Service Manual – D500GT Airpot Brewer
Contents
1. it cocoi o gt Model Included D500GT CAUTION Please use AD ji this setup procedure before attempting to use this brewer Failure to follow the instructions can result in injury or the voiding of the warranty CAUTION DO NOT N connect this brewer to hot water The inlet valve is not rated for hot water WARNING HOT LIQUID YN Scalding may occur Avoid splashing To avoid temperature drop when first brewing IMPORTANT coffee into the airpot preheat the airpot with hot water O W 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 COMPANY Service Manual D500GT Airpot Brewer Important Safeguards Conventions This appliance is designed for commercial use Any servicing other than cleaning and preventive maintenance should be performed by an authorized Wilbur Curtis service technician Do not immerse the unit in water or any other liquid e To reduce the risk of fire or electric shock do not open service panels No user serviceable parts inside Keep hands and other items away from hot surfaces of unit during operation e Never clean with scouring powders bleach or harsh chemicals Symbols WARNINGS To help avoid personal injury Important Notes Cautions from the factory2. gt Sanitation Requirements The Curtis G3 airpot brewer is Factory Pre Set and Ready to Go Right from the Box Following are the Factory Settings for Curtis airpot brewers Brew Temperature 200 F Brew Volume Set to vessel requirements 74 oz System Requirements Water Source 20 90 PSI minimum flow rate of 1 2 GPM Electrical See attached schematic for standard model or visit www wilburcurtis com for your model 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 1 2 GPM 1 GPM pre ferred NOTE A water filtration system must be used to help maintain trouble free operation 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 A water filtration system will greatly prolong the life of the unit and enhance the quality and taste of the product NSF International requires the following water connection 1 Aquick 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 backflow protection to comply with applicable federal state and local codes
3. 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 appropriate 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 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 For the latest specifications and information go to www wilburcurtis com Technical Support 1 800 995 0417 M F 5 30am 4 00pm PT Email techsupport wilburcurtis com Coffee Brewing Instructions 1 Brewer should be ON Confirm at rear toggle switch then press the ON OFF button Ready to Brew should be on the display 2 Place an empty airpot under the brewcone 3 Place a clean filter 4 Slide the filled brewcone 5 Press the brew button into the brewcone Fill into the brew rails on the Coffee will start to brew brewcone with the proper brewer into the airpot amount of ground coffee WARNING TO AVOID SCALDING Do not remove br
4. min Press to select Press gt to increase time to a maximum of 5 minutes or lt to decrease the time and turn OFF Time counts up in 5 second increments Press to set Model Select Press to select lt or gt Be sure that Airpot Brewer is selected Screen choices are ALPHA 1 ALPHA 2 ALPHA 3 4 5 Airpot Brewer and Thermo Alpha Press to set All menu settings will default to factory standards whenever a new model is selected Exit Press to select exits program mode and returns unit to operation Pressing gt returns you to Brew By Volume Cleaning the Brewer Regular cleaning of the airpot brewer will maintain the highest quality coffee your equipment is capable of producing Proper cleaning is essential to maintain that fresh appealing look to your coffee service 1 Turn off the brewer at the ON OFF button on the control panel Wipe any spills dust or debris from the exterior surfaces with a damp cloth Apply a stainless steel polish to prevent scratches Wipe down the sprayhead area with a moist cloth Slide out the brewcone and clean it with a mild detergent solution Turn on the brewer at the ON OFF button ak WN GD caution DO NOT use undiluted bleach or chlorine IMPORTANT Cleaning Airpots Clean with warm water and dish washing detergent Use a sponge cleaning brush to scrub inside Rinse thoroughly with hot water Do not immerse airpots in water Do not place in dishwa
5. to select Display will now show Select Button Select desired Brew button to program The next screen will promt you to press lt gt to select OFF or one of five pulse patterns A to E Guidelines for Pulse Brew This feature allows tuning of the coffee flavor The pot level should always be set first with this option OFF Depending on your grind profile and water conditions the five Pulse Brew options help tune or change the coffee flavor Filter Pack type coffees typically extract better with the A and B pulse setting Decaffienated coffees typically extract better with the B pulse setting High Yield coffees typically extract better with the C pulse setting Of course any of the A B or C settings may be used to suit your taste profile There are two additional settings D and E that alow you to manually set the ON TIME pulses and OFF TIME disappears from the list of program selections LU When Pulse Brew is ON Pre Infusion disappears from the list of program selections If Pulse Brew is selected ON Cold Brew Lock is set to Delta 1 within 5 F of set point Cold Brew Lock and Pre infusion I Display Brew Time Factory set to ON Press to display ON or OFF Pressing either lt or gt toggles between on and off to set When on the Display Brew Time feature allows you to see the remaining time in the brewcyle counting down Display Brew Time Drip Out Mode Model Select Drip Out Mode Factory set to 2
6. 34 WC 5310 TUBING SILICONE 5 16 1 D 1 FT SUGGESTED PARTS TO STOCK 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 replacement 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 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 The Wilbur Curtis Company Inc assumes no responsib
7. 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 XXX 8 10 12 EDR 7991 10 28 11 14 5 e WILBUR CURTIS CO INC wit 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 E Mail techsupport wilburcurtis com Web Site www wilburcurtis com FOR THE LATEST SPECIFICATION INFORMATION GO TO WWW WILBURCURTIS COM Printed in U S A 8 2012 F 3841 RevA
8. buttons The symbols near the buttons are lt Scroll LEFT SELECTION or ENTER to save new parameter D Scroll RIGHT Scroll through menu to Model Select Choices are ALPHA 1 ALPHA 2 ALPHA 3 4 5 Airpot Brewer and Thermo Alpha Select only Airpot IMPORTANT Brewer Model Select D500GT ONLY Always perform this first This feature re sets all settings to the factory defaults I Program Menus Program Menus From Program Menus press gt display will now show the next feature Selecting Brew by Volume or Brew by Time depends on whether you know your brew time before starting Brew by Volume Factory set to 740z Brew By Volume Press to Select display will now show Press BREW to Start Press the BREW button The unit will start spraying hot water Brew By Time into the brewcone When correct volume is reached press BREW button again to stop the flow Now the volume has been set Pressing gt button will display the subsequent menu features Energy Save Mode Brew Count Odom Brew by Time Factory set to 3 min Press to Select display will now show Select Button The current time is now shown By pressing lt gt you can toggle back and forth from minutes to seconds to exit ex Change the time or set and exit by pressing Temperature Factory set to 200 F Press to Select Press lt gt to move to desired temperature and then to set Temperature is programmable from 170 F to 206 F in 2 deg
9. ewcone while brew light is flashing QUICKESTA RIT Your Curtis G3 Gold Cup Series is Factory Pre Set for Optimum Performance After connection to water and power the rear toggle switch must be on You will hear a beep sound indicating power is available to the controller The control displays CURTS Press ON OFF button and the screen will display Curtis lAfter three seconds CURTIS displayed FILLING Water will fill the tank approximately 2 3 minutes depending on water flow rate When the proper level is reached will appear on the screen It takes approximately 20 minutes to reach the set point temperature Control will display era 70 See When temperature reaches the set point The unit is now ready to brew Programming with the Universal Control Module UCM Turn off the control panel by pressing ON OFF button Press and hold bottom right coffee brew button 4 in illustration and then press and release the ON OFF button ENTERING ENTER CODE Continue holding the bottom right brew button The screen will display _PROGRAM MODE wait until is displayed Enter the 4 digit access code the code corresponds to the buttons illustrated below The default code set at the factory is 1 2 3 4 TPOGRAUM MENUS will be displayed You can now enter the program menu features After the 4 digit code is entered All programming selections are performed with the three center
10. ility for substitute replacement 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 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 condit
11. ions The equipment must be maintained accord ing 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 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 All 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 equip ment 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
12. oint OFF is within 30 degrees of set point for the Ready to Brew message however it will brew at any temperature Master Reset Master Reset Press to display Are You Sure Then lt for Yes gt for No Brewer factory defaults are then reset Service Call Service Call Phone number Factory set to 1 800 000 0000x ens Press to display number and change number or lt to move place and EX to exit when complete This number will be dis played during a Heating system SENSOR ERROR or during a WATER ERROR Access Code Access Code Factory set to 1 2 3 4 Press to display number and change number the number can be change 1 to 4 or lt to move place and ex to exit when complete Continued Page 4 Banner Name Factory set to Curtis Banner Name press to display letters and change letters or lt to move place and EX to exit when complete This feature allows up to 14 letters to be programmed for company name or regional name Programming all blanks disables Banner Name lf programmed Banner Name is displayed every 5 sec on and off Beeper On Off Pulse Brew On Off P Maintenance Factory set to OFF Press to Select Set gallons brewed to indicate P Maintenance Press lt gt to adjust from Off to 3000 gallons Press to exit Beeper On Off Factory set to ON Press to display ON or OFF Pressing either lt gt toggles between on and off Oto set Pulse Brew Factory set to OFF Press
13. ree increments Energy Save Mode Factory set to OFF Press to Select lt gt ON OFF or ON 140 F to set When in ON unit will automatically shut off 4 hours from last brew When feature is OFF unit does not have the energy saving mode In the ON 140 F position temperature goes down to 140 F if unit has not brewed in 4 hours This feature will save energy by lowering the tank temperature during periods of non operation Brew Count Odom Press to display total gallons brewed Press ex or Reset Pre Infusion Factory set to OFF Prednfusiorn Press to Select Display will now show Select Button Select desired Brew button Current setting in seconds is displayed lt to decrease or select gt to increase range from OFF to 10 through 60 seconds to set If Pre infusion is selected ON Cold Brew Lock is set to Delta 1 within 5 F of set point and Cold Brew Lock and Pulse Hu Brew dissappears from the list of program selections Brew Count Total Brew Count Total Press to Select Shows total gallons and total brew cycles on the unit Cannot be reset Cold Brew Lock Factory set to 15 Press to select lt gt to select desired setting CBL 5 15 or OFF to set Cold Brew Lock The Cold Brew Lock feature allows the brewer to brew at three different temperature levels from the actual set point The first setting is within 5 degrees of set point next is within 15 degrees of set p
14. sher Electrical Schematic HEATSINK THERMOSTAT ASSEMBLY MAN RESET BLK 10GA BLK 14GA 1 _ 2 RED 14GA al D BLU 14GA OA 2 A2 o WHT 22GA 220F __ AS GRN 18GA LA POWER CORD HI 120V CAPACITOR 1600W HEATING ELEMENT COMMON STUD CHASSIS GROUND TOGGLE SW TRIAC PIN ASSIGNMENTS N C N C INLET VALVE BREW VALVE TRIAC GATE TRIAC A2 POWER INPUT HOT LI TEMPERATURE SENSOR TEMPERATURE SENSOR GROUND LEVEL PROBE N C N C N C POWER RETURN N MODULE CONTROL WHT a CAS sesa HEATING i TANK INLET VALVE 120V 12W so N alaf afo r w m o aalr vame 120 AMPERAGE 14 TITLE 2 DO NOT CHANGE NOR SUBSTITUTE WIRE COLORS 1 ALL WIRES SHALL BE 18AWG UNLESS OTHERWISE NOTED LADDER DIAGRAM NOTES UNLESS OTHERWISE SPECIFIED DWG NO REV LD D500G1T 10 D Rough In Drawing 9 250 gt Le 16 75 gt 23 5 cm 42 5 cm F h Hs Se K 3 75 g 9 5 cm x 24 500 62 2 cm 19 250 14 875 48 9 cm 37 8 cm LJ Parts Diagram Parts List Item Item No Part No Descrip
15. tion No Part No Description 1 WC 889 101 VALVE DUMP LEFT 120V 17 WC 830 WASHER FLW 1 7 1 0 GPM USE W WC 826 2 WC 37064 KIT LABEL amp UCM D500GT CURTIS 18 WC 5853 102 COVER TOP HEATING TANK GEN USE 3 WC 39346 LABEL CNTRL PNL CURTIS LOGO 19 WC 6277 TANK COMPLETE D500GT 120V 4 WC 37252 KIT HOT WATER FAUCET RPLCMNT 20 WC 37266 KIT TANK OVERFLOW ELBOW FITTING 5 WC 3418 BREW CONE ASSY W SPLASH POCKET 21 WOC 904 04 KIT ELEMENT HEATING 1 6KW120V W NUTS 5A WC 3316 BREWCONE ASSY S S OPTIONAL 22 WC 4394 GUARD SHOCK HEATING ELEMENT 6 WC 5450 COVER TOP OLDER MODELS 23 WC 523 THERMOSTAT MANUAL RESET 6A WC 58117 COVER TOP D500GT 24 WC 43062 GASKET HEATING TANK 7 WC 2962 101KKIT FITTING SPRAYHEAD KYNAR 25 WC 37357 KIT STRAIGHT PLSTC FITTING amp BSHNG 8 WC 13237 HARNESS ASSY D500GT H 10 26 WC 1438 101 SENSOR HEATING TANK 9 WC 29025 SPRAYHEAD PURPLE ADVANCE FLOW 27 WC 5231 COMPOUND SILICONE 5 OZ TUBE 10 WC 102 SWITCH TOGGLE 125 250 VAC RESISTIVE 28 WC 5502 01 KIT PROBE WATER LEVEL W O RING NUT 11 WC 8556 HEATSINK amp TRIAC ASSY 40A 600V 29 WC 37365 KIT TANK INLET FITTING 12 WC 3503 LEG SCREW BUMPER 3 8 16 STD 30 WC 3763 KIT VALVE REPAIR USE ON WC 889 13 WC 826L VALVE INLET 1 GPM 120V 10W 31 WC 6217 COVER FRONT 14 WC 3518 LEG GLIDE 3 8 16 STUD SCREW 32 WC 1806 SEAT CUP SILICONE USE ON WC 1809 15 WC 8591 CAPACITOR X2 33 WC 43058 PLUG TANK DRAIN PP RED 16 WC 3765L KIT VALVE REPAIR USE ON WC 826
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