Curtis GEM-120A User manual

Service Manual – GEM-120A Satellite Brewer
Wilbur Curtis Co., inC.
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: [phone]
Fax: [phone]
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, ip the toggle switch to the ‘ON’ position (located on the rear of
the unit), the water tank will begin to ll. 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 (fac-
tory setting of 200°F). When the water temperature in the heating tank is ready, the green "BREW WHEN
LIT" light will come on.
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back-owprotectiontocomplywithapplicablefederal,
state and local codes.
3.Waterpipeconnectionsandxturesdirectlyconnectedtoaportablewatersupplyshallbesized,
installedandmaintainedinaccordancewithfederal,state,andlocalcodes.
SYMBOLS:
WARNINGS – To help avoid personal injury
Important Notes/Cautions – from the factory
Sanitation Requirements
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 re 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.
INSTALLATION
This Curtis unit is pre-set and ready to go from the factory.
Factory settings for this unit are:
• Brew Temperature = 200°F
• Brew Volume = Set to vessel requirements (1 Gallon).
System Requirements:
• Water Supply 20 – 90 psi (minimum ow rate of 1 gpm)
• Electrical: See electrical schematic.
Important Safeguards/Symbols
Forthelatestspecicationsandinformationgotowww.wilburcurtis.com
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 tting on the rear of the unit. Water volume ow to the machine
should be consistent. Use tubing sized sufciently to provide a minimum ow rate of one gallon per minute.
Model:
 ●GEM-120A
CAUTION: DO NOT
connect the unit to
hot water supply.
The inlet valve is not rated for
hot water.
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:
Equipmentmustbe
installed to comply
with applicable federal, state,
and local plumbing/electrical
codes.
NOTE: A water ltration system must be used to help maintain trouble-free operation. Air must
be purged from the cartridge prior to connection to equipment. In areas with extremely hard
water, we highly recommend the use of a Curtis approved water lter. For our full line of lters,
please log on to www.wilburcurtis.com.

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WARNING: AVOID SCALDING - Do not remove the brew basket while
the brew light is ashing.
BREWING
1. Brewer should be ON (Conrm at rear toggle switch, then press the ON/OFF button). The Brew When Lit light should be on.
2. Place an empty satellite under the brew basket and press the warmer switch to pre-heat the satellite.
3. Place a clean lter into the brew basket.
6. Determine the brew volume
and ip the toggle switch to
desired size, ½ gallon (1) or
1 gallon (2). Press the brew
button. Brewing will begin
immediately.
5. Transfer the brew basket
to brewer, inserting it into
the brew basket rails.
4. Fill the brew basket with the
correct amount of ground
coffee.
CLEANING
Regular cleaning and preventive maintenance is essential in keeping your coffee brewer looking and working like new. To clean the coffee
brewer and components, prepare a mild solution of detergent and warm water.
CAUTION – Do not use cleaning liquids, compounds or powders containing chlorine (bleach) or corrosives. These products
promote corrosion and will pit the stainless steel. USE OF THESE PRODUCTS WILL VOID THE WARRANTY.
DAILY CLEANING
1. Wipe exterior surfaces with a damp cloth, removing spills and debris.
2. Slide the brew basket out and clean it. Wipe the spray head area with a cloth soaked in a mild detergent solution.
3. Rinse and dry the brew basket and spray head area.
4. Drain coffee from the drip trays.
5. Use a clean soft cloth to wipe dry the coffee brewer and drip tray.
WEEKLY CLEANING
1. Turn off unit at the power switch, behind the unit. Allow the brewer to cool.
2. Clean the spray head and dome plate area.
a. Remove the spray head, unscrewing counterclockwise from the dome plate.
b. Thoroughly clean the dome plate area with detergent solution.
c. Clean the brew basket rails with a brush soaked with the detergent solution. When clean, rinse the area with a cloth soaked with
clean water to remove all traces of detergent.
d. Use a clean soft cloth to dry the area.
c. Attach the spray head.

- 3 -
SETTING WC-603-101 BREW TIMER
Adjusting the brew timer is made on the calibrated dial. The dial range is from 0 to 100. This represents 2 to 20 minutes. Also in the timer
circuit, there is a brew selector switch on the front control panel of the brewer. This is marked 1 (half brew) and 2 (full brew).
To change the brew time setting:
Disconnect the power cord.
1. Flip the brew selector switch to 2.
2. Open the top cover and locate the brew timer.
3. On the brew timer, rotate timer arrow to change the setting. Rotating to the right will increase
the brew time, rotate to the left will decrease it. The timer arrow is usually set at 25. This set-
ting is intended to deliver one gallon of water (brew 24 cups) per brew cycle.
4. After making an adjustment, run a brew cycle with coffee to test the liquid level and the coffee
taste. If this is not satisfactory, repeat steps above.
5. Once you achieve an acceptable result, return the top cover onto the brewer.
CLEANING THE SATELLITE SERVER
1. Empty any remaining coffee from the satellite server.
2. Fill the liner with a mild detergent solution and let it stand for 10 to 15 minutes.
3. After about 15 minutes take a sponge brush and scrub out the stainless steel liner.
4. Drain out the detergent solution from the server. Rinse in a sink with running water.
5. Repeat this rinsing until the water runs clear.
CLEANING THE FAUCET
1. Remove the faucet handle assembly. Take hold of the bonnet and turn counterclockwise to unscrew it from
the faucet.
2. Clean the handle assembly with a mild detergent solution. When clean, rinse the handle with water. Inspect
for cracks or tears in the seat cup. Replace if the seat cup damaged.
3. Clean the coffee level gauge glass.
a. Remove the gauge glass cap unscrewing it from the top of the shield.
b. Carefully, pull out the gauge glass. Brush out the inside of the glass with a detergent solution. Rinse the
gauge glass tube with clear water, removing all traces of the detergent solution.
c. Inspect the gasket seals at the top and bottom of the gauge glass. Clean these gaskets.
d. Assemble the gauge glass. Make sure gaskets are properly seated.
e. Hand-tighten the gauge glass cap.
POUCH CLEANER
You may use a pouch or tablet cleaner to easily clean both the brew basket and the coffee vessel.
1. Place a pouch or tablet cleaner into the brew basket. Place an empty server on the brew
deck.
2. Press the brew button to run a full brew cycle into the server. You will see that the
cleaner pouring from the brew basket is blue.
3. At the end of the brew cycle, discard the used lter cleaner pouch. The tablets should have dissolved
in the brew cycle.
4. Allow the cleaner to soak in the coffee server for a few minutes.
5. Dump out the cleaner from the coffee server into a sink. Rinse the coffee server and brew basket with
clear running water.
6. Return the empty coffee server to the brew deck. Install the brew basket onto the brewer. Run another
brew cycle of hot water to rinse the brew basket and the server. Empty the rinse water from the coffee
server.
7. Dry the surfaces with a clean soft cloth and the brewer is ready to return to service.

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POSSIBLECAUSE SOLUTION
TROUBLE SHOOTING
Openthewaterlineandmakesurewaterowstothebrewer.
Turn off brewer. Disconnect wires from water inlet coil terminals and
connectapowercordtotheterminals.Plugcordintoa110voutlet
andverifythatwaterowwhenpluggedinandstopswhencord
is disconnected. If valve does not respond to this test, replace the
valve.
When water in the heating tank is below the probe tip, yet water is
notrelling,pullthewireofftheprobeterminal.Ifwaterstartsow-
ingintothetank,ndground,cleanorreplacetheprobe.
Pull the wire from the probe terminal. With a volt meter, check the
voltageatthewaterinletcoilterminals.Thisshouldread110to
115volts.Ifnovoltageispresent,checkthewaterlevelcontrol
board. Make sure that the back of the board is grounded securely
tothemountingbracket.Checkforloosewireconnections.Replace
board.
1. Waterlineturnedoffor
 ltercloggedup.
2. Waterinletvalvecoil
burned out.
3. Groundedprobe.
4. Defective or burned out
water level control board.
PROBLEM: WATER IN TANK DOES NOT GET HOT OR WATER TEMPERATURE TOO LOW
POSSIBLECAUSE SOLUTION
8. Thermostat is off. CheckthethermostattomakesureitisintheONposition.Turnthe
thermostat stem clockwise until it stops.
9. Burned out heating
element.
Checkelementforcontinuityand/orcheckwithclampammeter.This
shouldshowareadingofapproximately15amps.Ifnopowerisgo-
ing through element, replace it.
PROBLEM: WATER DOES NOT FLOW INTO HEATING TANK
POSSIBLECAUSE SOLUTION
Turn power off and observe the water level in the heating tank. If
watercontinuestoowin,cleanorreplacethevalve.
Pull wire off from probe terminal. Touch the water tank shell with
theterminalattheendofthiswire.Ifwaterstopsowing,cleanor
replace the probe.
If probe is okay, check the water level control board. The water level
controlboardmustbesecurelygrounded.Checkforlooseconnec-
tions.Checkforvoltageattheinletvalveterminals.Replaceboard.
5. Defectivewaterinlet
valve.
6. Probe limed up.
7. Loose or ungrounded
water level control board.
PROBLEM: WATER IN HEATING TANK OVERFLOWING

- 5 -
PROBLEM: WATER NOT FLOWING FROM Spray head.
SOLUTION
POSSIBLECAUSE
Checkwaterlevelintank.Ifwaterisnotowingintothetank,re-
viewsteps1thru4,previouspage.
Checkthecontinuitybetweenterminals5Band4BwhentheBREW
switch is pressed. If there is no continuity, replace the switch.
Makesurethetimerisreceiving110to120volts.Youcanverify
thisbytakingareadingwithyourmeterattheendoftheYELLOW
wire on terminal 5B of the ON/OFF switch and at terminal 9of the
timer. When the timer is activated by the brew switch, you should
read110to120voltsacrossterminals8and 9of the timer. The
REDwireonterminal8supplies power to open the dump valve. If
no voltage is present, replace the timer.
If the timer works when the brew switch is pressed, then check the
dumpvalveusingavoltmeterontheterminals.Ifitshows110to
120voltsbutnowaterowsthroughthevalve,cleanoutthevalve
or replace the coil.
11.Waterlevelistoolow 
in heating tank.
12.Defectivebrewswitch.
13.Defectivetimer.
14.Burnedoutdumpvalve 
coil.
PROBLEM: WATER IN TANK DOES NOT GET HOT OR WATER TEMPERATURE TOO LOW
POSSIBLECAUSE SOLUTION
10.Defectivethermostat. Thermostat may be cutting off before the water temperature reaches
operatingtemperature.Donottrytoresetthethermostat.Replaceit.
TROUBLE SHOOTING

- 6 -
GEMINI 120A Parts List
8
27
B
25
6
3
16
14
21
1
4
20
24
5
7
13
9
10
11
12
2
15
15
18
17
23
26
29
30
28
19
21
22

- 7 -
BREWCONE,NON-METALUNIVERSAL(WITHSPLASHPOCKET)
KIT,RETROFITTIMERBREWSELECTOR120VGEM-120A/12
KIT,LIQUIDLEVELCONTROLBOARDRETROFIT
SPRAYHEAD,RED(Ø.131)
KIT,PROBEWATERLEVELO-RING&NUTCURTIS
LABEL,SWITCHPANELGEM-120ACURTIS
LABEL,SWPANELGEM-120ACURTIS(OLDERUNITS)
KIT,ELEMENT,HEATING1.6KW120VW/JAMNUT&SILICONEO-RING
KIT,ELEMENT,HEATING2KW220VW/JAMNUT&SILICONEO-RING
CORD,14/3SJTO6'BLKW/PLUG
VALVE,INLET1GPM120V10WALP/AP/TLPGREYBODY
THERMOSTAT,CAPILLARYSPST250V25AGEM
KIT,DUMPVALVEFORWC-889,WC-817
VALVE,DUMPRIGHT120V12WW/RECTIFIERAP/GEM
FAUCET,PS/HPSSERIESHOTWTR1/2-20UNFAP/ALP
LIGHT,BREW115VGREEN
LIGHT,BREW250VGREEN
SWITCH,ROCKER(RED)120VNEONSPST15A250V
SWITCH,BREW(GREEN)120VNEONSPST15A250V
KIT,SPRAYHEADFITTINGPLASTIC
TUBE,5/16IDx1/8WSILICONEGENUSE
THERMOSTAT,MANUALRESET120/240VAC25A220DEGFMAX
THERMOSTAT,HILIMITHEATERCONTROLDPST277V40A
ELEMENT,WARMERASSY100W120VWITHSILICONEBOOTS
SWITCH,TOGGLENON-LITSPST15A125/6A250VACRESISTIVE
LEG,3/8"-16STUDSCREWBUMPER
B.CONE,ASSYW/SPLASHPOCK.NON-MTL.DLX.D500/D1000GT(OPT)
KIT,COVERFRONTGEM-120A/120P/230A/200R/300IL/600ILD
COVER,TOPALPGT/D500GT/D60GT/TLP/TCTS/CBS/GEMSS
PLUG,TANKDRAINULTEM1000F
KIT,INLETVALVEREPAIRUSEONWC-826/WC-826L/WC-847
LABEL,BOTTOMPANELGEM-120ACURTIS
KIT,TANKLIDROUND
TANK,COMPLETEGEM-120A/C500AP
TANK,COMPLETEGEM-120A120/220VDV
1
2
3
4
5
6
6A
7
7A
8
9
10
11
12
13
14
14A
15
16
17
18
19
19A
20
21
22
23
24
25
26
27
28
29
30
30A
WC-3621-101*
WC-603-101K-GEM*
WC-608-101K*
WC-2936*
WC-5527K*
WC-3920-01
WC-3920T
WC-904-04*
WC-906-04
WC-1200
WC-826L*
WC-504*
WC-3763*
WC-817*
WC-1809
WC-207
WC-208
WC-114R*
WC-122*
WC-2977-101K*
WC-5310*
WC-523*
WC-522
WC-970*
WC-102
WC-3503*
WC-3338-101
WC-5452
WC-58117
WC-43058
WC-3765L*
WC-3920B
WC-37008*
WC-5466
WC-54133
PAPER FILTERS
Part Number Description
CR-12
CR-10
FILTER,500PKG125/16X43/8FITSDELUXEBREWCONEWC-3338
FILTER,COFFEE#5061000/PK9-3/4"X4-1/2"
GEMINI 120A Parts List
ITEM№ PART№ DESCRIPTION
*RecommendedPartstoStock

- 8 -
DESCRIPTIONPART №INDEX №
GEM-5
WC-1201
WC-114R*
GEM-3
WC-5622
WC-2102
WC-2010C
WC-2025*
WC-2007
WC-1901A-103K
WC-1901A
WC-1800
WC-3705*
WC-3503*
WC-37102*
1
2
3
4
5
6
7
8
9
10
10A
11
12
13
14
SATELLITE WARMER STAND 120V 100W 120V 1A 1PH 50/60HZ 2W+G
CORD, 18/3 SJTO 6' BLK W/RED STRIPE W/PLUG
SWITCH, ROCKER (RED) 120V NEON SPST 15A 250V
SATELLITE SERVER, 1-1/2 GAL.
LID, SATELLITE PLASTIC GEM-3
GAUGE GLASS, ASSY 8"C
SHIELD, GAUGE GLASS 3/4"D.X 8"
GLASS, GAUGE 8"
BRACKET, GAUGE GLASS GEM-3
KIT, SHANK ASSY, FAUCET W/SHIELD BASE & O-RING
SHANK, FAUCET W/SHIELD BASE
FAUCET,"S" SERIES BLK LOCKING 1-1/32-14 UNS CURTIS
KIT, FAUCET S SERIES NONLOCK USE ON WC-1800
LEG, 3/8"-16 STUD SCREW BUMPER
KIT, WARMER ELEMENT 100W 120V GEN USE
ILLUSTRATED PARTS LIST GEM-3, 5, 8
11
13
12
10
9
14
1
3
4
5
2
6
7
8
*RecommendedPartstoStock

- 9 -
ELECTRICAL DIAGRAM – GEM120A-10

- 10 -
ELECTRICAL DIAGRAM – GEM120A-63

- 11 -
ELECTRICAL
DIAGRAM
GEM 5 & 8
ROUGH-IN DRAWING GEM-120A
ROUGH-IN DRAWING GEM-3 & GEM-5

ECN 16604 . 10/30/15 @ 16.2 rev K
10/2015F-1903revK
WILBUR CURTIS CO., INC.
6913 Acco St., Montebello, CA 90640-5403 USA | Phone: [phone] | Fax: [phone]
Technical Support Phone: [phone] (M-F 5:30 a.m.- 4:00 p.m.PST)
Email: [email protected] | Web: www.wilburcurtis.com
Product Warranty Information
Wilbur Curtis Co., Inc. certies 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, ttings and tubing.
1 Year, Labor, from original date of purchase on all electrical components, ttings 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 rst. 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. Wilbur Curtis Co., Inc., assumes no responsibility for substitute replace-
ment 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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uctuatingwaterow
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responsibil-
ity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repack-
aged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 nd an agent near you.