Service Manual – D500GT Airpot Brewer
Contents
1. WILBUR Curtis COMPANY Service Manual 5006 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 not immerse the unit in water or any other liquid 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 Never clean with scouring powders bleach or harsh chemicals symbols WARNINGS To help avoid personal injury Important Notes Cautions from the factory Sanitation Requirements Model Included D500GT 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 02 System Requirements e Water Source 20 90 PSI minimum flow rate of GPM CAUTION Please use this setup procedure Electrical See attached schematic for standard model or visit www wilburcurtis com for your model IMPORTANT before attempting to use SETUP STEPS this brewer Failure to follow the instructions can result in injury or the voiding of the warranty 2 Connect the water line to the water inlet fitting on the rear of the unit Water vo2. 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 ISO 9001 2008 REGISTERED 5 Water in the heating tank will require approximately a half hour before reaching operating temperature WILBUR CURTIS CO INC factory setting of 200 F Where applicable turn on the Universal Control Module UCM When the unit 6913 West Acco Street reaches operating temperature it will display READY TO BREW Montebello CA 90640 5403 For the latest information go to www wilburcurtis com For the latest specifications and information go to www wilburcurtis com Tel 800 421 6150 1 Fax 323 837 2410 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 6 Allow the brew cycle to into the brewcone Fill into the brew rails on the Coffee will start to brew finish before removing brewcone with the proper brewer into the airpot the airpot or brew cone amount of ground coffee Screen will read Brew Complete Afterwards it WARNING TO AVOID SCALDING Do not remove brewcone while unit is brewing a ian Ready to Brew OXY
3. 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 OFF Pressing either lt gt toggles between on and off Press to set Pulse Brew Factory set to OFF Press 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 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 features disappear from the list of program selections If Pulse Brew is selected ON Cold Brew Lock is set to within 5 F of set point Also the Cold Brew Lock and Pre infusion IMPORTANT Display Brew Time Factory set to ON Press to display ON or OFF Pressing either lt
4. 0 WC 37266 WC 904 04 WC 922 04 WC 4394 WC 523 WC 522 WC 43062 WC 37317 WC 1438 101 WC 5231 WC 5527K WC 37365 WC 3763 WC 6217 WC 1806 WC 43058 WC 5310 Description WASHER FLOW 7 1 0 GPM USE W WC 826 COVER TOP HEATING TANK GEN USE TANK COMPLETE D500GT 120V TANK COMPLETE 3 5KW 220V DS00GT KIT TANK OVERFLOW ELBOW FITTING KIT ELEMENT HEATING 1 6KW120V W NUTS KIT ELEMENT HEATING 3 5KW 220V GUARD SHOCK HEATING ELEMENT THERMOSTAT MANUAL RESET THERMOSTAT HI LIMIT DPST 277V 40A GASKET HEATING TANK KIT PLASTIC FITTING amp BUSHING SENSOR HEATING TANK COMPOUND SILICONE 5 OZ TUBE KIT PROBE WATER LEVEL O RING amp NUT KIT TANK INLET FITTING KIT VALVE REPAIR USE ON WC 889 COVER FRONT SEAT CUP SILICONE USE ON WC 1809 PLUG TANK DRAIN PP RED TUBING SILICONE 5 16 1 FT SUGGESTED PARTS TO STOCK Rough In Drawing 9 25 en 7 eed 19 25 14 88 48 9 37 8 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 a fresh appealing look to your coffee service For cleaning prepare a mild solution of dish washing detergent and warm water 1 Wipe the exterior surfaces with a cloth soaked in the cleaning solution Scrub off coffee spots spills or coffee grounds Remove the brew cone and clean it in a sin
5. END PIN ASSIGNMENT CONTROL BOARD INLET VALVE BREW VALVE TRIAC GATE WHT TRIAC A2 POWER INPUT HOT 1 HEATING TEMPERATURE SENSOR TANK TANK TEMPERATURE SENSOR GROUND INLET GROUND VALVE LEVEL PROBE N C 120V 12W N C COMMON STUD POWER RETURN CHASSIS GROUND 2 DO NOT CHANGE NOR SUBSTITUTE WIRE COLORS 1 ALL WIRES SHALL BE 18AWG UNLESS OTHERWISE NOTED LADDER DIAGRAM NOTES UNLESS OTHERWISE SPECIFIED LD D500GT 10 D SENSOR CONTROL MODULE HEATSINK amp TRIAC ASSEMBLY THERMOSTAT LIMIT DPST 277V 40A 600V 40A nacre Dt be faa CAPACITOR 47 275VAC A RE gt HEATING 3 ELEMENT a gt 220V 3500W DPST TOGGLE switcH OIA _ B GRN W YEL STP 14 125 250VAC 25A TERMINAL BLOCK COMMON STUD 5 STA 50A 600V CHASSIS GROUND TRIAC PIN ASSIGNMENTS use 187 terminal lug STP_YEL CONNECTOR PIN ASSIGNMENTS NOT USED NOT USED NOT USED INLET VALVE BREW VALVE GATE TRIAC TRIAC A2 POWER INPUT BLK TEMP SENSOR TEMP SENSOR GROUND COMMON STUD WATER LEVEL PROBE CHASSIS GROUND NOT USED NOT USED USE THIS DIAGRAM FOR OTHER MODELS WITH ADDED PREFIX AND OR DIFFERENT DASH NOT USED NUMBER PROVIDED THEY HAVE THE SAME ELECTRICAL SPECS 16 POWER RETURN WHT USE SWITCH GUARD 3249 AS REQUIRED BY UL TITLE DO NOT CHANGE NOR SUBSTITUTE WIRE COLORS p
6. LOS 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 CURTIS Press ON OFF button and the screen will display 20295 After 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 Approximately 20 minutes are required to reach the set point temperature Control will display 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 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 PROGRAM MENUS After the 4 digit code is entered lt SELECT gt will be displayed You can now enter the program menu features All programming selections are performed with the three center buttons The symbols near the buttons are lt 1 Scroll LEFT SELECTION o
7. ature 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 degree 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 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 Quality Timer Factory set to OFF Press to select Press gt to select OFF ON then increase time from 20 minutes to a maximum of 120 minutes Increments are 10 minutes Press to set Timing starts at the begining of a brew cycle An audible alarm will sound when time has expired Press the ON OFF button on the control pannel to shut it off Brew Count Total Press to Select Shows total gallons and total brew cycles on the unit Brew Count Total cannot be reset Cold Brew Lock Factory s
8. ectional 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 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 16011 7 15 14 10 revD WILBUR CURTIS CO INC wie 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 10 Printed in U S A 8 2014 F 3841 Rev D
9. es Ge Ge re eR a PART NUMBER REVISION NOTE UNLESS OTHERWISE SPECIFIED D D500GT 30 240V 10W SIP VEL GRN W YEL STP 18 UCM GROUND 220VAC UCM CONTROL BOARD NS Hak Parts Diagram Parts List Item No 1 1A 2 2 3 4 5 5A 6 6A Part WC 889 101 WC 860 WC 37064 WC 724 WC 39346 WC 37252 WC 3621 101 WC 3316 WC 5450 WC 58117 Description VALVE DUMP LEFT 120V VALVE DUMP LEFT 220V 12W KIT LABEL amp UCM D500GT CURTIS CONTROL MODULE AIRPOT 220V 16 PIN LABEL CONTROL PANEL CURTIS LOGO KIT HOT WATER FAUCET RPLCMNT BREW CONE NON METAL UNIVERSAL BREW CONE ASSY 5 5 OPTIONAL COVER TOP OLDER MODELS COVER TOP D500GT WC 2962 101K KIT FITTING SPRAYHEAD KYNAR WC 13237 WC 29025 WC 102 WC 103 WC 8556 WC 3503 WC 826L WC 856 WC 3518 WC 8591 WC 3765L HARNESS ASSY D500GT H 10 SPRAYHEAD PURPLE ADVANCE FLOW SWITCH TOGGLE 125 250 VAC RESISTIVE SWITCH TOGGLE NON LIT DPST 25A 220V HEAT SINK amp TRIAC ASSY 40A 600V LEG SCREW BUMPER 3 8 16 STD VALVE INLET 1 GPM 120V 10W VALVE INLET 1 GPM 240V 10W LEG GLIDE 3 8 16 STUD SCREW CAPACITOR X2 KIT VALVE REPAIR USE ON WC 826 Item No 17 18 19 19A 20 21 21A 22 23 23A 24 25 26 27 28 29 30 31 32 33 34 Part WC 830 WC 5853 102 WC 6277 WC 629
10. et to 15 Press to select lt gt to select desired setting CBL 5 15 OFF to set The Cold Brew Lock feature allows the brewer to brew at three different temperature levels below the actual set point The first setting is within 5 degrees of set point next is within 15 degrees of set point OFF is within 30 degrees of set point for the Ready to Brew message however it will brew at any temperature Master Reset Press to display Are You Sure Then lt for Yes or gt for No Brewer factory defaults are then reset Service Call Phone number Factory set to 1 800 000 0000X 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 Continued Page 4 Access Code Banner Name Beeper On Off Pulse Brew On Off Display Brew Time Drip Out Mode 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 Banner Name Factory set to Curtis 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 If programmed Banner is displayed every 5 sec on and off P Maintenance Factory set to OFF
11. k using the cleaning solution Rinse and dry the brew cone With the brew cone removed Wipe the spray head area with a cloth soaked in cleaning solution Rinse the area with a water soaked cloth removing any residual detergent With a dry cloth wipe the area Rub a stainless steel polish on the outside surfaces of the brewer cabinet as protection for the metal 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 dishwasher This Page Intentionally Left Blank 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
12. lume flow to the machine should be consistent Use tubing sized sufficiently to provide a minimum flow rate of 2 GPM 1 GPM pre 1 The unit should be level left to right front to back on a secure surface A CAUTION DO NOT ferred connect this brewer to hot POPO 8 ter The inlet valve is NOTE A water filtration system must be used to help maintain trouble free operation Air must be purged not rated for hot water 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 go to www wilburcurtis com WARNING HOT LIQUID Scalding may occur Avoid splashing 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 NSF 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 To avoid temperature drop when first brewing IMPORTANT coffee into the airpot preheat the airpot with hot water 3 Connect the unit to electrical outlet with appropriate amperage rating see serial tag on machine
13. 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 Drip Out Mode Factory set to 2 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 Display Messages Factory set to ON Press to turn ON or OFF The message displayed is Rinse Server Before Brewing This message will alternate two seconds with Rinse Server Before Brewing then Curtis READY TO BREW will appear for six seconds Language Factory set to English Pressing lt or gt toggles between English and French Press to set Model Select Press to select lt or gt Be sure that Airoot 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 Electrical Schematic HEATSINK THERMOSTAT ASSEMBLY MAN RESET BLK 10GA BLK 14GA RED 14GA BLU 14GA sc i WHT 22GA 2206 HEATING GRN 18GA ELEMENT POWER CORD O 120V CAPACITOR TOGGLE SW TRIAC PIN ASSIGNMENTS STP GRY Q Al COMMON STUD CHASSIS GROUND WHT 14GA LEG
14. 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 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 pressure and inadequate or fl
15. r ENTER to save new parameter 1 2 gt Scroll RIGHT ee IMPORTANT Brewer Program Menus Program Menus Brew By Volume Brew By Time Temperature Energy Save Mode Brew Count Odom Pre Infusion Quality Timer Brew Count Total Cold Brew Lock Master Reset Service Call Model Select D500GT ONLY Always perform this first This feature re sets all settings to the factory defaults Scroll through menu to Model Select Choices ALPHA 1 ALPHA 2 ALPHA 3 4 5 Brewer Thermo Alpha Select only Airpot 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 Press to Select display will now show Press BREW to Start Press the BREW button The unit will start spraying hot water 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 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 Temper
16. uctuating 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 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 corr
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