Page 1
Model Included
• D500GT
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.
CAUTION: DO NOT
connect this brewer to hot
water. The inlet valve is
not rated for hot water.
WARNING HOT LIQUID,
Scalding may occur.
Avoid splashing.
To avoid temperature
drop when rst brewing
coffee into the airpot,
preheat the airpot with hot water.
Wilbur Curtis Company, inC.
Service Manual – D500GT Airpot Brewer
Important Safeguards/Conventions
This appliance is designed for commercial use. Any servicing other than cleaning and preventive maintenance
should be performed by an authorized Wilbur Curtis 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. No user serviceable parts inside.
• Keep hands and other items away from hot surfaces of unit during operation.
• Never clean with scouring powders, bleach or harsh chemicals.
Symbols
WARNINGS – To help avoid personal injury
Important Notes/Cautions – from the factory
Sanitation Requirements
The Curtis G3 airpot brewer is Factory Pre-Set and Ready to Go… Right from the Box.
Following are the Factory Settings for Curtis airpot brewers:
• Brew Temperature = 200°F
• Brew Volume = Set to vessel requirements (74 oz).
System Requirements:
• Water Source 20 – 90 PSI (minimum ow rate of ½ 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 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 ½ GPM (1 GPM pre-
ferred).
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, go to www.wilburcurtis.com.
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 backow 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.
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). Where applicable, turn on the Universal Control Module (UCM). When the unit
reaches operating temperature, it will display “READY TO BREW”.
For the latest specications and information go to www.wilburcurtis.com
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Coffee Brewing Instructions
1. Brewer should be ON (Conrm at rear toggle switch, then press the ON/OFF button). Ready-to-Brew should be on the display.
2. Place an empty airpot under the brewcone.
3. Place a clean lter
into the brewcone. Fill
brewcone with the proper
amount of ground coffee.
4. Slide the lled brewcone
into the brew rails on the
brewer.
5. Press the brew button.
Coffee will start to brew
into the airpot.
6. Allow the brew cycle to
nish before removing
the airpot or brew cone.
Screen will read Brew
Complete. Afterwards it
WARNING – TO AVOID SCALDING, Do not remove brewcone while unit is brewing.
will read to Ready to Brew
or Heating.
Your Curtis G3/Gold Cup Series is Factory Pre-Set for Optimum Performance.
After connection to water and power; the rear toggle switch must be on. You will hear a beep sound, indicating power is available to the controller.
The control displays . Press ON/OFF button and the screen will display . After three seconds, is displayed.
Water will ll the tank (approximately 2-3 minutes depending on water ow rate). When the proper level is reached will appear on the screen.
Approximately 20 minutes are required to reach the set point temperature.
Control will display when temperature reaches the set point. The unit is now ready to brew.
Programming with the Universal Control Module (UCM)
Turn off the control panel by pressing ON/OFF button. Press and hold bottom/right coffee brew button (#4 in illustration) and then press and release the ON/OFF button.
Continue holding the bottom-right brew button. The screen will display , wait until is displayed. Enter the 4-digit access code, the code corresponds to
the buttons illustrated below. The default code set at the factory is 1-2-3-4.
After the 4-digit code is entered, will be displayed. You can now enter the program menu features.
All programming selections are performed with the three center buttons.
The symbols near the buttons are:
Scroll LEFT
SELECTION or ENTER to save new parameter
Scroll RIGHT
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Model Select - D500GT ONLY. Always perform this rst. This feature re-sets all settings to the factory defaults.
Scroll through menu to Model Select. Choices are: ALPHA-1, ALPHA-2, ALPHA-3/4/5, Airpot Brewer and Thermo-Alpha. Select only Airpot
Brewer.
Program Menus
Program Menus
Brew By Volume
Brew By Time
Temperature
Energy Save Mode
Program Menus
From Program Menus press > display will now show the next feature.
Selecting Brew by Volume or Brew by Time depends on whether you know your brew time before starting.
Brew by Volume (Factory set to 74oz)
Press to Select, display will now show Press BREW to Start. Press the BREW button. The unit will start spraying hot water
into the brewcone. When correct volume is reached press BREW button again to stop the ow. Now the volume has been set.
Pressing > button will display the subsequent menu features.
Brew by Time (Factory set to 3 min)
Press to Select, display will now show Select Button. The current time is now shown. By pressing < > you can toggle back
and forth from minutes to seconds to exit (ex). Change the time or set and exit by pressing .
Temperature (Factory set to 200°F)
Press to Select. Press < > to move to desired temperature and then to set. Temperature is programmable from 170ºF to
206ºF in 2-degree increments.
Energy Save Mode (Factory set to OFF)
Press to Select, < , >, ON, OFF or ON 140ºF , to set. When in ON, unit will automatically shut off 4 hours from last
brew. When feature is OFF, unit does not have the energy saving mode.
In the ON 140ºF position, temperature goes down to 140ºF. if unit has not brewed in 4 hours. This feature will save energy by
lowering the tank temperature during periods of non-operation.
Brew Count Odom
Pre-Infusion
Quality Timer
Brew Count Total
Cold Brew Lock
Master Reset
Brew Count Odom.
Press to display total gallons brewed. Press ex or Reset.
Pre-Infusion (Factory set to OFF)
Press to Select. Display will now show Select Button. Select desired Brew button. Current setting in seconds is displayed <
to decrease or select > to increase (range from OFF to 10 through 60 seconds), to set.
If Pre-infusion is selected (ON), Cold Brew Lock is set within 5ºF of set point and Cold Brew Lock and Pulse Brew
dissappears from the list of program selections.
Quality Timer (Factory set to OFF)
Press to select. Press > to select OFF, ON, then increase time from 20 minutes to a maximum of 120 minutes. Increments
are 10 minutes. Press to set. Timing starts at the begining of a brew cycle. An audible alarm will sound when time has
expired. Press the ON/OFF button on the control pannel to shut it off.
Brew Count Total
Press to Select, Shows total gallons and total brew cycles on the unit. Brew Count Total cannot be reset.
Cold Brew Lock . . . (Factory set to 15º)
Press to select, < > to select desired setting (CBL 5, 15 or OFF), to set.
The Cold Brew Lock feature allows the brewer to brew at three different temperature levels below the actual set point.
setting is within 5 degrees of set point, next is within 15 degrees of set point, OFF is within 30 degrees of set point for the Ready
to Brew message, however it will brew at any temperature.
Master Reset
Press to display Are You Sure? Then < for Yes, or > for No.
Brewer factory defaults are then reset.
The rst
Service Call
Service Call (Phone number Factory set to 1-800-000-0000X)
Press to display number and change number or < to move place and EX to exit when complete This number will be dis-
played during a Heating system SENSOR ERROR or during a WATER ERROR.
Continued, Page 4
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Access Code
Banner Name
Access Code (Factory set to 1-2-3-4)
Press to display number and change number, (the number can be change 1 to 4) or < to move place and ex to exit when complete.
Banner Name (Factory set to Curtis)
Press to display letters and change letters or < to move place 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. If programmed, Banner Name is displayed every 5 sec. on and off.
P-Maintenance
Beeper On/Off
Pulse Brew
On/Off
Display Brew
Time
Drip-Out Mode
Display Messages
P-Maintenance (Factory set to OFF)
Press to Select, Set gallons brewed to indicate P-Maintenance. Press < > to adjust from Off to 3000 gallons. Press to exit.
Beeper On/Off (Factory set to ON)
Press to display ON or OFF. Pressing either < > toggles between on and off. Press to set.
Pulse Brew (Factory set to OFF)
Press to select. Display will now show Select Button. Select desired Brew button to program. The next screen will promt you to
press < > to select OFF or one of ve pulse patterns (A to E) .
Guidelines for Pulse Brew:
This feature allows tuning of the coffee avor. The pot level should always be set rst with this option OFF. Depending on your grind
prole and water conditions, the ve Pulse Brew options help “tune” or change the coffee avor
extract better with the A and B pulse setting. Decafenated coffees typically extract better with the B pulse setting. High-Yield coffees
typically extract better with the C pulse setting. Of course, any of the A, B or C settings may be used to suit your taste prole. There are
two additional settings (D and E) that alow you to manually set the ON TIME pulses and OFF TIME.
If Pulse Brew is selected (ON), Cold Brew Lock is set to within 5ºF of set point. Also, the Cold Brew Lock and Pre-infusion
features disappear from the list of program selections.
Display Brew Time (Factory set to ON)
Press to display ON or OFF. Pressing either < or > toggles between on and off. to set. When on, the Display Brew Time feature
allows you to see the remaining time in the brewcyle counting down.
Drip-Out Mode (Factory set to 2 min)
Press to select. Press > to increase time (to a maximum of 5 minutes) or < to decrease the time and turn OFF.
second increments. Press to set.
Display Messages (Factory set to ON)
Press to turn ON or OFF. The message displayed is “Rinse Server Before Brewing”. This message will alternate; two seconds with
Rinse Server Before Brewing, then Curtis READY TO BREW will appear for six seconds..
. Filter Pack type coffees typically
Time counts up in 5
4
Language
Model Select
Exit
Language (Factory set to English)
Pressing < or > toggles between English and French. Press to set.
Model Select
Press to select, < or >. Be sure that Airpot Brewer is selected. Screen choices are: ALPHA-1, ALPHA-2, ALPHA-3/4/5, Airpot Brewer
and Thermo-Alpha. Press to set. All menu settings will default to factory standards whenever a new model is selected.
Exit
Press to select, exits program mode and returns unit to operation. Pressing > returns you to Brew By Volume.
Page 5
Electrical Schematic
5
Page 6
Parts Diagram
5
5A
6
7
1
2
3
4
9
10
8
11
13
14
15
31
12
30
1
16
16
33
34
4
32
24
25
22
18
28
20
19
21
23
17
26
27
29
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Parts List
Item
№
1
1A
2
2A
3
4
5
5A
6
6A
7
8
9
10
10A
Part № Description
WC-889-101*
WC-860
WC-37064*
WC-724
WC-39346
WC-37252*
WC-3621-101
WC-3316
WC-5450
WC-58117
WC-2962-101K
WC-13237
WC-29025*
WC-102*
WC-103
VALVE, DUMP LEFT 120V
VALVE, DUMP LEFT 220V 12W
KIT, LABEL & UCM D500GT CURTIS
CONTROL MODULE, AIRPOT 220V 16 PIN
LABEL, CONTROL PANEL (CURTIS LOGO)
KIT, HOT WATER FAUCET RPLCMNT
BREW CONE, NON-METAL UNIVERSAL
BREW CONE, ASSY S.S. (OPTIONAL)
COVER, TOP (OLDER MODELS)
COVER, TOP D500GT
KIT, FITTING SPRAYHEAD KYNAR
HARNESS, ASSY D500GT/H-10
SPRAYHEAD, PURPLE ADVANCE FLOW
SWITCH, TOGGLE 125/250 VAC RESISTIVE
SWITCH, TOGGLE NON-LIT DPST 25A 220V
Item
№
17
18
19
19A
20
21
21A
22
23
23A
24
25
26
27
28
Part № Description
WC-830
WC-5853-102
WC-6277
WC-6290
WC-37266*
WC-904-04*
WC-922-04
WC-4394
WC-523*
WC-522
WC-43062*
WC-37317*
WC-1438-101*
WC-5231*
WC-5527K*
WASHER, FLOW ½” 1.0 GPM USE W/WC-826
COVER, TOP HEATING TANK GEN USE
TANK COMPLETE, D500GT 120V
TANK, COMPLETE 3.5KW 220V D500GT
KIT, TANK OVERFLOW ELBOW FITTING
KIT,ELEMENT, HEATING 1.6KW120V W/NUTS
KIT,ELEMENT HEATING 3.5KW 220V
GUARD, SHOCK HEATING ELEMENT
THERMOSTAT, MANUAL RESET
THERMOSTAT, HI LIMIT DPST 277V 40A
GASKET, HEATING TANK
KIT, PLASTIC FITTING & BUSHING
SENSOR, HEATING TANK
COMPOUND, SILICONE 5 OZ TUBE
KIT, PROBE WATER LEVEL O-RING & NUT
11
12
13
13A
14
15
16
WC-8556*
WC-3503
WC-826L*
WC-856
WC-3518
WC-8591
WC-3765L*
HEAT SINK & TRIAC ASSY 40A 600V
LEG, SCREW BUMPER 3/8-16 STD
VALVE, INLET 1 GPM 120V 10W
VALVE, INLET 1 GPM 240V 10W
LEG, GLIDE 3/8”-16 STUD SCREW
CAPACITOR, X2
KIT, VALVE REPAIR USE ON WC-826
29
30
31
32
33
34
WC-37365*
WC-3763*
WC-6217
WC-1806*
WC-43058
WC-5310*
KIT, TANK INLET FITTING
KIT, VALVE REPAIR USE ON WC-889
COVER, FRONT
SEAT CUP, SILICONE (USE ON WC-1809)
PLUG, TANK DRAIN, PP RED
TUBING, SILICONE, 5/16” I.D. ( 1 FT.)
7
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Rough-In Drawing
Cleaning the Brewer
Regular cleaning of the airpot brewer will maintain the highest quality coffee your equipment is capable of producing. Proper cleaning is
essential to maintain a fresh, appealing look to your coffee service. For cleaning, prepare a mild solution of dish washing detergent and
warm water.
1. Wipe the exterior surfaces with a cloth soaked in the cleaning solution. Scrub off coffee spots, spills, or coffee grounds.
2. Remove the brew cone and clean it in a sink, using the cleaning solution. Rinse and dry the brew cone.
3. With the brew cone removed, Wipe the spray head area with a cloth soaked in cleaning solution.
4. Rinse the area with a water soaked cloth, removing any residual detergent. With a dry cloth, wipe the area.
5. Rub a stainless steel polish on the outside surfaces of the brewer cabinet as a protection for the metal.
CAUTION: DO NOT use undiluted bleach or chlorine.
Cleaning Airpots
– Clean with warm water and dish washing detergent. Use a sponge cleaning brush to scrub inside.
– Rinse thoroughly with hot water.
– Do not immerse airpots in water. Do not place in dishwasher.
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This Page Intentionally Left Blank
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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 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 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 accord ing 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 nd an agent near you.
ECN 16011 . 7/15/14@10º . revD
ECN 15838 . 4/29/14@7.5 . revC
ECN 15661 . 2/13/14@13.6 . revB
ECN 14333 . 8/10/12
EDR 7991.10/28/11@14.5
10
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: techsupport@wilburcurtis.com
Web Site: www.wilburcurtis.com
FOR THE LATEST SPECIFICATION INFORMATION GO TO WWW.WILBURCURTIS.COM
Printed in U.S.A. 8/2014 F-3841 Rev D
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