Part No. 69922
Revised May 2002
DISCOVERY
Instruction Manual
Model #2556
Cincinnati, OH 45241-4807 USA
www.gmpopcorn.com
SAFETY PRECAUTIONS
DISCOVERY
INSTALLATION INSTRUCTIONS
Inspection of Shipment:
Unpack the shipping container and thoroughly inspect the machine for any damage that may have occurred
during transit. Notify the freight carrier immediately in order to file a damage claim.
Setup:
Your new Discovery Popcorn Machine is completely assembled and tested at the factory.
Remove all packing material and tape before starting operation.
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 Discovery “uses” both “hot to neutral” legs, 120v. The machine does not “use” the
208v or 240v, “hot to hot” connection.
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.
If supplied with automatic oil delivery system:
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 or 2114EX) and Bag-in-a-Box
pump 2257H or 2257HX) have the same receptacle.
Follow the instructions provided in the oil pump manual to set the oil delivery amount.
The proper amount of oil for the 32oz. Discovery is between 8oz. to 9.6oz.
To check for proper amount of oil, and assure oil is liquid, dispense a “shot” into a
measuring cup.
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MODEL 2556
DISCOVERY
OPERATING INSTRUCTIONS
CONTROLS AND THEIR FUNCTIONS
LIGHT SWITCH
Operates on all the lights, interior and dome, on your popcorn machine.
WARMER SWITCH
Operates the warmer in the corn storage area, keeps popped corn warm.
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 (If supplied)
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. 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(If supplied)
When pushed, will dispense the predetermined amount of oil into the kettle.
SALT/SWEET SWITCH (If supplied)
Adjust the kettle temperature for salt or sugar based popcorn.
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
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MODEL 2556
DISCOVERY
POPPING CORN
1. Turn on all Switches.
2. When popping with coconut oil, be sure the oil is liquid. Dispense oil into a measuring cup first then
3.
4.
5.
6.
use that oil for the first popping cycle.
When the kettle is ready (about 5-8 minutes), the Light and Audible Signal turn on. Lift the kettle lid
and pour in 32 oz. of corn (use the supplied corn cup) and 8 teaspoons (21 cc) of Flavacol. Close lid.
Press the RED oil pump button (if supplied). The proper amount of oil is pumped into the kettle. The
Light and Signal will turn off.
When the popcorn has completed popping, the Light and Signal will turn on. Dump the Popcorn.
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 smoke and odor after you have stopped
popping.
REMEMBER:
If the kettle heat switch 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.
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MODEL 2556
DISCOVERY
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.
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 in 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 help you clean the kettle.
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. Ammonia cleaners will damage the plastic doors. Use only non-ammonia cleaners.
WEEKLY:
Clean the filters in the popcorn machine
1. Loosen the screw on the filter cover plate on the ceiling inside the popper. Remove the cover and mesh
filters. Clean 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.
1
Part No.
Description
41250
Metal mesh filter
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MODEL 2556
DISCOVERY
MAINTENANCE INSTRUCTIONS
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MODEL 2556
DISCOVERY
TROUBLESHOOTING
LONG POPPING CYCLES
If your pop cycle is longer than 4 minutes, it can be the result of several things:
A. HEATING ELEMENT - One of the heating elements in the kettle may be burned out. This would
result in the kettle never reaching the proper operating temperature.
B. 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.
C. 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.
D. 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 circuit breakers are
not tripped. Make sure all electrical connections are tight.
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
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 retighten 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 see the pump manual for instructions.
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MODEL 2556
DISCOVERY
TROUBLESHOOTING
REPLACING BROKEN GLASS
Should you accidentally break a panel of glass, it can be replaced very easily without disassembling the
popper.
1. Remove all loose pieces of glass.
2. Unscrew the glass retaining strips.
3. Remove all rigid glass channels from around the glass to be replaced. Set it aside as it must be
reused.
4. Carefully remove the rest of broken glass.
5. Apply decals to the new glass panel.
6. Slide rigid glass channels over the exposed sides and bottom. Maneuver the new glass into
position.
7. Replace glass retaining strips using the same screws you removed earlier.
Glass Size: (Front) 31 1/16” X 32 3 /16 " X 1 /8 "
(Sides) 23 15 /16" x 33 3 /16" x 1 /8"
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MODEL 2556
DISCOVERY
ELECTRONIC TEMPERATURE CONTROL
This section describes the Electronic Temperature Control on your 32oz. Discovery. The temperature of the
popcorn kettle is controlled by an Electronic Control. Mechanical high limit thermostats are still used as a
limit control. This model is also equipped with a pulsing buzzer and light that signal when the kettle heat
switch is on but the kettle is at or over the temperature set point.
Operation
The control is factory set to 412F – 415F which stops power to the kettle when the thermocouple reaches
412F – 415F. On the Discovery 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
If you would like to have the buzzer sound sooner or later than the factory setting, adjust the temperature
setting as follows:
1. To sound the buzzer sooner, lower the temperature setting. A change of 3 to 6 seconds can be
achieved with a change in temperature of 5 to 10 degrees.
2. To sound the buzzer later, raise the temperature setting.
The Electronic Control is located under the dome facing the operator on the left side. A calibrated dial is
located on the control for this purpose.
Adjustment of Buzzer Sound Level
If you would like to adjust the buzzer volume, turn the baffle on the buzzer.
1. If the kettle does not heat and the buzzer sounds continuously, then one of the following has happened:
a. The kettle plug is not tightened completely to the receptacle
b. The thermocouple wire is loose or broken.
2. If the kettle heats but the popping cycle is very long, check for a defective high limit thermostat. (buzzer
operates normally)
3. If the kettle is popping normally but the buzzer does not sound, check for a defective buzzer.
4. Caution: If the kettle pops too quickly, and the buzzer does not sound, do not continue popping
corn. Check for a loose thermocouple in the kettle. It is also possible the thermocouple leads are
“switched” from the correct polarity. (See note 2 below)
Either situation will result in the control to “ask” for more heat and the kettle will operate on the high limit
thermostats.
Notes:
1. Do not adjust the (3) potentiometers on the electronic control. If adjusted, the performance will be erratic
and could result in an over temperature condition. The only adjustment is described on page 1.
2. Thermocouple wire consists of (2) different wires made of different materials that are color-coded have a
polarity. It is important that red (-) is connected to red (-), and yellow (+) is connected to yellow (+), at
the lead-in plug, the receptacle, and at the electronic control. Note that the red lead is magnetic if you
have trouble determining which is which. If switched, the control will not operate.
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MODEL 2556
DISCOVERY
ORDER SPARE PARTS
1.
2.
3.
4.
Identify the worn or broken part by checking it with the illustrations and parts list.
When ordering parts, include part number, part name, and quantity required.
Include you model name and machine serial number (found on nameplate) with your order.
Address orders to:
Parts Department
Gold Medal Products Co.
10700 Medallion Drive
Cincinnati, Ohio 45241-4807
or, place orders at:
(800) 543-0862
(513) 769-7676
Fax: (513) 769-8500
E-mail: info@gmpopcorn.com
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MODEL 2556
DISCOVERY
HOW CHUTE DOOR WORKS
When filling bags of popcorn, take the chute door and turn it around so the front of the door is facing the
popcorn machine. Place the chute door back into the door guides.
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MODEL 2556
DISCOVERY
CABINET PART LIST
Item No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Part No.
41351
41352
41349
41350
41190
68896
82986
69914
40276
32112
47026
69801
41635
41013
50013
41941
41833
41618
41380
41432
Description
Female Long Right
Female Long Left
Male Short Left
Male Short Right
Side Glass
Door
Bag Filler Chute
Chute Door
Old Maid Pan
Lead In Cord
Strain Relief
Drop Panel With Chute (68895 Plastic Drop Panel)
Front Glass
Door Knob
Magnet
Hanger Arm Assembly
Shock Absorber Pin
Clean In Place Latch (Knob is 12319)
Spur Gear
Gear Block
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MODEL 2556
DISCOVERY
CABINET ASSEMBLY
14
15
1
2
3
4
5
6
13
12
7
11
8
9
10
14
MODEL 2556
DISCOVERY
CABINET ASSEMBLY
20
19
16
17
18
15
MODEL 2556
DISCOVERY
ELECTRICAL PARTS LIST
Item No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Part No.
41015
46081
48018
48664
47047
48547
48545
48547
61154
42798
48301
41449
47364
41516E
Description
Exhaust Blower, 115 V
Relay
Exhaust Blower, 120 V
Electronic Temperature Control
Lamp Holder
Lens (for Indicator Light)
Bulb (for Indicator Light)
Housing (for Indicator Light)
Buzzer
Switches
Motor Capacitor
Drive Motor
Circuit Breaker
Kettle Receptacle
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MODEL 2556
DISCOVERY
ELECTRICAL ASSEMBLY
1
2
3
4
5
17
MODEL 2556
DISCOVERY
ELECTRICAL ASSEMBLY
12
11
Control Panel
Without
Automatic Oil
Delivery, With
Optional
Salt/Sweet
Control.
7
9
8
6
10
9
10
13
14
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MODEL 2556
DISCOVERY
KETTLE PARTS LIST
Item No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
Part No.
41775
41867
41742
47976
41776
47749
41944
48977
12611
41400
41730
41380
47326
47977
47154
41936
41940
47751
41450
61108
41533
82231
41534
41536
47090
41491
82219
46311
41434
47999
41139
41597
41528
40963
48290
41129
40965
41296
61084
Description
Lid and Agitator Assembly
Oil Tube With Funnel *
Set Screw
Crossbar Fastener
Crossbar Assembly
Warning Label, Moisture
Front, Lid Assembly
Bushing
LH 5/16-18 Button Soc Head
Needle Bearing
Woodruff Key #3
Spur Gear
Set Collar (2 req)
Crossbar Fastener
Warning Label, Immerse
Rear, Kettle Lid
Agitator Weld Assembly
Set Screw
1/4-20 x 1/2" Countersink Screw
Thermostat Plate (Not Shown)
Kettle Welded Assembly
Heat Element, 1800 W
Heat Transfer Plate
Heat Element, 1000 W
Heat Element, 1050 W
Element Clamp
Thermostat (2)
Hex Grip Nut
Retaining Nut
Threaded Block (2)
Plastic Handle
Kettle to Shell Gasket (Not Shown)
Kettle Shell Assembly
Junction Box Gasket
Kettle Lead Assembly
Terminal Block
Junction Box Gasket
Junction Box Cover
Junction Box Assembly
* When Supplied with Oil Delivery System.
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MODEL 2556
DISCOVERY
KETTLE PARTS LIST
Item No.
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
Part No.
2027E
47953
82252-24
41252
48576
41253
82262
61074
61078
61075
61076
61077
61072
61073
62222
41748
48575
Description
Kettle Complete
Kettle Plug Assembly
9/16 Flexible Conduit
1/2" Connector Fitting
Thermocouple Wire Assembly
Conduit Bushing (2)
Brass Shim
Red Wire Assembly (.458 ft)
Black Wire Assembly (.458 ft)
Red Wire Assembly (.385 ft)
Green Wire Assembly (.646 ft)
Black Wire Assembly (.250 ft)
White Wire Assembly (.229ft)
White Wire Assembly (.677ft)
Red Wire Assembly (.229 ft)
Red Wire Assembly (.646 ft)
Wire Assembly (Does not include thermocouple)
20
MODEL 2556
DISCOVERY
KETTLE ASSEMBLY
21
MODEL 2556
DISCOVERY
KETTLE LEAD ASSEMBLY
22
MODEL 2556
DISCOVERY
KETTLE WIRING DIAGRAM
23
MODEL 2556
DISCOVERY
ELECTRICAL SCHEMATIC
24
MODEL 2556
DISCOVERY
WARRANTY
WE WARRANT to the original purchaser the Gold Medal equipment sold by us to
be free from defects in material or workmanship under normal use and service. Our
obligation under this warranty shall be limited to the repair or replacement of any
defective part for a period of six (6) months from the date of sale to the Original
Purchaser with regard to labor and two (2) years with regard to parts and does not
cover damage to the equipment caused by accident, alteration, improper use, voltage,
abuse, or failure to follow instructions.
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 MERCHANTIBILITY.
THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION
ON THE FACE HEREOF. We neither assume, nor authorize any other person
to assume for us, any other obligation or liability in connection with the sale of said
GOLD MEDAL equipment or any part thereof.
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 COMPANY, or their authorized distributor for the equipment.
THIS WARRANTY HAS NO EFFECT AND IS VOID UNLESS THE ORIGINAL
PURCHASER FIRST CALLS GOLD MEDAL PRODUCTS COMPANY AT 1-800543-0862 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.
GOLD MEDAL PRODUCTS COMPANY
10700 Medallion Drive
Cincinnati, Ohio 45241-4807 USA
25
MODEL 2556
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