Goldmedal Pop-O-Gold User manual

Part No. 41490
Revised: November 2007
Pop-O-Gold
32oz. Popcorn Machine
Instruction Manual
For Domestic Models Manufactured after December 2004
Cincinnati, OH 45241-4807 USA

Pop-O-Gold
For models made after 12/04
2
Table of Contents
I. Safety Precautions………………………………………………………………………. 3
II. Installation Instructions………………………………………………………………... 4
III. Operating Instructions………………………………………………………………… 5-6
Setting the Amount of Popping Oil
Model 2257, March 2003 – current……………….………………………. 7
Preventing and Troubleshooting Oil Delivery Issues………………………….…8-10
IV. Cleaning Instructions……………………………………………………...…………… 11
V. Maintenance Instructions……………………………………………………………….12
Electronic Temperature Control……………………………………………13
Troubleshooting………………………………………………………….…..14
Ordering Spare Parts………………………………………………………..15
VI. System Parts Location Guide………………………………………………….………..16
Figure 1: Dome Assembly………..……………………………………….………17-18
Figure 2: Cabinet Base and Doors……………………………………….………19-21
Figure 3: Cabinet Interior–Ceiling………………………………………...…….22-23
Figure 4: Motor Plate Assembly………………………………………..………..24-25
Figure 5: Kettle Shell Components…………………………………………….….26
Figure 6: Kettle Bottom…………………………………………………………….27
Figure 7: Lid and Agitator Assembly……………………………………………28-29
Figure 8: Kettle Lead-In Cord Assembly…………………………………………30
VII. Electrical Schematic…………………………………………………………………….31
VIII. Warranty………………………………………………………………………………...32

Pop-O-Gold
For models made after 12/04
3
SAFETY PRECAUTIONS

Pop-O-Gold
For models made after 12/04
4
INSTALLATION INSTRUCTIONS
Note: Make sure to have all employees watch the Popper Set-Up Video, and read
instruction manual thoroughly, before operating this machine. The video is located inside
the corn bin, (Drawer in the base of the popper) along with the instruction manual.
CHECKING SHIPMENT
Unpack all cartons and check thoroughly for any damage that may have occurred during transit.
Damage claims should be filed immediately with the transportation company. Gold Medal is not
responsible for damage that occurs in transit.
Electrical Requirements
Domestic models only: 120v/208v or 120v/240v 60 Hz.
A 30 amp – 4 wire wall receptacle is shipped with each machine. This receptacle will accept the
attachment plug on the popper and must be used. Your electrician must furnish sufficient current for
proper operation of your machine. We recommend this popper be on a dedicated and circuit
protected line. (note: The Pop-O-Gold “uses” both “hot to neutral” legs, 120v. The machine does not
“use” the 208v or 240v, “hot to hot” connection.
Domestic - 120/208V or 120/240V, 60 HZ
Note: Fire suppression components are in accordance with ANSUL R-102 specifications.
FINAL PREPARATIONS
The popcorn machine was adjusted, inspected, and tested before it left the factory. After
the machine has been installed, mount the kettle assembly in the hanger arms and plug
in the kettle lead-in cord. Tighten the ring on the kettle lead-in plug.
Connect the clear oil line from the pump to the aluminum line from the popper with the
supplied hose clamp. Connect the 6 pin connector from the popper to the receptacle on
the oil pump. Both Bucket pump (2114) and Bag-in-a-Box pump (2257) have the same
receptacle.
The Bag-in-Box oil pumps are pre-calibrated before leaving the factory, however, should
the oil setting need to be adjusted – see page 7 of this manual. The proper amount of oil
for the 32oz. Pop-O-Gold is between 8oz. and 9.6oz.
To check for proper amount of oil, and assure oil is liquid, dispense a “shot” into the
measuring cup that is provided with the machine.

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For models made after 12/04
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OPERATING INSTRUCTIONS
CONTROLS AND THEIR FUNCTIONS
LIGHT SWITCH
Operates on all the lights, interior and dome, on your popcorn machine.
WARMER SWITCH
Operates the forced air popcorn crisping system.
KETTLE HEAT SWITCH
Operates the heating elements in the popping kettle.
KETTLE MOTOR AND EXHAUST SWITCH
Operates both the kettle agitator motor, and the exhaust blower. The exhaust blower is only required
when popping corn.
OIL SYSTEM MASTER SWITCH
Sends power to the oil pump. (Either the Bucket Pump or Bag-in-a-Box models) The warmer/blower
on the oil pump is activated, as well as the heated line kits (If provided / purchased separately). The
warmer/blower on the oil pump will keep coconut popping oil liquid if the doors on the base are kept
closed. It may be desirable to keep this switch on at night, if you have problems keeping the coconut
oil liquid. Coconut oil will congeal at temperatures below approximately 76º F [24º C].
“RED” OIL DISPENSE MOMENTARY SWITCH
When pushed, will dispense the pre-set amount of oil into the kettle.
YELLOW LIGHT & AUDIBLE SIGNAL (LOAD – DUMP)
Alerts the operator to:
1. Load the corn and oil or
2. Dump the popped corn from the kettle or
3. Turn off the kettle heat switch if they are done popping corn
PASS THRU SWITCHES (IF EQUIPPED)
Has double switches for the kettle heat, motor, and oil on the front side and the operator side of
popper.
FLEXI-POP SWITCH (IF EQUIPPED)
Changes energy to kettle for the load switch from 32 oz to 18 oz. It will automatically adjust the oil
amount on the 2257D model of oil pump. The Blue light & the Blue cup are for the 32 oz and the
Red are for the 18 oz.
SALT-SWEET SWITCH (IF EQUIPPED)
Changes the temperature setting to 50ºF lower for the sweet option.

Pop-O-Gold
For models made after 12/04
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POPPING CORN
1. Turn on all Switches.
2. When popping with coconut oil, be sure the oil is liquid before attempting to pop corn.
3. When the kettle is ready (about 5-8 minutes), the Yellow Light and Audible Signal will turn on. Lift
the kettle lid and pour in 32 oz. of corn (use the supplied corn cup) and 8 teaspoons (21 cc – use the
supplied salt scoop.) of Flavacol. Close lid.
4. Press the RED oil pump button. The proper amount of oil will dispense into the kettle. The light and
audible signal will turn off after approximately 30 seconds.
5. When the popcorn has completed popping, the light and audible signal will turn on. Dump the
popcorn.
NOTE: The Signal “To Dump” was factory set based upon our oil and popcorn. If the signal occurs
before or after the popping has stopped, the signal timing must be adjusted as described on p. 10.
(See the “Kettle Dump” adjustment potentiometer at the right side of the control board image.)
6. On the final kettle of corn, turn the “KETTLE HEAT” switch off, just as the lids are forced open by the
popping corn. This saves electricity, and helps eliminate excessive smoke/steam after you have
stopped popping.
REMEMBER:
If the Yellow Load - Dump light is turned on and the Signal is sounding one of the following actions
should be taken:
1. Load the corn and oil or
2. Dump the popped corn from the kettle or
3. Turn off the kettle heat switch if you are done popping corn
When you are finished popping, make sure “KETTLE HEAT” and “KETTLE MOTOR”
switches are turned “OFF”.
NEVER LEAVE THE HEAT ON WHEN YOU ARE NOT POPPING CORN.

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For models made after 12/04
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Setting the Amount of Popping Oil with a Gold Medal BIB
System
In March 2003, we introduced the model 2257 with the E-Z Set control.
Note: When connecting the bag-in-box system, you
must be sure to connect the bag connectors as shown
in the picture to the left.
The dead-leg connector
(With only one hose
connected to it) must be
installed on the to
p
box.
The Pass-thru connector
(With two hoses
connected to it) must be
installed on the bottom
box.
The Pass-thru connector
(With two hoses
connected to it) must be
installed on the bottom
box.
With this system, it is not necessary to set a timer. To adjust the oil amount, follow these instructions:
Holding the RED Oil Dispense push button (on the popper) down while turning on the Oil System Master
switch (on the popper) puts the unit in the program mode. The oil light (on the popper) will start to blink off
and on indicating that the timer is in the program mode.
When in the program mode press and release the oil Dispense switch to start the oil flowing. When
the correct amount of oil has been dispensed into the measuring cup push the oil Dispense switch
again to stop the oil flow. The oil amount can be “topped off” by pushing the oil Dispense switch
on/off as many times as needed to finalize the oil amount. Turning the Oil System Master switch off
and then back on puts the unit in the regular mode. The unit will now dispense the “programmed”
amount of oil when the oil Dispense switch is pushed. The oil light will light only when the oil pump is
on.
You will need to perform this procedure with the oil lines full of oil. Otherwise, you are setting both the
amount of oil that goes in the kettle and the amount of oil required to fill the lines. Just fill the lines using the
process above, then reset the amount as described above.
NOTES:
Model 2257D is has the capability of “remembering” two different settings for poppers with the “Salt/Sweet”
option or “Flexi-Pop option.
- For Salt/Sweet models, just put the switch in the “salt” position, and set the oil amount as described
above. Then put the switch in the “sweet” position and repeat the setting procedure. The pump will
remember both settings.
- For Flexi-Pop models, just put the “Load” switch in one position, 32oz. for example, then set the oil
amount. Then put the load switch in the other position, 18oz. for example. And repeat the setting procedure.
- Model 2457 is the heated line option for the 2257 pump.

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For models made after 12/04
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Preventing and Troubleshooting Oil Delivery Issues
It may occur at times that the Bag-In-Box oil pumping system does not deliver oil to the kettle, or delivers it
in incorrect amounts. This section is intended to list the most common causes of these problems, and the
procedures necessary to prevent and, if necessary, correct them.
Oil Temperature – Coconut oil becomes a solid at temperatures above the average room temperature.
For this reason, it is necessary to ensure that the oil has been permitted to come to working temperature
before attempting to pump it through the system. If the machine has not been used for several days, the oil
master switch should be turned on the night before it is expected that the machine will be used. For
machines which are in daily use, even if not round the clock, leave the oil master switch on at all times,
and keep the base cabinet doors closed, to prevent the oil from becoming solid.
Bag-In-Box Mounting – Because the bag’s dispensing connector is offset toward the bottom of the box, to
permit free oil flow and complete emptying of the oil from the bag, the box should never be mounted upside
down. Most boxes supplied will be clearly marked as to which side should be up during dispensing. (Note
that in some cases the box is intended to be stored with one side up, but to be turned and used in
dispensing with the other side up.) Be sure to double check to ensure that the box is mounted in the correct
dispensing orientation.
You may encounter boxes with no clear markings to indicate dispensing orientation. A reliable guide in this
case (and also for those boxes which are marked), is the direction that the top side flap of the corrugated
box is folded. When the box is properly mounted for dispensing, the top side flap will fold down from the top
edge of the box, so that if one were to attempt to separate the flap it would be necessary to pull up from the
bottom edge. See the illustrations below.
TOP
Front Side Fla
p
Top Side Flap
This edge is
seamless. The side
flap folds down
from this ed
g
e.
The bottom of the side
flap can be seen to be
open, not seamless,
TOP
Looking at the box from the
bottom, the front and rear side
flaps can be seen folded along
the side of the box toward the
middle, and the outer, top side
flap folded down to cover them.
NOTE
The Bag-In-Box oil pumping system is NOT
designed to function when the bag has
been removed from the box. Service
results in such a situation are
unpredictable. Do not attempt to operate
the system with a bag which has been
removed from the box.
Rear Side Flap

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For models made after 12/04
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Bag and Hose Connector Issues – There are two different types of dispensing nozzles employed on the
Bag-In-Box oils, as well as two different types of connectors installed on the oil pumping system hoses
which connect to the bag’s dispensing nozzles. The particular combination of connectors in your system will
determine the appropriate method for connecting the Bag-In-Box oil bag to the system hosing. These
combinations will be illustrated and explained in the following section.
Bag Dispensing Nozzle – Blue Insert Bag dispensing Nozzle – White Insert
Blue Insert Bag Nozzle with
Blue/White Hose Connector
1. With the blue collar on the hose
connector retracted toward
crosspiece, slide hose connector
shell onto bag nozzle.
2. Holding the bag nozzle behind
the flange, slide the blue collar
forward to lock the hose connector
onto the bag nozzle.
3. Connector shown with shell
correctly engaged and collar
forward in lock position.
White Insert Bag Nozzle with
Blue/White Hose Connector
4. Place fingers behind flange and
use thumbs to slide the crosspiece
forward into the nozzle. Oil flow is
initiated.
1. With the blue collar on the hose
connector retracted toward
crosspiece, slide hose connector
shell onto bag nozzle.
2. Holding the bag connector, slide
the blue collar forward to lock the
hose connector onto the bag
nozzle.

Pop-O-Gold
For models made after 12/04
10
Blue Insert Bag Nozzle
with Gray Hose Connector
2. With the hose connector in
place, place fingers behind flange
on connector and press plunger
forward to lock.
1. Grasp the bag nozzle and slide
the gray hose connector on from
the side.
White Insert Bag Nozzle
3. Connector shown with shell
correctly engaged and collar
forward in lock position. Oil flow
commences. Do not slide
crosspiece forward.
with Gray Hose Connector
3. Connector shown with shell
correctly engaged and plunger
forward in lock position. Oil flow
commences.
1. Grasp the bag nozzle and slide
the gray hose connector on from
the side.
2. With the hose connector in
place, place fingers behind flange
on connector and press plunger
forward to lock.
NOTE:If the oil does not flow after engaging plunger on gray hose
connector, or if the crosspiece is inadvertently pushed forward when
using the blue hose connector with the white insert nozzle, the nozzle
center slider insert will be left pushed back into the bag, as shown
above left.
To correct this, place fingers behind nozzle as shown above
right. You will feel the center slider protruding slightly into the bag.
Holding the nozzle body from the front, press the slider from the back
side of the nozzle until it snaps outward into its correct position. The
nozzle is now read
y
to be used with a blue hose connector.
3. Connector shown with shell
correctly engaged and plunger
forward in lock position. Since the
White Insert Bag Nozzle is not
designed to work with the insert
pressed forward, this configuration
may or may not work. If it does
not, remove the gray hose
connector and order the blue hose
connector from Gold Medal.

Pop-O-Gold
For models made after 12/04
11
CLEANING INSTRUCTIONS
DAILY:
Clean the Kettle
1. As you pop corn, wipe the kettle with a clean cloth. It is easy to keep the outside clean when the
kettle is warm and the oil is not baked on. CAUTION: The hot kettle will cause burns if you touch
it with your hand. Allow the kettle to cool for at least 1 hour before attempting to clean.
2. Every night, mix a gallon of Heat’n Kleen solution (2 tablespoons per gallon of water). Turn on
the kettle heat. When the water starts to boil, turn off the heat and let it work overnight.
3. The next morning, dump the solution into a bucket and wipe the inside of the kettle with a cloth.
4. A CLEAN-IN-PLACE hook is located behind the operator side kettle support arm. Just tilt the
kettle to the dump position, and swing the hook into position to hold the kettle in the dumped
position. This feature will safely enable you to clean the kettle, with out removing it from the
machine.
Clean the Popcorn Machine
1. Wipe the stainless steel parts with a clean cloth and cleaner designed for stainless steel. Do not
use oven cleaners, as they will damage parts of the machine.
2. Remove and clean the 1st stage mesh filter. Cover removal not required. Clean filter in warm
soapy water.
3. Ammonia cleaners will damage the plastic doors. Use only non-ammonia cleaners, such as
Gold Medal’s – Watchdog Glass Cleaner – item number 2588.
WEEKLY:
Clean the filters in the popcorn machine
1. Loosen the 2 screws (no tools required), on the filter cover plate on the ceiling inside the popper.
Remove the cover, the bag and mesh filters. Clean the bag filter and the mesh filters in warm soapy
water. Let dry overnight and reinstall.
CAUTION: Keeping the filters clean is important to let the exhaust system “do its job”.
2. Check the condition of the clear oil lines and tighten or replace as required.
Item No. Part No. Description .
1 41250 Metal mesh filter
2 41169 Oil Mist Bag Filter
3 82015 Filter Pack (Includes all three filters)

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For models made after 12/04
12
MAINTENANCE INSTRUCTIONS

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For models made after 12/04
13
ELECTRONIC TEMPERATURE CONTROL
Operation
The control jumper is factory set to 440°F, which stops power to the kettle when the thermocouple reaches
440 degrees. On the Pop-O-Gold machine, this is also the ideal point to dump the popped corn out of the
kettle. On the first start-up this is also the ideal time to load the corn and oil. Therefore if the kettle heat
switch is turned 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 off the kettle heat switch if you are done popping corn
Adjustment of Electronic Control
The Pop-O-Gold has an electronic kettle control with 2 thermocouples, one for control and one for limit.
There are no mechanical thermostats in this kettle.
There are (4) factory adjustments on the control:
1. Control temperature – do not adjust.
2. Signal to dump – If you want the signal to dump to be a little sooner or later you can adjust the
potentiometer marked “kettle dump”. CW is sooner, CCW is later.
3. The patented overshoot circuit is tuned for the kettle, do not adjust this potentiometer.
4. The audible signal to dump has three options; full volume, half volume, no sound (just the yellow
light). Adjustments are by jumper positions. We ship with the signal at full volume.
This is the “Kettle Dump”
adjustment, and is factory
set to signal when the
kettle is ready to dump.
Turning CW will signal
sooner, CCW will signal
later. If you need to adjust,
make very small
adjustments.
Hot Lead is at L1,
Neutral lead at L2.
The control temperature is set
at 440°F. DO NOT ADJUST
Remove this
jumper for
no sound
Remove this
jumper for
lower volume
The overshoot
is set at -0%
(Full CCW).
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.

Pop-O-Gold
For models made after 12/04
14
TROUBLESHOOTING
LONG POPPING CYCLES
If your pop cycle is longer than 4 minutes, it can be the result of several things:
A. LOW VOLTAGE - If the machine is operated on low voltage, this could cause the kettle not to reach
the proper operating temperature. Voltage for each leg, with kettle turned on, must be at least 110v.
B. INADEQUATE SUPPLY LINES - 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.
C. INFERIOR CORN - 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 DOES NOT HEAT
Before you go any further, make sure the kettle lead-in cord is plugged in, and the kettle shunt trip
breaker is not tripped. (See figure 4.11 on page 21) The shunt trip breaker may trip during transit, if the
machine has been handled in a rough manner. If the breaker is re-set - then trips again - contact a service
technician for inspection/repair before going further.
A. KETTLE HEAT SWITCH - Check the voltage to and from the “KETTLE HEAT” switch, and if the
switch is defective replace it.
B. CONTROL - A defective thermocouple lead will cause the kettle not to heat. Check for good
connections from the kettle to the control.
C. MAIN RELAY. (See Figure 4, item 4.6)
MOTOR WILL NOT TURN AGITATOR
WARNING! If the kettle agitator shaft is not rotating, DO NOT pop corn. Adjust the clearance
between the kettle bottom and the stir blade to 1/32” (use a dime). Loosen the set screw in the collars
above and below the crossbar and adjust the agitator shaft as necessary. Then re-tighten the set screws
in the collars.
OIL PUMP DOES NOT DELIVER OIL TO KETTLE
If the pump is operating but oil is not dispensed, the oil may be solid in the oil lines.
If the pump is not operating at all, see the pump manual for instructions.

Pop-O-Gold
For models made after 12/04
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ORDERING SPARE PARTS
1. Identify the needed part by checking it against the photos, illustrations, and/or the parts list.
2. When ordering, please include part number, part name, and quantity needed.
3. Please include the machine’s model name, serial number, and date of manufacture (located on the
machine nameplate) with your order.
4. Address all parts orders to:
Parts Department
Gold Medal Products Co.
10700 Medallion Drive
Cincinnati, Ohio 45241-4807
or, place orders at:
[phone]
[phone]
Fax: [phone]
E-mail: [email protected]
Web Page: www.gmpopcorn.com

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For models made after 12/04
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Where To Find Parts
For Base parts
see pages: 16-17
For Kettle parts
see pages: 22-27
For Cabinet
Interior Ceiling
parts see pages:
19-20
For Cabinet and
Base parts see
pages: 16-20
For Interior Dome
parts see pages:
14-15
For Motor Plate
components see
pages: 21-22
Parts Location Guide

Pop-O-Gold
For models made after 12/04
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Dome Assembly
1a.1
–
Dome
Assembly, Complete
1a.7
–
Light Tube
Holde
r
1a.4 – FS-25 Starter
1a.5 – Light Ballast
1a.6
–
Sign Glass
with Graphics
1a.3
–
Light Tube
Holder for Starter
1a.2 – Molded Plug
Figure 1a – Dome Assembly, Fluorescent Light
Item Ref. Part No. Description
1a.1 41511 Dome Assembly, Complete
1a.2 47726 Molded Plug
1a.3 41021 Light Tube Holder for Starter
1a.4 41508 FS-25 Starter
1a.5 41509 Light Ballast
1a.6 41506 Sign Glass with Graphics
1a.7 41020 Light Tube Holder
Dome Assembly, Fluorescent Light (Figure 1a)

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For models made after 12/04
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1b.6
–
LED Sign
Assembly
1b.7
–
Sign
Brackets, 2 ea.
1b.3
–
Power Supply
Bracket Assembly
1b.2
–
12 Volt
Power Supply
1b.1
–
Molded Plug 1b.4
–
Dome
Assembly, Complete
1b.5
–
Clear Sign
Cover (Included
with 67524
)
Figure 1b – Dome Assembly, LED/Neon Light
Item Ref. Part No. Description
1b.1 47726 Molded Plug
1b.2 55231 12 Volt Power Supply
1b.3 55233 Power Supply Bracket Assembly
1b.4 48560 Dome Assembly, Complete
1b.5 67448 Clear Sign Cover (Included with 67524)
1b.6 67524 LED Sign Assembly
1b.7 67488 Sign Brackets, 2 ea.
Dome Assembly, LED/Neon Light (Figure 1b)

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For models made after 12/04
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Cabinet Breakdown
Figure 2a – Cabinet & Base
Figure 2b – Upper Cabinet Doors
2.19 - Wire Harness
for Oil Pump
2.2 - Plexiglas
Drop Panel
2.17 - Casters.
Swivel, 2 ea.
2.3 – Old Maid Pan
Forced Air Popcorn
Crisping System
(beneath Corn Pan
– See Fig. 2e)
2.1 – Corn Pan
2.4 - Power Supply
Cord / 10-4 Wire / 30
Amp Cord Cap
Hardware for
Doors (See Fig. 2f)
Corn Bin Retainer &
Drawer Slide Assys.
(See Fig. 2d, item 2.11)
2.5 - Plexiglas
Doors (Doors DO
NOT come
predrilled for
hardware)
2.18 - Casters,
Swivel, Locking, 2 ea.

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For models made after 12/04
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2.7
–
RH Cabinet
Drawer Slide
2.6
–
LH Cabinet
Drawer Slide
Figure 2c – Cabinet Drawer Slides
2.9
–
RH Corn Bin
Retainer Slide
2.11
–
Corn Bin
Retainer & Slide
Assy. (Comprising
Corn Bin Retainer
and Both Slides)
2.10
–
Corn Bin
Retainer
2.8
–
LH Corn Bin
Retainer Slide
Figure 2d – Corn Bin Retainer & Drawer Slides