Curtiss 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: 800-421-6150
Fax: 323-837-2410
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). 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. Thisunitmustbeinstalledwithadequatebackowprotectiontocomplywithapplicablefederal,stateand
local codes.
3.Waterpipeconnectionsandxturesdirectlyconnectedtoaportablewatersupplyshallbesized,installed
andmaintainedinaccordancewithfederal,state,andlocalcodes.
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
Forthelatestspecicationsandinformationgotowww.wilburcurtis.com
NOTE:Awaterltrationsystemmustbeusedtohelpmaintaintrouble-freeoperation.Inareaswithextremelyhard
water,wehighlyrecommendtheuseofaCurtisapprovedwaterlter.Forourfulllineoflters,pleaselogonto
www.wilburcurtis.com.Awaterltrationsystemwillgreatlyprolongthelifeoftheunitandenhancethequalityand
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 sufciently 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:
Equipmentmustbe
installed to comply
with applicable federal, state,
and local plumbing/electrical
codes.
- 2 -
WARNING: AVOID SCALDING Do not remove the brew cone while the
brew light is ashing.
BREWING
1. Brewer should be ON (Conrm 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 brewcone and press the warmer switch to pre-heat the Satellite.
3. Place a clean lter into the brewcone.
6. Determine ihe brew volume
and ip the toggle switch to
desired size, ½ gallon (1) or
1 gallon (2).
Press the brew button.
Brewing will begin immedi-
ately.
5. Transfer the brew cone to
brewer, inserting it into the
brew cone rails.
4. Fill the brewcone 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 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.
DAILY CLEANING
1. Wipe exterior surfaces with a damp cloth, removing spills and debris.
2. Slide the brewcone out and clean it. Wipe the sprayhead area with a cloth soaked in a mild detergent solution.
3. Rinse and dry the brewcone and sprayhead area.
4. Drain drip trays of coffee.
5. Dry the tray.
WEEKLY CLEANING
1. Turn off unit at the power switch, behind the unit. Allow the brewer to cool.
2. Clean the sprayhead and dome plate area.
a. Remove the sprayhead, unscrewing counterclockwise from the dome plate.
b. Thoroughly clean and rinse the dome plate area.
c. Clean the brewcone rails with a brush soaked with a mild detergent solution. Rinse the area with a cloth soaked with clean
water, removing any residual detergent.
d. Dry the area.
c. Attach the sprayhead.
- 3 -
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 1and 2.
To change the setting, ip the brew selector switch to 2. Locate the brew timer, in-
side 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..
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 sight glass
tube of all detergent residue.
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 cone and the coffee vessel.
1. Place a pouch or tablet cleaner into the brew cone. 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 cone is blue.
3. At the end of the brew cycle, discard the used lter cleaner pouch. The tablets should have disolved 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. You can simply open the faucet and let the
blue cleaning solution to ow out.
6. Return the empty coffee server to the brew deck. Install the brew cone onto the brewer. Run another
brew cycle of hot water to rinse the brew cone and into the server.
7. Empty the rinse water from the coffee server. Repeat the rinse cycle before putting the coffee server
back into service.
- 4 -
POSSIBLECAUSE SOLUTION
TROUBLE SHOOTING
Openthewaterlineandmakesurewaterowstothebrewer.
Turn off brewer. Disconnect wires from water inlet coil terminals and
connectapowercordtotheterminals.Plugcordintoa110voutlet
andverifythatwaterowwhenpluggedinandstopswhencord
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
notrelling,pullthewireofftheprobeterminal.Ifwaterstartsow-
ingintothetank,ndground,cleanorreplacetheprobe.
Pull the wire from the probe terminal. With a volt meter, check the
voltageatthewaterinletcoilterminals.Thisshouldread110to
115volts.Ifnovoltageispresent,checkthewaterlevelcontrol
board. Make sure that the back of the board is grounded securely
tothemountingbracket.Checkforloosewireconnections.Replace
board.
1. Waterlineturnedoffor
ltercloggedup.
2. Waterinletvalvecoil
burned out.
3. Groundedprobe.
4. Defective or burned out
water level control board.
PROBLEM: WATER IN TANK DOES NOT GET HOT OR WATER TEMPERATURE TOO LOW
POSSIBLECAUSE SOLUTION
8. Thermostat is off. CheckthethermostattomakesureitisintheONposition.Turnthe
thermostat stem clockwise until it stops.
9. Burned out heating
element.
Checkelementforcontinuityand/orcheckwithclampammeter.This
shouldshowareadingofapproximately15amps.Ifnopowerisgo-
ing through element, replace it.
PROBLEM: WATER DOES NOT FLOW INTO HEATING TANK
POSSIBLECAUSE SOLUTION
Turn power off and observe the water level in the heating tank. If
watercontinuestoowin,cleanorreplacethevalve.
Pull wire off from probe terminal. Touch the water tank shell with
theterminalattheendofthiswire.Ifwaterstopsowing,cleanor
replace the probe.
If probe is okay, check the water level control board. The water level
controlboardmustbesecurelygrounded.Checkforlooseconnec-
tions.Checkforvoltageattheinletvalveterminals.Replaceboard.
5. Defectivewaterinlet
valve.
6. Probe limed up.
7. Loose or ungrounded
water level control board.
PROBLEM: WATER IN HEATING TANK OVERFLOWING
GEMINI120A
- 5 -
PROBLEM: WATER NOT FLOWING FROM SPRAYHEAD.
SOLUTION
POSSIBLECAUSE
Checkwaterlevelintank.Ifwaterisnotowingintothetank,re-
viewsteps1thru4,previouspage.
Checkthecontinuitybetweenterminals5Band4BwhentheBREW
switch is pressed. If there is no continuity, replace the switch.
Makesurethetimerisreceiving110to120volts.Youcanverify
thisbytakingareadingwithyourmeterattheendoftheYELLOW
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
read110to120voltsacrossterminals8and 9of the timer. The
REDwireonterminal8supplies 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
dumpvalveusingavoltmeterontheterminals.Ifitshows110to
120voltsbutnowaterowsthroughthevalve,cleanoutthevalve
or replace the coil.
11.Waterlevelistoolow
in heating tank.
12.Defectivebrewswitch.
13.Defectivetimer.
14.Burnedoutdumpvalve
coil.
PROBLEM: WATER IN TANK DOES NOT GET HOT OR WATER TEMPERATURE TOO LOW
POSSIBLECAUSE SOLUTION
10.Defectivethermostat. Thermostat may be cutting off before the water temperature reaches
operatingtemperature.Donottrytoresetthethermostat.Replaceit.
GEMINI120A
- 6 -
GEMINI120APartsList
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
26
29
30
31
19
21
22
- 7 -
BREWCONE,UNIVERSAL7.38"D.
KIT,RETROFITTIMERGEM120A120V
KIT,LIQUIDLEVELCONTROL
SPRAYHEAD,RED(.131DIA)
KIT,PROBE,ASSYWATERLEVELW/HEXFITTING,O-RING&NUT
LABEL,SWITCHPANELGEM120ACURTIS(NEWERUNITS)
LABEL,SWPANELGEM-120ACURTIS(OLDERUNITS)
KIT,ELEMENT,HEATING1.6KW120VW/JAMNUT&SILICONEWASHERS
KIT,ELEMENT,HEATING2KW220VW/JAMNUT&SILICONEWASHERS
POWERCORD,6'14/3BLKSJTO
VALVE,INLET1GPM120V10WALP/AP/TLPYELLOWBODY
THERMOSTAT,CAPILLARYSPST250V25AGEM
KIT,VALVEREPAIRFORWC-866,WC-889,WC-816,WC-817,WC-818
VALVE,DELTROLDUMPRIGHT120V.
FAUCET,HOTWATERW/JAMNUT
LIGHT,BREW115VGREEN
LIGHT,BREW220V
SWITCH,ROCKER120VRED
SWITCH,ROCKERBREW120VGREEN
KIT,SPRAYHEADFITTINGPLASTIC
TUBE,5/16"I.D.SILICONEGENUSE
THERMOSTAT,MANUALRESET120/240VAC25A220DEGFMAX
THERMOSTAT,HILIMITHEATERCONTROLDPST277V40A
ELEMENT,WARMERASSY100W120VWITHSILICONEBOOTS
SWITCH,TOGGLESPST25A125/250VACRESISTIVE
LEG,SCREWBUMPER3/8-16STD
BREWCONE,ASSYW/SPLASHPOCKETNON-METALDELUXE(OPTIONAL)
COVER,FRONTGEM-120A/120P/230A/200R/300IL/600ILD
COVER,TOPALPGT/D500GT/D60GTTLP/TCTS/CBS/GEMSS
PLUG,TANKDRAINULTEM1000F
KIT,VALVEREPAIRUSEONWC-826/WC-826L/WC-847
WASHER,.35GPM.5"USEONWC-825
LIDASSEMBLY,TANK
TANK,COMPLETEGEM-120A120V
TANK,COMPLETEGEM-120A120/220VDV
LABEL,BOTTOMGEM-120A
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
31
WC-3621-101
WC-603-101K-GEM
WC-608-101K
WC-2936
WC-5502-01
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-203
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-829
WC-37008
WC-5466
WC-54133
WC-3920B
PAPER FILTERS
Part Number Description
CR-12
CR-10
FILTERFORBREWCONEWC-3338-101(500/PKG)
FILTERFORBREWCONEWC-3621-101(1000/PKG)
GEMINI120APartsList
ITEM№ PART№ DESCRIPTION
- 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 -
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 15040 . rev J 6/5/[email protected]
EAR 10574 . ECN 14101 . rev H
6/2013F-1903revJ
WILBUR CURTIS CO., INC.
6913 Acco St., Montebello, CA 90640-5403 USA
Phone: 800/421-6150 Fax: 323-837-2410
Web Site: www.wilburcurtis.com
Product Warranty Information
The Wilbur Curtis Company certies 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: Thisequipmentmustbeinstalledbyaprofessionaltechnicianandmustcomplywithalllocal
electrical,mechanicalandplumbingcodes.
3) Improper voltage: Equipment must be installed at the voltage stated on the serial plate supplied with this equipment.
4) Improper water supply: Thisincludes,butisnotlimitedto,excessiveorlowwaterpressure,andinadequateoructuatingwaterow
rate.
5) Adjustments and cleaning: Theresettingofsafetythermostatsandcircuitbreakers,programmingandtemperatureadjustmentsare
theresponsibilityoftheequipmentowner.Theownerisresponsibleforpropercleaningandregularmaintenanceofthisequipment.
6) Damaged in transit: Equipmentdamagedintransitistheresponsibilityofthefreightcompanyandaclaimshouldbemadewiththe
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: Thisshallinclude,butisnotlimitedto,lightbulbs,sheardisks,“0”rings,
gaskets,siliconetube,canisterassemblies,whipperchambersandplates,mixingbowls,agitationassembliesandwhipperpropellers.
9) Repairs and/or Replacements aresubjecttoourdecisionthattheworkmanshiporpartswerefaultyandthedefectsshowedupunder
normaluse.Alllaborshallbeperformedduringregularworkinghours.Overtimechargesaretheresponsibilityoftheowner.Charges
incurredbydelays,waitingtime,oroperatingrestrictionsthathindertheservicetechnician’sabilitytoperformserviceistheresponsibil-
ityoftheowneroftheequipment.Thisincludesinstitutionalandcorrectionalfacilities.TheWilburCurtisCompanywillallowupto100
miles,roundtrip,perin-warrantyservicecall.
RETURN MERCHANDISE AUTHORIZATION: AllclaimsunderthiswarrantymustbesubmittedtotheWilburCurtisCompanyTechnical
SupportDepartmentpriortoperforminganyrepairworkorreturnofthisequipmenttothefactory.Allreturnedequipmentmustberepack-
agedproperlyintheoriginalcarton.Nounitswillbeacceptediftheyaredamagedintransitduetoimproperpackaging.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.
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