Service Manual – PCGT - Newtech Beverage Systems
Contents
1. WHT 1 120Vac HOT 1 NOT USED 2 120Vac HOT 2 NOT USED 3 INLET VALVE 3 NOT USED 4 120Vac NEUTRAL 4 NOT USED 5 TRIAC A2 5 TEMPERATURE SENSOR 6 GATE TRIAC 6 TEMPERATURE SENSOR 7 GEAR MOTOR 5 7 WATER LEVEL PROBE 8 DUMP VALVE 5 8 TANK CHASSIS GROUND 9 DUMP VALVE 1 9 UCM DATA 10 GEAR MOTOR 1 10 UCM DATA GROUND 11 DUMP VALVE 2 11 Vdd 12 GEAR MOTOR 2 12 Vss 13 DUMP VALVE 3 14 GEAR MOTOR 3 15 DUMP VALVE 4 16 GEAR MOTOR 4 WHIPPER MOTOR 2 WHT DUMP VALVE 3 Sual WHIPPER MOTOR 3 WHT WHT WHT wye GRN GEAR MOTOR 3 J GRN DUMP VALVE 4 WHT WHIPPER MOTOR 4 WHT WHT T GRN GEAR MOTOR 4 GA GRN GRN WHIPPER MOTOR 5 WHT WHT WHT 0 GRN GEAR MOTOR 5 G5 ELECTRICAL RATING TABLE WHT 14 WHT 22 q gt WHT GRN Q 20 WHT WHT GRN WHT m GRN DUMP VALVE 5 5 WHT CHASSIS GROUND UCM CONNECTOR PIN ASSIGNMENTS 1 UCM DATA 2 UCM DATA GROUND 3 Vss 4 Vdd 5 120Vac NEUTRAL 6 NOT USED 7 NOT USED 8 120Vac HOT FRONT DOOR BLK or BLU BLK Vdd BLK 120VAC SUPPLY FOR UCM MODULE amp LAMP UCM DATA WHT or BRN GROUND WHT or ORG Vss UNIVERSAL CONTROL MODULE UCM I BALLAST TRIAC PIN ASSIGNMENTS Al ANODE1 A2 ANODE2 52. 5 USES VALVES 1 2 3 4 5 amp MOTORS 1 2 3 4 5 4 PCGT4 USES VALVES 1 2 4 5 amp MOTORS 1 2 4 5 3 PCGT3 USES VALVES 2 3 4 amp MOTORS 2 3 4 LD PCGT 10 made for manual with updates based on 5 revD 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 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
3. Models Included PCGT3 e PCGT4 5 CAUTION Use this setup procedure IMPORTANT before attempting to use this appliance Failure to follow the instructions can result in injury or the voiding of the warranty CAUTION DO NOT connect this unit to IMPORTANT hot water Inlet valve not rated for hot water WARNING HOT N LIQUID Scalding may occur Avoid splashing WARNING HOT LIQUID gt 9001 REGISTERED WILBUR CURTIS COMPANY Montebello CA 90640 WILBUR Curtis COMPANY Inc Service Manual PCGT Important Safeguards Conventions This appliance is designed for commercial use Any servicing other than cleaning and maintenance should be performed by an authorized Wilbur Curtis service center e Do NOT immerse the unit in water or any other liquid e To reduce the risk of fire or electric shock do NOT open top panel No user serviceable parts inside Repair should be done only by authorized service personnel e Keep hands and other items away from hot parts of unit during operation e Never clean with scouring powders or harsh implements Conventions WARNINGS To help avoid personal injury D Important Notes Cautions from the factory IMPORTANT ist Sanitation Requirements Your Curtis G3 System is Factory Pre Set and Ready to Go Right from the Carton Following are the Factory Settings for your Primo Cappuccino Beverage System e Tank Temperature 190 F e Flavor Contr
4. Press and the screen will display Powder Ratio Select Station Press desired station Powder ratio is program mable from 0 Hot Water to 100 in 5 increments Press lt or gt to increase or decrease ratio and then press to set Press gt to continue to the next menu amp Valves should not be field adjusted to change product strength tam Product strength adjustments should be done through programming on the front panel only Service Call Phone number Press to display number and press change number or gt to move places and EX to exit when complete This number will be displayed during a Heating system SENSOR ERROR or a WATER ERROR Press gt to continue to the next menu Banner Name Press to display letters press to change letters or gt to move places and EX to exit when complete This feature allows to 14 letters to be programmed for company name or regional name Programming all blanks disables Banner Name Press gt to continue to the next menu Model Select Press to select lt or gt to select desired model 1 2 3 4 5 Press to set and exit program mode Exit Press to select exits program mode and returns unit to operation Parts List Item 1 1A 2 2A 3 3A 3B 3G 4 5 5 11 11 12 13 14 15 16 17 18 19 20 21 21 22 22 23 23A 23B 24 25 26 27 WC 58110 WC 68159 WC 68165 WC 68167 CA 1109 01 CA 1110 01 C
5. 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 low water pressure and inadequate or fluctuating water flow rate 5 Adjustments and cleaning 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 car rier 7 Abuse or neglect including failure to period
6. LEFT PCGTs FITTING BULKHEAD WATER BUSHING DISCHARGE ELBOW PC CK HC STEAM TRAP A 4 5 S NCI BG A 7 AX 2 aX 7 Item 28 29 30 30 31 22 33 34 35 36 oF 38 39 40 41 42 43 44 45 46 47 48 49 50 50 50 51 51A 52 53 54 55 56 57 58 59 60 61 62 62 63 Part CA 1009 03 CA 1037 3Y CA 1002 01 WC 5664 05 CA 1047 WC 37054 WC 2626 03 WC 3739 WC 43791 WC 37118 CA 1008 07K CA 1006 06 CA 1024 05 WC 37174 CA 1036 WC 3765L WC 5231 WC 39350 02 WC 39203 WC 826L WC 8556 WC 5310 CA 1030 17 WC 6294 WC 6295 WC 6296 WC 58120 WC 58121 CA 1095 WC 8591 CA 1135 WC 3503 WC 3518 WC 4320 WC 4394 WC 3689 WC 68123 WC 68121 WC 66044 WC 66043 WC 43067 Description BOWL MIXING TUBE EXTENSION 3 0 LONG YELLOW LID CANISTER 5LB LID CANISTER 10LB PCGT s AUGER WIRE PCs amp PCGTs KIT SOCKET GEAR PC CK HC BUSHING AUGER PC CK HC MOTOR WHIPPER RING MOTOR SHAFT PLASTIC KIT WHIPPER PLATE W SEAL 3 PKG KIT PROPLR OFFSET BLADES PCGT PKG6 WHIPPER CHAMBER PILLAR LOCATION BLACK KIT GEAR MOTOR CORK BRAKE PCGT GEAR PLASTIC USE ON CA 1013 KIT INLET VALVE REPAIR USE ON WC 826L COMPOUND SILICONE 5 OZ TUBE LABEL PANEL FLAVOR CURTIS LABEL SERVICE amp PROG NOT SHOWN VALVE INLET HEAT SINK ASSEMBLY TUBE 5 16 ID X 1 8 w SILICONE HOSE EXTRACTOR FAN 17 LONG HEATING TANK COMPLETE
7. PCGT3 HEATING TANK COMPLETE PCGT4 HEATING TANK COMPLETE PCGT5 COVER DUMP VALVE PC 4GT amp 5GT COVER DUMP VALVE PC 3GT CONNECTOR ORIFICE WATER PCGT CAPACITOR X2 ALL ADS MODELS LATCHASSY DOOR NOT SHOWN LEG 3 8 16 STD SCREW BUMPER LEG GUIDE 3 8 16 STUD SCREW O RING 72 I D NOT SHOWN GUARD SHOCK HEATING ELEMENT INSULATION WRAP PCGT PANEL LEFT SIDE PCGTs PANEL RIGHT SIDE PCGTs CANISTER TRAY ASSY PLASTIC PCGT4 5 CANISTER TRAY ASSY PLASTIC PCGT3 O RING 4 1 2 I D 0 285 C S SILICONE Illustrated Parts List LABELING DETAL P6 Illustrated Parts List 39350 02 FAT FREE FRENCH VANILLA CAPPUCCINO CHOCOLATE ALMOND AMARETTO CAPPUCCINO HAZELNUT VANILLA FRENCH VANILLA ORIGINAL COFFEE CAPPUCCINO CINNAMON VANILLA NUT RASPBERRY M ALMOND AMARETTO CAPPUCCINO HOT CHOCOLATE FRENCH ICED CAPPUCCINO VANILLA A T Q z Shaft seals should be replaced with the groved side facing out ward Place a dab of food grade lubricant in the rear hole of the seal as shown below Before mounting a whipper plat
8. A 1144 01 CA 1148 01 CA 1127 WC 37126 WC 37127 WC 37128 WC 39763 WC 39350 01 WC 39351 01 WC 39753 CA 1159 CA 1156 CA 1123 WC 780 WC 799 WC 37123 CA 1039 WC 37008 WC 37278 WC 3734 WC 904 04 WC 1438 101 WC 523 WC 102 WC 68160 WC 68147 CA 1160 CA 1157 CA 1112 06 CA 1113 06R CA 1113 06L CA 1011 05 CA 1065 03 CA 1026 03 CA 1005 03 Description COVER TOP PCGT3 COVER TOP PCGT4 5 DOOR COMPLETE PCGT3 DOOR COMPLETE PCGT 5 FILM CURTIS LOGO PCGT 3 FILM CURTIS LOGO PCGT 4 5 FILM ICED CAPPUCINO PCGT3 FILM CURTIS LOGO PRE DISPENSE PCGT3 LAMP COMPLETE W 5K BULB KIT UCM BOARD amp LABEL PCGT3 KIT UCM BOARD amp LABEL PCGT4 KIT UCM BOARD amp LABEL PCGT5 LABELASSY UCM amp DOOR PCGT 3 LABEL UCM PANEL PCGT4 CURTIS LABEL UCM PANEL PCGT5 CURTIS MEMBRANE CONTRL PANEL PCGT4 5 CURTIS COVER ALCOVE PLASTIC PCGT 3 COVER ALCOVE PLASTIC PCGT 4 5 LAMP 30W 5K CIRCULAR CONTROL POWER MODULE CORK BRAKE CONTROL PWR MODULE PCGT3 PRESET KIT FAN EXTRACT 120V 29 CFM amp BRACKET O RING DUMP VALVE WC 880 KIT TANK LID ROUND KIT LIQUID LEVEL PROBE GT KIT RPL DUMP VALVE FOR WC 880E HEATING ELEMENT 1 6KW W IJAMNUTS SENSOR TEMERATURE TANK THERMOSTAT MNL RESET 120 240V 25A SWITCH TOGGLE NON LIT 25A 120 240V SCREEN DRIP TRAY PCGT 3 SCREEN DRIP TRAY PCGT 4 5 DRIP TRAY PLASTIC PCGT 3 DRIP TRAY PLASTIC PCGT 4 5 CANISTER ASSY 5LB PCGTs CANISTERASSY 10LB RIGHT PCGTs CANISTERASSY 10LB
9. e View of PCGT Unit with Side Panel Removed Showing place a dab of food grade lubri Location of Triac and Control Board cant in the rear hole of the seal CONFIGURATION OF CANISTERS ON PCGT MODELS MODEL 10 LB CANISTER 10 LB CANISTER 5 LB CANISTER P N CA 1113 06L P N CA 1113 06R P N CA 1112 06 Electrical Diagram GRN POWER CORD lt gt 6222 EIA SPST TOGGLE SW O Q POWER SUPPLY BLK 14 120V 60Hz 5 MANUAL RESET 220 F J THERMOSTAT N x l m BLK 2 2 Nee WATER LEVEL PROBE ASSY Aa D pp STP GaN 2 2 E STPBRN Q 5 z STP VIO VIO a 8 5 YEL _ STP YEL CHASSIS 0 3 _ WHTor BRN 2 GROUND RED 13 BLK Vdd T D fa STP RED GRY a H SS AH STP GRY P COMMUNICATION CABLE UPM CONNECTOR PIN ASSIGNMENTS Al CANADIAN US MODELS MODELS TOTAL TOTAL TOTAL TOTAL HEATING ges POWER CURRENT POWER CURRENT ELEMENT MACHINE WATTS AMP WATTS AMP WATTS TRIAC HEATING ELEMENT SC PCGTXX10000 1800 15 1600 y a2 RED 14 _ 2 WHT 14 SC PCGTXX20000 1350 12 1150 KX HEATSINK ASSY EXHAUST FAN 1GPM INLET VALVE DUMP VALVE 1 WHT Se WHIPPER MOTOR 1 WHT D WHT WHT
10. e valve behind the machine Water volume going to the machine should be stable Use tubing sized sufficiently to provide a minimum flow rate of one gallon per minute 2 Plug the power cord into an electrical outlet rated at 20A 3 Switch on the toggle switch behind the unit that runs power to the components in the machine The lights display window and row of buttons on the front door will activate and the heating tank will start to fill 4 Water in the heating tank will require about one hour to reach operating temperature factory setting of 190 F At this time the LCD will display READY TO DISPENSE 5 Remove and fill the canisters with powdered cappuccino product FOR THE LATEST SPECIFICATIONS AND INFORMATION GO TO WWW WILBURCURTIS COM 1 Operation Instructions 1 Choose a flavor Place your cup under the spout beneath the desired flavor Note When using Iced Cappuccino machine fill your cup with ice before dispensing product 2 Push and hold the dispensing button for this flavor 3 Release the button when the cup is full fe CANISTERS DAILY 1 Open the front door to access the product canisters 2 The canisters must be removed from the unit for filling Turn the powder delivery elbows clockwise pointing upward Pull all of the cansiters from the canister tray 3 Refill the canisters The small canisters hold five pounds of product Larger canisters hold 10 pounds each 3 Reposition the canister
11. er is Factory Pre Set for Optimum Performance Programming for all models is identical except where noted Program Menus Select Entering the Programing Menus Press and hold STOP WASH for about ten 10 seconds Display will read Program Menus See Illustra tion Manual Dispense Factory Default PROGRAMMING CONTROL BUTTONS Press or gt to go to Manual Dispense Select Press to go to Manual Dispense Select Station Choose the station and press the display will read Saving Complete To select another station for manual dispense press to go to Manual Dispense Select Station or press gt to continue to the next menu Dispense By Time The next screen is Dispense By Time lt Select gt Press to select a station Select the station and the screen will read To Begin Press Push Press desired dispense button Hot water will start to dispense and screen will display To Finish Press Push When Push is pressed time will be saved and you will exit back to Dispense by Time screen Continue with additional selections or press gt to continue to the next menu Temperature Factory set at 190 F Cold Cappuccino Units Set at 96 F Press and screen will show Tank Temperature Temperature is programmable from 80 F to 204 F in 2 degree increments Press lt or gt to go up or down in degrees Select desired temperature and then to set Press gt to con tinue to the next menu Powder Ratio Factory set at 60
12. ically 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 responsibility of the owner of the equipment This includes institutional and correctional facilities The Wilbur Curtis Company will allow to 100 miles round trip 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 equipment must be repackaged properly in the original carton No units will be accepted if they are damaged in transit due to im
13. inside using a narrow brush Vi 2 Remove the upper mixing Pull cup forward twist to the left lift it to separate the upper mixing cup from the lower mixing cup pe V 3 remove the lower mixing cup pull mixing cup forward to free it from the hot water inlet fitting 4 Remove the whipper chamber Take hold of the whipper chamber Turn it clock SA wise to free it from the mounting plate Pull the whipper propeller from the motor shaft 5 6 Wash Sanitize and Rinse using 3 sink method Air all parts RINS TE Re assemble cleaned parts onto the machine IMPORTANT When replacing the propeller make sure it is properly aligned and seated on the motor D FLAT shaft The propeller has an embossed D to properly align it on the motor shaft INDICATOR Failure to properly seat the propeller will cause it to fuse with the whipper chamber This condition will not be covered under warranty 6 Clean the mounting plate a Clean the shaft with a cloth and mild detergent before removing mounting plate b Twist the mounting plate clockwise and pull it from the motor shaft IMPORTANT Do not remove pillars to take off mounting plate c Clean the area behind the mounting plate d Clean the water inlet fitting e Lubricate the center seal of the mounting plate before reinstalling Steps to Programming Your Curtis Generation 3 cappuccino dispens
14. ols Set at 60 e Dispensing Mode Set for Manual Dispensing Generally there will never be a reason to change your G3 programming However should you need to make slight adjustments to meet your dispensing needs programming instructions are provided later in this manual System Requirements e Water Source 20 90 PSI Minimum Flow Rate of 1 GPM e Electrical See attached schematic for standard model or visit www wilburcurtis com for your model Equipment to be installed to comply with applicable federal state or local plumbing electrical codes having jurisdiction SETUP STEPS The unit should be level left to right and front to back located on a solid counter top Connect a water line from the water filter to the brewer NOTE Some type of water filtration device must be used to maintain a trouble free operation In areas with extremely hard water we suggest that a sedimentary and taste amp odor filter be installed This will prolong the life of your dispensing system and enhance cappuccino product quality NSF International requires the following water connection 1 A quick disconnect or additional coiled tubing at least 2x the depth of the unit so that the machine can be moved for cleaning underneath 2 This equipment is to be installed with adequate backflow protection to comply with ap plicable federal state and local codes 1 Connect a water line from your facility to the 1 4 flare water inlet fitting of th
15. proper 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 WILBUR CURTIS CO wie 6913 Acco St Montebello CA 90640 5403 USA 2 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 WWW WILBURCURTIS COM 8 Printed in U S A 9 09 F 3689 Rev NC 8 6 09 EDR 5946
16. s on the canister tray Properly mate the gear socket with the gear on the motor shaft when aligning canisters Turn the elbows clockwise pointing downward Cleaning the Curtis Primo Cappuccino GT Beverage Dispenser CAUTION Do not use cleansers liquid bleach powders or any other substance containing chlorine These products promote corrosion and will pit the stainless steel THE USE OF THESE PRODUCTS WILL VOID YOUR WARRANTY 1 EVERY 3 4 HOURS OR MORE OFTEN IF NECESSARY A Make sure power is ON B Place a container under the dispense spout to catch the rinse water Locate the WASH button on the front control panel D E Rinse each flavor by pressing and holding the WASH button while at the same time pressing one of the PUSH dispensing buttons on the control panel Continue holding the WASH button until the water running from the spout runs clear 1 DAILY A Switch OFF the unit at the power toggle switch located behind the unit B Wipe all exterior surfaces with a damp cloth removing any spills residue or dust from the unit C Remove both the drip drawer and louvered screen then wash out its contents For hard to clean deposits use a mild nonabrasive detergent Rinse with water D Wipe and clean the dispensing area with a mild detergent cleaner II WEEKLY OR MORE OFTEN IF NECESSARY A Clean the the parts from the whipper assembly 2 1 Remove the dispensing nozzle from the whipper chamber Clean the
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