Cretors HDLL20CP Service Manual

HDLL20/32-M-A/E-S

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3243 North California Avenue, Chicago, IL 60618

HEADLINER POPCORN MACHINE
with LOGIC II OPTION SERVICE
MANUAL

120/208 - 240 Volt,
Single and Three Phase, 60 Hz

230 Volt
Single Phase, 50 & 60 Hz

400 Volt, 3N∼∼∼∼

Three Phase, 50 Hz

100/200 Volt,
Single Phase, 50 & 60 Hz

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READ and UNDERSTAND these service, and safety
instructions before servicing this popcorn machine

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SAFETY FIRST

The information in this manual is essential for the safe installation of your
Cretors popcorn machine. The manual must be read and understood before
installing, servicing this equipment, or equivalent training must be provided.

"The employer shall instruct each employee in the recognition and avoidance
of unsafe conditions and the regulations applicable to his work environment
to control or eliminate any hazards or other exposure to illness or injury".
Ref.: 29 CFR 1926.20 (b)(4)(a)(2)

It is understood that safety rules within individual companies vary. If a
conflict exists between the safety procedures contained in this manual and
the rules of a using company, the more stringent rule should take
precedence.

HDLL20/32-M-A/E-S

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I INTRODUCTION

This manual is filled with time-saving and money-saving information regarding your Cretors
popcorn machine. There is nothing, however, more important than the safety aids and warnings
that are found throughout this document. The Safety Alert Symbol is used to identify topics of
primary safety concern wherever they appear. Furthermore, a separate section has been included
which deals exclusively with operation and accident prevention.

If, after reviewing this manual, anything is unclear or technical problems are encountered, contact
the dealer from whom you purchased your machine for assistance and if there are any additional
questions, feel free to contact our Customer Service Department at the address and/or phone
number listed on the front and back covers of this manual. Always have the model and serial
number of your machine available to assist in obtaining the correct information.

II SAFETY ALERT SYMBOL

The symbol shown below is used to call your attention to instructions concerning your personal
safety and the safety of others. Watch this symbol. It points out important safety precautions. It
means "ATTENTION! Become Alert! Your personal safety is involved!" Read the message that
follows and be alert to the risk of personal injury or death.

III PURPOSE OF MANUAL

This instruction manual is intended to familiarize owners with the service,
and safety procedures associated with your Cretors popcorn machine.

This manual should be kept available to service personnel.

A person who has not read and understood all service and safety instructions
is not qualified to service the machine.

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IV PRODUCT IDENTIFICATION

CRETORS POPCORN MACHINE WITH LOGIC OPTION
HEADLINER Models: HDLL20CP, HDLL32CP, HDLL20FP, HDLL32FP

ELECTRICAL SPECIFICATIONS: Headliner Models are available in the following Electrical
configurations:

120/208 - 240Volt, Single and Three Phase, 60 Cycle
230 Volt, Single Phase, 50 & 60 Cycle
400 Volt, Three Phase, 50 Cycle

SPECIFICATIONS:

MODEL HDLL20CP HEADLINER 20 OZ. ELECTRIC COUNTER MODEL

Capacity: 20 oz. All-Steel Kettle, 400 one-ounce servings per hour

Electrical: 5600 watts

Dimensions: 28"D x 36"W x 47"H - - - - 71 cm D x 91 cm W x 119 cm H

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Net Weight: 250lbs. (113 kg.)

MODEL HDLL32CP HEADLINER 32 OZ. ELECTRIC COUNTER MODEL

Capacity: 32 oz. All-Steel Kettle, 640 one-ounce servings per hour

Electrical: 6600 watts

Dimensions: 28"D x 36"W x 47" H - - - - 71 cm D x 91 cm W x 119 cm H

Net Weight: 250 lbs. (113 kg.)

MODEL HDLL20FP HEADLINER 20 OZ. ELECTRIC FLOOR MODEL

Capacity: 20 oz. All-Steel Kettle, 400 one-ounce servings per hour

Electrical: 5600 watts

Dimensions: 28"D x 36"W x 74"H - - - - 71 cm D x 91 cm W x 188 cm H

Net Weight: 250 lbs. (168 kg.)

MODEL HDLL32FP HEADLINER 32 OZ. ELECTRIC FLOOR MODEL

Capacity: 32 oz. All-Steel Kettle, 640 one-ounce servings per hour

Electrical: 6600 watts

Dimensions: 28"D x 36"W x 74"H - - - - 71 cm D x 91 cm W x 188 cm H

Net Weight: 350 lbs. (168 kg.)

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V PRINCIPLES OF POPCORN MACHINE OPERATION

Theory And Observations Of Popcorn Machine Operation

1. The efficient production of popcorn requires the presence of popcorn kernels, heat,
and oil. The purpose of the oil is to distribute the heat throughout kernels evenly
and quickly. If the heat is not distributed evenly and quickly, the kernels may burn
instead of pop.

2. In order to pop corn in oil, the kettle, oil and parts near the heating elements are
necessarily and unavoidably heated to temperatures high enough to pop popcorn.
The temperature control uses a sensing element located inside the kettle to
maintain the kettle at an operating temperature of approximately 410° F(210°C).
Contact with these surfaces will burn and scald you. Do not touch the kettle, oil or
parts in the direct vicinity of the heating elements.

3. The kettle is provided with an agitator to assist in the quick and even distribution
of heat throughout the kernels.

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4. The oil is heated to high temperatures in a kettle provided with electric heating
elements to reach proper popping temperature. An operator is required in the
vicinity of the kettle only when handling corn or dumping popped corn from the
kettle. Neither of these operations requires direct contact with the kettle. Direct
contact with the hot oil, kettle, or heating elements could result in serious burns or
scalds. Keep away from the kettle whenever possible. Use the handle when
dumping the kettle, and use the provided cups when necessary to measure corn,
oil and salt.

5. As the popcorn pops, it will push the lid open and discharge into the cabinet.
When the corn finishes popping, the corn remaining in the kettle can be removed
by holding the kettle handle in your right hand and rotating down in a clockwise
direction to dump the kettle.

6. Your Headliner model Cretors popcorn popper is equipped for a pump, which,
when properly adjusted, automatically delivers the proper amount of oil to the
popping kettle.

7. A cornditioner is provided consisting of a blower and heating element. The
cornditioner circulates hot air through the corn stored in the popcorn case to keep
the product hot and crisp.

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8. A two stage filter system traps odor and smoke produced by popping corn.

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VI THE LOGIC OPTION

The Logic Option uses integrated microprocessor control to simplify and increase the safety of
operating a popcorn machine. The Logic Option simplifies the operation by providing a single
button to push to begin a popping cycle. The LCD display, allows the operator to view instructions
and comments in four languages: Spanish, German, French or English. The LCD display gives
specific feedback to the operators, managers, and service personel. Cretors recommends
depressing the “Kettle Preheat” button prior to the first popping cycle. Operation is as simple as
loading your corn and salt in the kettle and pressing the “START” button.

When the “START” button is pressed, the pre-set oil amount will despense into the kettle and the
popping cycle will begin. The “START” button is then locked out for two minutes to prevent
accidental double charging of oil. The popping cycle will continue until the kettle reaches the
temperature set point or a programmed time limit is reached. At that time, a beeper sounds for two
minutes. This audible warning signals the operator that the kettle is ready to be dumped.
Depressing the “KETTLE PREHEAT” button will turn off the beeper. The beeper will also be
deactivated by depressing the “START” button, after the popped corn is dumped and raw corn and
salt are added again. If the operator is not available to dump the kettle, the kettle heat will
automatically shut off. The agitator and the exhaust will remain on for twenty minutes or until the
“START” or “STOP” buttons are pressed. This reduces any chance of burning corn and eliminates
possible odors.

In addition to ease of start-up and normal operation, the Logic Option serves as a backup to
perform functions that the operator may forget.

For those operators who pop both salted and sugar popcorn, there is menu to set your kettle
temperature set point for each mode. To switch back and forth between corn type, simply press a
few menu keys. “Program” button for 5 seconds and use the arrow key to change mode.

Safety Features:

If the 'Start' button (indicating another popping cycle has been started) is not pressed for nine
minutes, the kettle heat is automatically shut off.

Additionally, if Logic II detects the kettle temperature rises to an unsafe level (exceeds
570°F/298°C) a dangerous situation exists. The Logic Option will: Sound an alarm, disable the oil
pump, and shut off all auxiliary components, except exhaust. If exhaust was “OFF”, it is turned
“ON”. This continues until power is removed or kettle temperature goes below set point. If high
temperature alarm is detected more than once in an eight hour period, the controller reverts to a
“CALL FOR SERVICE” mode (non-operating). A technician must be called to evaluate and reset
the system.

If the Logic board detects the thermocouple is damaged or disconnected, the LCD display shows
‘CALL FOR SERVICE’ ‘T-COUPLE FAILURE’ and all outputs, except exhaust, lights and
cornditioner are disabled until the condition is fixed.

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Logic Option Switches and Controls

There are nine keys on the touch panel. The left side buttons are used for accessing and
maneuvering through various menus and options. The right side buttons turn on the kettle
pre-heat program, starts the cleaning cycle, turns on the cabinet light, corditioner, and sign
and one to turn the oil heater on and off.

PROGRAM -Select SALT versus SUGAR modes,

Enter programming mode,turn exhaust ON/OFF

STOP -Emergency stop (stops everthing except for

Oil heat. Oil heat is turned ON/OFF by pressing
The oil heat button only)
Stops current cook or clean sequence
Restores controller to standby condition

UP/DOWN -Used to increment or decrement parameters and

to scroll through memu selections

START (with LED) -Used to initiate cooking sequence

KETTLE PREHEAT (with LED) -Pressed before initial cooking sequence

of a cold machine. Maintains kettle
temperature at 190°F for 45 minute

-Turns off beep

OIL HEAT (with LED) -Turns oil pump heat ON/OFF

CABINET (with LED) -Turns ON/OFF cornditioner blower, heater

and all lights including sign.

CLEAN (with LED) -Initiates “CLEAN CYCLE” (See Clean cycle)

LED INDICATORS -(Light Emitting Diodes) Indicate switch condition.

(ON/OFF or SPECIAL CYCLE)

Logic Option Microprocessor Control Functions

All machine functions are controlled with the touch pad. If equiped, the LED on the switch is lit
when the switch is activated. When a switch is pressed it will "BEEP" to let the operator know that
the microprocessor will perform the desired function. A two tone "BEEP" indicates that the desired
function will not or cannot be performed. The switches activate the following functions:

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1. START

Begins the AUTO CYCLE process. Press START key, auto pop cycle process begins. Kettle
heater relay will energize and Start LED will light. Agitator relay will energize for twenty
minutes. Exhaust relay will energize for twenty minutes. Pump relay is energized until
programmed time setting is reached. Start key is locked out from further activation for two
minutes.

LCD displays “POPPING CYCLE” on top line and shows running time (count-up) of cycle
(cycle consists of KETTLE HEATER on time) on bottom line “xMIN xx SECONDS.”

When temperature setpoint is reached or programmed time limit is reached:

Kettle relay is deactivated. (Heat shuts off)
Start key LED blinks on/off and beeper sounds for two minutes,
Beeper can be silenced by pushing the PREHEAT key

Cycle is recored in memory.
Start key LED is de-activated.

NOTE: If the START key is pressed at any time after the two minutes safety delay,

the buzzer will be de-energized and a new popping cycle will begin.
Also, if the temperature is already above the setpoint at the time of the START
key being pressed, the controller will recognize this and compensate for it by
giving the kettle heater some time to equalize before energizing.

2. CABINET

Press CABINET key to turn to Cornditioner and lights. These items will remain on until
turned off or Stop is pressed. CABINET key LED will light as long as Cornditioner is
activated.

3. Press OIL HEAT key and oil pump heater relay will energize and Oil Heat LED and OIL

HEAT key LED will light depending on setting:

7700 Model Relay energizes full power “on” for 20 minuets, reverts to a 10% duty

cycle on (3 min. on/30 min. off). Oil Heat switch can be pressed to
terminate cycle. LED flickers for 20 minutes, then blinks 50% on/off
until Oil Heat switch is pressed to turn off.

7900 Model Relay energizes full power on until Oil Heat switch is press to

turn off LED 100% on until Oil Heat switch is pressed
to turn off.

4. KETTLE PRE-HEAT:

Press KETTLE PREHEAT key, KETTLE PREHEAT key LED will light.

The LCD displays “KETTLE PRE HEAT”
Kettle heater relay is energized and is controlled at 190°F.
Once kettle reaches set point, the LCD display “READY – ADD CORN, press
START.”

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If Start key is not pressed within 45 minutes, kettle pre-heat cycle is terminiated.
KETTLE PREHEAT key LED is de-activated.
If Start key is pressed within 45 minutes, kettle pre-heat cycle is terminated and KETTLE
PREHEAT key must be pressed again to initiate pre-heat operation.
Kettle preheat cycle can also be terminated by pressing KETTLE PREHEAT or STOP key.

5. SAFETY SITUATION:

If kettle temperature sensor exceeds 570°F, all outputs excep thet exhaust relay are disabled
until normal conditions are restored. If high temperature alarm is detected more than once
per 8 hours, controller reverts to a “CALL FOR SERVICE” mode (non-operating) and must
be reset by a technician.

6. SETTING CORRECT OIL VOLUME (MANAGEMENT LEVEL ACCESS):

Cretors allows the user to set the amount of oil to be dispensed by two different methods:

A. Press and hold KETTLE PREHEAT switch for three seconds to enter “learning”

mode.. LCD reads “OIL AMOUNT PROGRAM,” place a measuring cup under the
oil tube and press and hold Start key until desired amount of oil has dispensed.
Controller will “learn” associated time needed to dispense and store as the program
time until changed by either method

B. Press and hold the PROGRAM key and the up and down key for five seconds to

display “PUMP TIME-SALT” xx,x seconds or:”PUMP TIME-SUGAR xx,x seconds”
depending on which mode is currently selected. Use up or down keys to adjust to
desired time. Oil pump time values are adjustable from 5.0 seconds to 30.0 seconds
in 0.5 second increments, with a factory setting of 8 seconds in both modes.

7. CLEAN CYCLE:

Press CLEAN key, CLEAN key LED will light.
When clean cycle is selected, normal operation (including pump and cornditioner), pre-heat
operations are disabled, cabinet lights remain on.
Kettle heater relay is energized and controlled at 190°F for a total of 15 minutes from the
start of the clean cycle, then is de-energized (end of Clean cycle). Agitator relay is
energized at the start of the clean cycle and is de-energized when temperature falls below
150°F. End of clean cycle is signaled by five beeps.
Clean LED is 100% on until end of clean cycle, then 50% on/off until CLEAN key is pressed
to take machine out off Clean cycle and return to normal operation. LCD display shows
time left in clean cycle (count-down). Cleaning cycle is recorded in memory (incomplete
cycles are not counted).
CLEAN key LED will de-activate. Cleaning works best when used in conjunction with the
Cretor’s cleaning kit and supplies. See “Sanitation Instructions.”

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VII INSTALLATION INSTRUCTIONS

1. Location

Choose a location for your Cretors popcorn machine to maximize the ease of operation and
maintenance procedures. Check your local building and fire codes for location restrictions.

2. Power Supply

A. Check the nameplate to determine the required power supply.

Connect your popcorn popper only to the correct power source. Failure to do so may
result in personal injury or death and may damage your popper.

B. C. Cretors and Company recommends dedicated circuits for the Diplomat model

popcorn machine. The Headliner model poppers require a dedicated circuit to avoid
voltage drop in the supply wiring. Check your local electrical codes regarding fuse or
circuit breaker requirements.

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Make certain your popcorn machine is properly grounded. Failure to do so may result
in damage to your equipment or present a shock hazard.

3. Connecting Machine to Power Supply

A. Perform work only on de-energized circuits. Failure to do so may lead to electrical

shock resulting in personal injury or death.

B. Make certain that power supply circuit breakers are in the ‘OFF’ position.

C. Push the plug completely into the receptacle. If the cord has a twist lock plug be

sure to turn to lock in position.

4. Pump Installation

7700-L PUMP

Cretors 7700-L series Oil Pumps and Hot Rod are intended for use in standard steel pails
only. The following instructions assume the presence of a Deluxe or Economy base.

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A. Make certain the OIL HEAT switch on the control panel is in the ‘OFF’ position.

B. Insert the pump into the pail.

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