Service Manual – GEM-120A Satellite Brewer
Contents
1. Model e GEM 120A CAUTION Equi t tb must be installed to comply with applicable federal state and local plumbing electrical codes CAUTION Follow met 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 connect the unit to IMPORTANT hot water supply The inlet valve is not rated for hot water ISO 9001 2008 REGISTERED WILBUR CURTIS CO ING 6913 West Acco Street Montebello 90640 5403 For the latest information go to www wilburcurtis com Tel 800 421 6150 Fax 323 837 2410 WILBUR CURTIS COMPANY 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 ME Important Notes Cautions from the factory IMPORTANT Sanitation Requirements INSTALLATION This Curtis unit is pre set and2. 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 C f 5 Defective water inlet Turn power 0 and observe the water level in the heating tank If valve item 9 water continues to flow in clean or replace the valve 6 Probe limed up item 5 Pull wire 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 If probe is okay check the water level control board The water level water level control board control board must be securely grounded Check for loose connec item 33 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 item 10 Check the thermostat to make sure it is in the ON position Turn the thermostat stem clockwise until it stops 9 Burned out heating Check element for continuity and or check with clamp ammeter This element should show a reading of approximately 15 amps If no power is go ing through element replace it 120 PROBLEM WATER IN TANK DOES HOT WATER TEMPERATURE LOW POSSIBLE CAUSE SOLUTION 10 Defective thermostat Thermostat may be
3. an InterLock grinder the grinder should be on When Interlock con nection is made grind coffee at this time 2 Place an empty Satellite under the brewcone and press the warmer switch to pre heat the Satellite 3 Place clean filter into the brewcone 4 Fill brew 9 Transfer 6 Press Brew cone with filled brew button ground cof cone to Brewing will fee brewer begin im mediately WARNING TO AVOID SCALDING Do not remove brewcone while brew light is flashing CARE AND MAINTENANCE OF THE GEMINI 120A Regular cleaning and preventive maintenance Is essential in keeping your Gemini Coffee Brewer looking and work ing like new WARNING not use cleansers liquids bleaches or powder that contain chlorine These products cause I and pitting on stainless steel and will void your warranty mm mam mam mam mam mam wm mm m ma ma ma ma ma ma ma m m ma ma ma ma ma m sl PREVENTIVE MAINTENANCE 1 Remove the sprayhead from the Gemini 120A and clean once a week or more often in heavy lime areas 2 Clean the faucet seat cups twice a week and replace when they are cracked or leaking 3 Periodic temperature checks or adjustment of thermostat by authorized personnel CLEANING To maintain optimum coffee flavor the Gem 3 Satellite should be cleaned daily after the last batch of coffee is used We recommend the use of urn clean
4. cutting off before the water temperature reaches operating temperature Do not try to reset the thermostat Replace it PROBLEM WATER NOT FLOWING FROM SPRAYHEAD POSSIBLE CAUSE SOLUTION 11 Water level is too low Check water level in tank If water is not flowing into the tank re heating tank view steps 1 thru 4 previous page 12 Defective brew switch Check the continuity between terminals 5B and 4B when the BREW item 41 switch is pressed If there is no continuity replace the switch 13 Defective timer item 2 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 58 of the ON OFF switch and at terminal A of the timer When the timer is activated by the brew switch you should read 110 to 120 volts across terminals 6 of the timer The RED wire on terminal 6 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 item 34 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 120 Parts List N ae ui 5 PER 120 Parts List 2 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
5. 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 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 2 44 WILBUR CURTIS CO INC 6913 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 ECN 13180 5 16 11 8 9 Printed U S A 5 11 F 1903 Rev G
6. 0ILD COVER 0500 G230A G120A PTB PLUG DRAIN PP RED KIT VALVE REPAIR USE ON WC 825 WC 826 WASHER 35 GPM 5 USE ON WC 825 LID ASSEMBLY TANK TANK COMPLETE GEM 120A TANK COMPLETE GEM 120A 120 220V DV LABEL BOTTOM GEM 120A LEG GLIDE 3 8 16 STUD SCREW THERMOSTAT MANUAL RESET 120 240 VAC 25A 220 DEG F MAX THERMOSTAT HI LIMIT HEATER CONTROL DPST 277V 40A Description FILTER FOR BREW CONE WC 3338 500 PKG FILTER FOR BREW CONE WC 3621 1000 PKG ILLUSTRATED PARTS LIST GEM 3 5 8 INDEX PART N N DESCRIPTION 1 GEM 5 SATELLITE WARMER STAND 115V 2 WC 1201 POWER CORD 6 18 3 BLK 3 WC 114 SWITCH ROCKER 120V RED 4 GEM 3 SATELLITE SERVER 1 GAL 5 WC 3307 LID GEMINI SATELLITE SA WC 5622 LID SATELLITE PLASTIC GEM3 OPTIONAL 6 WC 2102 GAUGE GLASS ASSEMBLY 8 C 7 WC 2010C SHIELD 8 INCH GAUGE GLASS 8 WC 2025 GAUGE GLASS 8 INCH 9 WC 2007 BRACKET GAUGE GLASS FORMED 10 WC 1901 SHANK FAUCET D amp T CHROME 11 WC 1800 FAUCET 5 NONLOCKING 11A WC 1841 FAUCET ESP BLACK NONLOCKING OPTIONAL 12 WC 3705 KIT FAUCETS SERIES 13 GEM4 SATELLITE STAND 14 WC 3503 LEG SCREW BUMPER 3 8 16 STD 15 WC 37102 KIT WARMER ELEMENT 100W 120 8 WIRING DIAGRAM GEM120A 10 BREW SW BED SPST 120V GRN NEON BREW LAMP 120V NEON WARMER SW SPST 120V SPST 120V RED NEON 5 4B 3A a i WHT BLK THERMOSTAT LIQUID SPST 277V 22A LEVEL CONTROL 120V WARMER ELEMENT
7. 120V 100W HI LIMIT THERMOSTAT SET 220 F SPST HEATING ELEMENT 1600W 120V COMMON STUD CHASSIS GROUND YEL BLK14 COMMON STUD CHASSIS GROUND POWER CORD 14 3 5 BLK 2 WHT xe TOGGLE SWITCH 129 250V TA BLK14 COMMON STUD CHASSIS GROUND VOLTAGE 120 WATTAGE 1775 2 DO NOT CHANGE NOR SUBSTITUTE WIRE COLORS ME i5 TITLE 1 ALL WIRES SHALL BE 18 AWG MINIMUM WIRING DIAGRAM NOTES unless otherwise specified 2 GND 1 20 210 PHASE 1 WIRING DIAGRAM GEM120A 63 RED BREW SW SPST 120V GRN NEON BLU WHT WARMER SPST 120V ON OFF BREW LAMP _ SPST 120V aN RED NEON THERMOSTAT LIQUID SPST 277V 22A LEVEL CONTROL 120V WARMER ELEMENT 120V 100W GRN14 COMMON STUD I LL CHASSIS GROUND WHT14 HEATING ELEMENT 1600W 120V HEATING ELEMENT 2000W 220V COMMON STUD CHASSIS GROUND BLU 14 HIGH LIMIT F THERMOSTAT DPST 220 F 40A 277V BLU14 RED14 BLK14 84014 TOGGLE SWITCH FE 240V 25 ha 2 BLK14 BAAL COMMON STUD CHASSIS GROUND 1 WHT14 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 VOLTAGE 120 220 5 FOR 220 OPERATION CONNECT 66014 WIRE TO POINT C O
8. 30A 31 32 33 33A PAPER FILTERS Part 2 WC 3621 WC 603RDS WC 603 101 WC 608 WC 2936 WC 37278 WC 3920T WC 904 WC 906 04 WC 1200 WC 826 WC 517 WC 3763 WC 817 WC 1809 WC 202 WC 203 WC 114R WC 122 WC 2977 01 WC 5310 WC 5451 WC 947 WC 102 WC 3503 WC 3338 WC 5452 WC 5450 WC 43058 WC 3765 WC 829 WC 37008 WC 5466 WC 54133 WC 3920B WC 3518 WC 523 WC 522 Part Number CR 12 CR 10 Description BREW CONE UNIVERSAL 7 1 8 BLK PLASTIC TIMER BREW SELECTOR 120V GEM 120A OLDER UNITS TIMER BREW SELECTOR 120V 2 20 MIN GEM 120A RU S NEWER UNITS LEVEL CONTROL WATER 120V SPRAYHEAD RED 131 DIA KIT LIQUID LEVEL PROBE GT LABEL TOP GEM 120A ELEMENT ENVELOPE HEATING w SCREWS GEN USE HEATING ELEMENT 2000W 220V W JAM NUTS POWER CORD 6 14 3 BLK SJTO VALVE INLET 1 GPM 120V 10W THERMOSTAT CAPILLARY SPST 277V 22A GEN USE KIT VALVE REPAIR FOR WC 866 WC 889 WC 816 WC 817 WC 818 VALVE DELTROL DUMP RIGHT 120V FAUCET HOT WATER W JAM NUT LIGHT BREW 115V LIGHT BREW 220V SWITCH ROCKER 120V RED SWITCH ROCKER BREW 120V GREEN FITTING ASSY SPRAYHEAD PLATED TIN NICKEL TUBE 5 16 1 0 SILICONE GEN USE WARMER DECK NO ELEMENTS ELEMENT WARMER 90W 115V SWITCH TOGGLE SPST 25 125 250 VAC RESISTIVE LEG SCREW BUMPER 3 8 16 STD KIT BREW CONE W BASKET SS 7 1 8 DELUXE BLK HANDLE OPTIONAL COVER FRONT GEM 120A 120P 230A 200R 300IL 60
9. N POWER BLOCK WC 314 amp STOW BLK14 ee 1775 2100 mE 4 FOR 120VAC OPERATION CONNECT BLK14 WIRE TO POINT C ON POWER BLOCK WC 314 amp STOW RED14 15 19 AMPERAGE 3 DO NOT CHANGE NOR SUBSTITUTE WIRE COLORS 15 10 WIRING DIAGRAM 2 TEFLON WIRES 14 AWG MAY BE USED AS A SUBSTITUTE FOR THE 14 AWG APPLIANCE WIRE HERTZ 50 60 1 WIRES SHALL BE 18 AWG UL APPROVED APPLIANCE WIRE WIRES 2W 3W GND PART NUMBER REVISION NOTES unless otherwise specified PASE WD G120A 63 gt ra WIRING DIAGRAM GEM 5 amp 8 WARMER ELEMENT 100W 120VAC WARMER SWITCH SPST 15 250V 120V NEON 1 POWER CORD 10A 125 TE WIRING DIAGRAM GEM 5 AND 8 WD G5 G8 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 purcha
10. 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 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 30 4 00 Email techsupport wilburcurtis com 120 UNPACKING All products manufactured by the Wilbur Curtis Company are thoroughly inspected at the factory and are warranted to be free of all defects faulty workmanship The Gemini unit is packaged for maximum protection while being shipped Make sure the shipping carton is not damaged or punctured Unpack the carton carefully inspecting the contents for any damage that may have occurred in transit Report any damage immediately to the freight company 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 If the brewer is connected to
11. e 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 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
12. ing powder or Scotch Bright pads for cleaning inside the coffee container The outside of the brewer and Satellite should be cleaned with a soft cloth and stainless steel polish only to prevent scratching the surface Deliming of the heating tank should be done every six 6 months more often in heavy lime areas 2 120 SETTING THE WC 603 101 BREW Adjustment of the timer is made on a calibrated dial with a range from 0 to 100 This is a range of 2 to 20 minutes The front control panel has a brew selector switch marked FULL 1 2 To change the setting flip the brew selector switch to FULL Locate the brew timer inside the top cover Rotate timer arrow to the right to increase the brew time rotate to the left to decrease the brewing time The indicator dial is normally set pointing at 25 This setting is intended to deliver one gallon of water brew 24 cups brew cycle brew 72 gallon flip the brew selector switch to 1 2 SETTING TIMER WC 603RDS This timer is the previous version of the WC 603 101 above The timer is mounted inside the upper com partment with the brew selector knob protruding from the center of the front panel see illustration left The brewer is designed to brew 24 cups one gallon maxi mum Adjustment of the timer is made on the timer calibration dial The knob indicator must be set at the 480 second mark on the dial On the front panel the brew selector switch
13. ready to go from the factory Factory settings for this unit are Brew Temperature 200 F e Brew Volume Set to vessel requirements 1 Gallon System Requirements e 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 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 NSF 1 A quick disconnect or additional coiled tubing at least 2x the depth of the unit is required so that the unit 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
14. se 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 equip ment 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 Ef fective 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 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 pressur
15. should be at 2 This setting will deliver one gallon of water brew 24 cups per brew en x cycle To brew 12 cups simply turn the brew selector 460 knob to 1 If finer adjustments are needed rotate timer 2407 og 48o knob to the right to increase the brew time rotate to FULL BREW the left to decrease the brewing time 340 31 8 cm ENER 22 9 cm 120 TROUBLE SHOOTING PROBLEM WATER DOES NOT FLOW INTO HEATING TANK POSSIBLE CAUSE SOLUTION 1 Water line turned off or Open the water line and make sure water flows to the brewer filter clogged up 2 Water inlet valve coil Turn off brewer Disconnect wires from water inlet coil terminals and burned out 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 16 disconnected If valve does not respond to this test replace the valve Grounded probe item When water in the heating tank is below the probe tip yet water is 5 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 Pull the wire from the probe terminal With a volt meter check the water level control board voltage atthe water inlet coil terminals This should read 110 to item 3 115 volts If no voltage is present check the water level control
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