THERMA Big Dipper IS Series Installation instructions

Copyright ©2003 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-IS5000
* Please consult Thermaco, Inc. for specific models tested,
certified and/or listed by these organizations.
RL
**

©2003 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-IS5000 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
○○○○○○○○○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○○○
○○○○○○○○
○○○○○○○○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○○○○○○○○○○○
○○○○○○○○○○○○○○○○○○

©2003 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-IS5000 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 al-
ready know, grease buildup within a building’s
plumbing drainage system is a major cause of
problemsduetodrainlineblockages. Theseprob-
lemsjeopardizenormal operations as wellascre-
ate health and safety hazards within the facility
itself.
The proper installation of a Big Dipper System
canreduce oreliminate grease problems. Use of
theBig Dipper assuresminimization and/or elimi-
nation 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 render-
ing 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. Atimer 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 system’s 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.

©2003 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-IS5000 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) Emptytheclearplasticgrease/oilscollectioncontainer(locatedbesidetheunit)onceeachday
(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
accumulated 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
amountofgreaseoroilleftinthetankimmediatelyafterthedailyautomaticskimmingcycle. Ifthere
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
appearanceisobtainedaftertheautomaticskimmingcycle(Asimpleguideistoincrease the"on"
time by 30 minutes for each 1” (25 mm) of grease layer observed after the skimming cycle).
(D)Theinternalstrainerbasketintheunitisdesignedtoremovecoarsesolidsfromthewastewater.
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.

©2003 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-IS5000 5
®
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
isconsistently thicker,increase the operating times ofthe Big Dipper IS System by 30minutes 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.
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
ormorecompleterevolutionsuntil
the present time is aligned with
the time-of-day indicator point.
3.Filltheunitwithwaterbyturning
on the sink water taps, then plug
the Big Dipper unit into grounded
electrical outlet.
321
4
5
6
7
8
9
10
1112 12345
67
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

©2003 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-IS5000 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

©2003 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-IS5000 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

©2003 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-IS5000 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

©2003 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-IS5000 9
®
14.000"
1) Unlatch the Unit lid. 2) Lift the lid up off of the unit,
ensuring clearance for the heater.
3) Rotate the lid 180º. 4) Put the lid back down on top
of the unit and relatch.
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
How To Reverse Big Dipper®
IS System Unit Operation

©2003 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-IS5000 10
®
Big Dipper®IS System
Plumbing Installation
Locating the Unit
To minimize grease build-up in piping, a Big
Dipper system should be located as close as
possible to the fixture it is serving. The system
shouldbevisibleandeasilyaccessibleformain-
tenance and inspection. Make sure that ad-
equate room is provided around the system to
allow easy removal of the grease collection
containerandtoaccesstheelectricalassembly.
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
pipingasstraightaspossible. Useonly"sweep"
connections. Do not reduce the pipe sizing on
theoutletpiping. Donotinstall"P"traponoutlet
connection of system. (Note: The system al-
ready has a internal gas trap)
Flow Controls
Big Dipper systems are equipped with an inter-
nalflowcontrollocatedinsidetheinletendofthe
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 heat-
ing element. These elements will NOT be
replaced under Thermaco's Limited Warranty.
Venting the Outlet
Anoutletventorapprovedvacuumbreakerofat
least 1/2 the diameter of the system's outlet
connection must be present as close as pos-
sibletotheBigDipperoutlettopreventpossible
siphonage problems.
Failure to provide a vent
for the system voids Thermaco's 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.
recommendsaninletventonthepipingconnec-
tion as close a possible to the inlet of the Big
Dipperandtiedintothefacilityvent. Pleasesee
the following page for installation instructions.
Do Not Use With Food Grinders, Po-
tato 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 Thermaco's
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

©2003 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-IS5000 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 VFCAVented
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

©2003 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-IS5000 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)
120 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
controller. Thetimerislocatedunderthehingedlidofthemotorenclosure
ontop ofthe lidof BigDipper(See TimerOperation Instructions). TheBig
Dippershouldonly bepluggedinto aproperlygrounded 3-prong120VAC
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.
Note: The Big Dipper unit will not operate when the lid is removed.
Timer
(Under Hinged Lid)
Big Dipper Electrical Requirements
3.0 Amps @ 120 VAC 60Hz (360 Watts)

©2003 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-IS5000 13
®
Big Dipper®IS System
Wiring Diagram
SPLICE
WHITE
WHITE
BLACK
MOTOR BLACK
BLACK
4 1 3 2 5
TIMER
BLACK
BLACK
BLACK
WHITE
THERMOSTAT
HEATER
WHITE
RING TERMINAL TO
GROUND STUD
WHITE
INTERLOCK
SWITCH
4 8
3
2
7
6
BLACK
1 5
BLACK
POWER SUPPLY CORD
GREEN
DIST.
BLOCK
DISTRIBUTION
BLOCK
Simply Pull Wire
To Remove
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

©2003 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-IS5000 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-2
Wheel Drive Sprocket
Part #WDS-2
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

©2003 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-IS5000 15
®
Big Dipper®IS System Replacement Parts
NOT SHOWN:
INTERNAL FLOW CONTROL (1 per unit)
PART# MFC-20 for W-200-IS & W-250-IS
PART# MFC-35 for W-350-IS & 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-2
SKIMMING WHEEL ASSEMBLY (1 per unit)
PART# PDA-2
SOLIDS STRAINER BASKET
FOR MODEL# USE PART#
W-200-IS & W-250-IS ST-17
W-350-IS & W-500-IS ST-57
GREASE/OILS COLLECTION CONTAINER
FOR ALL MODELS USE PART# GC-6
TIMER (Under Cover)
FOR ALL MODELS USE PART# ETC-1
Big Dipper®IS System Replacement Parts

©2003 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-IS5000 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 Thermaco's
factory, 646 Greensboro Street, Asheboro, NC 27203, transportation charges prepaid, for war-
ranty evaluation. At Thermaco's 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, mainte-
nance 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 manufacturer's guidelines. This warranty is void if equipment is used in excess of
rated flow. Thermaco's products are intended to remove only free floating animal fats, vegetable
oils and cooking grease. Thermaco's 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 warranties, 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 Thermaco,
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 Thermaco's option,
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 sub-
stitution of Thermaco parts, assemblies, accessories including electrical and/or mechanical com-
ponents voids Thermaco's warranty.
Thermaco®Big Dipper®Automatic Grease/Oils Removal Units and system parts may be sold
locally by Thermaco Sales Affiliates.