Service Manual – GEM-120A Satellite Brewer
Contents
1. Model e GEM 120A CAUTION AEN Equipment must be installed to comply with applicable federal state and local plumbing electrical codes CAUTION Follow NA thi t d et this setup procedure before attempting to use this unit Failure to follow these instructions can result in injury and or void of warranty CAUTION DO NOT AD connect the unit to hot water supply The inlet valve is not rated for hot water ISO 9001 2008 REGISTERED WILBUR CURTIS CO INC 6913 West Acco Street Montebello CA 90640 5403 For the latest information go to www wilburcurtis com Tel 800 421 6150 Fax 323 837 2410 WiLBUR Curtis Co INc Service Manual GEM 120A Satellite Brewer Important Safeguards Symbols This equipment is designed for commercial use Any servicing other than cleaning and routine maintenance should be performed by an authorized Wilbur Curtis Company Service Technician DO NOT immerse the unit in water or any other liquid To reduce the risk of fire or electric shock DO NOT open service panels There no user serviceable parts inside Keep hands and other items away from hot areas of the unit during operation Never clean with scouring powders or harsh chemicals SYMBOLS WARNINGS To help avoid personal injury Important Notes Cautions from the factory Sanitation Requirements INSTALLATION This Curtis unit is pre set and ready to go from the fact2. claims under this warranty must be submitted to the Wilbur Curtis Company Technical Support Department prior to performing any repair work or return of this equipment to the factory All returned equipment must be repack aged properly in the original carton No units will be accepted if they are damaged in transit due to improper packaging NO UNITS OR PARTS WILL BE ACCEPTED WITHOUT A RETURN MERCHANDISE AUTHORIZATION RMA RMA NUMBER MUST BE MARKED ON THE CARTON OR SHIPPING LABEL All in warranty service calls must be performed by an authorized service agent Call the Wilbur Curtis Technical Support Department to find an agent near you ECN 16604 10 30 15 16 2 rev K 2 9 WILBUR CURTIS CO INC 777 6913 Acco St Montebello CA 90640 5403 USA Phone 800 421 6150 Fax 323 837 2410 Technical Support Phone 800 995 0417 M F 5 30 a m 4 00 PST Email techsupport wilburcurtis com Web www wilburcurtis com 10 2015 F 1903 rev K
3. WATTAGE 1775 TITLE PARUS 45 LADDER DIAGRAM ALL WIRES SHALL BE 18AWG MINIMUM UL APROVED APPLIANCE WIRE T MENU TN DO NOT CHANGE OR SUBSTITUTE WIRE COLORS WIRES 2 GND PART NUMBER REVISION NOTES UNLESS OTHERWISE SPECIFIED DUE M ma LD Gl204 10 A ELECTRICAL DIAGRAM GEM120A 63 RED14 BLK 14 POWER BLOCK 5 STATION THERMOSTAT SPST BLK 14 5 BRN 14 READY LIGHT 220V HEATING ELEMENTS TE eer 2KW 220V 16 120 THERMUSTAT WHT14 WARMER SW 120V WARMER 100W 120V DUMP VALVE 9W 120V BREW SW LIGHT 120V BREW TIMER 2 20Min 120V BREW SW 120V LIQ LEVEL 120 240V INLET VALVE 10W 120V 6 USE THIS DIAGRAM FOR ALL OTHER MODELS WITH ADDED PREFIX LETTERS AND OR DIFFERENT DASH NUMBER ON THEIR PART NUMBERS HAVING THE SAME ELECTRICAL RATINGS Ex 5 120 63 and or 120 63 01 5 FOR 220VAC OPERATION CONNECT RED14 WIRE TO POINT ON POWER BLOCK WC 314 amp STOW 14 2 FOR 120VAC OPERATION CONNECT BLK14 WIRE TO POINT ON POWER BLOCK WC 314 CAP amp STOW RED14 3 NOTE DELETED 2 TEFLON WIRES 14 AWG MAY BE USED AS A SUBSTITUTE FOR THE 14 AWG APPLIANCE WIRE 1 ALL WIRES SHALL BE 18 AWG UL APPROVED APPLIANCE WIRE 120 220 NOTES unless otherwise specified WATTAGE 1775 2100 LADDER DIAGRAM GEM 1204 63 2W 3W GRD MOE 0 6120 635 wv NC ELECTRICAL DIAGRAM GEM 5 am
4. adjustments are the responsibility of the equipment owner The owner is responsible for proper cleaning and regular maintenance of this equipment 6 Damaged in transit Equipment damaged in transit is the responsibility of the freight company and a claim should be made with the carrier 7 Abuse or neglect including failure to periodically clean or remove lime accumulations Manufacturer is not responsible for variation in equipment operation due to excessive lime or local water conditions The equipment must be maintained according to the manufacturer s recommendations 8 Replacement of items subject to normal use and wear This shall include but is not limited to light bulbs shear disks 0 rings gaskets silicone tube canister assemblies whipper chambers and plates mixing bowls agitation assemblies and whipper propellers 9 Repairs and or Replacements are subject to our decision that the workmanship or parts were faulty and the defects showed up under normal use All labor shall be performed during regular working hours Overtime charges are the responsibility of the owner Charges incurred by delays waiting time or operating restrictions that hinder the service technician s ability to perform service is the responsibil ity of the owner of the equipment This includes institutional and correctional facilities Wilbur Curtis Co Inc will allow up to 100 miles round trip per in warranty service call RETURN MERCHANDISE AUTHORIZATION
5. onto the brewer 3 TROUBLE SHOOTING PROBLEM WATER DOES FLOW INTO HEATING TANK POSSIBLE CAUSE SOLUTION 1 Water line turned off or filter clogged up Open the water line and make sure water flows to the brewer Water inlet valve coil burned out Turn off brewer Disconnect wires from water inlet coil terminals and connect a power cord to the terminals Plug cord into a 110v outlet and verify that water flow when plugged in and stops when cord is disconnected If valve does not respond to this test replace the valve Grounded probe When water in the heating tank is below the probe tip yet water is not refilling pull the wire off the probe terminal If water starts flow ing into the tank find ground clean or replace the probe Defective or burned out water level control board Pull the wire from the probe terminal With a volt meter check the voltage at the water inlet coil terminals This should read 110 to 115 volts If no voltage is present check the water level control board Make sure that the back of the board is grounded securely to the mounting bracket Check for loose wire connections Replace board PROBLEM WATER IN HEATING TANK OVERFLOWING POSSIBLE CAUSE SOLUTION 5 Defective water inlet valve Turn power off and observe the water level in the heating tank If water continues to flow in clean or replace the valve 6 Probe limed up Pull wi
6. the BREW switch is pressed If there is no continuity replace the switch 13 Defective timer Make sure the timer is receiving 110 to 120 volts You can verify this by taking a reading with your meter at the end of the YELLOW wire on terminal 5B of the ON OFF switch and at terminal 9 of the timer When the timer is activated by the brew switch you should read 110 to 120 volts across terminals 8 and 9 of the timer The RED wire on terminal 8 supplies power to open the dump valve If no voltage is present replace the timer 14 Burned out dump valve If the timer works when the brew switch is pressed then check the Coil dump valve using a voltmeter on the terminals If it shows 110 to 120 volts but no water flows through the valve clean out the valve or replace the coil GEMINI 120A Parts List GEMINI 120A Parts List ITEM No PART No DESCRIPTION 1 WC 3621 101 BREW CONE NON METAL UNIVERSAL WITH SPLASH POCKET 2 WC 603 101K GEM KIT RETROFIT TIMER BREW SELECTOR 120V GEM 120A 12 3 WC 608 101K KIT LIQUID LEVEL CONTROL BOARD RETROFIT 4 WC 2936 SPRAYHEAD RED 9 131 5 WC 5527K KIT PROBE WATER LEVEL O RING amp NUT CURTIS 6 WC 3920 01 LABEL SWITCH PANEL GEM 120A CURTIS 6A WC 3920T LABEL SW PANEL GEM 120A CURTIS OLDER UNITS 7 WC 904 04 KIT ELEMENT HEATING 1 6KW120V W JAM NUT amp SILICONE O RING WC 906 04 KIT ELEME
7. NT HEATING 2KW 220V W JAM NUT amp SILICONE O RING 8 WC 1200 CORD 14 3 SJTO 6 BLK W PLUG 9 WC 826L VALVE INLET 1 GPM 120V 10W ALP AP TLP GREY BODY 10 WC 504 THERMOSTAT CAPILLARY SPST 250V 25A GEM 11 WC 3763 KIT DUMP VALVE FOR WC 889 WC 817 12 WC 817 VALVE DUMP RIGHT 120V 12W W RECTIFIER AP GEM 13 WC 1809 FAUCET PS HPS SERIES HOT WTR 1 2 20 UNF AP ALP 14 WC 207 LIGHT BREW 115V GREEN 14A WC 208 LIGHT BREW 250V GREEN 15 WC 114R SWITCH ROCKER RED 120V NEON SPST 15A 250V 16 WC 122 SWITCH BREW GREEN 120V NEON SPST 15A 250V 17 WC 2977 101K KIT SPRAYHEAD FITTING PLASTIC 18 WC 5310 TUBE 5 16 ID x 1 8W SILICONE GEN USE 19 WC 523 THERMOSTAT MANUAL RESET 120 240 VAC 25A 220 DEG F MAX 19A WC 522 THERMOSTAT HI LIMIT HEATER CONTROL DPST 277V 40A 20 WC 970 ELEMENT WARMER ASSY 100W 120V WITH SILICONE BOOTS 21 WC 102 SWITCH TOGGLE NON LIT SPST 15A 125 6A 250VAC RESISTIVE 22 WC 3503 LEG 3 8 16 STUD SCREW BUMPER 23 WC 3338 101 B CONE ASSY W SPLASH POCK NON MTL DLX D500 D1000GT OPT 24 WC 5452 KIT COVER FRONT GEM 120A 120P 230A 200R 3001L 600ILD 25 WC 58117 COVER TOP ALPGT D500GT D60GT TLP TCTS CBS GEMSS 26 WC 43058 PLUG TANK DRAIN ULTEM 1000F 27 WC 3765L KIT INLET VALVE REPAIR USE ON WC 826 WC 826L WC 847 28 WC 3920B LABEL BOTTOM PANEL GEM 120A CURTIS 29 WC 37008 KIT TANK LID ROUND 30 WC 5466 TANK COMPLETE GEM 120A C500AP 30A WC 54133 TANK COMPLETE GEM 120A 120 220V DV PAPER FILTERS Recommended Parts to S
8. a mild solution of detergent and warm water e CAUTION Do not use cleaning liquids compounds or powders containing chlorine bleach or corrosives These products promote corrosion and will pit the stainless steel USE OF THESE PRODUCTS WILL VOID THE WARRANTY DAILY CLEANING 1 Wipe exterior surfaces with a damp cloth removing spills and debris 2 Slide the brew basket out and clean it Wipe the spray head area with a cloth soaked in a mild detergent solution 3 Rinse and dry the brew basket and spray head area 4 Drain coffee from the drip trays 5 Usea clean soft cloth to wipe dry the coffee brewer and drip tray WEEKLY CLEANING 1 Tum off unit at the power switch behind the unit Allow the brewer to cool 2 Clean the spray head and dome plate area a Remove the spray head unscrewing counterclockwise from the dome plate b Thoroughly clean the dome plate area with detergent solution c Clean the brew basket rails with a brush soaked with the detergent solution When clean rinse the area with a cloth soaked with clean water to remove all traces of detergent d Usea clean soft cloth to dry the area c Attach the spray head CLEANING THE SATELLITE SERVER Empty any remaining coffee from the satellite server Fill the liner with a mild detergent solution and let it stand for 10 to 15 minutes 1 2 3 After about 15 minutes take sponge brush and scrub out the stainless steel liner 4 Drain out the detergent solution from
9. e amperage rating see serial tag on machine 4 Once power has been supplied to the unit flip the toggle switch to the ON position located on the rear of the unit the water tank will begin to fill When the water level in the tank reaches the probe the heating element s will turn on 5 Water in the heating tank will require approximately a half hour before reaching operating temperature fac tory setting of 200 F When the water temperature in the heating tank is ready the green BREW WHEN LIT light will come on For the latest specifications and information go to www wilburcurtis com BREWING 1 Brewer should be ON Confirm at rear toggle switch then press the ON OFF button The Brew When Lit light should be on 2 Place an empty satellite under the brew basket and press the warmer switch to pre heat the satellite 3 Place a clean filter into the brew basket 4 Fill the brew basket with the 5 Transfer the brew basket 6 Determine the brew volume correct amount of ground to brewer inserting it into and flip the toggle switch to coffee the brew basket rails desired size 7 gallon 1 or 1 gallon 2 Press the brew button Brewing will begin WARNING AVOID SCALDING Do not remove the brew basket while USO the brew light is flashing CLEANING Regular cleaning and preventive maintenance is essential in keeping your coffee brewer looking and working like new To clean the coffee brewer and components prepare
10. ited warranty period of the equipment in which the component is installed All in warranty service calls must have prior authorization For authorization call the Technical Support Department at 1 800 995 0417 Effective date of this policy is April 1 2003 Additional conditions may apply Go to www wilburcurtis com to view the full product warranty information CONDITIONS amp EXCEPTIONS The warranty covers original equipment at time of purchase only Wilbur Curtis Co Inc assumes no responsibility for substitute replace ment parts installed on Curtis equipment that have not been purchased from Wilbur Curtis Co Inc Wilbur Curtis Co Inc will not accept any responsibility if the following conditions are not met The warranty does not cover and is void under the following circumstances 1 Improper operation of equipment The equipment must be used for its designed and intended purpose and function 2 Improper installation of equipment This equipment must be installed by a professional technician and must comply with all local electrical mechanical and plumbing codes 3 Improper voltage Equipment must be installed at the voltage stated on the serial plate supplied with this equipment 4 Improper water supply This includes but is not limited to excessive or low water pressure and inadequate or fluctuating water flow rate 5 Adjustments and cleaning The resetting of safety thermostats and circuit breakers programming and temperature
11. ory Factory settings for this unit are Brew Temperature 200 F Brew Volume Set to vessel requirements 1 Gallon System Requirements Water Supply 20 90 psi minimum flow rate of 1 gpm Electrical See electrical schematic SETUP STEPS 1 The unit should be level left to right front to back on a secure surface 2 Connect the water line to the water inlet fitting on the rear of the unit Water volume flow to the machine should be consistent Use tubing sized sufficiently to provide a minimum flow rate of one gallon per minute be purged from the cartridge prior to connection to equipment In areas with extremely hard water we highly recommend the use of a Curtis approved water filter For our full line of filters please log on to www wilburcurtis com e NOTE A water filtration system must be used to help maintain trouble free operation Air must IMPORTANT NSF International requires the following water connection 1 A quick disconnect or additional coiled tubing at least 2x the depth of the unit is required so that the unit can be moved for cleaning 2 This unit must be installed with adequate back flow protection to comply with applicable federal state and local codes 3 Water pipe connections and fixtures directly connected to a portable water supply shall be sized installed and maintained in accordance with federal state and local codes 3 Connect the unit to electrical outlet with appropriat
12. p 8 WARMER SWITCH SPST 15 250V WARMER ELEMENT 120 100W 120 POWER 104 125 VOLTAGE 120V wow ee WIRING DIAGRAM GEM 5 AND 8 HERTZ 50 60Hz ROUGH IN DRAWING GEM 120A ROUGH IN DRAWING GEM 3 amp GEM 5 11 25 28 6cm 10 00 2 25 4 cm 350 8 9 cm 9 00 22 9 cm Product Warranty Information Wilbur Curtis Co Inc certifies that its products are free from defects in material and workmanship under normal use The following limited warranties and conditions apply 3 years parts and labor from original date of purchase on digital control boards 2 years parts from original date of purchase on all other electrical components fittings and tubing 1 Year Labor from original date of purchase on all electrical components fittings and tubing Additionally Wilbur Curtis Co Inc warrants its grinding burrs for forty 40 months from date of purchase or 40 000 pounds of coffee whichever comes first Stainless steel components are warranted for two 2 years from date of purchase against leaking or pitting and replacement parts are warranted for ninety 90 days from date of purchase or for the remainder of the lim
13. re off from probe terminal Touch the water tank shell with the terminal at the end of this wire If water stops flowing clean or replace the probe 7 Loose or ungrounded water level control board If probe is okay check the water level control board The water level control board must be securely grounded Check for loose connec tions Check for voltage at the inlet valve terminals Replace board PROBLEM WATER IN TANK DOES NOT GET HOT OR WATER TEMPERATURE TOO LOW POSSIBLE CAUSE SOLUTION 8 Thermostat is off Check the thermostat to make sure it is in the ON position Turn the thermostat stem clockwise until it stops 9 Burned out heating element Check element for continuity and or check with clamp ammeter This should show a reading of approximately 15 amps If no power is go ing through element replace it TROUBLE SHOOTING PROBLEM WATER IN TANK DOES GET HOT OR WATER TEMPERATURE TOO LOW POSSIBLE CAUSE SOLUTION 10 Defective thermostat Thermostat may be cutting off before the water temperature reaches operating temperature Do not try to reset the thermostat Replace it PROBLEM WATER NOT FLOWING FROM Spray head POSSIBLE CAUSE SOLUTION 11 Water level is too low Check water level in tank If water is not flowing into the tank re in heating tank view steps 1 thru 4 previous page 12 Defective brew switch Check the continuity between terminals 5B and 4B when
14. the server Rinse in a sink with running water 5 Repeatthis rinsing until the water runs clear CLEANING THE FAUCET 1 Remove the faucet handle assembly Take hold of the bonnet and turn counterclockwise to unscrew it from the faucet 2 Clean the handle assembly with a mild detergent solution When clean rinse the handle with water Inspect for cracks tears in the seat cup Replace if the seat damaged 3 Clean the coffee level gauge glass ASSEMBLY FROM 5 x FAUCET BODY a Remove the gauge glass cap unscrewing it from the top of the shield b Carefully pull out the gauge glass Brush out the inside of the glass with a detergent solution Rinse the gauge glass tube with clear water removing all traces of the detergent solution c Inspect the gasket seals at the top and bottom of the gauge glass Clean these gaskets d Assemble the gauge glass Make sure gaskets are properly seated e Hand tighten the gauge glass cap POUCH CLEANER You may use a pouch or tablet cleaner to easily clean both the brew basket and the coffee vessel POUCH TABLET CLEANER CLEANER 1 Place a pouch or tablet cleaner into the brew basket Place an empty server on the brew deck EL 2 Press the brew button to run full brew cycle into the server You will see that the cleaner pouring from the brew basket is blue 3 Atthe end of the brew cycle discard the used filter cleaner pouch The tablets should have dissolved in the bre
15. tock Part Number Description CR 12 FILTER 500 PKG 12 5 16 X4 3 8 FITS DELUXE BREWCONE WC 3338 CR 10 FILTER COFFEE 506 1000 PK 9 3 4 X 4 1 2 xy ILLUSTRATED PARTS LIST GEM 3 5 8 INDEX PART DESCRIPTION 1 GEM 5 SATELLITE WARMER STAND 120V 100W 120V 1A 1PH 50 60HZ 2W G 2 WC 1201 CORD 18 3 SJTO 6 BLK W RED STRIPE W PLUG 3 WC 114R SWITCH ROCKER RED 120V NEON SPST 15A 250V 4 GEM 3 SATELLITE SERVER 1 1 2 GAL 5 WC 5622 LID SATELLITE PLASTIC GEM 3 6 WC 2102 GAUGE GLASS ASSY 8 7 WC 2010C SHIELD GAUGE GLASS 3 4 D X 8 8 WC 2025 GLASS GAUGE 8 9 WC 2007 BRACKET GAUGE GLASS GEM 3 10 WC 1901A 103K KIT SHANK ASSY FAUCET W SHIELD BASE amp O RING 10A WC 1901A SHANK FAUCET W SHIELD BASE 11 WC 1800 FAUCET S SERIES BLK LOCKING 1 1 32 14 UNS CURTIS 12 WC 3705 KIT FAUCET 5 SERIES NONLOCK USE ON WC 1800 13 WC 3503 LEG 3 8 16 STUD SCREW BUMPER 14 WC 37102 KIT WARMER ELEMENT 100W 120V GEN USE Recommended Parts to Stock ELECTRICAL DIAGRAM GEM120A 10 CURL 14 3 6 BLK W PLUG NEUTRAL ses TOGGLE SW SPST 15 6 185 850VAC 5 BLK 14 HI LIMIT 220 F THERMOSTAT THERMOSTAT SPST HEATING ELEMENT 16KW 120V WARMER 100W 120V Sm ON OFF SW 120V WHT DUMP VALVE 9W 120V BREW SW LIGHT O TOGGLE SW SPST 15 6A 125 250 BREW TIMER 2 20Min 120V LIQ LEVEL 120 240 INLET VALVE 10W 120V VOLTAGE 120
16. w cycle 4 Allow the cleaner to soak in the coffee server for a few minutes Dump out the cleaner from the coffee server into a sink Rinse the coffee server and brew basket with clear running water 6 Return the empty coffee server to the brew deck Install the brew basket onto the brewer Run another brew cycle of hot water to rinse the brew basket and the server Empty the rinse water from the coffee server T Drythe surfaces with a clean soft cloth and the brewer is ready to return to service SETTING WC 603 101 BREW TIMER Adjusting the brew timer is made on the calibrated dial The dial range is from 0 to 100 This represents 2 to 20 minutes Also in the timer circuit there is a brew selector switch on the front control panel of the brewer This is marked 1 half brew and 2 full brew To change the brew time setting Disconnect the power cord 1 Flip the brew selector switch to 2 2 Open the top cover and locate the brew timer 3 On the brew timer rotate timer arrow to change the setting Rotating to the right will increase the brew time rotate to the left will decrease it The timer arrow is usually set at 25 This set ting is intended to deliver one gallon of water brew 24 cups per brew cycle 4 After making an adjustment run a brew cycle with coffee to test the liquid level and the coffee taste If this is not satisfactory repeat steps above 5 Once you achieve an acceptable result return the top cover
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