out there is a thermal fuse. When you remove the plastic bottom there should be a rectangle brown plastic object screwed in the centre with wired connected to lugs at the end. I had to replace that and everything worked fine after that. I actually retrofit a resettable one. You can find good information here;
http://www.pavoniexpress.com/trouble.html

Hope that helps.

Thanks Sam. The link helped me identify the problem. The thermal fuse was replaced with a connecting block at some point, so that lazy repair probably cost me a heating element.

Yeah, the Elektra T1 I'm rebuilding had a odd empty bolt hole near the heating element. An astute HB reader (SylvainMtl) asked me where the thermal fuse was on mine while comparing it against his machine and sure enough mine was missing. It also explained why a big wire nut (that sure didn't look factory original) was used. Someone was in a hurry and omitted a $20 resettable fuse on a $$$ machine. Kind of hard to believe. Lucky for me to have found out before something really bad happened.

Mark

The Pavoni Express website doesn't provide a wiring diagram for an early Pre Millennium heating element to connect to a replacement double switch. The white OEM switch configuration doesn't work with the new black replacement switch, continuity testing confirms contact at different settings. The original switch has 2 brass power terminals, the replacement switch only one. Each switch has 6 numbered terminals, but in different order, with the red power switch on top. Matching terminal numbers to wires was also a dead end.

Anyone know the correct configuration?

hi Doug

a mate who knows more about these than I tells me that the fusible link was only added in 1978. Imagine, production for 17 years without bothering to include a fuse

good luck sorting the wiring.

Hi Doug,
You have probably seen this link before. If it does not help PM me.
very-old-pavoni-two-element-wiring-diagram-needed-t6052.html
I have an older Pavoni that I worked on a few years back that I can confirm the wiring on but if you have the newer switch this should be the setup.

Thanks Bob,
That is the correct switch, but my heating element is even more ancient than the one pictured, four single terminal poles, no fuse.

I believe I have the wiring configuration figured out, thanks to the continuity tester and a little bit of luck. I'll know for sure when I get it back together. I am waiting for delivery of the PTFE gasket material you recommend.

Where did you get the high temp wire sleeves? I searched for them online, but nada.

BTW: nice wiring job Bob!

Cheers,
Doug