Curtis GEM-120A User manual

C
Service Manual – GEM-120A Satellite Brewer
Wilbur Curtis Company, 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 (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”.
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
Technical Support: 1-800-995-0417 M-F 5:30am-4:00pm PT
Email: [email protected]
NOTE:Awaterltration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lter.Forourfulllineoflters,pleaselogonto
www.wilburcurtis.com.Awaterltrationsystemwillgreatlyprolongthelifeoftheunitandenhancethequalityand
taste of the product.
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.

- 2 -
All products manufactured by the Wilbur Curtis Company are thoroughly inspected at the factory and are warranted
to be free of all defects or faulty workmanship. The Gemini unit is packaged for maximum protection while being
shipped. Make sure the shipping carton is not damaged or punctured. Unpack the carton carefully, inspecting the
contents for any damage that may have occurred in transit. Report any damage immediately to the freight company.
UNPACKING
WARNING: TO AVOID SCALDING, Do not remove brewcone while brew light is ashing.
BREWING INSTRUCTIONS
1. Brewer should be ON (Conrm at rear toggle switch, then press the ON/OFF button). Ready-to-Brew should be
on the display. If the brewer is connected to an InterLock grinder, the grinder should be on. When Interlock con-
nection is made, grind coffee at this time.
2. Place an empty Satellite under the brewcone and press the warmer switch to pre-heat the Satellite.
3. Place a clean lter into the brewcone.
6.Press Brew
button.
Brewing will
begin im-
mediately.
5.Transfer
lled brew
cone to
brewer.
4. Fill brew-
cone with
ground cof-
fee.
Regular cleaning and preventive maintenance is essential in keeping your Gemini Coffee Brewer looking and work-
ing like new.
WARNING Do not use cleansers, liquids, bleaches, or powder that contain chlorine. These products cause cor-
rosion and pitting on stainless steel and will void your warranty.
CARE AND MAINTENANCE OF THE GEMINI 120A
1. Remove the sprayhead from the Gemini 120A and clean once a week or more often in heavy lime areas.
2. Clean the faucet seat cups twice a week and replace when they are cracked or leaking.
3. Periodic temperature checks or adjustment of thermostat by authorized personnel.
PREVENTIVE MAINTENANCE
To maintain optimum coffee avor, the Gem 3 Satellite should be cleaned daily after the last batch of coffee is used.
We recommend the use of urn cleaning powder or Scotch Bright pads for cleaning inside the coffee container.
The outside of the brewer and Satellite should be cleaned with a soft cloth and stainless steel polish only, to prevent
scratching the surface.
Deliming of the heating tank should be done every six (6) months; more often in heavy lime areas.
CLEANING
GEMINI120A

- 3 -
SETTING TIMER WC-603RDS
This timer is the previous version of the WC-603-101,
above. The timer is mounted inside the upper com-
partment with the brew selector knob protruding from
the center of the front panel (see illustration, left). The
brewer is designed to brew 24 cups (one gallon maxi-
mum). Adjustment of the timer is made on the timer
calibration dial. The knob indicator must be set at the
480 second mark on the dial. On the front panel, the
brew selector switch should be at 2. This setting will
deliver one gallon of water (brew 24 cups) per brew
cycle. To brew 12 cups, simply turn the brew selector
knob to 1. If ner adjustments are needed, rotate timer
knob to the right to increase the brew time, rotate to
the left to decrease the brewing time.
GEMINI120A
ROUGH-IN DRAWING
SETTING THE WC-603-101 BREW TIMER
Adjustment of the timer is made on a calibrated dial with a range from 0 to 100.
This is a range of 2 to 20 minutes. The front control panel has a brew selector
switch marked FULL and 1/2.
To change the setting, ip the brew selector switch to FULL. Locate the brew
timer, inside the top cover. Rotate timer arrow to the right to increase the brew
time, rotate to the left to decrease the brewing time. The indicator dial is normally
set pointing at 25. This setting is intended to deliver one gallon of water (brew 24
cups) per brew cycle. To brew ½ gallon, ip the brew selector switch to 1/2.

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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(item
 #5)
4. Defective or burned out
water level control board
 (item#3)
PROBLEM: WATER IN TANK DOES NOT GET HOT OR WATER TEMPERATURE TOO LOW
POSSIBLECAUSE SOLUTION
8.Thermostatisoff(item#10) 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(item#9)
6.Probelimedup(item#5)
7. Looseorungrounded
water level control board
 (item#3)
PROBLEM: WATER IN HEATING TANK OVERFLOWING
GEMINI120A

- 5 -
PROBLEM: WATER NOT FLOWING FROM SPRAYHEAD.
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 Nof the
timer. When the timer is activated by the brew switch, you should
read110to120voltsacrossterminalsNO and Nof the timer. The
REDwireonterminalNO supplies 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 
 (item#41)
13.Defectivetimer(item#2).
14.Burnedoutdumpvalve 
 coil(item#34)
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.
GEMINI120A

- 6 -
GEMINI120APartsList
8
27
28 B
25
6
3
16
14
21
1
4
20
24
5
7
13
9
10
11
12
2
15
15
18
17
23
22
26
29
30
31
19
21
2A

- 7 -
Description
BREWCONE,UNIVERSAL7.38"D.
TIMER,BREWSELECTOR120V2-20MINGEM-120A/RU'S(NEWERUNITS)
TIMER,BREWSELECTOR120VGEM-120A(OLDERUNITS)
CONTROLBOARD,LIQUIDLEVEL
SPRAYHEAD,RED(.131DIA)
KIT,PROBE,ASSYWATERLEVELW/HEXFITTING,O-RING&NUT
LABEL,SWITCHPANELGEM120ACURTIS(NEWERUNITS)
LABEL,SWPANELGEM-120ACURTIS(OLDERUNITS)
KIT,ELEMENT,HEATING1.6KW120VW/JAMNUT&SILICONEWASHERS
KIT,ELEMENT,HEATING2KW220VW/JAMNUT&SILICONEWASHERS
POWERCORD,6'14/3BLKSJTO
VALVE,INLET1GPM120V10WALP/AP/TLPYELLOWBODY
THERMOSTAT,CAPILLARYSPST277V22AGENUSE
KIT,VALVEREPAIRFORWC-866,WC-889,WC-816,WC-817,WC-818
VALVE,DELTROLDUMPRIGHT120V.
FAUCET,HOTWATERW/JAMNUT
LIGHT,BREW115VGREEN
LIGHT,BREW220V
SWITCH,ROCKER120VRED
SWITCH,ROCKERBREW120VGREEN
FITTING,SPRAYHEADULTEM
TUBE,5/16"I.D.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SPST25A125/250VACRESISTIVE
LEG,SCREWBUMPER3/8-16STD
KIT,BREWCONEW/BASKETSS71/8"DELUXEBLKHANDLE(OPTIONAL)
COVER,FRONTGEM-120A/120P/230A/200R/300IL/600ILD
COVER,TOPALPGT/D500GT/D60GTTLP/TCTS/CBS/GEMSS
PLUG,DRAINPPRED
KIT,VALVEREPAIR(USEONWC-825WC-826)
WASHER,.35GPM.5"USEONWC-825
LIDASSEMBLY,TANK
TANK,COMPLETEGEM-120A120V
TANK,COMPLETEGEM-120A120/220VDV
LABEL,BOTTOMGEM-120A
1
2
2A
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
31
WC-3621-101
WC-603-101
WC-603RDS
WC-608-101
WC-2936
WC-5502-01
WC-3920-01
WC-3920T
WC-904-04
WC-906-04
WC-1200
WC-826L
WC-517
WC-3763
WC-817
WC-1809
WC-207
WC-203
WC-114R
WC-122
WC-2977-101
WC-5310
WC-523
WC-522
WC-970
WC-102
WC-3503
WC-3338
WC-5452
WC-58117
WC-43058
WC-3765
WC-829
WC-37008
WC-5466
WC-54133
WC-3920B
Item
Nº
Part
Nº
PAPER FILTERS
Part Number Description
CR-12
CR-10
FILTERFORBREWCONEWC-3338(500/PKG)
FILTERFORBREWCONEWC-3621-101(1000/PKG)
GEMINI120APartsList

- 8 -
DESCRIPTION
PART
Nº
INDEX
Nº
GEM-5
WC-1201
WC- 114R
GEM 3
WC-5622
WC-2102
WC-2010C
WC-2025
WC-2007
WC-1901
WC-1800
WC-1841
WC-3705
GEM 4
WC-3503
WC-37102
1
2
3
4
5
6
7
8
9
10
11
11A
12
13
14
15
SATELLITE WARMER STAND,115V
POWER CORD 6’ 18/3 BLK
SWITCH, ROCKER 120V RED
SATELLITE SERVER 1½ GAL
LID, SATELLITE PLASTIC GEM3
GAUGE GLASS ASSEMBLY, 8” C
SHIELD, 8 INCH GAUGE GLASS
GAUGE GLASS, 8 INCH
BRACKET, GAUGE GLASS FORMED
SHANK, FAUCET D&T CHROME
FAUCET S’ NONLOCKING
FAUCET, "ESP" BLACK NONLOCKING (OPTIONAL)
KIT FAUCET S’ SERIES
SATELLITE STAND
LEG, SCREW BUMPER 3/8"-16 STD
KIT, WARMER ELEMENT 100W 120VAC
ILLUSTRATED PARTS LIST GEM-3, 5, 8
11
13
12
10
9
14
17
1
3
4
5
2
15
6
7
8

- 9 -
WIRING DIAGRAM – GEM120A-10

- 10 -
WIRING DIAGRAM – GEM120A-63

- 11 -
WIRING DIAGRAM – GEM 5 & 8

EAR 10574 . ECN 14101 . rev H
ECN 13180 . 5/16/1[email protected]
PrintedinU.S.A.5/11F-1903RevH
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
Product Warranty Information
The Wilbur Curtis Company 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, the Wilbur Curtis Company 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 equip-
ment 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. Ef-
fective 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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.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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.