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.

Pop-O-Gold
For models made after 12/04
5
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
6
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.

Pop-O-Gold
For models made after 12/04
7
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.

Pop-O-Gold
For models made after 12/04
8
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

Pop-O-Gold
For models made after 12/04
9
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.