Gold Medal Products 2258 Service Manual
© 2017 Gold Medal Products Co.
Part No. 110095
Instruction Manual
10700 Medallion Drive, Cincinnati, Ohio 45241-4807 USA
36, 48, & 60 oz. Cornados
Model Series 2149, 2258, and 2297 (100, 110, and 101, 111)
48 oz. Unit Shown
36, 48 & 60 oz.
Cornados Model Series 2149, 2258, and 2297 (100, 110, and 101, 111)
Page 2
gmpopcorn.com
Table of Contents
................................................................................................................................................................................. 1
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 ..................................................................................................................................... 8
Before You Plug In Machine .............................................................................................................................. 9
OPERATING INSTRUCTIONS ...................................................................................................................... 10
Controls and Their Functions ........................................................................................................................ 10
Program the E-Z Set Timer .................................................................................................................... 13
Popping Corn Instructions .................................................................................................................... 14
Care and Cleaning .................................................................................................................................... 16
Troubleshooting ....................................................................................................................................... 19
MAINTENANCE INSTRUCTIONS ................................................................................................................ 21
Removing Agitator Assembly and Shaft Maintenance ............................................................... 22
Replacing the Packing Cord on Kettle Hub...................................................................................... 23
Kettle and Drive Shaft Alignment ....................................................................................................... 24
Electronic Temperature Control......................................................................................................... 25
Operation ............................................................................................................................................................... 25
Control Description ........................................................................................................................................... 25
Programming the Electronic Control ......................................................................................................... 26
Error Conditions for the Electronic Control ............................................................................................ 27
Kettle Circuit Breaker ............................................................................................................................. 28
ORDERING SPARE PARTS ............................................................................................................................ 29
Unit Exterior – Front View – Filter .............................................................................................................. 30
Unit Exterior – Rear View - Oil Line ............................................................................................................ 31
Unit Exterior – Kettle Mount – Parts Breakdown .................................................................................. 32
Kettle Assembly (36, 48, and 60 oz.) – Parts Breakdown ................................................................... 34
36 oz. Kettle Bottom – Element View ......................................................................................................... 36
48 oz. Kettle Bottom – Element View ......................................................................................................... 37
60 oz. Kettle Bottom – Element View ......................................................................................................... 38
Pedestal Interior – Motor and Shaft ............................................................................................................ 39
Pedestal Interior – Electrical – Parts Breakdown .................................................................................. 40
Control Box/Control Panel – Parts Breakdown...................................................................................... 42
Safety Labels ......................................................................................................................................................... 43
Accessories ........................................................................................................................................................... 44
Wiring Diagram ........................................................................................................................................ 45
WARRANTY ...................................................................................................................................................... 46
36, 48 & 60 oz.
Cornados Model Series 2149, 2258, and 2297 (100, 110, and 101, 111)
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gmpopcorn.com
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.
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
To avoid burns, DO NOT touch the kettle or any heated surface.
DO NOT place or leave objects in contact with heated surfaces.
013_092414
WARNING
ALWAYS wear safety glasses when servicing this equipment.
010_010914
WARNING
No user serviceable parts inside. Refer servicing to qualified service
personnel.
011_051514
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.
Cornados Model Series 2149, 2258, and 2297 (100, 110, and 101, 111)
Page 4
gmpopcorn.com
SAFETY PRECAUTIONS (continued)
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.
012_010914
WARNING
This machine is NOT to be operated by minors.
007_010914
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.
Cornados Model Series 2149, 2258, and 2297 (100, 110, and 101, 111)
Page 5
gmpopcorn.com
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)
NEMA L14-30 Receptacle
(PN 82208)
NEMA 14-50 Receptacle
(PN 82920)
36, 48 & 60 oz.
Cornados Model Series 2149, 2258, and 2297 (100, 110, and 101, 111)
Page 6
gmpopcorn.com
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.
10.472”
0.878”
6.5”
5.221”
8.437”
16.03” (36 oz.)
18.03” (48 oz.)
19.51” (60 oz.)
12.072”
Ø.375 Dia.
Suggested Table
Hole Ø.500
5/16-18
Grade 5 Nut
2” Dia. X 1/8” Thick
Fender Washer
5/16-18
Grade 5 Bolt
Hole Locations
Counter Mounting Requirements
3/16” Minimum
Thickness for
Stainless Steel
over Wood
3/4” Minimum
for Wood or
Wood Plastic
Products
Remove front panel to access mounting holes
on bottom of pedestal interior.
8” minimum clearance required between
kettle and any combustible surface.
35.9”
(36 & 48 oz.)
38.9”
(60 oz.)
Oil Tube
Mounting Instructions
Pedestal Interior
(4) Mounting Locations
Secure Pedestal to table or counter.
36, 48 & 60 oz.
Cornados Model Series 2149, 2258, and 2297 (100, 110, and 101, 111)
Page 7
gmpopcorn.com
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).
36, 48 & 60 oz.
Cornados Model Series 2149, 2258, and 2297 (100, 110, and 101, 111)
Page 8
gmpopcorn.com
Electrical Requirements
The following power supply must be provided:
36 oz. Cornado - 2149 Series:
120/208 V~ or 120/240 V~, 5500 W, 60 Hz (watts for 2114 Series Bucket Pump included)
Unit designed to operate on single phase, 30 AMP, 4 wire supply, 120/208 or 120/240 V~
(2 Hot, 1 Neutral, 1 Ground). All electrical components in this machine are 120 V (motors,
heat elements, lights, etc.) and therefore require “Hot to Neutral” connection (NOT “Hot to
Hot”). A 30 AMP wall receptacle (NEMA L14-30) is supplied with the machine. The
receptacle will accept the attachment plug on the machine and must be used; reference the
Receptacle Wiring Diagram for NEMA L14-30 for receptacle installation instructions.
48 and 60 oz. Cornados - 2258 and 2297 Series:
120/208 V~ or 120/240 V~, 6350 W, 60 Hz (watts for 2114 Series Bucket Pump included)
Unit designed to operate on single phase, 50 AMP, 4 wire supply, 120/208 or 120/240 V~
(2 Hot, 1 Neutral, 1 Ground). All electrical components in this machine are 120 V (motors,
heat elements, lights, etc.) and therefore require “Hot to Neutral” connection (NOT “Hot to
Hot”). A 50 AMP wall receptacle (NEMA 14-50) is supplied with the machine. The
receptacle will accept the attachment plug on the machine and must be used; reference the
Receptacle Wiring Diagram for NEMA 14-50 for receptacle installation 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
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.
Receptacle Wiring Diagram for NEMA L14-30 (36 oz. Units)
A certified electrician must follow the IMPORTANT instructions below for installation of the
NEMA L14-30 Receptacle (Gold Medal Item No. 82208) provided with the unit.
If the receptacle is wired incorrectly, the heat elements/kettle and other electrical components could
be at 208 or 240 V potential instead of the needed 120 V, resulting in excessive temperatures in
the heat elements (i.e.: kettle) and possible fire, and/or damage to electrical components.
36, 48 & 60 oz.
Cornados Model Series 2149, 2258, and 2297 (100, 110, and 101, 111)
Page 9
gmpopcorn.com
Receptacle Wiring Diagram for NEMA 14-50 (48 and 60 oz. Units)
A certified electrician must follow the IMPORTANT instructions below for installation of the
NEMA 14-50 Receptacle (Gold Medal Item No. 82920) provided with the unit.
If the receptacle is wired incorrectly, the heat elements/kettle and other electrical components could
be at 208 or 240 V potential instead of the needed 120 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.
039_080614
NEMA 14-50 Receptacle (Front View)
NEMA 14-50 Receptacle (Back View)
Connect to Green
(Ground) Wire
Connect to Red
(Hot) Wire
Connect to Black
(Hot) Wire
Connect to White
(Neutral) Wire
NEMA L14-30 (Front View)
NEMA L14-30 (Back View)
Green Terminal
Connect to Green
(Ground) Wire
Brass Terminal
Connect to Red
(Hot) Wire
G
Y
Brass Terminal
Connect to Black
(Hot) Wire
Silver Terminal
Connect to White
(Neutral) Wire
X
W
36, 48 & 60 oz.
Cornados Model Series 2149, 2258, and 2297 (100, 110, and 101, 111)
Page 10
gmpopcorn.com
OPERATING INSTRUCTIONS
Controls and Their Functions
This section describes the unit controls (reference image at end of section, for control locations).
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.
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.
Auto Shut Off / Error Codes – The Load/Dump light is used to indicate Auto Shut Off (if
enabled) and Control Board Error Codes (qualified service personnel reference the
Electronic Temperature Control section of the Parts Manual for a full description of the
Auto Shut Off feature and for the Control Board Error Code descriptions).
36, 48 & 60 oz.
Cornados Model Series 2149, 2258, and 2297 (100, 110, and 101, 111)
Page 11
gmpopcorn.com
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.
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.
Cornados Model Series 2149, 2258, and 2297 (100, 110, and 101, 111)
Page 12
gmpopcorn.com
Control Panel View
Kettle Motor Switch
High/Low Kettle
Temperature Switch
Kettle Heat Switch
Circuit Breakers
Push Button
Switch
Temperature/Cycle Count
Digital
Display
Oil PB Switch
Load/Dump Indicator
Green Oil Light
Oil System
Master Switch
36, 48 & 60 oz.
Cornados Model Series 2149, 2258, and 2297 (100, 110, and 101, 111)
Page 13
gmpopcorn.com
Program the E-Z Set Timer
The oil dispense volume is set using the programmable timer on the electronic control board of
the popper, or by using the internal timer of 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 NO TIMER oil unit: 2 timer settings are available on the control board of the popper.
If using a DUAL TIMER oil unit: 2 internal timer settings are available on 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.
Cornados Model Series 2149, 2258, and 2297 (100, 110, and 101, 111)
Page 14
gmpopcorn.com
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!
Units with an auto kettle heat shut off feature will automatically shut kettle heat OFF after
15 min. of idle time (no popcorn popped). To restart heating, cycle the Heat Switch OFF-ON.
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