Service Manual – G4 Gemini IntelliFresh Twin

Wilbur Curtis Company, Inc.
Service Manual – G4 Gemini IntelliFresh 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
Model
G4GEMTIF
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.
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:
• 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).
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
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”.
FOR THE LATEST SPECIFICATIONS AND INFORMATION GO TO WWW.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
. Next
When the proper level is reached
FILLING
HEATING will
is displayed. Water will fill the tank (2-3 minutes depending on water flow rate).
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 satellite server on the warmer deck, under the brewcone and touch the warmer icon to Preheat the satellite.
3. Place a clean filter
into the brewcone.
4. Fill brewcone with
correct amount of
ground coffee.
5. Transfer filled
brewcone to
brewer.
6. Touch desired
brew button.
Brewing will begin
immediately.
WARNING TO AVOID SCALDING, Do not remove brewcone while brew light is flashing.
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
WARMERS
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, SETTINGS SUMMARY, and
EXIT.
Menu Tree
This chart explains how to enter the program mode and menu selections available from the MAIN MENU.
Single
Twin
Single
Twin
3
Menu Features
Recipes
Control Settings
4
Menu Features
Brew Settings
5
System Fault Messages
6
Illustrated Parts
Main View
7
Illustrated Parts
Top Wrap
39
40
41
33
34
35
36
37
42
38
43
ITEM NO.
1
1A
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
19A
20
21
PART NO.
WC-5421-BLK
WC-5421
WC-37008
WC-43067*
WC-5502-02*
WC-62033
WC- 934-04*
WC-4382
WC- 522*
WC-43055
WC-1438-101*
WC-29050*
WC-8559*
WC-14045-101
WC-39745
WC-1809
GEM-6*
WC-3417
WC-61954-BLK
WC-61960-BLK
WC-61960
WC-61962
WC-61963
DESCRIPTION
COVER, TOP - PAINTED BLACK TEXTURE PC
COVER, TOP STAINLESS GEMTIF
KIT, TANK LID ROUND
O-RING, 4-1/2 I.D. x Ø.285 C.S. SILICONE
KIT, PROBE, ASSY WATER LEVEL W/HEX FITTING, O-RING & NUT
TANK COMPLETE, GEMTS WITH ULTEM FITTINGS
KIT, HEATING ELEMENT 2.5KW 220V W/JAM NUT & SILICONE WASHERS
GUARD, SHOCK - DOUBLE HEATING ELEMENTS
THERMOSTAT, HI LIMIT HEATER DPST 277V-40A
GUARD, SHOCK RESET THERMOSTAT
SENSOR, TEMPERATURE TANK
SPRAYHEAD ASSY, AFS-AMBER
RELAY, SOLID STATE 40A w/INTEGRATED HEATSINK
CURRENT SENSOR ASSY G4
LABEL, BOTTOM WRAP - GEMTIF
FAUCET, PS/HSP SERIES HOT WATER 1/2-20 UNF
FILTER, 500PK GEM-12/230A
BREW CONE, ASSY W/STEAM GUARD STYLIZED “FRESH COFFEE”
PLATE, BREW CONE STOP GEMTIF BLK
COVER, FRONT W/A GEMTIFBLK
COVER, FRONT W/A GEMTIF SS
DECK, WARMER W/A GEMTIF
PLATE, HOLDER IF CONNECTORS
* RECOMMENDED PARTS TO STOCK
8
Illustrated Parts List
ITEM NO.
22
22A
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
PART NO.
WC- 571K-R
WC- 571K-L
WC-43133
WC-3528
WC-5310*
WC-5350*
WC-2402P
WC- 847*
WC-13450
WC-1501
WC- 102 *
WC-4212-02
WC-37121
WC- 442*
WC-2977-101
WC-43089*
WC-39812
WC-10000*
WC- 589-101
WC- 844-101*
WC-37122*
WC-10008
WC-10001*
GEM3IF
DESCRIPTION
KIT, IF CONNECTOR- RIGHT
KIT, IF CONNECTOR- LEFT
O-RING, 1.424ID X 1.630 OD X .103 WALL GEMIF’s
LEG, 4” ADJUSTABLE 3/8-16 THRD STYLIZED
TUBE, 5/16 ID x 1/8W SILICONE
TUBE, SILICONE Ø1/2” ID x Ø3/4” OD x 1/8” WALL
ELBOW, 3/8 NPT x 3/8 FLARE PLATED
VALVE, INLET 2 GPM 120V-10W
HARNESS ASSY, COMPLETE TP2T10G4/GEMTS10G4/GEMTIF10G4
FUSE, HOLDER ASSY w/5A FUSE
SWITCH, TOGGLE SPST 15A 125Vac RESISTIVE
NUT, 5/8-18 JAM PLASTIC-ULTEM
KIT, DUMP VALVE LEFT
SOLENOID, LOCK BREW CONE RIGHT 120VAC
FITTING, SPRAYHEAD ULTEM
GASKET, 1.00”OD x .625” I.D. x .030” THK RED SILICONE 40 SHORE
LABEL, OUTER TOUCHSCREEN GEMTSG4 CURTIS LOGO
CONTROL MODULE, TOUCH SCREEN G4
TRANSFORMER, 120/230VAC - 24VAC 4.8VA w/LEADS & TERMINALS
VALVE, BYPASS 120V-14W NON ADJUSTABLE WITH RESTRICTOR (WC-2945)
KIT, DUMP VALVE RIGHT
UNIVERSAL HOST ADAPTER (USB)
UNIVERSAL POWER MODULE - G4
1½ GALLON SATELLITE SERVER WITH INTELLI-FRESH
* RECOMMENDED PARTS TO STOCK
Rough-In Drawing
22.250"
(56.5 cm)
SHOWING WC-3422
BREW CONE ASSEMBLY
18.125"
(46.0 cm)
.125"
.875"
(2.2 cm)
(.3 cm)
.250"
(.6 cm)
30.625"
(77.8 cm)
11.875"
(30.2 cm)
12.625"
(32.1 cm)
7.750"
(19.7 cm)
5.500"
(14.0 cm)
4.000"
(10.2 cm)
9
Electrical Schematic
G4GEMTIF-10
10
Cleaning the Coffee Brewer
Regular cleaning and preventive maintenance is essential in keeping your coffee brewer looking and working like new.
CAUTION – Do not use cleansers, bleach liquids, powders or any other substance containing chlorine. These
products promote corrosion and will pit the stainless steel. USE OF THESE PRODUCTS WILL VOID THE
WARRANTY.
1. Wipe exterior surfaces with a moist cloth, removing spills and debris.
2. Slide the brewcone out and clean it. Clean the sprayhead area with a moist clean cloth.
3. Rinse and dry the brewcone.
4. Drain drip tray of coffee. Wash out the drip tray. Dry the tray.
5. Rub a stainless steel polish on the outside surfaces to protect the brewer.
Cleaning the Satellite Server
To clean the Satellite components, prepare a mild solution of detergent and warm water..
DO NOT immerse the Satellite in water or any other liquid.
1. Remove lid from Satellite. Clean the lid at the funnel area with a spiral brush and detergent solution.
2. Rinse the lid, removing all traces of cleaning solution.
3. Clean inside of the Satellite. Remove coffee residue with the detergent solution.
4. Thoroughly rinse out the Satellite with clean warm water.
5. Unscrew the handle/bonnet assembly and remove it from the
dispensing faucet.
CAP
WASHER
6. Inspect the silicone seat cup for wear, cracks, or hardening. If
okay, then leave the seat cup attached on the handle/bonnet assembly. Soak then wipe clean. Replace the seat cup if damaged.
7. Remove the gauge glass tube by unscrewing the gauge glass
cap.
8. Clean the gauge glass tube with a gauge brush soaked with
detergent solution. Soak and wipe the two washers. Rinse with
clean water. Dry the parts and assemble them onto the Satellite.
Hand tighten the cap.
GLASS TUBE
SEAT
CUP
WASHER
9. Clean all parts. Thoroughly rinse with clean warm water.
10. Dry and assemble the parts. Hand-tighten when assembling.
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.
ECN 14434 . 9/21/12@11.8
ECN 13971 . 4/2/12@15.5
6/30/11@14.9 . EDR 7785
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
9/2012 . F-3803 rev B
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