Cretors DIGITAL DIPLOMAT 48 User manual

DI48/60-M-A/E-O
3243 North California Avenue, Chicago, IL 60618
DIGITAL DIPLOMAT 48 and 60 oz
POPCORN MACHINE
OPERATION MANUAL
120/208, 120/ 240 Volt,
Single and Three Phase, 60 Hz
230 Volt,
Single Phase and Three Phase, 50 Hz
400 Volt, 3N∼
Three Phase, 50 Hz
Included in this manual:
*One Pop Option
*Salt/Sugar Option
*Ventless Hood Option
*Ansul Option
READ and UNDERSTAND these operating, and safety
instructions before operating this popcorn machine
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TABLE OF CONTENTS
I. Safety Alert Symbol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
II. Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
III. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
IV. Purpose of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
V. Product Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
VI. Principles of Popcorn Machine Operation. . . . . . . . . . . . . . . . 4
VII. Control Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
VIII. Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
IX. Sanitation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
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I. SAFETY ALERT SYMBOL
The symbol shown below is used to call your attention to instructions concerning your personal
safety and the safety of others. Watch this symbol. It points out important safety precautions. It
means ATTENTION! Become Alert! Your personal safety is involved! Read the message that
follows and be alert to the risk of personal injury or death.
II. SAFETY FIRST
The information in this manual is essential for the safe installation and
operation of your Cretors popcorn machine. The manual must be read and
understood before installing, or operating this equipment, or equivalent
training must be provided.
"The employer shall instruct each employee in the recognition and avoidance
of unsafe conditions, as well as, the regulations applicable to his work
environment to control or eliminate any hazards or other exposure to illness
or injury". Ref.: 29 CFR 1926.20 (b)(4)(a)(2)
It is understood that safety rules within individual companies vary. If a
conflict exists between the safety procedures contained in this manual and
the rules of a using company, the more stringent rule should take precedence.
III. INTRODUCTION
This manual is filled with time-saving and money-saving information regarding your Cretors
popcorn machine. There is nothing more important than the safety aids and warnings that are
throughout this document. The Safety Alert Symbol is used to identify topics of primary safety
concern wherever they appear. Furthermore, a separate section has been included which deals
exclusively with operation and accident prevention.
If, after reviewing this manual, anything is unclear or technical problems are encountered, contact
the distributor from whom you purchased your machine for assistance. If there are any additional
questions, feel free to contact our Customer Service Department at the address and/or phone
number listed on the last page of this manual. Always have the model and serial number of your
machine available to assist in obtaining the correct information.
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IV. PURPOSE OF MANUAL
This instruction manual is intended to familiarize owners with the operation, and safety
procedures associated with your Cretors popcorn machine.
It is important that this manual be kept available to operating personnel.
A person who has not read and understood all operating and safety instructions is
not qualified to operate the machine.
V. PRODUCT IDENTIFICATION
CRETORS POPCORN MACHINE DIPLOMAT MODELS:
DI48___-____-__
DI60___-____-__
VI. PRINCIPLES OF POPCORN MACHINE OPERATION
Theory and Observations of Popcorn Machine Operation
A. The efficient production of popcorn requires the presence of popcorn kernels, heat, and oil.
The purpose of the oil is to distribute the heat throughout kernels evenly and quickly. If the
heat is not distributed evenly and quickly, the kernels may burn instead of pop.
B. In order to pop corn in oil, the kettle, oil and parts near the heating elements are necessarily
and unavoidably heated to temperatures high enough to pop popcorn. The temperature
controlled using a thermostat located inside the kettle to maintain the kettle at an operating
temperature of approximately:
410°F (210°C) for salted corn
375°F (188°C) for sugar corn
Contact with these surfaces will burn and scald you. Do not touch the
kettle, oil or parts in direct vicinity of the heating elements.
C. The kettle is provided with an agitator to assist in the quick and even distribution of heat
throughout the kernels.
The oil is heated to high temperatures in a kettle provided with electric heating
elements to reach proper popping temperature. An operator is required in the vicinity
of the kettle only when handling corn or dumping popped corn from the kettle.
Neither of these operations requires direct contact with the kettle. Direct contact with
the hot oil, kettle, or heating elements could result in serious burns or scalds. Keep
away from the kettle whenever possible. Use the handle when dumping the kettle,
and use the provided cups when necessary to measure corn, oil and salt.
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D. As the popcorn pops, it will push the lid open and discharge into the cabinet. When the
corn finishes popping, the corn remaining in the kettle can be removed by holding the kettle
handle in your right hand and rotating down in a clockwise direction to dump the kettle.
E. Your Diplomat model Cretors popcorn popper is equipped for a pump, which, when
properly adjusted, automatically delivers the proper amount of oil to the popping kettle.
F. A cornditioner is provided consists of a blower, heating element and thermostat. The
cornditioner circulates hot air through the corn stored in the popcorn case to keep the
product fresh and crisp.
G. A two-stage filter system traps odor and smoke produced by popping corn. This is replaced
when the Ventless Hood option is supplied. The ventless hood is integrated into the
popping circuit, as such the popper will not operate if the hood is not functioning!
H. One Pop Option only allows the kettle to pop one batch of corn at a time and then shut
down. The One Pop Option makes it impossible to leave a kettle heat turned on.
I. With the One Pop Option, the kettle heat switch is turned on; however, the kettle will not
begin to heat until the One Pop button is pressed. When the One Pop button is pressed the
green indicator light will go on, the kettle will begin to heat, and the kettle heat indicator
light will turn on. The kettle will then heat until the temperature control at the end of the
popping cycle. When the temperature control opens at the end of the popping cycle the
kettle heat indicator light goes out and the heat turns off. The kettle will not begin to heat
again until the kettle has cooled and the One Pop button is pressed.
J. If the machine is equipped with an oil pump, and the pump switch is turned on, pressing
the One Pop button will begin the pumping cycle, as well as, the heat cycle. (When cleaning
the kettle and oil is not wanted, turn off the oil switch and the oil pump will not run.)
K. If the machine is equipped with the Salt/Sugar option, the operator moves the toggle switch
to either the salt or sugar position for desired corn type. Kettle temperature and oil amount
will change automatically. In the salt position, the thermostat will turn off at the sugar
temperature but a timer will allow the heat to remain on until it reaches the salt
temperature.
L. With the Digital Temperature Control, the operator can adjust the set point of the popping
cycle on the controller. There is no thermostat in side the kettle. Temperature of kettle will
also be displayed. To adjust, see service manual.
M. If the machine is supplied with the Ventless Hood, refer to the Giles instruction manual for
more details on the operation and components. The popcorn popper will not operate if the
Giles hood is not fully functional, as part of the UL / EPA testing requires.
N. If the machine is supplied with the ansul option, in the case of a fire, fire suppression liquid
will be discharged into the kettle and cabinet to put out the fire. Power to the circuits will
also be cut except the Giles hood. Ansul must be called to initiate the system at start up.
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VII. CONTROL SWITCHES
*KETTLE HEAT -Turns the kettle heat On/Off (see exhaust for ventless option)
AGITATOR -Turns the stirrer blade motor On/Off.
*EXHAUST -Turns exhaust blower On/Off.
*Ventless Hood option -The exhaust switch must be turned on for the kettle to heat.
CORNDITIONER -Turns the cornditioner blower and heat On/Off.
LIGHTS -Turns interior lights On/Off.
OIL -Provides power to the oil pump.
DELIVERY -Initiates the pump cycle.
FUSE/CIRCUIT BREAKER -Provides protection to all circuits, except the kettle.
ROTARY SWITCH -Turns power On/Off to all circuits.
ONE POP -Turns the kettle heat on and initiates the pump cycle.
SALT/SUGAR -Sets the pump and kettle temperature to proper settings.
DIGITAL CONTROLLER -Displays and controls kettle temperature.
VIII. OPERATING INSTRUCTIONS
Do not attempt to operate your Cretors popcorn machine until you have read and
understood this manual. Failure to do so may result in serious injury or death.
Do not attempt to operate your Cretors popcorn machine unless the installation
instructions have been strictly adhered to. Failure to do so may result in serious injury
or death.
Operate your popcorn machine only if it is in sanitary condition (See SANITATION
INSTRUCTIONS). Failure to do so may result in illness to your customers.
Always turn the kettle switch off when not popping corn. Failure to do so will cause
oil to stain the kettle, possibly resulting in an unsanitary condition. It may also cause a
"flash" fire if oil is added to a kettle left unattended with the heat on, resulting in
serious burns or death.
If this machine is equipped with the Ansul option, an ansul representative must be
called out to activate the ansul system prior to use. Call 1.800.TO ANSUL for the
closest representative.
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To operate your Cretors popcorn popping machine:
1. Fill the corn drawer with corn on floor models.
2. Fill the salt box and hang it on the inside edge of the corn drawer.
3. Connect and adjust the pump as explained in the installation instructions. Preheat the
popping oil until liquid, if necessary.
4. Fill the corn measure with corn and the salt measure with the salt, and empty these into
the kettle. When making sugar corn, add the correct amount of sugar, rather than salt,
with the measure for corn.
WARNING! Always add corn to the kettle before pressing the pressing the oil
delivery button or adding oil. Failure to do so may result in the oil being heated too
rapidly resulting in a fire.
Avoid contact with the kettle. Contact with a hot popping kettle may result in serious
burns or scalds.
5. Close the kettle lid by pulling the kettle cover knob down.
6. If equipped, move Salt/Sugar switch to desired mode.
7. Turn on the agitator, the exhaust fan, and then turn on the kettle heat and press the oil
delivery button. For a ventless hood machine, the exhaust must be turned on and be
functional for the popper heat to function. When the exhaust switch is turned on, an
audible alarm will sound for a few seconds, clicking will be heard, and then the
machine will be operational. If the Giles hood will not run, the popping circuit will
be disabled until the problem is resolved.
8. If machine is with the One Pop option, press the One Pop button to begin the popping
cycle, and oil delivery.
WARNING! After the first popping the kettle is hot. Avoid contact with the kettle
when adding corn or salt. Failure to do so may result in serious burns or scalds.
Measuring cups have been provided to accurately measure the proper amounts of popcorn, salt and
oil. The correct amount for each popping is:
SALTED CORN
VOLUMETRIC MEASURE
Kettle Size Corn Oil Salt
48 oz. 16 oz. 4 tsp.
48 oz. 1420 ml 473 ml 20 ml
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60 oz. 20 oz. 5 tsp.
60 oz. 1775 ml 591 ml 20 ml
SUGAR CORN
VOLUMETRIC MEASURE
Kettle Size Corn Oil Sugar
48 oz. 32 oz. 11 oz. 22 oz.
850 ml 945 ml 325 ml 650 ml
60 oz. 48 oz. 15 oz. 29 oz.
850 ml 1420 ml 445 ml 860 ml
9. As the corn pops, it will push the lid open. When the lid has moved about one and one-
half inches, it will open completely, allowing the corn to discharge from the kettle.
When the corn finishes popping, when there are four seconds between pops dump the
kettle by pulling the large black handle down as far as it will go. Then when the pan is
empty, return the handle to its upright position.
Avoid contact with the kettle when dumping popped corn. Failure to do so may result
in serious burns or scalds.
10. Repeat steps 4-9 as desired, adding corn to the corn drawer and salt to the salt box as
necessary.
11. When the oil container is empty, replace with new full container of oil. See Pump
instruction manual.
NOTE:The ideal time for maximum volume (corn expansion) is between 2-3/4 to 3-1/2
minutes from the time the corn is placed into the kettle until the time it is dumped. Check
the popping time after several popping cycles. The pilot light should turn off approximately
10-20 seconds before the corn finishes popping. If this is not the case, please refer to the
Trouble Shooting Section in your Service Manual.
IX. SANITATION INSTRUCTIONS
Be certain the machine is turned off and power is unplugged before sanitizing this
machine unless a specific cleaning procedure requires power to the machine. Failure
to do so could result in injury or death.
Do not clean heated surfaces until they have been given sufficient time to cool. Failure
to do so may result in serious burns or scalds.
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A. Popping Kettle
1. The Cretors kettle is designed to be cleaned in place. There is no need to remove the
kettle to clean.
Do not immerse an assembled kettle in water. This will damage the electrical
components and my cause short circuits resulting in electrical shock hazard if power is
applied.
2. Do not use steel wool or other similar abrasives to clean the nickel plated kettles, as they
will ruin the kettle by removing the nickel plating. Stainless steel kettles can be cleaned
aggressively.
3. Do not attempt to clean the kettle with power connected unless you are boiling the CKC
cleaning compound to clean the inside of the kettle. Follow the instructions in step 6.
Do not attempt to clean a hot kettle. Failure to do so may result in serious burns or
scalds.
Do not throw ice into a hot kettle. Doing so can cause damage to the pan and
invalidate the warranty.
4. The kettle has a polished nickel finish or is a polished stainless steel finish and is very
easy to clean if oil is not allowed to burn. After the final popping, the best practice is to
wait until the oil just begins to solidify, then take a cotton towel or absorbent rag and
wipe the kettle. Once the oil is allowed to completely solidify, it can become more
difficult to remove. We recommend coconut oil for your Cretors popper; it will not stick
or burn as easily as other oils
5. A thorough cleaning every week with CKC cleaning compound is recommended. This
will prevent the accumulation of carbon on the bottom and internal sides of the kettle.
When boiling the CKC cleaning compound in the kettle, do not fill the kettle with more
than ¾” high of water inside the kettle. If the kettle has been overheated or oils that
tend to carbonize are used the normal cleaning procedures may not suffice. Increase
frequency as needed.
Cretors has developed a cleaning kit for your Diplomat machine. The kit is sold separately
under P/N 10831. If you need more information, please feel free to contact your local
distributor or call Cretors at 1-800-228-1885.
6. Cretors Outside Kettle Cleaner COC should be used periodically to remove popping oil
that may become baked on to the outside of the kettle.
7. The kettle agitator assembly should be removed weekly for thorough cleaning. The
stirrer blade is disassembled by removing the spring pin that goes through the top of the
stirrer blade. Lift off the stirrer blade.
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8. Clean all parts thoroughly, making sure to use CKC. Do not use any harsh abrasives or
cleaning materials. Clean the interior of the kettle every week with "CKC" cleaning
compound. This will prevent the accumulation of carbon on the bottom and internal
sides of the kettle. When using "CKC" cleaning compound in the kettle, do not fill
the kettle with more than 3/4" high of water inside the kettle. Heat the water to
boiling and turn off the kettle heat, don't boil the kettle dry. If the kettle has been
overheated or oils that tend to carbonize are used, the normal cleaning procedures
may not suffice. Increase frequency as needed.
9. There are two new Cretors cleaners. Carbon OFF in the blue can is to be used with no
heat and the red can would require the kettle to be heated. Read the directions on the
cans.
10. Reassemble in reverse order, following the directions given.
B. Cabinet
1. Remove and empty the waste clean-out drawer daily or whenever it is full. Under
heavy use this may need to be done more often.
Failure to empty the drawer and clean cabinet may result in a fire hazard due to
restricted air flow.
2. The cabinet glass and cabinet base can be cleaned with any good grade glass or
household cleaner suitable for glass and plastic surfaces. The inside of the cabinet can
be cleaned with the same cleaner as the outside, if it is the type that has a cleaning agent
to cut the oil remaining from the popping operation, and it is acceptable for food contact
surfaces. Do not soak unit with water. Avoid wetting of inside of electrical enclosure.
3. The doors can be cleaned with Cretors’ Plastic Polish. This product is specially
formulated to clean plastic doors. Do not use cleaners that have ammonia or alcohol.
The use of these cleaners will cause the doors to become brittle and crack.
4. Counter model Diplomats require the installation of 4” legs, which are included with
this unit. The use of the 4” legs is to conform to food sanitation regulations.
5. The popper case bottom of the 48”, 60” and 72” cabinets should be removed at least
weekly to thoroughly clean the air chamber beneath. Empty the scraps in the hot air
well by removing the clean-out drawer from under the popper case bottom and sliding
it under the hot air well. Pull out the clean-out slide and the scrap will fall into the scrap
drawer. Dispose of the products found in the popper case bottom, and replace the
clean-out slide and the clean-out drawer.
6. Grease filters should be checked and cleaned weekly. They can be washed in sink with
hot soapy water or can be run through a dishwasher. Charcoal should be replaced when
the holder is shook and the charcoal is no longer free to move
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7. Ventless hood filters need to be cleaned and replaced regularly, see manual for
recommended schedule and procedures. Care and caution needs to be taken when
cleaning filters as to not damage them, especially the electrostatic filter
This appliance shall not be cleaned with a water jet.
This manual is filled with time-saving and money-saving information regarding your Cretors
popcorn popper. There is nothing, however, more important than the safety aids and warnings
found throughout this document.
If you have any questions regarding the operation or cleaning of your Cretors popcorn popper,
contact your local distributor. Should you have any difficulties or are unable to reach them, feel
free to contact the Customer Service Department at C. Cretors and Company.
Additional copies of this manual can be obtained from C. Cretors and Company at the address
listed below. Please provide model and serial number when requesting additional copies of this
manual. There will be a nominal charge for additional copies.
Cretors guarantees this machine to be free of defects in parts, materials and workmanship for two
years. Please take this time to fill out the factory registration card and return it to the factory to
activate your warranty. If you have any questions concerning the Cretors' warranty, please contact
your local distributor or the Customer Service Department at C. Cretors and Company.
C. CRETORS AND COMPANY
3243 N. CALIFORNIA AVENUE
CHICAGO, IL 60618
PHONE [phone], FAX [phone]
WEB SITE: http://www.cretors.com Email: [email protected]
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