Gold Medal 100 Series, Cornado, 110 Series, 111 Series, 101 Series Instruction Manual

Part No. 110172

Instruction Manual

10700 Medallion Drive, Cincinnati, Ohio 45241-4807 USA

36, 48, & 60 oz. Cornados

Export Model Series 2149, 2258, and 2297

(100, 110, and 101, 111)

48 oz. Unit Shown

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

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Table of Contents

SAFETY PRECAUTIONS ................................................................................................................................... 3

INSTALLATION INSTRUCTIONS ................................................................................................................... 5

Inspection of Shipment ....................................................................................................................................... 5

Manual ....................................................................................................................................................................... 5

Model Description ................................................................................................................................................. 5

Items Included with this Unit ........................................................................................................................... 5

Setup ........................................................................................................................................................................... 6

Electrical Requirements ..................................................................................................................................... 7

Before You Plug In Machine .............................................................................................................................. 8

OPERATING INSTRUCTIONS ......................................................................................................................... 9

Controls and Their Functions ........................................................................................................................... 9

Program the E-Z Set Timer .................................................................................................................... 12

Popping Corn Instructions .................................................................................................................... 13

Care and Cleaning .................................................................................................................................... 15

Troubleshooting ....................................................................................................................................... 18

MAINTENANCE INSTRUCTIONS ................................................................................................................ 20

Removing Agitator Assembly and Shaft Maintenance ............................................................... 21

Replacing the Packing Cord on Kettle Hub...................................................................................... 22

Kettle and Drive Shaft Alignment ....................................................................................................... 23

Electronic Temperature Control (Export)....................................................................................... 24

Operation ............................................................................................................................................................... 24

Control Description ........................................................................................................................................... 24

Probe LED Indicator Light – Thermocouple Error Condition ........................................................... 25

Kettle Circuit Breaker ............................................................................................................................. 26

ORDERING SPARE PARTS ............................................................................................................................ 27

Model Variations (Voltage Specific Parts) ................................................................................................ 27

Unit Exterior – Front View – Filter .............................................................................................................. 28

Unit Exterior – Rear View - Oil Line ............................................................................................................ 29

Unit Exterior – Kettle Mount – Parts Breakdown .................................................................................. 30

Kettle Assembly (36, 48, and 60 oz.) – Parts Breakdown ................................................................... 32

36 oz. Kettle Bottom – Element View ......................................................................................................... 34

48 oz. Kettle Bottom – Element View ......................................................................................................... 35

60 oz. Kettle Bottom – Element View ......................................................................................................... 36

Pedestal Interior – Motor and Shaft ............................................................................................................ 37

Pedestal Interior – Electrical – Parts Breakdown .................................................................................. 38

Control Box/Control Panel – Parts Breakdown...................................................................................... 40

Safety Labels ......................................................................................................................................................... 41

Accessories ........................................................................................................................................................... 42

Wiring Diagram ........................................................................................................................................ 43

WARRANTY ...................................................................................................................................................... 44

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

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SAFETY PRECAUTIONS

DANGER

Machine must be properly grounded to prevent electrical shock to personnel. Failure to do so could result in serious injury, or death. DO NOT immerse any part of this equipment in water. DO NOT use excessive water when cleaning. Keep cord and plug off the ground and away from moisture. Always unplug the equipment before cleaning or servicing. Make sure all machine switches are in the OFF position before plugging the equipment into the receptacle.

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DANGER

Improper installation, adjustment, alteration, service, or maintenance can cause property damage, injury, or death. Any alterations to this equipment will void the warranty and may cause a dangerous condition. This appliance is not intended to be operated by means of an external timer or separate remote-control system. NEVER make alterations to this equipment. Read the Installation, Operating, and Maintenance Instructions thoroughly before installing, servicing, or operating this equipment.

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WARNING

To avoid burns, DO NOT touch the kettle or any heated surface. DO NOT place or leave objects in contact with heated surfaces.

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WARNING

ALWAYS wear safety glasses when servicing this equipment.

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WARNING

No user serviceable parts inside. Refer servicing to qualified service personnel.

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WARNING

Read and understand operator’s manual and all other safety instructions before using this equipment. To order copies of the operator’s manual go to

gmpopcorn.com or write to Gold Medal Products Co., 10700 Medallion Drive, Cincinnati, OH 45241 USA 1-(800)-543-0862

022_060215

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

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WARNING

DO NOT allow direct contact of this equipment by the public when used in food service locations. Only personnel trained and experienced in the equipment operation may operate this equipment. Carefully read all instructions before operation.

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WARNING

This machine is NOT to be operated by minors.

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This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety.

Note: Improvements are always being made to Gold Medal’s equipment. This information

may not be the latest available for your purposes. It is critical that you call Gold Medal’s Technical Service Department at 1-800-543-0862 for any questions about your machine operations, replacement parts, or any service questions. (Gold Medal Products Co. does not assume any liability for injury due to careless handling and/or reckless operation of this equipment.) General images may be used in manual for reference only.

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

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INSTALLATION INSTRUCTIONS

Inspection of Shipment

After unpacking, check thoroughly for any damage which may have occurred in transit. Claims should be filed immediately with the transportation company. The warranty does not cover damage that occurs in transit, or damage caused by abuse, or consequential damage due to the operation of this machine, since it is beyond our control (reference warranty in back of manual).

Manual

Read and understand the operator’s manual and all other safety instructions before using this equipment. To order copies of the operator’s manual go to gmpopcorn.com or write to Gold

Medal Products Co., 10700 Medallion Drive, Cincinnati, OH 45241 USA 1-(800)-543-0862.

Model Description

This manual covers 2149 (36 oz.), 2258 (48 oz.), and 2297 (60 oz.) Series, tall pedestal, Cornado units (motor is located in pedestal). See below for series specific RH, LH, and Pass Thru Handle descriptions.

Model Series

100: Right Hand Dump 110: Left Hand Dump 101: Right Hand Dump, Pass Thru Handle 111: Left Hand Dump, Pass Thru Handle

Items Included with this Unit

2 TBS. Flavacol Measure 36 oz. Units (PN 47681)

Corn Cup

Unit specific: 36 oz. (PN 67905-36), 48 oz. (PN 17757-48), 60 oz. (PN 17757-60)

RH Jet Scoop (PN 2072)

Flavacol Container

(PN 41752)

Instruction Manual

Registration Warranty Card

1/4 Cup Flavacol Measure 48 and 60 oz. Units (PN 47169)

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

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Setup

The Cornado Popper has been inspected and tested at the factory. Installation of the popper should be performed by qualified service personnel. Read and perform all Setup steps prior to operating the unit.

1. Remove all packaging and tape.

2. Install unit on a level surface; the popper must have an 8” minimum clearance

required between the popper kettle and any combustible surface. See counter mounting requirements and hole locations below.

Mounting Instructions: 8” minimum clearance required between kettle and

any combustible surface.

Pedestal Interior

(4) Mounting Locations

Secure Pedestal to table or counter.

Counter Mounting Requirements

2” Dia. X 1/8” Thick

Fender Washer

3/4” Minimum

for Wood or

Wood Plastic

Products

5/16-18 Grade 5 Bolt

5/16-18 Grade 5 Nut

3/16” Minimum Thickness for Stainless Steel over Wood

Oil Tube

35.9”

(36 & 48 oz.)

38.9”

(60 oz.)

16.03” (36 oz.)

18.03” (48 oz.)

19.51” (60 oz.)

8.437”

12.072”

6.5”

5.221”

0.878”

10.472”

Ø.375 Dia.

Suggested Table

Hole Ø.500

Hole Locations

Remove front panel to access mounting holes on bottom of pedestal interior.

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

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3. The main power cord extends out the bottom of the cabinet base. A secondary, smaller

power cord, is provided for powering the oil dispense unit. Before plugging in machine, have a certified electrician follow all requirements listed

in the Electrical Requirements section of this manual.

4. The small power cord (6 pin Jones Plug) is the oil pump harness which connects the

popper to the oil dispense unit. To connect/calibrate the oil dispense system to the popper; refer to the Instruction Manual included with the oil dispense unit (reference the Program the EZ-Set Timer section to set the oil dispense timer(s).

5. After setup, the unit should be cleaned. The kettle has a food grade protective coating

applied to the cooking surfaces, this coating must be removed prior to operating the unit (see Care and Cleaning section of this manual).

Electrical Requirements

The following power supply must be provided (reference unit Data Plate):

220-230 V~, 50/60 Hz

Potential Electrical Variations: 220 V~, 60 Hz

Export units are designed to operate on single phase, 16 AMP, 4 wire supply, 230 V~ (2 Hot, 1 Neutral, 1 Ground). All electrical components in this machine are 230 V (motors,

heat elements, lights, etc.) and therefore require “Hot to Neutral” connection (NOT “Hot to Hot”). A certified electrician must supply and install the wall receptacle for this unit;

reference the Receptacle Wiring Diagram for Export Units.

DANGER

Machine must be properly grounded to prevent electrical shock to personnel. Failure to do so could result in serious injury, or death. DO NOT immerse any part of this equipment in water. DO NOT use excessive water when cleaning. Keep cord and plug off the ground and away from moisture. Always unplug the equipment before cleaning or servicing. Make sure all machine switches are in the OFF position before plugging the equipment into the receptacle.

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A certified electrician must furnish sufficient power for proper machine operation and install any supplied receptacle. We recommend this equipment be on a dedicated and protected circuit. Failure to wire properly will void the warranty and may result in damage to the machine. It is Gold Medal Products Co.’s recommendation that this machine be plugged directly into a wall outlet. The use of extension cords is not recommended due to safety concerns, and may cause sacrificed and/or reduced performance. Make sure cord is located to prevent a trip hazard or unit upset.

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

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Receptacle Wiring Diagram (for all Export Units)

A certified electrician must supply and install the required wall receptacle for this unit, follow the IMPORTANT instructions shown.

This unit is designed to operate on single phase, 16 AMP, 4 wire supply. All electrical components in this machine are 230 V. If the receptacle is wired incorrectly, the heat elements/kettle and other electrical components could be at 400 V potential instead of the needed 230 V, resulting in excessive temperatures in the heat elements (i.e.: kettle) and possible fire, and/or damage to electrical components.

Before You Plug In Machine

1. Make sure all machine switches are OFF before plugging equipment into receptacle.

2. Make sure wall outlet can accept the grounded plugs (where applicable) on the power

supply cord.

3. The wall outlet must have the proper polarity. If in doubt, have a competent

electrician inspect the outlet and correct if necessary.

4. DO NOT use a grounded to un-grounded receptacle adapter (where applicable).

5. Install unit in a level position.

CAUTION

If the supply cord is damaged, it must be replaced by Gold Medal Products Co., its service agent or similarly qualified persons in order to avoid a hazard.

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3P+N+E IEC 309

(Front View)

3P+N+E IEC 309

(Back View)

PE-G

L2

L1

Connect to Black

(Hot) Wire

Connect to Brown (Hot) Wire

Connect to Green/Yellow (Ground) Wire

Connect to Blue

(Neutral) Wire

L3

N

Not Used

(If 5 wires provided,

connect Grey here.)

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

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OPERATING INSTRUCTIONS

Controls and Their Functions

This section describes the unit controls (reference image below).

KETTLE HEAT SWITCH (Kettle Circuit Breaker)

Two position, ON/OFF lighted rocker switch - supplies power to the heating elements in the popping kettle by sending power to the “Big Eye” Electronic Temperature Control System.

IMPORTANT NOTE: The Kettle Heat Switch is inactive if the Kettle Circuit Breaker is

tripped. If unit is plugged in, but green Heat Switch light does not come on when activated, then the Kettle Circuit Breaker may be tripped. Reference the Kettle Does Not Heat section in the Troubleshooting section of this manual.

KETTLE MOTOR SWITCH

Two position, ON/OFF lighted rocker switch - supplies power to the kettle agitator motor. The Kettle Motor Switch MUST be ON at all times when there is popcorn (popped or unpopped) in the kettle.

HIGH/LOW KETTLE TEMPERATURE SWITCH

Two position rocker switch – adjusts kettle temperature for Salt (HIGH) or Sweet (LOW) popping mode.

Control Panel View

Circuit Breakers

Push Button Switch

Temperature/Cycle Count

Digital Display

High/Low Kettle Temperature Switch

Kettle Heat Switch

Load/Dump Indicator

Kettle Motor Switch

Oil PB Switch

Green Oil Light

Oil System

Master Switch

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

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LOAD/DUMP INDICATOR LIGHT & AUDIBLE SIGNAL

During normal popper operation, the yellow Load/Dump light and audible sound (if

engaged), are used to signal Load/Dump. If the yellow indicator light is ON, and the buzzer is sounding, one of the following actions should be taken:

• Load the corn and oil or

• Dump the popped corn from the kettle or

• Turn the Kettle Heat Switch OFF if you are finished popping corn.

During calibration of the oil dispense unit, the indicator light (Oil Light or Load/Dump Light) is used to indicate when the oil dispense unit is in program mode.

OIL SYSTEM MASTER SWITCH

Two position, ON/OFF lighted rocker switch - supplies power to the oil pump (either the Bag-in-a-Box or Bucket Pump model). Reference the Instruction Manual for the oil dispense unit.

Bag-in-a-Box Model: Oil System Master Switch ON, provides power to the oil dispense unit, activates the warmer/blower, and the heated line kit (if equipped).

Note: Coconut oil will congeal at temperatures below approximately 76°F (24°C). For

machines used daily, leave the Oil System Master Switch on at all times and keep the cabinet doors closed to prevent the oil from becoming solid. If the machine has not been used for several days, turn the Oil System Master Switch ON the night before it is expected to be used.

Bucket Pump Model: Oil System Master Switch ON, activates the 30 watt heating element on the bucket pump to keep the coconut oil liquid.

RED OIL DISPENSE PUSH BUTTON (PB) SWITCH & GREEN OIL LIGHT

Red Push Button Switch - dispenses a predetermined amount of oil into the kettle when pressed. The Oil System Master Switch must be ON for the Oil Dispense PB Switch to activate. The Oil Light on the popper will light continuously when oil pump is dispensing. Reference the Instruction Manual for the oil dispense unit.

During calibration of the oil dispense unit, the indicator light (Oil Light or Load/Dump Light) is used to indicate when the oil dispense unit is in program mode.

CIRCUIT BREAKERS

Two mini Circuit Breakers are located on the control panel, to protect the popper unit from overload condition. If unit is plugged in, but the kettle motor or oil system does not come on when activated, then the circuit breaker(s) may be tripped. (Reference the Troubleshooting section of this manual).

TEMPERATURE/CYCLE COUNT (Digital Display and RED Push Button Switch)

The Digital Display shows the popping temperature of the kettle and number of popcorn cycles completed by the unit. Set the Digital Display to show the cycle count. The temperature portion is for troubleshooting purposes for qualified service personnel reference (temperature has degree (°) symbol after the number). To alternate between popping temperature and cycle counts, press the RED Temp/Count Push Button Switch.

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

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To reset the popcorn cycle count, press and hold the RED Temp/Count Push Button Switch for 5 seconds, the display count will start to blink to warn the user the count is about to be reset to zero. Continue to hold the push button 3 more seconds and the count will reset to zero.

Note: Display is selectable to show either °F or °C Temperatures (unit is preset at

installation, replacement display must be set by qualified service personnel only).

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

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Program the E-Z Set Timer

The oil dispense volume is set using the programmable timer in the oil dispense unit (reference the Oil Dispense Unit manual). The number of timer settings available for the popper can be determined as follows:

If using a DUAL TIMER oil unit: 2 internal timer settings are available in the oil dispense unit. If using a SINGLE TIMER oil unit: 1 internal timer setting is available in the oil dispense unit.

Follow the steps below to program the timer to dispense the oil amount needed to pop a batch of popcorn. It is recommended to set the oil volume to approx. 30% of the raw popcorn charge used.

To program, use the Oil Dispense Switch and the Oil System Master Switch located on the control panel of the popper.

Note: Take volume measurements from oil delivery tube located in popper above the

kettle. Allow kettle to cool completely prior to taking volume measurements.

Priming the Unit:

1. Turn Oil System Master Switch ON.

2. Hold a cup under the oil delivery tube in popper, PUSH and RELEASE the Oil Dispense

Switch to START dispensing oil.

3. As soon as oil flows steady, turn Oil System Master Switch OFF; unit is now primed.

Wait 30 seconds to allow oil to settle/drain before programming.

Programming the Unit:

4. Hold down Oil Dispense Switch and turn Oil System Master Switch ON, continue to hold

Oil Switch for 5 seconds until the indicator light (OIL Light or LOAD/DUMP Light) on

popper starts to blink ON-OFF, then release switch; unit now in program mode.

5. Hold a measuring cup under the oil delivery tube in popper; PUSH and RELEASE the

Oil Dispense Switch to START oil flow.

6. When correct amount of oil has been dispensed, PUSH and RELEASE Oil Dispense

Switch again to STOP oil flow. The Oil Switch may be pushed ON/OFF as many times as needed to finalize (“top off”) the oil amount.

7. Turn Oil System Master Switch OFF, then back ON to SAVE the setting. Unit will now

dispense the “programmed” amount of oil when the Oil Dispense Switch is pushed. The Oil Light on the popper will light continuously when oil pump is dispensing.

8. Wait 30 seconds to allow oil to settle/drain, then re-check the oil quantity.

Dual Timer Note: Units with two oil timer settings available must be set for Flexi-Pop, if

available on the unit (Flexi-Pop option not available on Cornado units). Otherwise, the two settings must be used for Salt/Sweet (High/Low) option. Select one corn amount and program the first timer; then select the other corn amount and program the second timer. (Pumps with a single timer will only remember the last setting programmed.)

Manual Mode (Oil only dispenses when the Oil Dispense Switch is held IN):

OPTIONAL - Use to manually dispense oil, or for cleaning. Follow Step 4 then skip to Step 6.

To use a timer setting after using Manual Mode, the unit MUST be reprogrammed.

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

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Popping Corn Instructions

This section describes popping instructions for Salted Popcorn and Sweet Popcorn (if equipped with Salt-Sweet or High-Low temperature option).

Remember (for all popping modes): When the Load/Dump Light comes ON, and Audible Signal (if enabled) is sounding, one of the following actions should be taken:

• Load the corn and oil or

• Dump the popped corn from the kettle or

• Turn OFF the Kettle Heat if you are finished popping corn.

The popper is equipped with a corn, salt, and oil measure. We recommend flavored and colored coconut oil. Popcorn popped in coconut oil stays fresh longer and does not leave black deposits in the kettle like other oils. Use only top quality, fresh popcorn from reputable suppliers.

Popping Salted (Standard) Popcorn

Raw Popcorn Charge:

Use corn measure provided (ex: for 36 oz. Kettle, use 36 oz. corn)

Recommended Oil Volume:

Oil volume is approx. 30% of corn amount (ex: for 36 oz. corn, use 10.8 oz. oil)

Flavacol (Salt) Amount:

Use small Flavacol scoop provided

Note: When using coconut oil, be sure the oil is liquid. As a check, dispense oil into a

measuring cup first, then use that oil for the first popping cycle.

1. Turn all switches ON; set popping temperature option (if equipped) to Salt (High)

mode.

2. Kettle is ready to pop (about 5-8 minutes), when the yellow Load/Dump Light and

Audible Signal (beeper, if enabled) turn ON.

3. Lift kettle lid and pour in pre-measured popcorn and Flavacol; close lid.

4. Press the “Red” Oil Dispense PB Switch to add oil (if equipped), or add oil manually

before closing lid (light and beeper will turn OFF in approx. 20 seconds).

5. When the light and beeper come on again, gently dump the kettle.

Note: The signal “To Dump” was factory set based on Gold Medal popcorn and oil. If,

after 3 consecutive batches, the signal occurs before or after popping has stopped, then the signal timing can be adjusted by a qualified service person (reference Electronic Temperature Control section).

Popping Tip: On final batch, turn Kettle Heat Switch OFF just as lids are forced open

by the popping corn (kettle has plenty of heat to finish popping). This helps eliminate smoke/odor from any oil residue remaining in kettle. With the Heat Switch OFF, the light and beeper will not activate for the last batch.

6. When finished popping, turn KETTLE HEAT and KETTLE MOTOR switches OFF.

NEVER LEAVE THE HEAT ON WHEN YOU ARE NOT POPPING CORN!

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

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Popping Sweet Popcorn

Gold Medal recommends white coconut oil for popping Glaze Pop (colored oil can change the popcorn color). Glaze Pop cooks directly in the kettle. DO NOT use popcorn seasoning salt when popping Glaze Pop.

Raw Popcorn Charge:

Use corn measure provided (ex: for 36 oz. Kettle, use 36 oz. corn)

Recommended Oil Volume:

Oil volume is approx. 30% of corn amount (ex: for 36 oz. corn, use 10.8 oz. oil)

Glaze Pop/Sugar Amount:

Use amount equal to 1/2 the quantity of corn (ex: for 36 oz. corn, use 18 oz. Glaze Pop)

Note: When using coconut oil, be sure the oil is liquid. As a check, dispense oil into a

measuring cup first, then use that oil for the first popping cycle.

1. Turn all switches ON; set popping temperature option (if equipped) to Sweet (Low)

mode.

2. Kettle is ready to pop (about 5-8 minutes), when the yellow Load/Dump Light and

Audible Signal (beeper, if enabled) turn ON.

3. Lift kettle lid and pour in pre-measured popcorn and Flavacol; close lid.

4. Press the “Red” Oil Dispense PB Switch to add oil (if equipped), or add oil manually

before closing lid (light and beeper will turn OFF in approx. 20 seconds).

5. Add pre-measured amount of Glaze Pop or Sugar (when using sugar, we recommend

using Compound “S” to help keep kettle clean); close lid.

6. When the light and beeper come on again, gently dump the kettle.

Note: The signal “To Dump” was factory set based on Gold Medal popcorn and oil. If,

after 3 consecutive batches, the signal occurs before or after popping has stopped, then the signal timing can be adjusted by a qualified service person (reference Electronic Temperature Control section).

Popping Tip: On final batch, turn Kettle Heat Switch OFF just as lids are forced open

by the popping corn (kettle has plenty of heat to finish popping). This helps eliminate smoke/odor from any oil residue remaining in kettle. With the Heat Switch OFF, the light and beeper will not activate for the last batch.

7. When finished popping, turn KETTLE HEAT and KETTLE MOTOR switches OFF.

NEVER LEAVE THE HEAT ON WHEN YOU ARE NOT POPPING CORN!

8. Clean kettle when finished popping Glaze Pop or sugar corn, and prior to switching to

salted popcorn.

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

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Care and Cleaning

DANGER

Machine must be properly grounded to prevent electrical shock to personnel. DO NOT immerse in water. DO NOT clean appliance with a water jet. Always unplug the equipment before cleaning or servicing.

025_111616

WARNING

To avoid serious burns, DO NOT touch the kettle while it is hot!

028_082715

Good sanitation practice demands that all food preparation equipment be cleaned regularly (only use non-toxic, food grade cleaners). A clean looking, well-kept machine is one of the best ways of advertising your product.

Note: It is extremely important to follow all cleaning procedures, otherwise parts

damage and equipment failure will result. The warranty does not cover parts that are damaged due to improper cleaning.

Daily Kettle Cleaning Instructions

CAUTION: A hot kettle will cause burns if you touch it with your hand. Allow kettle to cool

at least 1 hour before attempting to clean. DO NOT use ice or water to cool down a hot kettle! Severe kettle damage will result!

1. When cool, wipe outside of kettle with a clean, soft cloth. DO NOT use oven cleaners or

abrasive materials as they will damage the kettle.

2. Every night, mix Gold Medal’s Heat’n Kleen solution (Item No. 2095), 2 tablespoons

per gallon of water. It is not necessary to use the entire gallon at once; only use enough to fill the kettle 1/2 inch deep.

3. Turn kettle heat ON. When water starts to boil, turn kettle heat OFF.

4. Allow to cool at least 1 hour, then dump solution into a bucket and wipe inside of

kettle with a clean cloth. Make sure all solution goes into the bucket; do not spill any in the interior of machine.

For an extra dirty kettle, the process may be repeated; or, after turning kettle heat OFF, allow solution to sit in kettle overnight. The next morning, dump solution into a bucket and wipe inside of kettle with a clean cloth.

5. With unit OFF and unplugged, wipe kettle lead cord with a clean SLIGHTLY damp cloth.

DO NOT get moisture into the kettle lead-in cord, severe damage will result.

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

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Daily Unit Cleaning Instructions

1. Turn machine OFF, unplug unit and allow it to cool before attempting to clean.

2. Clean all pans/accessories in order to sanitize them before each use.

3. Take a clean, SLIGHTLY damp cloth and wipe excess grease from unit.

4. Wipe stainless steel parts with a clean cloth and cleaner designed for stainless steel,

such as Gold Medal Watchdog Stainless Cleaner (Item No. 2088). DO NOT use oven cleaners or abrasive materials as they will damage parts of machine.

Sanitizing the Tubing and Pump

Reference the Oil Dispense Unit manual for oil system cleaning instructions.

To Remove/Install Kettle Lid (if needed)

To Remove Kettle Lid:

Lift TAB slightly, rotate lid assembly to disengage raised hooks; then lift lid off. (Reverse steps to install lid.)

1

2

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

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Weekly Agitator and Hub Seal Assembly Cleaning Instructions

Important: For proper machine performance, keep agitator and hub assembly clean.

Follow the steps below weekly to ensure proper machine performance.

Step 3: Leave the Packing Cage and Packing Cord intact. ONLY wipe hub

assembly surfaces to remove product residue, and clean the inside of the agitator hub to remove any nicks and carbon build-up.

If packing cage is removed, then the packing cord should be replaced (see Replacing the Packing Cord on Kettle Hub in the Maintenance section of this manual.)

Step 4: Reinstall agitator assembly.

Step 1: Turn unit OFF, and allow it to cool

completely before attempting to remove agitator shaft.

On the bottom side of the kettle, hold the Agitator Shaft firmly with Channel Lock pliers.

NOTE: The shaft has a left handed thread.

Steps to Clean Agitator and Hub Assembly

Agitator Assy’s Welded Bar

Tap bar in a CLOCKWISE direction

Step 2: To loosen the Agitator Assembly,

tap the agitator’s welded bar with a

rubber mallet in a CLOCKWISE direction, and unscrew to remove.

Packing Cage

Kettle Hub

Packing Cord

Kettle Bushing

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

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Troubleshooting

Issue

Possible Cause

Solution

Power to the Unit

A. Power to the Unit

A. Make sure the unit’s lead-in cord is plugged in.

B. Mini Circuit Breaker(s) on

popper tripped

B. Mini Circuit Breaker(s) supplies power to all

unit features. The Mini Circuit Breaker(s), will be located on the control panel of the popper. If breaker(s) is reset, then trips again, the unit must be inspected/repaired before going any further.

Kettle Does Not Heat

A. Kettle Circuit Breaker

A. If unit is plugged in, and the Kettle Heat Switch

is ON, but the small green indicator switch light is off, then the Kettle Circuit Breaker may be tripped.

Have a qualified service person check if the

breaker has tripped (breaker is located behind the front cover plate). The Kettle Circuit Breaker may trip during transit; if reset then trips again, the unit must be inspected/ repaired before going any further (reference the Kettle Circuit Breaker in the Maintenance section).

B. Kettle Heat Switch

B. Have a qualified service person check the

voltage to and from the Kettle Heat switch; and if the switch is defective replace it.

C. Temperature Control

Board

C. A defective thermocouple lead will cause the

kettle not to heat. Check for control error conditions and have a qualified service person check for good connections from the kettle to the control. (Reference the Error Conditions of the Electronic Temperature Control in the Maintenance section.)

Oil Pump Does Not Deliver Oil to Kettle

A. Mini Circuit Breaker(s) on

popper tripped

A. Check the Mini Circuit Breaker(s); if reset,

then trips again, the unit must be inspected/ repaired by qualified service personnel.

B. Oil Dispense Unit

C. Check for air leaks into the oil line; be sure the

filter in the line is not loose.

For additional possible causes/solutions,

reference the Troubleshooting section of the Oil Dispense Unit Manual.

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

Page 19

gmpopcorn.com

Issue

Possible Cause

Solution

Long Popping Cycles

(Longer than 4 minutes for Salt Popcorn)

A. Heating Element

A. One of the heating elements in the kettle may

be burned out. This would result in the kettle never reaching the proper operating temperature. Check with a qualified service person for inspection/repair.

B. Low Voltage

B. If the machine is operated on low voltage, this

could cause the kettle not to reach the proper operating temperature. Check with a qualified electrician.

C. Inadequate Supply Lines

C. Inadequately sized electrical supply lines, in

addition to being a fire hazard, would also prevent the kettle from reaching the proper operating temperature. Check with a qualified electrician.

D. Inferior Corn

D. Inferior quality corn would result in longer

popping cycles. Use only top quality hybrid popcorn from reputable suppliers. Even then, if you let your corn pick up moisture or dry out, your popping cycles will be slow.

Kettle Agitator Shaft not Rotating

A. Kettle Motor Switch

A. If the kettle agitator shaft is not rotating, DO

NOT pop corn. Check to make sure the Kettle Motor Switch is ON. If the switch is ON, and the shaft is not rotating, the switch or motor may be faulty, contact qualified service personnel for inspection/repair.

B. Mini Circuit Breaker on

popper tripped

B. Check the Mini Circuit Breaker(s); if reset,

then trips again, the unit must be inspected/ repaired by qualified service personnel.

Kettle Shaft “binds” when

dumped.

A. Shaft Misalignment

A. The upper and lower shafts must align with

one another, and the two shafts must not

“bind” when the kettle is dumped. Have

qualified service personnel adjust alignment (reference the Kettle Drive Shaft Alignment section of this manual).

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

Page 20

gmpopcorn.com

MAINTENANCE INSTRUCTIONS

DANGER

Machine must be properly grounded to prevent electrical shock to personnel. Failure to do so could result in serious injury, or death. DO NOT immerse any part of this equipment in water. DO NOT use excessive water when cleaning. Keep cord and plug off the ground and away from moisture. Always unplug the equipment before cleaning or servicing. Make sure all machine switches are in the OFF position before plugging the equipment into the receptacle.

008_051514

DANGER

Improper installation, adjustment, alteration, service, or maintenance can cause property damage, injury, or death. Any alterations to this equipment will void the warranty and may cause a dangerous condition. This appliance is not intended to be operated by means of an external timer or separate remote-control system. NEVER make alterations to this equipment. Read the Installation, Operating, and Maintenance Instructions thoroughly before installing, servicing, or operating this equipment.

014_020416

WARNING

No user serviceable parts inside. Refer servicing to qualified service personnel.

011_051514

CAUTION

THE FOLLOWING SECTIONS OF THIS MANUAL ARE INTENDED ONLY FOR QUALIFIED SERVICE PERSONNEL WHO ARE FAMILIAR WITH ELECTRICAL EQUIPMENT. THESE ARE NOT INTENDED FOR THE OPERATOR.

027_010914

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

Page 21

gmpopcorn.com

Removing Agitator Assembly

and Shaft Maintenance

The kettle’s agitator shaft should be removed every 3 months and lubricated with Never Seez® (Item No. 68751). See below for steps to remove and lubricate the agitator shaft.

Step 3: Remove the agitator shaft and lubricate with Never Seez® (Item No.

68751). Apply a small amount on the slope and side of pin on the matching shaft.

Step 4: Reinstall agitator assembly for use.

Step 1: Turn unit OFF, and allow it to cool

completely before attempting to remove agitator shaft.

On the bottom side of the kettle, hold the Agitator Shaft firmly with Channel Lock pliers.

NOTE: The shaft has a left handed thread.

Steps to Remove the Agitator Assembly and Lubricate Shaft

Tap bar in a CLOCKWISE direction

Step 2: To loosen the Agitator Assembly,

tap the agitator’s welded bar with a rubber mallet in a CLOCKWISE direction, and unscrew to remove.

Leave the Packing Cage/ Packing Cord on the kettle hub intact. If packing cage is

removed, then the packing cord should be replaced (see next page, Replacing the Packing Cord on Kettle Hub.)

Agitator Shaft

Agitator Assy’s. Welded Bar

Apply Never Seez® to Agitator Shaft

Apply a small amount of Never Seez®

on slope and pin of the matching shaft.

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

Page 22

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Replacing the Packing Cord on Kettle Hub

The kettle hub assembly (Packing Cage and Packing Cord) is designed for long use if not disturbed. When the unit is properly maintained, the packing cord should not need to be changed. If it is removed, or if the kettle bushings are replaced, then the packing cord should be replaced. Follow the steps below to replace the packing cord.

Step 3: Wind the new packing cord on the hub. Start at the bottom, and wind up in a CLOCKWISE direction.

Steps to Replace Packing Cord

Step 1: Remove agitator assembly (see

Removing Agitator Assembly section), then remove the packing cage and the old packing cord.

For older models which have an oil seal, remove the oil seal from inside the agitator hub and replace with the Cornado Packing Kit (Item No. 69305) as described here.

Kettle Hub

(Packing Cord will ride

on this surface)

Step 4: Push packing cage down onto the packing cord and rotate CLOCKWISE.

Step 5: Before reinstalling agitator assembly, clean the inside of the agitator hub to remove all nicks and carbon build-up.

Step 2: Clean the surfaces of the kettle hub with a Scotch Brite pad or fine sandpaper.

Packing Cage

Kettle Hub

Packing Cord

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

Page 23

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Kettle and Drive Shaft Alignment

Step 2: Adjust the plate back and forth, and side-to-side, until the lower shaft lines up with the upper shaft in the kettle.

It is important to have the two shafts align with one another, and that the two

shafts do not “bind” when the kettle is

dumped.

Step 3: Once properly aligned, re-tighten the two hex bolts on the adjusting plate.

Step 1: To adjust the lower agitator shaft, loosen the two hex bolts for the adjusting plate. It may be necessary to use a socket/wrench on the hex nuts (located inside the pedestal).

Loosen (2) Hex Bolts

Adjusting Plate

Lower Agitator Shaft

Lower Agitator Shaft (attached to motor)

Upper Agitator Shaft (attached to kettle)

Steps to Adjust the Kettle Drive Shaft

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

Page 24

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Electronic Temperature Control (Export)

Operation

The temperature control is factory set to stop the power to the kettle when the thermocouple reaches set point. This is also the ideal point to dump the popped corn out of the kettle. On the first start-up, this is the ideal time to load the corn and oil. Therefore, if the Kettle Heat Switch is turned ON, the yellow light and buzzer are ON, one of the following actions should be taken:

• Load the corn and oil or

• Dump the popped corn from the kettle or

• Turn OFF the Kettle Heat Switch if you are finished popping corn.

Control Description

This unit has an electronic kettle heat control with 2 thermocouples (TC), one for set point control and one for fixed high limit. There are no mechanical thermostats in this kettle.

There are (4) factory settings on the control (see descriptions below). If needed, adjustments may be made to the Kettle Dump and Audible Signal to Dump. The remaining settings are factory set for the unit, DO NOT adjust.

1. Control Set Point Temperature – This is factory set, DO NOT adjust.

2. The Overshoot circuit is tuned for the kettle at the factory, DO NOT adjust.

It does not matter which TC goes to A or B; it DOES matter that the yellow leads go to the positive terminals.

Remove this jumper for no sound.

Remove this jumper for lower volume.

Control Setpoint Temperature This is factory set, DO NOT ADJUST.

Audible Signal to Dump

Probe Fault LED – LED light ON

indicates a thermocouple issue.

Overshoot – This is factory set,

DO NOT ADJUST.

Kettle Dump - This is factory set

to signal when kettle is ready to dump. Turn CW to signal sooner; CCW to signal later. ONLY make small adjustments if needed.

L2 Neutral Lead

L1 Hot Lead

Jumper Wire C for 230 VAC

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

Page 25

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3. Kettle Dump – The Kettle Signal to Dump (yellow light/buzzer) is factory set. For the

signal to dump to be a little sooner or later, adjust the Kettle Dump potentiometer (reference image shown). Turn clockwise (CW) to signal sooner, counterclockwise (CCW) to signal later.

4. Audible Signal to Dump - The buzzer has three options; full volume, half volume, or

no sound (yellow light only). Unit is preset at the factory to full volume. Adjustments are made by jumper positions (reference image shown).

Probe LED Indicator Light – Thermocouple Error Condition

The Dump Light on the Popper will be on steady and the unit will beep (if Audio Signal engaged) when there is a Probe issue (the kettle will not heat enough to pop corn). Check the control board, the red Probe LED light ON will indicate one of two thermocouple error conditions.

• Reversed Probe – Indicates the thermocouple probe has been connected in reverse. (The

yellow leads must go to the positive terminals.)

If the kettle heats for a short time and then stops, and the red Probe LED light is ON, then one (or both) Thermocouple is wired in reverse. Check TC-A and TC-B; make sure the yellow leads go to the positive terminals.

• Open Probe – Indicates the thermocouple probe is disconnected.

If the kettle does not heat and/or the beeper sounds continuously, and the red Probe LED light is ON, there is an issue with the Thermocouple wiring.

For removable kettles - make sure the kettle lead-in cord is plugged in completely and the locking ring is fully screwed onto the kettle receptacle.

For hard wired kettles - A loose kettle lead-in connection can cause a thermocouple lead issue. Check the terminal blocks for a loose connection, and check the kettle wiring for a loose or broken thermocouple.

For more in-depth Temperature Control Board troubleshooting, for Qualified Service Personnel ONLY, please reference Gold Medal Service Bulletin 0074.

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

Page 26

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Kettle Circuit Breaker

This machine is equipped with a Kettle Circuit Breaker. The circuit breaker may trip during shipment of the unit due to vibrations encountered in transit. If the breaker is tripped the kettle will not heat. The circuit breaker must be reset by qualified service personnel only.

IMPORTANT NOTE: Various issues may prevent the kettle from heating. Prior to

checking the Kettle Circuit Breaker, reference the Troubleshooting section of the Instruction Manual to check for other possible issues.

Checking the Kettle Circuit Breaker

Note for PopClean Units: The Heat Switch is inactive unless the Filter Switch is ON, all

filter lights are GREEN, and the Change Filter light is OFF.

To check if the Kettle Circuit Breaker has tripped, turn the Kettle Heat Switch ON. The small green indicator light on the Kettle Heat Switch should turn ON. If the green indicator light is OFF, when the Kettle Heat Switch is in the ON position, the circuit breaker is tripped. (For Flexi-Pop units with a combined Flexi-Pop/Kettle Heat Switch, the green light on the Kettle Motor Switch is used to indicate the Kettle Circuit Breaker is tripped.)

• For hanging kettle machines – On Standard Poppers, the Kettle Circuit Breaker is

located under the dome. An additional cover must be removed to reset the circuit breaker. On PopClean Poppers, the side dome panel must be removed to access the circuit breaker located on the vertical controls panel in the dome interior (reference images below).

• For pedestal mounted kettle machines - the front cover plate must be removed to

access the Kettle Circuit Breaker (reference image below).

The circuit breaker should only be reset after a qualified service person has checked the complete kettle circuit for faults. The limit and heating contactors/relays should be checked to ensure that the contacts are not welded together. The kettle receptacle and plug (if equipped) should be checked for loose contacts or shorted wiring. The popcorn kettle bottom must be examined to ensure there is no loose hardware or other items causing a short circuit. All wiring in the kettle circuit should be checked for fraying wires, short circuits, and loose connections.

PopClean Poppers

Kettle Circuit Breaker is located on

Vertical Controls Panel in dome interior; remove breaker cover to access CB.

Hanging Kettle Poppers

Cornado Poppers (Pedestal Style)

Kettle Circuit Breaker is

located behind front cover plate; remove breaker cover to access the CB.

Standard Poppers

Kettle Circuit Breaker is

located under dome, remove breaker cover to access CB.

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

Page 27

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ORDERING SPARE PARTS

1. Identify the needed part by checking it against the photos, illustrations, and/or

parts list. (General images may be used in manual for reference only.)

2. Use only approved replacement parts when servicing this unit.

3. When ordering, please include part number, part name, and quantity needed.

4. Please include your model number, serial number, and date of manufacture (located

on the machine nameplate/data plate) with your order.

5. Address all parts orders to Parts Department, Gold Medal Products Co., 10700

Medallion Drive, Cincinnati, Ohio 45241-4807 or place orders by phone or online:

Phone: (800) 543-0862

(513) 769-7676

Fax: (800) 542-1496 (513) 769-8500

E-mail: info@gmpopcorn.com Web Page: gmpopcorn.com

Model Variations (Voltage Specific Parts)

Kettle Model

Part Description and Part Number (PN)

111606-14 and

111606L-14

KETTLE LEAD ASSY - 10 GA (PN 111596-14) (used for Australian 60 oz. Kettle)

111607-14 and

111607L-14

KETTLE LEAD ASSY - 10 GA (PN 111596-14) (used for Australian 48 oz. Kettle)

111608-14 and

111608L-14

KETTLE LEAD ASSY – 12 GA (PN 111601-14) (used for Australian 36 oz. Kettle)

Kettle Lead Assembly

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

Page 28

gmpopcorn.com

Unit Exterior – Front View – Filter

Item

Part Description

Part Number

All Models

1

TEMP/CYCLE COUNT LABEL

111529

2

6-32 X 3/8 PHIL PAN M/S

39000

3

GLIDE SCREW #8-32X3/8 PAN HD PH

74141

4

8-32 X 3/4 PHIL FLAT M/S

47125

5

FILTER AND GUARD ASSY (includes Guard, Filter, and Cover)

63707

6

FILTERS(BAG OF 5)

69917

See Control Box section.

See Kettle Assembly section.

See Unit Exterior,

Kettle Mount section.

For Labels, see Safety Label Section.

4 5 6

3

2

1

See Pedestal Interior, Electrical section.

2258-00-100

General image shown for parts reference only.

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

Page 29

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Unit Exterior – Rear View - Oil Line

Item

Part Description

Part Number

36 and 48 oz.

60 oz.

1

CONTROL BOX COVER

111528

2

SCREW #8-32X3/8 PAN HD PH

74141

3

OIL DELIVERY TUBE

111517

111518

4

SPOUT SET COLLAR

17891

5

8-32 X 1/4 PHIL PAN M/S

87314

6

26 IN SS TUBE

17900

7

HEATED OIL LINE BRACKET

111537

8

BUSHING, SNAP 1.125 IN

82221

9

TOP LID

17899

10

8-32 X 1/2 PHIL PAN M/S

47141

11

JUNCTION BOX BOTTOM

111536

12

JUNCTION BOX TOP

111535

13

BOTTOM JUNCTION BOX LID

17672

14

8-32X3/8 FL HD PH MS

20065

15

STRAIN RELIEF T&B 3302

89045

16

16W FOIL HEAT ELEMENT

17898EX

17

8-32 X 3/8 PAN HD PH M/S

12389

18

8-32 SERRATED FLANGE NUT

61151

19

3/4" EMT CONNECTOR

17892

20

PEDESTAL EXHAUST COVER

111539

21

PEDESTAL REAR COVER

111538

3

4, 5

6

Data Plate

8 1 2

7

2258-00-100

21

20

9

10

11

17, 18

19

15

12

13, 14

16

General image shown for parts reference only.

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

Page 30

gmpopcorn.com

Unit Exterior – Kettle Mount – Parts Breakdown

5

6

7

10

4

8

9

15, 16

14

2, 3

1

18

19

20

17

21

8

24

22*

23

*NOTE: Concave side of Large Spacer fits up

against bracket weld on Dump Bar Shaft.

12

11

13

See Unit Exterior,

Oil Line section.

2258-00-100

2297XE RH Dump Lever

RH Dump Handle shown for parts reference (see next page for Pass Thru Handle)

General images shown for parts reference only.

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

Page 31

gmpopcorn.com

Item

Part Description

Part Number

RH Units

LH Units

RH Pass Thru

LH Pass Thru

1

BOT KETTLE PIVOT MACHINED

106060

2

1/4-20x3/4 BUTTON HD SC

67927

3

HEX NUT 1/4-20 ESLOK

42361

4

ADJUSTING PLATE,WELD ASSY (includes Flat Plate, Agitator Seal, and Formed Bottom Plate)

82099

5

PLATE/FLAT

82328

6

AGITATOR SEAL

79437

7

FORMED BTM PLATE

83300

8

1/4-20 X 3/4 GRADE 5 BOLT

74520

9

FLAT WASHER 1/4 STAINLESS

87261

10

1/4-20 SERRATED LOCK NUT

46311

11

KETTLE REST BUMPER

83111

12

KETTLE REST (aluminum)

83110

13

1/4-20X3/4 LG HEX HD BOLT

13164

14

SPRING RETAINER ROD

82551

15

SET COLLAR 1/2ID X 7/8OD

47326

16

SET SCREW 1/4-20 X 3/16 (1 req’d. per collar)

47751

17

COLLAR

74661

18

5/16-18 X 1.25 SQ HD CP

40785

19

TORSION SPRING

74660

20

SPACER

74658

21

SPACER,LARGE (CUSTOMER SIDE)

74690

22

SPACER,LARGE (DUMP SIDE) - Concave side fits up against bracket weld on Dump Bar Shaft

74659

23

DUMP LEVER ASSY, RIGHT

82253

DUMP LEVER ASSY, LEFT

82276

24

PLASTIC HANDLE

57028

25

DUMP HANDLE RH PASS THRU

82685

DUMP HANDLE LH PASS THRU

82686

26

COUPLING DUMP LEVER

82688

27

SET SCREW 1/4-20 X 1/4

46610

Models w/Vertical

Pass Thru Handle

Dump Handle

For 60 oz. (PN 115076)

27

24

26

Models w/Pass

Thru Handle

2258-00-100

27

25

24

26

Models w/Vertical Handle

24

Dump Handle

For 36 and 48 oz. (PN 56116) For 60 oz. (PN 69873)

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

Page 32

gmpopcorn.com

Kettle Assembly (36, 48, and 60 oz.) – Parts Breakdown

15

16, 17

19

18

Cornado Kettle Complete

(36 oz. Kettle shown for general parts reference only)

Kettle Bottom/Junction Box View

21, 22

23

20

24

5

1

2, 3

4, 3

6

7

2149XES - 69550EX Kettle images

9

11

12

13

Agitator Drive Assembly

(includes Agitator, Packing Kit, Thrust Washer, and Shaft)

8

10

14

To Remove Kettle Lid:

Lift TAB slightly, rotate lid assembly to disengage raised hooks; then lift lid off. (Reverse steps to install lid.)

28

27

25

26

29

3, 29

1

2

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

Page 33

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Kettle Assembly (36, 48, and 60 oz.) – Parts List

Item

Part Description

Part Number

Right Hand Kettle

Left Hand Kettle

36 oz.

111608-01

48 oz.

111607-01

60 oz.

111606-01

36 oz.

111608L-01

48 oz.

111607L-01

60 oz.

111606L-01

1

KETTLE LID ASSEMBLY

83044

83046

83320

83044

83046

83320

2

KNOB LID LIFT

47120

3

8-32 X 1/2 PHIL PN M/S SS

42226

4

COUNTER WEIGHT

83114

5

CORNADO KETTLE BOTTOM (see Element View for additional parts breakdown)

69551EX

69554EX

83318EX

69551EX

69554EX

83318EX 6

KETTLE DUMP CHUTE ASSY

82636

82830

83304

82636

82830

83304

7

KETTLE LEAD ASSY

111601

111596

111601

111596

8

AGITATOR DRIVE ASSY (includes Agitator, Packing Kit, Thrust Washer, and Agitator Shaft)

83348

83346

83348

83346

9

AGITATOR WELDMENT

83347

83344

83313

83347

83344

83313

10

CORNADO PACKING KIT (includes Packing Cage and Packing Cord)

69305

11

PACKING CAGE CORNADO AGIT

69302

12

PACKING CORD 7 IN

69304-7

13

THRUST WASHER

67852

14

AGITATOR SHAFT

83287

15

KETTLE BASE PLATE

83258

83264

83302

83258

83264

83302

16

ACORN NUT 1/4-20

49068

17

FLAT WASHER 1/4 STAINLESS

87261

18

THERMOSTAT COVER

83267

19

8-32 x 5/16 SLOTTED HEX

49594

20

HEX JAM NUT

82137

21

TOP PIVOT CASTING MACHINED

83281

22

HEX BOLT 3/8-16 X 3/4 (fastens Pivot Casting)

20051

23

10-32 X 1 UNSL NON-IND

49376

24

8-32 X 1/2 SLOTTED H W H (Screw)

49379

25

JUNCTION BOX TERMINAL SIDE

83261

26

JUNCTION BOX LEAD SIDE

83260

55313

83260

55313

27

8-32 SERRATED FLANGE NUT

61151

28

TERMINAL BLOCK KETTLE

41129

29

8-32 HEX M/S NUT

74149

For Model variations or country specific part variations, reference the Model Variations section on the Order Spare Parts page.

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

Page 34

gmpopcorn.com

36 oz. Kettle Bottom – Element View

Item

Part Description

Part Number

111608-01

1

36 oz. CORNADO KETTLE (weldment)

69552

2

KETTLE GASKET

83279

3

TRANSFER PLATE

69337

4

SPACER

83278

5

BEARING, KETTLE HUB (2 required)

82079

6

TOP BEARING

83252

7

ELEMENT SHIM (optional, only used as needed)

68787

8

ELEMENT CLAMP (8 required)

68778

9

1/4-20 X 1.25 SET SCREW

69140

10

1/4-20 RND TOP SQ NUT

69156

11

HEX NUT 1/4-20

74133

12

NUT RETAINER

50190

13

1/4-20 X 1.75 SET SCREW

76444

14

HEAT ELEMENT,1350W

82386

15

TUBULAR ELEMENT, 1800W

48650EX

16

TUBULAR ELEMENT, 1250W

48801EX

17

RETAINING NUT (fastens lead to kettle bottom)

41434

11

12

9

10

Hand tighten snug; then tighten one full turn. DO NOT use a torque wrench.

Form a tab UP on flat of nut to retain nut position.

Element Bracket

Heat Transfer Plate

14

15

16

1

5*, 6

2

8

7

3

*Bottom Bearing

shown.

4

69553EX Element View

69550EX Clamping Views

Form a tab UP on

flat of nut to retain

nut position.

Form tab DOWN.

11

13

10

12

36 oz. Kettle Element View

(General image shown for parts reference only.)

17

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

Page 35

gmpopcorn.com

48 oz. Kettle Bottom – Element View

Item

Part Description

Part Number

111607-01

1

48 oz. CORNADO KETTLE (weldment)

69555

2

KETTLE GASKET

83280

3

TRANSFER PLATE

69336

4

SPACER

83278

5

BEARING, KETTLE HUB (2 required)

82079

6

TOP BEARING

83252

7

ELEMENT SHIM (optional, only used as needed)

68787

8

ELEMENT CLAMP (8 required)

68780

9

1/4-20 X 1.25 SET SCREW

69140

10

1/4-20 RND TOP SQ NUT

69156

11

HEX NUT 1/4-20

74133

12

NUT RETAINER

50190

13

1/4-20 X 1.75 SET SCREW

76444

14

HEAT ELEMENT, 2700W

82598

15

TUBULAR ELEMENT, 1500W

48800EX

16

TUBULAR ELEMENT, 1050W

48651EX

17

RETAINING NUT (fastens lead to kettle bottom)

41434

11

12

9

10

Hand tighten snug; then tighten one full turn. DO NOT use a torque wrench.

Form a tab UP on flat of nut to retain nut position.

Element Bracket

Heat Transfer Plate

14

15

16 1 5*, 6

2

8

7

3

*Bottom Bearing

shown.

4

69553EX Element View

69550EX Clamping Views

Form a tab UP on

flat of nut to retain

nut position.

Form tab DOWN.

11

13

10

12

17

48 oz. Kettle Element View

(General image shown for parts reference only.)

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

Page 36

gmpopcorn.com

60 oz. Kettle Bottom – Element View

Item

Part Description

Part Number

111606-01

1

60 oz. CORNADO KETTLE (weldment)

83301

2

KETTLE GASKET

83315

3

TRANSFER PLATE

68053

4

SPACER

83278

5

BEARING, KETTLE HUB (2 required)

82079

6

TOP BEARING

83252

7

ELEMENT SHIM (optional, only used as needed)

68787

8

ELEMENT CLAMP (medium clamp; 6 required)

83317

9

ELEMENT CLAMP (large clamp; 8 required)

83316

10

ELEMENT CLAMP (small clamp; 2 required)

83349

11

1/4-20 X 1.25 SET SCREW

69140

12

1/4-20 RND TOP SQ NUT

69156

13

HEX NUT 1/4-20

74133

14

NUT RETAINER

50190

15

1/4-20 X 1.75 SET SCREW

76444

16

TUBULAR ELEMENT 2300W

68052EX

17

TUBULAR ELEMENT 1850W

68051EX

18

500W HEAT ELEMENT

68106EX

19

TUBULAR ELEMENT, 1050W

48651EX

20

RETAINING NUT (fastens lead to kettle bottom)

41434

60 oz. Element View

69550EX Clamping Views

Form a tab UP on

flat of nut to retain

nut position.

Form tab DOWN.

13

15

12

14

13

14

11

12

Hand tighten snug; then tighten one full turn. DO NOT use a torque wrench.

Form a tab UP on flat of nut to retain nut position.

Element Bracket

Heat Transfer Plate

9

10

16

17

18

19

20

1

5*, 6

2

8

7

3

*Bottom Bearing

shown.

4

60 oz. Kettle Element View

(General image shown for parts reference only.)

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

Page 37

gmpopcorn.com

Pedestal Interior – Motor and Shaft

Item

Part Description

Part Number

36 oz.

48 and 60 oz.

1

LOWER AGIT DR SHAFT ASSY (complete assy. includes coupler, set screw, spring, shaft and pin)

82496

2

SET SCREW 1/4-28 X 1/4

82067

3

COUPLING, DRIVE MOTOR

82287

4

SPRING OUTPUT COUPLING

74013

5

SPRING PIN 3/16 X 7/8

82421

6

LOWER AGIT DRIVE SHAFT

82447

7

8-32 X 1 PH PAN M/S S.S. (ground fastener)

12219

8

#8 INT. TOOTH L/W 410SS (ground fastener)

12132

9

HEX NUT #8-32 STAINLESS (ground fastener)

89129

10

1/4-20 X 1 1/4 PH PAN MS

51030

11

WASHER 1/4 INTERNAL TOOTH

12383

12

FLAT WASHER 1/4 STAINLESS

87261

13

1/4-20 SERRATED LOCK NUT

46311

14

KETTLE DRIVE MOTOR (includes motor spacers)

82413R

15

BAFFLE

111909

16

8-32 X 3/8 PAN HD PH M/S

12389

17

8-32 SERRATED FLANGE NUT

61151

18

POWER SUPPLY CORD ASSEMBLY

82943

19

STRAIN RELIEF T&B 3304

82227

20

WIRE HARNESS,OIL PUMP

41499

21

STRAIN RELIEF T&B 3302

89045

22

EXHST BLOWER PLUG & CORD

47199

5

6

4 3 2

1

14

15, 16, 17

10, 11, 12, 13

7, 8, 9

See, Pedestal Interior Electrical section.

Power Cord Strain Relief

Oil Power Cord Strain Relief

*CAUTION: If supply cord

is damaged, it must be replaced by Gold Medal Products Co., its service agent, or similarly qualified persons in order to avoid a hazard.

2258-00-100 Pedestal

36oz Shaft View

22

18*

20

19

21

General image shown for parts reference only.

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

Page 38

gmpopcorn.com

Pedestal Interior – Electrical – Parts Breakdown

Pedestal Interior (Front Cover Removed) - General images shown for parts reference only.

2258-00-100

20

21

22

18

12, 13

19

25

26

23

24

12, 13

9

14

15

16

17

10, 11

3

*Jumper set to

Fahrenheit

*Jumper set

to Celsius

2 4 3

5

6 7 8

1

*Temp/Cycle Count Board displays

either Fahrenheit (°F) or Celsius (°C) depending on jumper placement (qualified service personnel set jumper placement when board is installed).

27

28, 12, 13

12, 13

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

Page 39

gmpopcorn.com

Pedestal Interior – Electrical – Parts List

Item

Part Description

Part Number

All Models

1

PEDESTAL FRONT COVER

111540

2

COUNT AND TEMP DISPLAY

55185

3

FEMALE CONNECTOR

111628

4

SWITCH OIL PUMP

41031

5

EXHST BLOWER PLUG & CORD

47199

6

EXHAUST BLOWER

48037

7

FINGER GUARD

47200

8

10-24 X 5/8 PHIL PAN M/S

76000

9

MALE CONNECTOR W/FLANGES

111627

10

3-48X1/2 SS SLOTTED SCREW

111804

11

3-48 SS HEX NUT

111805

12

8-32 X 3/8 PAN HD PH M/S

12389

13

8-32 SERRATED FLANGE NUT

61151

14

TRANSFORMER, 12/24 VOLT

39459

15

5 POSITION WIRE CONNECTOR

55245

16

3 POSITION WIRE CONNECTOR

55244

17

2 POSITION WIRE CONNECTOR

55621

18

CAPACITOR 5 MFD

82217

19

CAPACITOR STRAP

48301

20

CIRCUIT BREAKER COVER

55253

21

CB WARNING LABEL

55252

22

SCREW #8-32X1/4 PAN HD PH

74142

23

CIRCUIT BREAKER BRACKET

114176

24

CB INFORMATION LABEL

55251

25

CIRCUIT BREAKER, 13A

55225

26

6-32 X 3/16 PH PAN M/S

38149

27

IEC CONTACTOR 3 POLE 25A

55564

28

DIN RAIL

48604

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

Page 40

gmpopcorn.com

Control Box/Control Panel – Parts Breakdown

15

Control Box Interior View

Control Panel Exterior View

12, 13

14

9

10

11

2

4

6

3

1

5

7

8

7 2 5

8

16

3

6

2258-00-100

12

General images shown for parts reference only.

General image shown, reference Electronic Control section for control board view.

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

Page 41

gmpopcorn.com

Control Box/Control Panel – Parts List

Item

Part Description

Part Number

RH Units

LH Units

1

CONTROL BOX (includes supports; order cover and label separately)

111519

111520

2

SWITCH, LIGHTED ROCKER GR

42798

3

SWITCH, ROCKER DPDT

48615

4

5 POSITION WIRE CONNECTOR

55245

5

SWITCH OIL PUMP

41031

6

PILOT LIGHT, GREEN

48660EX

7

PILOT LIGHT, AMBER

55039EX

8

CIRCUIT BREAKER, 10A

48659

9

4IN DIN RAIL

111532

10

RELAY, DPDT

89086

11

RELAY SOCKET 2 POLE

89085

12

6-32 X 1/2 PHIL PAN M/S

42237

13

6-32 GRIP NUT ZINC PLATED

47517

14

SCREW #8-32X3/8 PAN HD PH

74141

15

TEMPERATURE CONTROL

41001

16

LABEL, CORNADO CONTROLS

111526

Safety Labels

Item

Part Description

Part Number

All Models

1

UNIVERSAL ELEC LABEL

105007

2

WARNING LABEL

68805

3

KETTLE LABEL

83047

4

CB INFORMATION LABEL

55251

5

CB WARNING LABEL

55252

6

MAIN GROUND LABEL

42375

7

WARNING LABEL CORD

68720

Unit Interior Label

7

Power Cord Label

4

Unit Exterior Labels

1 2 3 5 6

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

Page 42

gmpopcorn.com

Accessories

Item

Part Description

Part Number

36 oz.

48 oz.

60 oz.

1

36OZ CORN CUP ASSEMBLY

67905-36

48OZ CORN CUP ASSEMBLY

17757-48

60OZ CORN CUP ASSEMBLY

17757-60

2

FLAVACOL CONT WELDMENT

41752

3

PERF JET SCOOP REGULAR RH

2072

4

MEASURE 2 TBS, 29.6cc (Flavacol measure)

47681

5

MEASURE 1/4 CUP (Flavacol measure)

47169

1

5

2

3

4

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

Page 43

gmpopcorn.com

Wiring Diagram

For wiring information, please reference

the Wiring Diagram shipped with the popper.

36, 48 & 60 oz. Export Model Series 2149, 2258, and 2297 Cornados (100, 110, and 101, 111)

Page 44

gmpopcorn.com

WARRANTY

© 2018 – The text, descriptions, graphics, layout, and other material in this publication are the exclusive property of Gold Medal Products Co. and shall not be used, copied, reproduced, or published in any fashion, including website display, without its express written consent.

WARRANTY

Gold Medal Products Co. warrants to the original purchaser each item of its manufacture to be free of defects in workmanship and material under normal use and service. Gold Medal Products Co.’s obligation under this warranty is limited solely to repairing or replacing parts, f.o.b. Cincinnati, Ohio, which in its judgment are defective in workmanship or material and which are returned, freight prepaid, to its Cincinnati, Ohio factory or other designated point. Except for “Perishable Parts” on specific machines, the above warranty applies for a period of two (2) years from the date of original sale to the original purchaser of equipment when recommended operating instructions and maintenance procedures have been followed. These are packed with the machine. Parts warranty is two (2) years, labor is six (6) months.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED, AND OF ALL OTHER OBLIGATIONS OR LIABILITIES ON OUR PART, INCLUDING THE IMPLIED WARRANTY OF MERCHANTABILITY. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HEREOF. In no event shall Gold Medal Products Co. be liable for special, incidental or consequential damages. No claim under this warranty will be honored if the equipment covered has been misused, neglected, damaged in transit, or has been tampered with or changed in any way. No claim under this warranty shall be honored in the event that components in the unit at the time of the claim were not supplied or approved by Gold Medal Products Co. This warranty is effective only when electrical items have been properly attached to city utility lines only at proper voltages. This warranty is not transferable without the written consent of Gold Medal Products Co.

The term “Original Purchaser” as used in this warranty shall be deemed to mean that person, firm, association, or corporation who was billed by the GOLD MEDAL PRODUCTS CO., or their authorized distributor for the equipment.

THIS WARRANTY HAS NO EFFECT AND IS VOID UNLESS THE ORIGINAL PURCHASER FIRST CALLS GOLD MEDAL PRODUCTS CO. AT 1-800-543-0862 TO DISCUSS WITH OUR SERVICE REPRESENTATIVE THE EQUIPMENT PROBLEM, AND, IF NECESSARY, FOR INSTRUCTIONS CONCERNING THE REPAIR OR REPLACEMENT OF PARTS.

NOTE: This equipment is manufactured and sold for commercial use only.

10700 Medallion Drive, Cincinnati, Ohio 45241-4807 USA

gmpopcorn.com

Phone: (800) 543-0862 Fax: (800) 542-1496 (513) 769-7676 (513) 769-8500