Curtis PCGT5 Service manual

Models Included

• PCGT4

• PCGT5

CAUTION: Equipment must be installed to comply with applicable federal, state, and local plumbing/ electrical codes having jurisdiction.

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Service Manual – PCGT4 & PCGT5

Important Safeguards/Symbols

This appliance 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

Your Curtis G3 System is Factory Pre-Set and Ready to Go, Right from the Box.

Following are the Factory Settings for your Primo Cappuccino Beverage System:

• Tank Temperature = 190°F

• Flavor Controls= Set at 60%

• Dispensing Mode Set for Manual Dispensing

Generally there will never be a reason to change your G3 programming. However, should you need to make slight adjustments to meet your dispensing needs, programming instructions are provided later in this manual.

System Requirements:

• Water Source 20 – 90 PSI (Minimum Flow Rate of 1 GPM)

• Electrical: See electrical schematic on page 7.

CAUTION: Follow 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 hot water. The inlet valve is not rated for hot water.

ISO 9001:2008 REGISTERED

WILBUR CURTIS CO.

6913 Acco Street,

Montebello, CA 90640-5403

For the latest information go to www.wilburcurtis.com

Tel: 800/421-6150

Fax: 323/837-2410

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 going to the machine should be consistent. Use tubing sized sufficiently to provide a minimum flow rate of one gallon per minute.

NOTE: Some type of water filtration device must be used to maintain a trouble-free operation.

(In areas with extremely hard water, we suggest that a sedimentary and taste & odor filter be installed.) This will prolong the life of your brewing system and enhance tea quality.

NSF International requires the following water connection:

1. A quick disconnect or additional coiled tubing (at least 2x the depth of the unit) so that the machine

can be moved for cleaning underneath.

2. This equipment is to 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 potable water supply shall be sized,

installed and maintained in accordance with federal, state, and local codes.

3. Plug the power cord into an electrical outlet rated at 20A.

4. Turn on power at the toggle switch behind the unit. The lights (display window and row of buttons) on the front door will activate and the heating tank will start to fill.

5. Water in the heating tank will require about one hour to reach operating temperature (factory setting of 190°F). At this time the LCD will display “READY TO DISPENSE”.

6. Remove and fill the canisters with powdered cappuccino product.

C

FOR THE LATEST SPECIFICATIONS AND INFORMATION GO TO WWW.WILBURCURTIS.COM

Technical support: 1-800-995-0417. M-F 5:30am-4:00pm PST.

Email: [email protected]

1

Operating Instructions

1. Choose a flavor. Place your cup under the spout beneath the desired flavor.

2. Push and hold the dispensing button for this flavor.

3. Release the button when the cup is ¾ full.

FILL CANISTERS DAILY

1. Open the front door to access the product canisters.

2. The canisters must be removed from the unit for filling. Turn the powder delivery elbows clockwise, pointing upward. Pull all of the canisters from the canister tray.

3. Refill the canisters. The small canisters hold five pounds of product. Larger canisters hold 10 pounds each. See Configuration of Canisters on page 6.

3. Reposition the canisters on the canister tray. Properly mate the gear socket with the gear on the motor shaft when aligning canisters. Turn the elbows clockwise, pointing downward.

Cleaning the Curtis Primo Cappuccino GT Beverage Dispenser

CAUTION Do not use cleansers, liquid bleach, powders or any other substance containing chlorine. These products promote corrosion and will pit the stainless steel. THE USE OF THESE PRODUCTS WILL VOID YOUR WARRANTY.

I. EVERY 3 - 4 HOURS OR MORE OFTEN IF NECESSARY

A. Make sure power is ON.

B. Place a container under the dispense spout to catch the rinse water.

C. Locate the WASH button on the front control panel.

D. Rinse each flavor by pressing and holding the WASH button, while at the same

time pressing one of the PUSH dispensing buttons on the control panel.

E. Continue holding the WASH button until the water running from the spout runs clear.

II. DAILY

A. Switch OFF the unit at the power toggle switch, located behind the unit.

B. Wipe all exterior surfaces with a damp cloth, removing any spills, residue or dust

from the unit.

C. Remove both the drip drawer and louvered screen; then wash out its contents. For

hard to clean deposits, use a mild, nonabrasive detergent. Rinse with water.

D. Wipe and clean the dispensing area with a mild detergent cleaner.

III. WEEKLY OR MORE OFTEN IF NECESSARY

A. Clean the parts from the whipper assembly.

1. Remove the dispensing nozzle from the whipper chamber. Clean the inside using a

narrow

2. Remove the upper mixing cup. Pull cup forward, twist to the left and lift it to separate

the upper mixing cup from the lower mixing cup.

3. To remove the lower mixing cup, pull mixing cup up and forward to free it from the hot water inlet fitting.

4. Remove the whipper chamber. Take hold of the whipper chamber. Turn it

clock wise to free it from the mounting plate.

5. Pull the whipper propeller from the motor shaft.

6. Wash, Rinse and Sanitize using a 3-sink method. Air dry all parts.

7. Re-assemble cleaned parts onto the machine.

DETERGENT

SOLUTION

RINSE

WATER

SANITIZER

IMPORTANT - When replacing the propeller, make sure it is properly aligned and seated on the motor shaft. The propeller has an embossed ‘ D’ to properly align it on the motor shaft.

Failure to properly seat the propeller will cause it to fuse with the whipper chamber. This condition will not be covered under warranty.

6. Clean the mounting plate.

a. Clean the shaft with a cloth and mild detergent before removing mounting plate.

b. Twist the mounting plate clockwise and pull it from the motor shaft.

IMPORTANT - Do not remove pillars to take off mounting plate.

c. Clean the area behind the mounting plate.

d. Clean the water inlet fitting.

e. Lubricate the center seal of the mounting plate before reinstalling.

2

Steps to Programming

Your Curtis Generation 3 cappuccino dispenser is Factory Pre-Set for Optimum

Performance. Programming for all models is identical except where noted.

Entering the Programing Menus

Press and hold STOP/WASH for about ten [10] seconds. Display will read Program Menus,(See Illustration).

Manual Dispense (Factory Set to Manual Dispense)

Press  or > to go to Manual Dispense Select.

Press  to go to Manual Dispense Select Station.

Choose the station and press, the display will read Saving Complete! To select another station for manual dispense, press  to go to Manual Dispense Select Station or press > to continue to the next menu.

Dispense By Time (Factory Setting OFF)

The next screen is Dispense By Time < Select >. Press  to select a station. Select the station and the screen will read To Begin Press Push. Press desired dispense button. Hot water will start to dispense and screen will display

To Finish Press Push. When Push is pressed, time will be saved and you will exit back to Dispense by Time screen.

Continue with additional selections or press > to continue to the next menu.

Temperature (Factory set at 190°F – Cold Cappuccino Units Set at 96ºF)

Press  and screen will show Tank Temperature. Temperature is programmable from 80°F to 204°F in 2-degree increments. Press < or > to go up or down in degrees. Select desired temperature and then  to set. Press > to continue to the next menu.

Powder % Ratio (Factory set at 60%)

Press  and the screen will display Powder % Ratio Select Station. Press desired station. Powder ratio is programmable from 0% (Hot Water) to 100%, in 5% increments. Press < or > to increase or decrease ratio and then press

 to set. Press > to continue to the next menu.

Valves should not be field adjusted to change product strength.

Product strength adjustments should be done through programming on the front panel only.

Service Call (Factory Set to 1-800-000-0000 x0000)

Press  to display number and press  change number or > to move places and EX to exit when complete This number will be displayed during a Heating system SENSOR ERROR or a WATER ERROR. Press > to continue to the next menu.

Banner Name (Factory Set to Curtis)

Press  to display letters, press  to change letters or > to move places 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. Press > to continue to the next menu.

Model Select

Press  to select, < or > to select desired model (PC-1, -2, -3, -4, -5) . Press  to set and exit program mode.

Exit

Press  to select, exits program mode and returns unit to operation.

3

Parts List

ITEM Nº PART Nº

27

28

29

23B

24

25

26

21

22

23

23A

17

18

19

20

13

14

15

16

9

10

11

12

6A

7

7A

8

4

5

5A

6

1

2

2A

3

WC-37008

WC-43067

WC-5502-01

WC-3734

WC- 904-04

WC-1438-101

WC- 523

WC- 102

WC-68147

CA-1157

CA-1112-06

CA-1113-06R

CA-1113-06L

CA-1011-05

CA-1065-03

CA-1026-03

CA-1005-03

CA-1009-03

CA-1037-3Y

WC-68159

WC-68167-101

WC-68167

CA-1110-01

CA-1174

WC-37127

WC-37128

WC-39350-01

WC-39351-01

WC-39957

WC-39753

CA-1171

CA-1174-101

WC- 780

WC-37123

CA-1039

DESCRIPTION

COVER, TOP PCGT4/5

DOOR COMPLETE PCGT-5

DOOR COMPLETE PCGT-5 (OLDER VERSION)

FILM, CURTIS LOGO PCGT-4/5

LED LAMP ASSY - 11-12W 36VDC

KIT, UCM BOARD & LABEL PCGT4

KIT, UCM BOARD & LABEL PCGT5

LABEL, UCM PANEL PCGT4 CURTIS

LABEL, UCM PANEL PCGT5 CURTIS

MEMBRANE CONTRL PANEL PCGT4/5 CURTIS

MEMBRANE CNTRL PNL PCGT4/5 (OLD VER)

COVER, ALCOVE PCGT-4/5

POWER SUPPLY, 100-240VAC TO +36VDC .55A

CONTROL, POWER MODULE CORK BRAKE

KIT, FAN EXTRACT 120V 29 CFM & BRACKET

O-RING, DUMP VALVE (WC-880)

KIT, TANK LID ROUND

O-RING, 4-1/2 I.D. x Ø.285 SILICONE

KIT, LIQUID LEVEL PROBE

KIT, RPL DUMP VALVE FOR WC-880E PCGTs

HEATING ELEMENT, 1.6KW W/JAMNUTS

SENSOR, TEMPERATURE TANK

THERMOSTAT, MNL RESET 120/240V 25A

SWITCH, TOGGLE NON LIT 15A 120/240V SPST

SCREEN, DRIP TRAY PCGT-4/5

DRIP TRAY, PLASTIC PCGT-4/5

CANISTER ASSY, 5LB PCGTs

CANISTER ASSY, 10LB RIGHT PCGTs

CANISTER ASSY, 10LB LEFT PCGTs

FITTING, BULKHEAD WATER PCGTs

BUSHING, DISCHARGE PC/CK/HC

ELBOW, PC/CK/HC

STEAM TRAP PC/CK/HC

BOWL, MIXING PC/CK/HC

TUBE, EXTENSION 3.0” LONG YELLOW

WC-5231

WC-39350-02

WC-39203

WC- 826L

WC-8556

WC-5310

CA-1030-17

WC-6295

WC-6296

WC-58120

CA-1095

WC-8591

CA-1135

WC-3503

WC-3518

WC-4320

PART Nº

CA-1002-01

WC-5664-05

CA-1047

WC-37054

WC-2626-03

WC-3739

WC-43791

WC-37118

CA-1008-07K

CA-1006-06

CA-1024-05

WC-37174

CA-1036

WC-3765L

WC-4394

WC-3689

WC-68123

WC-68121

WC-66044

CA-1107

54

55

56

57

50A

51

52

53

47

48

49

50

43

44

45

46

58

59

60

61

62

63

39

40

41

42

35

36

37

38

ITEM Nº

30

30A

31

32

33

34

DESCRIPTION

LID, CANISTER, 4/5LB CHAMFERED

LID, CANISTER, 10LB PCGT’s

AUGER, WIRE PCs & PCGTs

KIT, SOCKET GEAR PC/CK/HC

BUSHING, AUGER PC/CK/HC

KIT, WHIPPER MOTOR, SCREWS & INSTR

RING, MOTOR SHAFT PLASTIC

KIT, WHIPPER PLATE (W/SEAL) 3/PKG

KIT, PROPLR OFFSET BLADES PCGT PKG6

WHIPPER CHAMBER OFFSET PCGTs

PILLAR, LOCATION BLACK

KIT, GEAR MOTOR, CORK BRAKE PCGT

GEAR, PLASTIC USE ON CA-1013

KIT, INLET VALVE REPAIR USE ON WC-826L

COMPOUND, SILICONE 5 OZ TUBE

LABEL, PANEL FLAVOR CURTIS PCGTs

LABEL, SERVICING INSTR (NOT SHOWN)

VALVE, INLET 1 GPM 120V 10W YELLOW

HEAT SINK ASSEMBLY DV PCGTs

TUBE, 5/16” ID X 1/8”W SILICONE

HOSE, EXTRACTOR FAN 17” LONG

HEATING TANK, COMPLETE PCGT4

HEATING TANK, COMPLETE PCGT5

COVER, DUMP VALVE PC-4/5GT

CONNECTOR, ORIFICE WATER PCGT

CAPACITOR, X2 ALL ADS MODELS

LATCH ASSY, DOOR (NOT SHOWN)

LEG, 3/8”-16 STD SCREW BUMPER

LEG, GUIDE 3/8”-16 STUD SCREW

O-RING, ½” I.D. (NOT SHOWN)

GUARD, SHOCK HEATING ELEMENT

INSULATION, WRAP PCGT

PANEL, LEFT SIDE PCGTs

PANEL, RIGHT SIDE PCGTs

CANISTER TRAY, ASSY PLASTIC PCGT4/5

WINDOW, FRONT CLEAR PCGT-4/-5

Detail Bubbles

35

36

37

42

18

43

38

39

4

Illustrated Parts

1

60

62

3

7

5

6

8

21

22

2

4

9

63

LABELING

DETAIL P6

40

41

48

49

23

52

24

25

26

27

28

29

15

16

17

58

19

32

33

34

30

31

5

13

14

50

59

20

61

46

55

56

53

Illustrated Parts

6A

6

7

45

47

10

11

Shaft seals should be replaced with the groved side facing outward. Place a dab of food grade lubricant in the rear hole of the seal, as shown below.

View of PCGT Unit with Side Panel Removed, Showing

Location of Triac and Control Board.

CONFIGURATION OF CANISTERS

ON PCGT MODELS

Before mounting a whipper plate, place a dab of food grade lubricant in the rear hole of the seal.

MODEL

PCGT4

PCGT5

10 LB. CANISTER

P/N CA-1113-06L

ONE

ONE

10 LB. CANISTER

P/N CA-1113-06R

ONE

ONE

5 LB. CANISTER

P/N CA-1112-06

TWO

THREE

6

Electrical Diagram

7

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 car- rier.

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.

8

RevD.3/1/12.ECN13663

RevC . 10/10/11 . ECN 13522

RevB . 9/2/11 . ECN 13441

RevA . 3/8/11 . ECN 13021

NC . 8/6/9 . EDR5946

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) E-Mail: [email protected]

Web Site: www.wilburcurtis.com

Printed in U.S.A. 3/2012 . F-3689_rev D