Service Manual – G4 Gemini Twin Coffee Brewer
Contents
1. 10 Hr on GEMTIF GEMSIF gt OFF HIGH lt MED gt LOW MED During Brewing Note This function is only visible on Gemini Units Quality Timer OFF 20min 240min 10 Minute Increments OFF on GEMTS GEMSS gt 120min on GEMTIF GEMSIF gt Audible alarm when time is expired Only shows available when a machine has Warmer Elements Also this function is visible when Gemini models are selected Energy Save Mode On On 140 F Off Tank temperature maintained at 200 On Tank temperature is not maintained On 140 Tank temperature maintained at 140F Beeper On Off On Turns Board sounds Off or On Voice Sounds On Off Off Turns Speaker On or Off If Applicable Voice Volumes 0 10075 5 Increments 0 Turns Speaker Volume Up or Down If Applicable Diagnostics Auto Test This Function Runs A Diagnostic Test On All Systems In The Brewer Brew Cones Must Be Inserted And Vessels Must Be Placed Under Brew Cones With Auto Test Auto Test Must Be Limited To Only Two Cycles Three Cycles Will Overflow The Tank Display Settings Show Brew Time On Off Displays Brew Time Show Quality Timer On Off Displays Quality Timer Screen Saver On Off Displays Screen Saver Display Name Curtis Displays Banner Name Prev Maint Maintenance Interval Off Off 1000 to 20000 Gall2. ENTER ACCESS CODE MAIN MENU screen contains five contol icons RECIPES CONTROL SETTINGS BREW SETTINGS MODEL SELECT and EXIT This chart explains how to enter the program mode and menu selections available from the MAIN MENU Es ER I 7 o RECIPES Gourmet STD Light Roast Dark Roast High Yield Tap Curtis Logo 5 Times to Enter Programming Mode CONTROL SETTINGS Temp Settings Warmer Settings Quality Timer Energy Saving Diagnostics Display Settings Brew Counter Passwords Master Reset Enter 1 2 3 4 to access the Main Menu E BREW SETTINGS Select Button Pre Infusion A n MODEL SELECT Thermopro Single Cup Ex Paper Cup MODEL SELECT Recipe and brew parameters will be reset CANCEL One Batch Two Batch Three Batch Three Batch Menu Features Recipes FUNCTION TO SET SEITING RANGE FACTORY SET DEFAULT NOTES COMMENTS Gourmet STD Light Global Recipes Control Settin FUNCTION TO SET Roast Dark Roast High Yield Filter Pack Decaf SEITING RANGE Gourmet STD FACTORY SET DEFAULT NOTES COMMENTS Temp Settings 170 F 206 F 2 F Increments 200 F Warmer Settings Disabled 1 Hr 12 Hr 1 Hr Increments lt Disabled on GEMTS GEMSS gt 1 Hr 12 Hr 1 Hr Increments
3. Service Required 1 800 000 0000x Open Sensor Break in the temperature thermistor circuit or short curcuit Over Temp Error Service Required 1 800 000 0000x Excess Temperature The sensor is reading that temperature in the heating tank has risen above 210 F or sensor has shorted to ground Lime Scale Error Service Required 1 800 000 0000x Water level probe resistance above error threshold test value 180kOhm Internal Error 1 Service Required 1 800 000 0000x UPM UCM Communication Break in the UPM UCM Communication circuit Illustrated Parts Main View ON DO c Illustrated Parts Top Wrap Rough In Drawing 1 000 01 000 11400 100 mmm 11 000 mm 10 11 1 00 010 1000 Hom 1 000 010 1000 Parts List ITEM NO PART NO DESCRIPTION 1 WC 5421 BLK COVER TOP PAINTED BLACK TEXTURE PC 1A WC 5421 COVER TOP STAINLESS GEMTIF 2 WC 37
4. TP2T10 TPC2T10 TP1T10 TP1TT10 7600 345 5100 23 0 TP2T10 TPC2T10 TP1T1O TP1TT10 w HORER TPIT 7600 34 5 10 THERMOSTAT MAN RESET DPST SSR 1 40A 277V 40A 600V BLU 10GA TOGGLE SW SPST 15A 125 250V FUSE 5A 250V 14 PIN CONNECTOR 20 PIN CONNECTOR STP VIO UNIVERSAL POWER MODULE UPM 120Vac 5WVac STP RED BLK 10GA RED 10GA HEATI RED 10GA BLK 10GA RED 10GA NG ELEMENTS 2 5KW 220V STP GRY B BLK BLK 10W 120V BREW CONE LOCK RIGHT 10W 120V BREW CONE LOCK LEFT OPTIONAL COMPONENT 2 0 GPM 5 GPM 5 5 STP BRN 5 GPM 12W 120V wi 1 B 2 10W 120V INLET VALVE 12W 120V BREW VALVE RIGHT BREW VALVE 12W 120V LEFT 1gw 120v BYPASS VALVE WHT RIGHT HT BYPASS VALVE LEFT WARMER RIGHT 100W 120V om WARMER LEFT 100W 120V GEMINI UNITS ONLY 5 H1 AND H2 CONNECTION ONLY REMOVE amp BRN WIRE END FROM H3 H1 H2 AND H3 CONNECTION REMOVE CAP amp CONNECT BRN WIRE FROM H3 TO C COMMON ON POWER BLOCK amp USE THIS DIAGRAM FOR ALL OTHER MODELS WITH ADDED PREFIX LETTERS AND OR SUFFIX NUMBERS ON THEIR PART NUMBERS HAVING THE SAME ELECTRICAL RATINGS 3 LOCATE CONNECTORS AWAY FROM HEAT 2 INSTALL GROUND LUG OVER THE SENSOR ON TANK SENSOR STUD 1 ALL WIRES SHALL BE 18AWG UNLESS NOTE
5. 008 KIT TANK LID ROUND 3 WC 43067 O RING 4 1 2 I D x 0 285 C S SILICONE 4 WC 37406 KIT FAIL SAFE PROBE NON METALLIC ROD 5 WC 62033 TANK COMPLETE GEMTS WITH ULTEM FITTINGS 6 WC 934 04 HEATING ELEMENT 2 5KW 220V W JAM SILICONE WASHERS 7 WC 4382 GUARD SHOCK DOUBLE HEATING ELEMENTS 8 WC 522 THERMOSTAT HI LIMIT HEATER DPST 277V 40A 9 WC 43055 GUARD SHOCK RESET THERMOSTAT 10 WC 1438 101 SENSOR TEMPERATURE TANK 11 WC 29050 SPRAYHEAD ASSY AFS AMBER 12 WC 8559 RELAY SOLID STATE 40A w INTEGRATED HEATSINK 13 WC 14045 101 CURRENT SENSOR ASSY G4 14 WC 39745 LABEL BOTTOM WRAP GEMTIF 15 WC 1809 FAUCET PS HSP SERIES HOT WATER 1 2 20 UNF 16 GEM 6 FILTER 500PK GEM 12 230A 17 WC 37308 KIT BREW CONE GEMINI NON METAL with FRESH COFFEE LOGO 18 WC 37310 KIT BREWCONE ALIGNMENT BRACKET STAINLESS 19 WC 61309 COVER FRONT CENTER WRAP W A STAINLESS GEMTIF 20 WC 61301 DECK WARMER WELD ASSEMBLY GEMTIF 21 WC 37102 KIT WARMER ELEMENT 22 WC 3528 LEG 4 ADJUSTABLE 3 8 16 THRD STYLIZED 23 GEM 3 SATELLITE SERVER 1 1 2 GAL 24 WC 5310 TUBE 5 16 ID x 1 8W SILICONE 25 WC 5350 TUBE SILICONE 1 2 ID x 03 4 OD x 1 8 WALL 26 WC 2402P ELBOW 3 8 NPT x 3 8 FLARE PLATED 27 WC 847 VALVE INLET 2 GPM 120V 10W 28 WC 589 101 TRANSFORMER 120 230VAC 24VAC 4 8VA w LEADS 8 TERMINALS 29 WC 13450 HARNESS ASSY COMPLETE TP2T10G4 GEMTS10G4 GEMTIF10G4 30 WC 1501 FUSE HOLDER ASSY w 5A FUSE 31 WC 102 SWITCH TOGGLE SPST 15A 1
6. 25Vac RESISTIVE 32 WC 4212 02 5 8 18 JAM PLASTIC ULTEM 33 WC 37121 KIT DUMP VALVE LEFT 34 WC 442 SOLENOID LOCK BREW CONE RIGHT 120VAC 35 WC 2977 101 FITTING SPRAYHEAD ULTEM 36 WC 43089 GASKET 1 00 OD x 625 I D x 030 THK RED SILICONE 40 SHORE 37 WC 37122 KIT DUMP VALVE RIGHT 38 WC 39812 LABEL OUTER TOUCHSCREEN GEMTSG4 CURTIS LOGO 39 WC 10000 CONTROL MODULE TOUCH SCREEN G4 40 WC 844 101 VALVE BYPASS 120V 14W NON ADJUSTABLE WITH RESTRICTOR WC 2945 41 WC 10001 UNIVERSAL POWER MODULE G4 42 WC 10008 UNIVERSAL HOST ADAPTER USB RECOMMENDED PARTS TO STOCK Electrical Schematic POWER BLOCK 57 65 300 450 ALTERNATE TRANSFORMER WIRE HOOKUPS 5 STP BLU Vss 8 CONNECTOR UNIVERSAL TOUCH SCREEN 12Vac 5 CONNECTOR WHT 22AWG BLK 22AWG RED 22AWG USB 5 6 CONNECTOR ELECTRICAL RATING TABLE 18 RED GRN 12GA S 10GA CHASSIS GROUND HEATING TANK CHASSIS GROUND Vdd_ 5Vde Logic_Common BLU GRY GRINDER INTERLOCK SSR PIN ASSIGNMENTS Data Communication First UJ RED 5 SHIELDED CABLE WHT Z STP YEL UPM GROUND E STP YEL P HEATING MACHINE ELEMENTS WARMERS RIGHT TOTAL POWER WATTS TOTAL CURRENT AMPERES 510 amp GEMTN10 5200 23 6 GEMTS10 amp GEMTN10 W H3
7. D NOTES UNLESS OTHERWISE SPECIFIED VOLTAGE 220V WATTAGE SEE TABLE AMPERAGE SEE TABLE HERTZ 50 60 HZ WIRES IW LADDER DIAGRAM PHASE 1 PHASE LD GTPTG4 10 Cleaning the Coffee Brewer Regular cleaning and preventive maintenance is essential in keeping your coffee brewer looking and working like new IMPORTANT ak WN gt CAUTION Do not use cleansers bleach liquids powders or any other substance containing chlorine These products promote corrosion and will pit the stainless steel USE OF THESE PRODUCTS WILL VOID THE WARRANTY Wipe exterior surfaces with a moist cloth removing spills and debris Slide the brewcone out and clean it Clean the sprayhead area with a moist clean cloth Rinse and dry the brewcone Drain drip tray of coffee Wash out the drip tray Dry the tray Rub a stainless steel polish on the outside surfaces to protect the brewer Cleaning the Satellite Server To clean the Satellite components prepare a mild solution of detergent and warm water 1 TX Remove lid from Satellite Clean the lid at the funnel area with a spiral brush and detergent solution Rinse the lid removing all traces of cleaning solution Unscrew the handle bonnet assembly and remove it from the dispensing faucet Pull the silicone seat cup from faucet stem and inspect it for wear cracks or hardening Replace the seat cup if necessary Clean all parts Thoroughly rinse with
8. WiLBUR Curtis Inc Service Manual G4 Gemini Twin Coffee 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 Toreduce the risk offire or electric shock DO NOT open service panels There are 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 is Sanitation Requirements Model This Curtis Generation 4 Unit is Factory Pre Set and Ready to Go Right from the Box Following are the Factory Settings for your G4 Coffee Brewing System Brew Temperature 200 F Water Bypass On for LARGE amp MEDIUM Brew Only Brew Volume Set to Vessel Requirement System Requirements e CAUTION Please use Water Source 20 90 PSI Minimum Flow Rate of 1 GPM this setup procedure Electrical See attached schematic for standard model or visit www wilburcurtis com for your model before attempting to use this brewer Failure to follow the instructions can result in injury or the SETUP STEPS voiding of the warranty 1 The unit should be level left to right front to back on
9. 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 IMPORTANT Equipment should be consistent Use tubing sized sufficiently to provide a minimum flow rate of one gallon per minute Wied to be installed to comply with applicable govern NOTE A water filtration system must be used to help maintain trouble free operation In areas with mental plumbing electrical codes extremely hard water we highly recommend the use of a Curtis approved water filter For our full line having jurisdiction of filters please log on to www wilburcurtis com A water filtration system will greatly prolong the life of the unit and enhance the quality and taste of the product tthis brewer to hot h T a Sea niet 4 1 A quick disconnect or additional coiled tubing at least 2x the depth of the unit is required so not rated for hot water that the unit can be moved for cleaning 2 This unit must be installed with adequate backflow 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 CAUTION DONOT NSF International requires the following water connection IMPORTANT 3 Connect the unit to electrical outlet with appropriate amperage rating see
10. clear warm water Dry and assemble the handle bonnet parts Hand tighten the assembly onto the faucet Remove the gauge glass tube by unscrewing the gauge glass cap Clean the gauge glass tube and the two washers with a gauge brush and detergent solution Rinse with clear water Dry the parts and assemble them onto the Satellite DO NOT immerse the Satellite in water or any other liquid 9 Clean inside of the Satellite Remove coffee residue with the detergent solution 10 Thoroughly rinse out the Satellite with clear warm water 11 Product Warranty Information The Wilbur Curtis Company 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 the Wilbur Curtis Company 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 replace ment parts are warranted for ninety 90 days from date of purchase or for the remainder of the limited warranty period of the equipment in which t
11. he 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 The Wilbur Curtis Company Inc assumes no responsibility for substitute replace ment parts installed on Curtis equipment that have not been purchased from the Wilbur Curtis Company Inc The Wilbur Curtis Company 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 adjustments are the res
12. ons 1000 Increments Service Telephone Number 1 800 000 0000 x0000 Brew Counter Resetable Resetable For maintenance purpose Resetable Passwords Resetable 1234 Not Resetable Menu Features Control Settings Continued Master Reset Reset Are you sure Yes No 7 Resetto Restore Factory Home Select to go to Home Page Brew Settings FUNCTION TO SET SETTING RANGE FACTORY SET DEFAULT NOTES COMMENTS LARGE BREW 2000z 8oz using a Amber AFS Sprayhead OFF 30sec to Brew by Volume 19Min 59sec MEDIUM BREW 13207 4oz using a Amber AFS Sprayhead Set Press Brew to stat Press Brew to stop SMALL BREW 640z 40z using a Amber AFS Sprayhead LARGE BREW 5min 25secs using a Amber AFS Sprayhead 0 to 19Min 59sec pew Py Time 1min 01secs increments Note These are the default times MEDIUM BREW 3min 32secs using a Amber AFS Sprayhead for a Amber AFS Sprayhead SMALL BREW 1min 52secs using a Amber AFS Sprayhead Disabled 10 secs On 10 secs Off 20 secs On 20 secs Off 30 secs On 30 secs Off Pre Infusion Disabled 40 secs On 40 secs Off 50 secs On 50 secs Off 60 secs On 60 secs Off Pulse Brew On Off LARGE BREW 35 using a Amber AFS Sprayhead n n Note These are the default times MEDIUM BREW 1075 using a Amber AFS Sprayhead for a Amber AFS S
13. ponsibility 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 car rier 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 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 responsibility of the owner of the equipment This includes institutional and correctional facilities The Wilbur Curtis Company will allow up to 100 miles round trip per in warranty service call RETURN MERCHANDISE AUTHORIZATION claims under thi
14. prayhead SMALL BREW Off using a Amber AFS Sprayhead By Pass On Off Off 5 50 in 5 increments Off 5 Seconds 15min 7 Drip Out Mode 10 Second Increments 2 min Reprogrammable Home Select to go to Home Page System Fault Messages WARNING MESSAGES ALLOWS BREWING MESSAGE DISPLAY Component Failure Service Required 1 800 000 0000x WARNING DESCRIPTION A Component has Failed CAUSE Current in one of the components is not within normal range Maintenance Required Service Required 1 800 000 0000x Maintenance Required Brew count Gallons Since Reset exceeds programmed Preventative Maintenance period Lime Scale Warning Service Required 1 800 000 0000x Scale Starting to Build Up Water Level Probe Water level probe resistance above warning threshold test value 23k Ohm Low Water Flow Warning Service Required 1 800 000 0000x MESSAGE DISPLAY Water Level Error Service Required 1 800 000 0000x Low Water Flow If the Inlet valve remains on longer than 40 Seconds during the brew cycle only and repeats TWICE during that brew cycle It shall clear upon the next brew and if the same low flow exists again it will re appear ERROR MESSAGES STOPS BREWING ERROR DESCRIPTION Fill run error Overflow The fill solenoid has either run for more than 10 minutes on the initial tank fill or 1 5 minutes in normal operation Sensor Error
15. rol will display when temperature reaches the set point The unit is now ready to brew COFFEE BREWING INSTRUCTIONS 1 Brewer should be ON Confirm at the rear toggle switch The LCD screen should read Ready to Brew 2 Place an empty satellite server on the warmer deck under the brewcone and touch the warmer icon to Preheat the satellite 3 Placea clean filter 4 Fill brewcone with 5 Transfer filled 6 Touch desired into the brewcone ground coffee brewcone to brew button brewer Brewing will begin immediately WARNING TO AVOID SCALDING Do not remove brewcone while brew light is flashing Touch Screen Control Module The touch screen turns on when power is available to the controller The screen will contain standard control feature such as symbols and but tons Pressing these elements with your finger tip will activate the programming functions The default screen as well as some added control buttons are shown in the illustration below STATUS LIGHTS WARMERS BREW BUTTONS CURTIS LOGO TO ENTER PROGRAMMING Tap Curtis logo 5 times to bring up the ACCESS CODE screen CONTROL SYMBOLS All of these symbols may not be visible at one time n 2 RETURN TO HOME UNDO SCROLL RETURN TO PREVIOUS PROGRAMMING ACCESS CODE screen Default is 1 2 3 4 Once the code is entered press OK The Main Menu screen will appear Menu Tree
16. s 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 repackaged 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 Sup port Department to find an agent near you 7 6 11 10 3 EDR 7842 2 9 WILBUR CURTIS CO INC 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 30A 4 00P PST Web Site www wilburcurtis com E Mail techsupport wilburcurtis com 7 11 F 3804 rev NC
17. 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 ISO 9001 2008 REGISTERED 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 WILBUR CURTIS CO INC 6913 West Acco Street Montebello CA 90640 5403 For the latest information go to 5 Water in the heating tank will require approximately a half hour before reaching operating temperature factory setting of 200 F Where applicable turn on the Universal Control Module UCM When the unit reaches operating temperature it will display READY TO BREW www wilburcurtis com For the latest specifications and information go to www wilburcurtis com Tel 800 421 6150 Technical Support 1 800 995 0417 M F 5 30am 4 00pm PT Fax 323 837 2410 Email techsupport wilburcurtis com 1 QUICK START Your Curtis G4 Gold Cup Series is Factory Pre Set for Optimum Performance After connection to water and power turn on the brewer at the rear toggle switch You will hear a beep and the status lights will come on for a moment The screen will display Next FILLING is displayed Water will fill the tank 2 3 minutes depending on water flow rate When the proper level is reached HEATING will appear on the screen It takes approximately 30 minutes to reach the set point temperature Cont
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