Service Manual – GEM-12D
Contents
1. WHT VALVE ONLY T WHT STP YEL CONTROL DOME PLATE GRN YEL BOARD 120V 12W BREW VALVE TANK STUD 120V 50 60 Hz RIGHT GROUND 3b DOME PLATE 120V 12W BREW VALVE GRN YEL LEFT UCM GROUND WARMER RIGHT i STP RED LEGEND WARMER PIN ASSIGNMENT LEFT 1 WARMER LEFT MEMBRANE CONTROL PANEL i 2 HOT WATER VALVE 3 BREW VALVE RIGHT 4 BREW VALVE LEFT 9 INLET VALVE 5 USE THIS DIAGRAM FOR ALL OTHER MODELS PALE Use Per 6 TRIAC RETURN WITH ADDED PREFIX LETTERS AND OR DIFFERENT terminal lug 7 TRIAC GATE DASH NUMBER ON THEIR PART NUMBERS HAVING THE SAME ELECTRICAL RATINGS Ex TRIAC PIN ASSIGNMENTS 42 ae SCGEM 12D 10 or GEM 12D 12 _ Dc 22222 22 11 120 VAC 4 LOCATE MATED CONNECTOR AWAY FROM HEAT 12 GND CHASSIS 3 USE SWITCH GUARD WC 3249 AS REQUIRED BY UL 14 PROBE 2 INSTALL GROUND LUG ON TANK STUD AMPERAGE 29A En 15 SENSOR 1 ALL WIRES SHALL BE 22AWG TEFLON LADDER DIAGRAM 16 SENSOR NOTES UNLESS OTHERWISE SPECIFIED WRES 3w 6G per TIT rar LD G12D 10 C1 Product Warranty Information Wilbur Curtis Co Inc certifies that its products are free from defects in material and workmanship under normal use The following limited war ranties and conditions apply 3 years parts and labor from original date of purchase on digital control boards 2 years part from original date of purchase on all other electrical components fittings and tubing 1 year labor from original da2. 10 15 F 3191 S Rev C
3. ENTERING THE PROGRAM MODE 1 Turn OFF the power from the control panel by pressing fuer Press and HOLD ren ana press and RELEASE Continue HOLDING until Ng starts blinking RELEASE READY TO BREW CAUTION Hot Water Take precautions to place a con tainer on the brew deck before adjusting the brew volume An empty satellite can be used to measure the proper brew level IMPORTANT BREW CYCLE COUNTER ENTER THE PROGRAM MODE 2 Turn OFF the power from the Control Panel by pressing Press and HOLD and press and RELEASE Continue HOLDING renun Wie STOPS blinking RELEASE READY TO BREW PROGRAMMING ONLY REQUIRED IF FACTORY SETTINGS MUST BE CHANGED IMPORTANT Before entering the program mode allow the unit to reach brewing temperature then press the BREW button to dispense at least 12 ounces of water to clear any air that may be trapped within the water lines NOTE For ALL functions you must first enter the programming mode Brew Temperature Factory Pre Set to 200 F Function to set brew temperature 170 to 204 F Brew temperature will be indicated by READY TO BREW light blinking CONFIRM RESET BREW TEMPERATURE Factory Preset to 200 ENTER THE PROGRAMMING MODE 1 Press for two seconds then RELEASE will start blinking Each blink equals 2 F starting at 170 READY TO BREW e To change temperature press and HOLD se will start QUICK flashing Eac
4. F button to stop the brew cycle 2 Divide the number of ounces collected from the by pass outlet into the total ounces collected from the spray head and by pass This will determine the percentage of by pass 3 To increase or decrease the volume of by pass water turn the adjustment screw on the by pass fitting as show in the illustration left Turn clockwise for less water counterclockwise for more water 4 After making the adjustment you must reprogram the brew volume to maintain the proper total amount of finished coffee brewing into the insulated server This reprogramming is required every time you make a by pass adjustment or when a different spray head us installed ILLUSTRATED PARTS ITEM PART DESCRIPTION 1 WC 5421 COVER TOP SS GEM 12D GEM 612ILD TL9002 3121L Recommended parts to stock 2 WC3417 BREW CN ASSY WISPLPOC BRWN STYLIZED GEMINHOTCOFF 3 WC 5423 WARMER W ASSY GEM12 3121L 612IL 12ILD 612ILD Component used on earlier models of GEM12D 3A WC 54300 WARMER DECK COMPLETE WWARMER ELEMENTS GEM 12 12i Pilt before 4 12 equipped with electric faucet 3B WC 3716308 WARMER ELEMENT 100W 220V GEN USE Used on model GEM 12D 10 4 WC 38310 LABEL CAUTION HOT SURFACE GEN USE 5 WC 970 ELEMENT WARMER ASSY 100W 120V WITH SILICONE BOOTS d Used on model GEM 12D 16 WC 9730 ELEMENT WARMER ASSY 100W 220V 6 WC 1809 FAUCET PS HPS SERIES HOT WTR 1 2 20 UNF AP ALP 6A WC 2912BK SPOUT H
5. OT WATER NO SPLASH 7 WC 3528 LEG 4 ADJUSTABLE 3 8 16 THRD ITALIAN STYLE 8 WC 39198 LABEL BOTTOM PANEL GEM12D 612 ILD CURTIS 9 WC 8560 HEATSINK ASSY 1PH GEM612ILD GEM 12D TL9002 10 D1000AP T 0 5829 COVER FRONT W A GEM 12 GEM 12D 3121L 6121LD 1 WC 15012 FUSE HOLDER ASSY W 5A FUSE 12 WC 102 SWITCH TOGGLE NON LIT SPST 15A 125 6A 250VAC RESISTIVE 12A WC 10309 SWITCH TOGGLE NON LIT DPST 25A 125 250VAC RESISTIVE 13 WC 391977 MEMBRANE CONTRL PANEL CURTIS GEM 12D 14 WC 670 CONTROL BOARD 120V 50 60HZ GEM 12D 14A WC 758 CONTROL BOARD 220V 50 60HZ GEM12D 30 15 WC 847 VALVE INLET 15A 98326 VALVE INLET 2 GPM 240V 10W 16 WC 892 HOT WATER 220V 17W GEM 12D 16 WC 888P VALVE HW 120V 14W NSI TL9001 2 GEM 12D 600ILD 612ILD Used on model GEM 12D 30 ILLUSTRATED PARTS ITEM PART DESCRIPTION 17 WC 290252 SPRAYHEAD PURPLE ADVANCE FLOW Recommended parts to stock 18 WC 37122 DUMP VALVE RIGHT b 18A WC 8549 VALVE BREW DUMP RIGHT 240V 12W GEM12D TP TPC Component used on earlier models of GEM12D ee es Se EMEN POTE equipped with electric faucet built before 4 12 19 WC 2987 BYPASS ASSEMBLY ADJUSTABLE WC 2984 WC 2985 amp WC 43011 20 WC 371219 DUMP VALVE LEFT Used on model GEM 12D 10 MAS oo oVvo IIIma 20 WC 853 VALVE BREW DUMP LEFT 240V 12W GEM12D TP TPCELEMENT KIT AS a d _21 __WC 37132 KI
6. T VALVE REPAIR USE ON WC 820WDRWC 821WDR WC B44WDR_ 988 on model GENEISD I _22__WC 37367 __KiT STRAIGHT PLASTIC FITTING AND BUSHING 12MM Used on model GEM 12D 30 23 WC 2962 101K8 KIT FITTING SPRAYHEAD KYNAR 24 WC 1438 101 SPOUT HOT WATER NO SPLASH f For units with a capillary thermostat 25 WC 5231 COMPOUND SILICONE 5 OZ 26 WC 54005 TANK COMPLETE GEM 6121LD G12D TL9002 26 WC 543 TANK ASSY COMPLETE GEM 12 GEM 312IL 27 WC 4382 GUARD SHOCK HTNG ELMNT DOUBLE 28 WC 5222 THERMOSTAT HI LIMIT HEATER CONTROL DPST 277V 40A 29 WC 906 ELEMENT HEATING 2KW 220V W JAM NUTS 30 WC 43055 GUARD SHOCK RESET THERMOSTAT WC 522 31 WC 5527K8 KIT PROBE WATER LEVEL O RING amp NUT 32 WC 37008 KIT TANK LID ROUND 33 WC 37365 KIT FITTING TANK INLET 34 WC 37266 KIT FITTING TANK OVERFLOW ELECTRICAL SCHEMATIC POWER BLOCK 220 F THERMOSTAT HEATING ELEMENT 57 65A 300 450V MAN RESET 40A 277V 3X 2000W 220V i BLK 10GA BLK I0GA Cl A7MF Y NL EI22GA 275 D TRIAC 40A 600V 2 RED 10GA BLU 10GA UIN Eas 25 WHT WHT TOGGLESW 6 COMMON STUD SPST gt gt CHASSIS GROUND 25A 125 250V O FUSE Bk 21 5A 250V BLK ORG REAR PROBE 120V 10W INLET VALVE NUN wem SPYE E uU BASE 9 120V 12W HOT WATER FOR OLDER UNITS HEATING g lt TEMP VALVE WITH HOT WATER TANK H SENSOR
7. WiLBUR Curtis Co INc Service Manual GEM 12D Important Safeguards 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 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 SEN Important Notes Cautions from the factory IMPORTANT Sanitation Requirements Your Curtis ADS System is factory pre set and ready to go right from the carton Following are the factory settings for your interlock coffee brewing systems Model GEM 12D Brew Temperature 200 F Water By pass ON recommended 36 cup brew Brew Volume Set to 36 cup vessel requirements Sleep Mode Off System Requirements CAUTION Please use e Water Source 20 100 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 Setup Steps instructions can result in injury or the The unit should be located on a solid counter top and leveled left to right a
8. behind the unit The heating tank will start to fill When the water level in the tank rises to the correct volume the heating elements will energize automatically With ADS Systems there is no danger of element burnout caused by an empty tank 4 The heating tank will require 20 to 30 minutes to reach operating temperature 200 F as indicated by the READY TO BREW indicator 5 Prior to brewing dispense 12 ounces of hot water through the hot water faucet 6 Brew a cycle of at least 12 ounces to purge the water lines of any air that may be trapped after filling WARNING TOAvOID Brewing Instructions SCALDING do not 1 Brewer should be ON Confirm this at the rear power switch then press the ON OFF button The Ready to Brew light should be ON remove brew cone while 2 Place a clean empty satellite on the warmer deck and press the warmer switch brew light is flashing ISO 9001 2008 Wilbur Curtis Co Inc 3 Place a clean filter into 4 Pour in the correct 5 Transfer the brew 6 Press the Brew but the brew cone measure of ground cone to the brew ton Brewing will start Montebello CA 90640 coffee rails immediately Tel 323 837 2300 N TO WWW WILBURCURTIS COM www wilburcurtis com FOR THE LATEST SPECIFICATIONS AND INFORMATION GO TO WILBURCURTIS CO STEPS TO PROGRAMMING WARNING These steps involve working with hot water Scalding may occur if care is not taken against spilling P
9. 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 varia tion 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 propel lers 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 du
10. h QUICK flash equals 2 F After 204 temperature starts over at 170 READY TO BREW RELEASE when the desired temperature is reached To set and exit press fer BREW VOLUME Factory Preset to Brewer Requirements CHANGE BREW VOLUME ENTER THE PROGRAMMING MODE 1 Press and HOLD until hot water starts running from spray head then RELEASE When desired volume is reached press again to stop flow To set and exit press ps TO ACCESS BREW CYCLE COUNTER ENTER THE PROGRAMMING MODE 2 will now start a pattern of LONG and SHORT blinks READY TO BREW This pattern identifies the number of brew cycles SHORT blinks indicate the brew number from one 1 to nine 9 LONG blinks separate the 1 s 10 s 1 000 s and 10 000 s NENNEN SLEEP MODE 220V Models Only Factory Preset to Disabled This function conserves energy by automatically reducing tank temperature to 140 F when the unit sits idle for more than two hours To recover simply press any BREW or ON OFF button Once the water in the tank reaches brewing temperature the brew cycle will automatically start Recovery is indicated by a yellow RECOVERY light on the membrane control panel Recovering from a SLEEP mode is faster and more efficient than heating after switching off the power eee WARMERS Setting the Temperature Gemini warmers feature three temperature settings Warmers are rated at 90W with High 100 Med 60 Low 30 Pressing the WARMER but
11. nd front to back Connect a water line from the water filter to voiding of the warranty the brewer NOTE A water filtration system must be used to help maintain trouble free operation Air must be purged from the cartridge e prior to connection to equipment In areas with extremely hard water we highly recommend the use of a Curtis approved IMPORTANT IMPORTANT Equipment NK fo be installed to comply water filter For our full line of filters please log on to www wilburcurtis com IMPORTANT with applicable federal NSF International requires the following water connection State or local plumbing electrical 1 A quick disconnect or additional coiled tubing at least 2x the depth of the unit so that the machine be moved for clean codes having jurisdiction ing underneath the unit 2 This equipment is to be installed with adequate back flow protection to comply with applicable federal state and local codes 3 Water pipe connections and fixtures directly connected to a potable water supply shall be sized installed and maintained in accordance with federal state and local codes CAUTION DO NOT e connect this brewer to hot water The inlet valve 1 A 3 8 NPT x 1 4 flare elbow has been supplied for water line connection Use tubing sized sufficiently to provide a minimum of 1 0 is not rated for hot water gpm 2 Connect the unit to an appropriate electrical power circuit 3 Turn on the toggle STANDBY ON switch
12. ring 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 Wilbur Curtis Co Inc 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 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 16832 10 01 15 13 4 rev C 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 30 a m 4 00 PST Email techsupport wilburcurtis com Site www wilburcurtis com FOR THE LATEST SPECIFICATION INFORMATION GO WWW WILBURCURTIS COM Printed in U S A
13. te of purchase on all electrical components fittings and tubing Additionally Wilbur Curtis Co Inc 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 Wilbur Curtis Co Inc assumes no responsibility for substitute replacement parts installed on Curtis equipment that have not been purchased from Wilbur Curtis Co Inc Wilbur Curtis Co Inc 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
14. ton once will place it on High A second time Med Third time Low as indicated by the warmer lights A fourth press of the warmer button turns off the warmer When the system is turned off at the ON OFF button it will remember the last warmer setting Additionally if the warmer is off the unit is designed to automatically turn the warmer on Med setting when the BREW button is pressed SLEEP MODE Factory Preset to DISABLED To ENABLE Sleep Mode UNIT MUST BE ON Press and until gt SLEEP light turns ON press again Sleep Mode is now ENABLED To DISABLE Sleep Mode UNIT MUST BE ON Press and until gt SLEEP light turns OFF press again Sleep Mode is now ENABLED To Determine Timer Setting and the Change Time WARMER MUST BE OFF Press and HOLD until the light comes ON and goes OFF RELEASE The light will start blinking Count the blinks Each blink 20 minutes maximum 200 min WARMER At the end of the flashing cycle press and HOLD until the light begins QUICK flashing The cycle will start over after 11 flashes Note A setting of 11 flashes is the OFF position When you come to the desired time RELEASE c To set and exit press By Pass Flow Adjustment Slide brew cone out to expose by pass outlet Place one measuring cup under the by pass fitting and another measuring cup under the brew cone outlet Press the LARGE brew button for 15 seconds then press the ON OF
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