THERMA Big Dipper IS Series Installation instructions

Copyright ©2005 Big Dipper® Thermaco, Inc. • P.O.Box 2548 • Asheboro, NC 27204
Toll Free: [phone] • V: [phone] • F: [phone]
E-mail: [email protected] • Online: www.big-dipper.com
Installation & Operation Instructions
For Big Dipper Internal Strainer
(IS) Series Units
Big Dipper W-200-IS Servicing
A Pre-Rinse Sink
Big Dipper W-200-IS Servicing
A 3-Compartment Sink
®
Part# MNL-IS6000
* Please consult Thermaco, Inc. for specific models tested,
certified and/or listed by these organizations.
TC
**
*

©2005 Thermaco, Inc. All rights reserved • Patented/Patents Pending • Specifications subject to change without notice
Thermaco, Inc. • 646 Greensboro St. • Asheboro, N. C. 27204-2548 • Phone [phone] MNL-IS6000 2
®
Table of Contents
Table of Contents
IS System Overview 3
IS System Maintenance 4
IS Timer Operation 5
IS System Troubleshooting 6
How To Reverse IS System Operation 9
Plumbing Installation 10
Electrical Installation 12
IS System Wiring Diagram 13
IS Component Identification 14
IS Replacement Parts 15
Limited Warranty 16

©2005 Thermaco, Inc. All rights reserved • Patented/Patents Pending • Specifications subject to change without notice
Thermaco, Inc. • 646 Greensboro St. • Asheboro, N. C. 27204-2548 • Phone [phone] MNL-IS6000 3
®
Big Dipper® Internal Strainer (IS)
System Overview
Big Dipper® Internal Strainer (IS) System Overview
The Thermaco, Inc. Big Dipper® Automatic
Grease and Oils Removal System removes free-
floating grease & oils from kitchen drain water
flows. As most food service facility managers
already know, grease buildup within a buildingʼs
plumbing drainage system is a major cause of
problems due to drain line blockages. These
problems jeopardize normal operations as well
as create health and safety hazards within the
facility itself.
The proper installation of a Big Dipper System
can reduce or eliminate grease problems. Use
of the Big Dipper assures minimization and/or
elimination of costly sewer surcharges and fines
through efficient separation and removal of free-
floating grease & oils. In addition, the Big Dipper also helps reduce and/or eliminate pumping and
disposal costs associated with conventional grease traps or interceptors. The recovered grease
& oils are virtually water-free so local rendering companies or recyclers can collect it.
The Big Dipper system is an automatic, self-cleaning device. As greasy kitchen effluent drains
from kitchen fixtures, the unit traps the grease & oils. These separate from the effluent and rise
to the surface of the stainless steel tank. The unit automatically skims the trapped grease & oils
at least once per day and transfers the grease & oils to a collection container. A timer controls
the self cleaning operation, activating the skimming wheel at the proper time. Only the “cleaned”
water exits the unit and flows into the facility drain lines. The Big Dipper IS automatic systems
operate most efficiently when servicing single fixtures such as a 1 to 3-compartment sink or a
pre-rinse station.
The Big Dipper systemʼs stainless steel construction and compact footprint allows installation
directly at the source, where grease problems originate. The system design also allows easy
maintenance and operation by non-skilled personnel and requires only a minimal amount of daily
and weekly maintenance to maintain peak operating performance.
The Big Dipper system design allows for maximum installation flexibility. Reversing the system
operation is a simple as rotating the cover assembly of the unit.

©2005 Thermaco, Inc. All rights reserved • Patented/Patents Pending • Specifications subject to change without notice
Thermaco, Inc. • 646 Greensboro St. • Asheboro, N. C. 27204-2548 • Phone [phone] MNL-IS6000 4
®
Big Dipper® Internal Strainer (IS)
System Maintenance
*CAUTION! DISCONNECT POWER TO UNIT BEFORE CLEANING
to prevent damage to the unit and personal injury
*NOTE: Before energizing unit after cleaning, fill tank with water
to protect wipers and heater from damage
Big Dipper® Internal Strainer (IS) System Maintenance
Daily Maintenance:
(A) Empty the clear plastic grease/oils collection container (located beside the unit) once each
day (or more frequently, if necessary). The Big Dipper recovers grease and oil virtually water-free
so that they can be recycled. The collector container should be washed periodically.
(B) The internal strainer basket should be emptied into a garbage container by shaking briskly.
Wash the inside and outside surfaces of the strainer after emptying.
Weekly Maintenance:
(A) Check the collection trough and the wiper blades for any solids build-up. Wipe off any accu-
mulated deposits and assure that the wiper blades are clipped in place properly.
(B) Check the Timer to be sure it is set and operating correctly.
(C) Check the thickness of the grease layer at the top of the unit. There should be no appreciable
amount of grease or oil left in the tank immediately after the daily automatic skimming cycle. If
there is more than a 1/2” (13 mm) thick layer of grease after the skimming cycle, this indicates
a need to increase the skimming time. Increase the timer settings accordingly until a clean unit
appearance is obtained after the automatic skimming cycle (A simple guide is to increase the “on”
time by 30 minutes for each 1” (25 mm) of grease layer observed after the skimming cycle).
(D) The internal strainer basket in the unit is designed to remove coarse solids from the wastewater.
Over a period of time, sediment consisting of very fine particles may begin to accumulate on the
bottom of the unit. If this build-up is allowed to continue, it may eventually block the outlet baffle.
To prevent this from occurring, remove the lid and stir the bottom of the unit with a long handled
spatula while water is flowing to flush out the sediment. It may also be necessary to occasionally
drain and clean the unit thoroughly. A wet vac works well for this purpose.

©2005 Thermaco, Inc. All rights reserved • Patented/Patents Pending • Specifications subject to change without notice
Thermaco, Inc. • 646 Greensboro St. • Asheboro, N. C. 27204-2548 • Phone [phone] MNL-IS6000 5
®
TO SET TIMER:
1. Push on/off tabs on the outer
ring of timer inward into dial at
desired “ON” times. 1 Tab = 15
minutes. Minimum of one (1) tab
(15 minutes) recommended.
2. Turn dial CLOCKWISE
one or more complete revolutions
until the present time is aligned
with the time-of-day indicator
point.
3. Fill the unit with water by turning
on the sink water taps, then plug
the Big Dipper unit into grounded
electrical outlet.
Big Dipper® IS System Suggested Settings/Timer Operation
NOTE: IN CASE OF POWER FAILURE, RESET TIMER. (See Step 2 above).
After the plumbing installation is complete, the Big Dipper unit needs to be set for the proper
automatic self-cleaning operation for the facility. All Big Dipper IS models are equipped with a 24
Hour/96 Event time controller. This time controller is located under the lid of the motor housings
mounted on top of the Big Dipper lid (See Pages labeled “Electrical Connection Detail” sketches
of this location).
Depending upon the amount of accumulated grease and oils, the system may need to be reset
to operate more or less time to skim all separated grease and oils. This can be determined by
removing the top cover and observing the depth of the separated grease layer shortly after a
cleaning cycle is completed. This layer should not be more than 1/2” (13 mm) thick. If this layer
is consistently thicker, increase the operating times of the Big Dipper IS System by 30 minutes for
each additional 1” (25 mm) of grease not to exceed 2 hours in a complete run cycle. If required,
additional run cycles can be added throughout the day.
3
2
1
4
5
6
7
8
9
10
11
12
1
2
3
4
5
6
7
8
9
10
11
12
Time-of-day
indicator point Tabs punched in
indicate “ON”setting
Tabs NOT
punched
in indicate
“OFF”setting
Big Dipper® IS System
Suggested Settings/Timer Operation

©2005 Thermaco, Inc. All rights reserved • Patented/Patents Pending • Specifications subject to change without notice
Thermaco, Inc. • 646 Greensboro St. • Asheboro, N. C. 27204-2548 • Phone [phone] MNL-IS6000 6
®
Big Dipper® IS System Series
Troubleshooting
Big Dipper ®
unit overflows
If installation is
new
Make sure no
P-Traps are
installed on outlet
Make sure outlet
piping is not
reduced in size
Have as few 90˙
on outlet piping
as possible
Vent outlet pipe
Make sure flow rate
does not exceed
maximum flow rate as
listed on unit
Make sure internal
strainer basket is in
place and emptied
regularly
Check bottom for excessive
silt & solids buildup;
periodically disconnect
power, drain unit, and clean
out bottom
If installed into
existing facility
Check downstream for
proper rooting and/or
blockages
Make sure flow
control is in place. If
it is, install smaller
flow control orifice
assembly
All 90˚ bends
should be
sweeps

©2005 Thermaco, Inc. All rights reserved • Patented/Patents Pending • Specifications subject to change without notice
Thermaco, Inc. • 646 Greensboro St. • Asheboro, N. C. 27204-2548 • Phone [phone] MNL-IS6000 7
®
Big Dipper® IS System Series
Troubleshooting
No grease
collected in
container
Make sure power
in on and timer is
set correctly
"On" time should
be no less than 15
minutes per day
Timer should be
set to activate
during periods of
no or low flow
Open Wheel
Cover
Clean wiper blades
& collection trough
Make sure wiper
blades are properly
attached
Replace wiper
blades when
worn
Set timer to "On"
position
Make sure
skimmer wheel
turns
Check heater
assembly
The heater is on at all
times. If the water in the
tank is not warm, the
heater should be
replaced
If skimmer motor
does not
activate:
Check motor
coupling for
tightness
If coupling tightness is
assured, motor needs
to be replaced
If skimmer motor
activates:
Check tightness of safety
switch & assure switch is fully
depressed when lid is
fastened to unit

©2005 Thermaco, Inc. All rights reserved • Patented/Patents Pending • Specifications subject to change without notice
Thermaco, Inc. • 646 Greensboro St. • Asheboro, N. C. 27204-2548 • Phone [phone] MNL-IS6000 8
®
Big Dipper® IS System Series
Troubleshooting
Objectionable
odor
Make sure fats, oils
and grease are being
properly skimmed
from the unit
Check for excessive
silt/solids buildup in
bottom of unit
Empty internal strainer
basket and/or grease
collector more frequently
Check timer
settings
Increase in
operation period
or frequency
Wash down after
emptying
Make sure timer is set
to operate unit during
period of low or no
wastewater flow
Excessive water
observed in
grease collector
Make sure waste water
flow to unit does not
exceed rated flow
Check timer for
excessive "On" time
Check for blockages
downstream of unit

©2005 Thermaco, Inc. All rights reserved • Patented/Patents Pending • Specifications subject to change without notice
Thermaco, Inc. • 646 Greensboro St. • Asheboro, N. C. 27204-2548 • Phone [phone] MNL-IS6000 9
®
How To Reverse Big Dipper®
IS System Unit Operation
1) Unlatch the Unit lid. Pull the
side wings outward.
2) Lift the center module up off of
the unit, ensuring clearance for the
heater.
3) Rotate the center module
180º.
4) Lower the center module back
down on top of the unit. Move the
two side wings back into place & fas-
ten all six latches.
1) 2)
4)3)
Grease
Outlet
Heater
Power
Cord
How To Reverse Big Dipper® IS System Unit Operation
Clearance Required
To Remove Lid
*ALWAYS UNPLUG UNIT BEFORE REMOVING LID
*SYSTEM WILL NOT OPERATE UNLESS CENTER LID LATCHES ARE FASTENED
14.000”

©2005 Thermaco, Inc. All rights reserved • Patented/Patents Pending • Specifications subject to change without notice
Thermaco, Inc. • 646 Greensboro St. • Asheboro, N. C. 27204-2548 • Phone [phone] MNL-IS6000 10
®
Big Dipper® IS System
Plumbing Installation
Locating the Unit
To minimize grease build-up in piping, a Big Dip-
per system should be located as close as possible
to the fixture it is serving. The system should
be visible and easily accessible for maintenance
and inspection. Make sure that adequate room
is provided around the system to allow easy
removal of the grease collection container and
to access the electrical assembly. Make sure
the height above the Big Dipper access cover
is enough to properly service the system.
Inlet/Outlet Piping
The inlet and outlet piping connections require
flexible sleeve pipe couplings. Keep outlet pip-
ing as straight as possible. Use only “sweep”
connections. Do not reduce the pipe sizing
on the outlet piping. Do not install “P” trap on
outlet connection of system. (Note: The system
already has a internal gas trap)
Flow Controls
Big Dipper systems are equipped with an internal
flow control located inside the inlet end of the
system. Verify its location and placement prior
to connecting the inlet piping.
Fill Unit With Water Before Applying
Power
Big Dipper systems, equipped with an electric
heating element, MUST be filled with water before
energizing the power to the system. Failure to
do so may damage the electric heating element.
These elements will NOT be replaced under
Thermacoʼs Limited Warranty.
Venting the Outlet
An outlet vent or approved vacuum breaker of
at least 1/2 the diameter of the systemʼs outlet
connection must be present as close as pos-
sible to the Big Dipper outlet to prevent possible
siphonage problems. Failure to provide a vent
for the system voids Thermacoʼs Limited War-
ranty for the system.
For High Head Height Applications
Over Six (6) Feet (1.95 m)
For installations where there is head height of
greater than 6 feet (1.95 meters), Thermaco, Inc.
recommends installation of the optional VFCA
Vented Flow Control. Thermaco, Inc. recom-
mends an inlet vent on the piping connection
as close a possible to the inlet of the Big Dipper
and tied in to the facility vent. Please see the
following page for installation instructions.
Do Not Use With Food Grinders, Potato
Peelers or Waste Disposal Units
Installations where the internal solids strainer
basket is not used or where the system is
connected to a Waste Disposal Unit, Garbage
Grinder or potato peeler will void Thermacoʼs
Limited Warranty for the system.
Note: This equipment must be
installed to comply with all
applicable national, state, and local
plumbing codes for your area.
Installation should only be
performed by a qualified plumber.
Big Dipper® IS System Plumbing Installation

©2005 Thermaco, Inc. All rights reserved • Patented/Patents Pending • Specifications subject to change without notice
Thermaco, Inc. • 646 Greensboro St. • Asheboro, N. C. 27204-2548 • Phone [phone] MNL-IS6000 11
®
Big Dipper® IS System Plumbing Installation
(For Installations With Head Height Greater Than 6 feet (1.95m))
For installations where there is a significant amount of head height (More than 6
ft./1.95 m), Thermaco, Inc. recommends installation of the optional VFCA Vented
Flow Control module.
Big Dipper® Unit
Connect To Facility Vent
VFCA-20 Vented Flow Control for W-200-IS
VFCA-25 Vented Flow Control for W-250-IS
VFCA-35 Vented Flow Control for W-350-IS
VFCA-50 Vented Flow Control for W-500-IS
Connect To Facility Vent
Installations where head height is
greater than 6 feet (1.95 m)
Note: This equipment must be installed to comply with all
applicable national, state, and local plumbing codes for your area.
Installation should only be performed by a qualified plumber.
* Installation in high head height locations requires
removal of the Internal Flow Control (small rubber
cap under no-hub coupling over the Inlet).
Big Dipper® IS System
Plumbing Installation

©2005 Thermaco, Inc. All rights reserved • Patented/Patents Pending • Specifications subject to change without notice
Thermaco, Inc. • 646 Greensboro St. • Asheboro, N. C. 27204-2548 • Phone [phone] MNL-IS6000 12
®
Big Dipper® IS System
Electrical Installation
Big Dipper® IS System Electrical Installation
NOTE:
Time Clock is supplied with system.
This equipment must be installed to comply with all national, state
and local electrical codes for your area. Installation should only
be performed by a qualified electrician.
Electrical Panel
(NOT SUPPLIED)
115 VAC Circuit,
From Ground Fault
Circuit Breaker
(NOT SUPPLIED)
Socket Outlet
(NOT SUPPLIED)
Big Dipper Internal Strainer (IS) Models
Big Dipper Internal Strainer Series Models utilize one 24 hour time control-
ler. The timer is located under the hinged lid of the motor enclosure on top
of the lid of Big Dipper (See Timer Operation Instructions). The Big Dipper
should only be plugged into a properly grounded 3-prong 120 VAC outlet.
If possible, the power supply outlet for the Big Dipper should be connected
to an electrical circuit controlled by a ground fault circuit breaker.
This Big Dipper unit is shipped from the Factory wired for Simultaneous
Operation. This means the Heater and Motor operate at the same time
under timer control. Continuous Heater Operation is where the Heater is
active at all times. To switch to Continuous Heater Operation, switch the
RED WIRE on the THERMOSTAT with the BLACK WIRE. (Instructions are
on the wiring Diagram in the electrical enclosure.
Note: The Big Dipper unit will not operate when the lid is removed.
Timer
(Under Hinged Lid)
Big Dipper Electrical Requirements
4.5 Amps @ 120 VAC 60Hz (520 Watts)

©2005 Thermaco, Inc. All rights reserved • Patented/Patents Pending • Specifications subject to change without notice
Thermaco, Inc. • 646 Greensboro St. • Asheboro, N. C. 27204-2548 • Phone [phone] MNL-IS6000 13
®
Big Dipper® IS System
Wiring Diagram
NOTE:
220-240V Units (International Units) have the
following wire color changes:
On the POWER SUPPLY CORD:
The Black Wire becomes Brown
The White Wire becomes Blue
The Green Wire becomes Yellow/Green
Wiring Diagram For Big Dipper Models
W-150-IS Through W-500-IS
POWER SUPPLY CORD
MOTOR
INTERLOCK�
SWITCH
HEATER
THERMOSTAT
GREEN
BLACK
WHITE
BLACK
WHITE
WHITE
BLACK
RING TERMINAL TO�
GROUND STUD
BLACK
FULLY INSULATED�
QUICK CONNECT
FULLY INSULATED�
QUICK CONNECT
PIGGY-BACK�
CONNECTOR
FULLY INSULATED�
FEMALE CONNECTOR
BLACK
RED
WHITE
WHITE
WHITE
BLACK
BLACK
BLACK
TIMER
RED
1 2 3 4 5
UNIT IS SHIPPED FROM
THE FACTORY WIRED�
FOR SIMULTANEOUS
OPERATION. THIS MEANS
THE HEATER AND MOTOR
OPERATE AT THE SAME
TIME UNDER TIMER
CONTROL. CONTINUOUS
HEATER OPERATION IS
WHERE THE HEATER IS
ACTIVE AT ALL TIMES. TO
SWITCH TO CONTINUOUS
HEATER OPERATION,
SWITCH THE RED WIRE
ON THE THERMOSTAT
WITH THE BLACK WIRE.

©2005 Thermaco, Inc. All rights reserved • Patented/Patents Pending • Specifications subject to change without notice
Thermaco, Inc. • 646 Greensboro St. • Asheboro, N. C. 27204-2548 • Phone [phone] MNL-IS6000 14
®
Big Dipper® IS System
Component Identification
Hinged Skimming Wheel
Cover Motor/Electrical
Cover
Timer
Cover
Grease
Collector
Strainer Basket
Cover
Big Dipper Internal Strainer (IS) Lid Components (With Covers In Place)
Inlet Outlet
Wheel Wiper Assembly
Part #WWA-2
Skimming Wheel Assembly
Part #PDA-3
Wheel Drive Sprocket
Part #WDS-3
Big Dipper Internal Strainer (IS) Lid Components (With Wheel Cover Removed)
Wiper Blades (2)
Part #PB-3
Inlet Outlet
Flow Control
(Covering Inlet)
Safety Switch (Under Motor Cover)
Part #MSS-5
Big Dipper® IS System Component Identification

©2005 Thermaco, Inc. All rights reserved • Patented/Patents Pending • Specifications subject to change without notice
Thermaco, Inc. • 646 Greensboro St. • Asheboro, N. C. 27204-2548 • Phone [phone] MNL-IS6000 15
®
Big Dipper® IS System Replacement Parts
NOT SHOWN:
INTERNAL FLOW CONTROL (1 per unit)
PART# MFC-15 FOR W-150-IS
PART# MFC-20 FOR W-200-IS
PART# MFC-25 FOR W-250-IS
PART# MFC-35 FOR W-350-IS
PART# MFC-50 FOR W-500-IS
LID GASKET
PART# RG-7
WIPER BLADES (2 per unit)
PART# PB-3
WHEEL WIPER ASSEMBLY (1 per unit)
PART# WWA-2
WHEEL DRIVE SPROCKET (1 per unit)
PART# WDS-3
SKIMMING WHEEL ASSEMBLY (1 per unit)
PART# PDA-3
SOLIDS STRAINER BASKET
FOR MODEL# USE PART#
W-150-IS THROUGH W-250-IS ST-17
W-350-IS & W-500-IS ST-57
GREASE/OILS COLLECTION CONTAINER
FOR MODEL W-150-IS USE PART# GC-4
FOR W-200-IS THROUGH W-500-IS USE PART# GC-6
TIMER (Under Cover)
FOR ALL MODELS USE PART# ETC-1
Big Dipper® IS System Replacement Parts

©2005 Thermaco, Inc. All rights reserved • Patented/Patents Pending • Specifications subject to change without notice
Thermaco, Inc. • 646 Greensboro St. • Asheboro, N. C. 27204-2548 • Phone [phone] MNL-IS6000 16
®
Big Dipper® Limited Warranty & Remedy
Thermaco, Inc. warrants, to the original user, that those products supplied by it and used in the
service and in the manner for which they are intended shall be free from defects in materials
and workmanship for a period of one year after installation, but not longer than 15 months from
date of shipment from the factory. All replacement parts have a 30 day replacement warranty.
Clean defective parts shall be returned, within the warranty period, with proof of purchase to
Thermacoʼs factory, 646 Greensboro Street, Asheboro, NC 27203, transportation charges pre-
paid, for warranty evaluation. At Thermacoʼs option, based on the determination of the warranty
evaluation, Thermaco may repair or supply a replacement part from its factory. Any and all items
which may be returned shall include the serial number from which the item was removed, and a
return goods authorization number issued by Thermaco. This warranty is void if the product has
been damaged by its customer prior to acceptance or as a result of unreasonable use, neglect,
flooding, alteration, damage incurred by/during facility construction, improper installation, improper
service, maintenance neglect, improper electrical service, installation and/or operation without timer
controls, or other causes not arising out of defects in material or workmanship. Equipment must
be installed according to manufacturerʼs guidelines. This warranty is void if equipment is used
in excess of rated flow. Thermacoʼs products are intended to remove only free floating animal
fats, vegetable oils and cooking grease. Thermacoʼs products do not remove emulsified fats
and oils. Thermaco shall not be responsible for damage to equipment which results from vault
flooding, sewer line backup, pumping or lift station failure, ambient water flow or other sources
of water damage. This warranty is void if the serial number on the product has been altered
or defaced. Thermaco will not replace timers which have been installed in underground vaults.
This warranty is void should use, installation and application be contrary to a written agreement
between Thermaco and the user. Thermaco does not make any other representations or war-
ranties, express or implied, including, but not limited to, any implied warranty of Merchantability
and any implied warranty of fitness or performance for a particular purpose.
The sole and exclusive remedy with respect to the above limited warranty or with respect to any
other claim relating to defects or any other condition or use of the product supplied by Ther-
maco, however caused, and whether such claim is based upon warranty, contract, negligence,
strict liability or any other theory, is LIMITED to the repair or replacement of the part or product,
excluding labor or any other cost to remove or install said part or product or, at Thermacoʼs op-
tion, to repayment of the purchase price. Notice of any such claim must be given in writing to
Thermaco, Inc., PO Box 2548, 646 Greensboro Street, Asheboro, NC, USA 27204-2548 within 15
months after the first installation or use of the products. In no event shall Thermaco be liable for
special, direct, indirect, incidental, personal, property or consequential damages, including, but not
limited to, loss of use or profits or to interruption of business activity. Thermaco neither assumes
nor authorizes any representative or any other person to assume any liability in connection with
the sale of its products. Thermaco makes no warranties, express or implied, with respect to
parts, accessories, components or other goods not manufactured by Thermaco. Alteration and/or
substitution of Thermaco parts, assemblies, accessories including electrical and/or mechanical
components voids Thermacoʼs warranty.
Thermaco® Big Dipper® Automatic Grease/Oils Removal Units and system parts may be sold lo-
cally by Thermaco Sales Affiliates.