Wilbur Curtis Company G4 ThermoPro G4TP2T Service manual

Wilbur Curtis Company, Inc.
Service Manual – G4 ThermoPro Twin 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 are 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
Important Notes/Cautions – from the factory
Sanitation Requirements
This Curtis Generation 4 Unit is Factory Pre-Set and Ready to Go Right from the Box.
Following are the Factory Settings for your G4 Coffee Brewing System:
Model
G4TP2T
CAUTION: Please use
this setup procedure
before attempting to use
this brewer. Failure to follow the
instructions can result in injury or the
voiding of the warranty.
IMPORTANT: Equipment
to be installed to comply
with applicable governmental plumbing/electrical codes
having jurisdiction.
CAUTION: DO NOT
connect this brewer to hot
water. The inlet valve is
not rated for hot water.
• Brew Temperature = 200°F
• Water Bypass = On for LARGE & MEDIUM Brew Only
• Brew Volume = Set to Vessel Requirement.
System Requirements:
• Water Source 20 – 90 PSI (Minimum Flow Rate of 1 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 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:
1. A quick 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. 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”.
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
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
1
Your Curtis G4/Gold Cup Series is Factory Pre‑Set for Optimum Performance.
After connection to water and power; turn on the brewer at the rear toggle switch. You will hear a beep and the status lights will come on for a moment.
The screen will display
MODEL NUMBER
CONTROL BD NUMBER
When the proper level is reached
FILLING
. Next
HEATING
is displayed. Water will fill the tank (2-3 minutes depending on water flow rate).
will appear on the screen. It takes approximately 30 minutes to reach the set point temperature.
Control will display
READY TO BREW when temperature reaches the set point. The unit is now ready to brew.
COFFEE BREWING INSTRUCTIONS
1. Brewer should be ON (Confirm at the rear toggle switch). The LCD screen should read Ready to Brew.
2. Place an empty ThermoPro 2 gallon server under the brewcone.
3. Place a clean filter
into the brewcone.
4. Fill brewcone with
ground coffee.
5. Transfer filled
brewcone to
brewer.
WARNING TO AVOID SCALDING, Do not remove brewcone while brew light is flashing.
6. Touch desired
brew button.
Brewing will begin
immediately.
Touch Screen Control Module
The touch screen turns on when power is available to the controller. The screen will contain standard control feature such as symbols and buttons. Pressing these elements with
your finger tip will activate the programming functions. The default screen, as well as some added control buttons are shown in the illustration below.
STATUS LIGHTS
BREW BUTTONS
CURTIS LOGO
TO ENTER PROGRAMMING
Tap Curtis logo 5 times to bring
up the ACCESS CODE screen.
CONTROL SYMBOLS
All of these symbols may not
be visible at one time.
2
RETURN TO HOME
UNDO
SCROLL
RETURN TO PREVIOUS
PROGRAMMING
ACCESS CODE
screen. Default is 1
2 3 4. Once the code
is entered, press
OK. The Main Menu
screen will appear.
MAIN MENU screen
contains five contol
icons: RECIPES,
CONTROL SETTINGS,
BREW SETTINGS,
MODEL SELECT and
EXIT.
Menu Tree
This chart explains how to enter the program mode and menu selections available from the MAIN MENU.
Tap "Curtis" Logo 5 Times
to Enter Programming Mode
Enter 1-2-3-4 to access the Main Menu
Gourm e t STD
Te m p Se tti ngs
Se l e ct Button…
Light Roa st
W a rm e r Se tti ngs
Bre w By Vol um e
Da rk Roa st
Qua l i ty Ti m e r
Bre w By Ti m e
Hi gh Yi e l d
Ene rgy Sa vi ng
Pre -I nfusi on
Fi l te r Pa ck
S ounds
Pulse Bre w On/Off
De ca f
Di a gnosti cs
Bypa ss On/ Off
Hom e
Di spl a y Se tti ngs
Dri p Out
Pre v - Ma i nt
Hom e
Gemini
S i ngl e
One Ba tch
Tw i n
Tw o Ba tch
Gemini IF
Three Batch
Thermopro
Milano
Si ngl e Cup
Ce ra m i c Cup
Thre e Ba tch
Paper Cup
Brew Counter
Passwords
Master Reset
Home
3
Menu Features
4
Menu Features
5
System Fault Messages
WARNING MESSAGES - ALLOWS BREWING
MESSAGE DISPLAY
Component Failure
Service Required
1-(800)-000-0000x
WARNING DESCRIPTION
CAUSE
A Component has Failed
Current in one of the components is not within normal
range.
Maintenance Required
Service Required
1-(800)-000-0000x
Maintenance Required
Lime Scale Warning
Service Required
1-(800)-000-0000x
Scale Starting to Build Up
Water Level Probe
Low Water Flow Warning
Service Required
1-(800)-000-0000x
Low Water Flow
Brew count "Gallons Since Reset" exceeds
programmed Preventative Maintenance period
Water level probe resistance above warning
threshold (test value 23k Ohm)
If the Inlet valve remains on longer than 40
Seconds (during the brew cycle only) and repeats
TWICE during that brew cycle. It shall clear upon
the next brew and if the same low flow exists
again, it will re-appear.
ERROR MESSAGES - STOPS BREWING
MESSAGE DISPLAY
6
ERROR DESCRIPTION
CAUSE
Water Level Error
Service Required
1-(800)-000-0000x
Fill run error / Overflow
Sensor Error
Service Required
1-(800)-000-0000x
Open Sensor
Break in the temperature thermistor circuit or short
curcuit.
Over Temp. Error
Service Required
1-(800)-000-0000x
Excess Temperature
The sensor is reading that temperature in the
heating tank has risen above 210ºF, or sensor has
shorted to ground.
Lime Scale Error
Service Required
1-(800)-000-0000x
Probe
Water level probe resistance above error threshold
(test value 180kOhm)
Internal Error 1
Service Required
1-(800)-000-0000x
UPM-UCM Communication
The fill solenoid has either run for more than 10
minutes on the initial tank fill or 1.5 minutes in
normal operation
Break in the UPM-UCM Communication circuit.
Illustrated Parts
Main View
7
Illustrated Parts
Top Wrap
23
30
24
31
32
33
34
25
26
35
7
36
27
37
28
ITEM NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
PART NO.
WC-5459
WC-37008*
WC-43067*
WC-37406*
WC-37121*
WC- 844-101*
WC-10000
WC-37308
WC-4382*
WC-1438-101*
WC-43055*
WC- 522 *
WC-1825
WC-8559
WC-3528
WC-14045-101*
WC- 102 *
WC-58037-101
WC-2402P
WC- 847 *
WC-62030
WC-1501
WC-2977-101
WC-43089
WC- 589-101
WC-39812
WC-4212-02
WC-29050*
WC-37365
WC-5310*
WC-5350*
WC-37122*
WC- 442 *
WC-13450
WC-10001*
WC-10008
GEM-6 *
WC- 314
DESCRIPTION
COVER, TOP WRAP
KIT, TANK LID ROUND
O-RING, 4-1/2 I.D. x Ø.285 C.S. SILICONE
KIT, LIQUID LEVEL PROBE FAIL SAFE NON-METALLIC ROD
KIT, DUMP VALVE LEFT
VALVE, BYPASS 120V-14W NON ADJUSTABLE w/RESTRICTOR (WC-2945)
CONTROL MODULE, TOUCH SCREEN G4
KIT, BREW CONE GEMINI NON-METAL with “FRESH COFFEE” LOGO
GUARD, SHOCK (HEATING ELEMENT)
SENSOR, TEMPERATURE TANK
GUARD, SHOCK RESET THERMOSTAT
THERMOSTAT, HI LIMIT HEATER DPST 277V-40A
FAUCET ASSY, HOT WATER
RELAY, SOLID STATE 40A w/INTEGRATED HEATSINK
LEG, 4” ADJUSTABLE 3/8-16 THRD STYLIZED
CURRENT SENSOR ASSY G4
SWITCH, TOGGLE SPST 15A 125Vac RESISTIVE
COVER, CENTER WRAP
ELBOW, 3/8 NPT x 3/8 FLARE PLATED
VALVE, INLET 2 GPM 120V-10W
TANK, COMPLETE TP2T W/ULTEM FITTINGS
FUSE, HOLDER ASSY w/5A FUSE
FITTING, SPRAYHEAD ULTEM
GASKET, 1.00”OD x .625” I.D. x .030” THK RED SILICONE 40 SHORE
TRANSFORMER, 120/230VAC - 24VAC 4.8VA w/LEADS & TERMINALS
LABEL, OUTER TOUCHSCREEN TP2T CURTIS LOGO
NUT, 5/8-18 JAM PLASTIC-ULTEM
SPRAYHEAD ASSY, AFS-AMBER
KIT, FITTING TANK INLET
TUBE, 5/16 ID x 1/8W SILICONE
TUBE, SILICONE Ø1/2” ID x Ø3/4” OD x 1/8” WALL
KIT, DUMP VALVE RIGHT
SOLENOID, LOCK BREW CONE RIGHT 120VAC
HARNESS ASSY, COMPLETE TP2T10G4/GEMTS10G4/GEMTIF10G4
UNIVERSAL POWER MODULE - G4
UNIVERSAL HOST ADAPTER (USB)
FILTER, 500PK GEM-12/230A
POWER BLOCK, 5 STATION
* RECOMMENDED PARTS TO STOCK
8
Electrical Schematic
ThermoPro Twin, TP2TG4-10
9
Cleaning and Sanitizing Instructions for
ThermoPro Server
CAUTION
Do not immerse in water.
Do not place in dishwasher.
Do not use harsh powders or cleansers containing chlorine.
Do not use a wire brush or pot scourer to clean inside liner.
These cleaning and sanitizing instructions are only a guide line to be used for the cleaning and sanitizing of the ThermoPro
server. Your current in-house cleaning and sanitizing methods may be just as effective.
For cleaning and sanitizing of the server, the three sink method is recommended. This method consists of a sink with a detergent
and water solution, a fresh water rinse, and a sink filled with an aqueous sanitizing solution. Immerse in commercial BarTabs/
Sani-Tabs sanitizing solution. The solution must be warm. Let the parts soak at least one minute.
1. Daily, Rinse the unit after use.
a. Rinse unit with warm water and empty completely.
b. Fill unit with warm water.
c. Open unit and empty contents completely.
2. Clean and sanitize the lid assembly.
a. Remove lid from unit and submerse it in cleaning solution, cleaning thoroughly.
b. Using the supplied brush, clean inside the filling tube.
c. Rinse with clean water.
d. Submerse in sanitizing solution for 5 minutes then air dry completely.
3. Cleaning and sanitizing body assembly.
a. Pour a cleaning solution into the open server. With a sponge brush, thoroughly clean inside liner.
b. Rinse the unit using a fresh water rinse.
c. Fully fill unit with sanitizing solution. Allow to sit for 5 minutes then drain through the faucet.
d. Remove faucet and gauge glass from unit and brush out with cleaning solution.
e.
f.
With the faucet removed, clean the silicone elbow fitting (Tank to Faucet Tube). Use a tube brush soaked in cleaning solution, insert it through the faucet shank. Rinse by pouring water from inside the unit, allowing rinse water to flow into a sink until water runs clear.
Wipe outside the outside surfaces of the unit with a moist clean cloth.
g. Place the body assembly upside down on a rack to thoroughly air dry.
4. Cleaning the faucet parts.
a. Unscrew the bonnet/handle assembly from the faucet and disassembly removing spring, seat cup and shaft.
b. Clean and rinse parts. Place in sanitizing solution for 5 minutes, remove and air dry,
5. Assemble.
a.
When all pieces are completely dry assemble the server.
10
Rough-In Drawing
11
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 & 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 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 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 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.
7/1/11@13.8 . EDR 7776
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 5:30A - 4:00P PST)
Web Site: www.wilburcurtis.com
E-Mail: techsupport@wilburcurtis.com
7/11 . F-3802 rev NC