Thermaco W-1250-AST Installation Manual

Installation & Operation Instructions

For Big Dipper 40000 Series

Automatic Solids Transfer (AST) Units

Models W-250-AST, W-750-AST and W-1250-AST

(Including 230 VAC Units)

A Big Dipper W-750-AST in a

Basement Location

Kitchen Drainage Piping

ADJ

* Please consult Thermaco, Inc. for specic models

tested, certied and/or listed by these organizations.

®

Copyright ©2015 Big Dipper® Thermaco, Inc. • P.O. Box 2548 • Asheboro, NC 27204

Toll Free: [phone] • V: [phone] • F: [phone]

[e-mail] • www.big-dipper.com

Part# MNL-AST40000

40000 Series

Table of Contents

Table of Contents

AST System Overview 3

AST System Maintenance 4

AST Digital Control Operation 5

AST Function Operation 7

AST System Troubleshooting 8

How To Reverse AST System Operation 9

Plumbing Installation 10

Electrical Installation 13

AST System Wiring Diagram 14

AST Component Identication 16

AST Replacement Parts 18

Limited Warranty 19

©2015 Thermaco, Inc. All rights reserved • Patented/Patents Pending • Specications subject to change without notice

Thermaco, Inc. • 646 Greensboro St. • Asheboro, N. C. 27204-2548 • Phone [phone]

MNL-AST40000 2

40000 Series

Big Dipper® Automatic Solids Transfer

(AST) System Overview

The Thermaco, Inc. Big Dipper® Automatic Grease and Oils

Removal System removes free-oating grease & oils from kitchen
drain water ows. As most food service facility managers already
know, grease buildup within a building’s 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 nes through efcient separation and removal of free-oating grease & oils.
In addition, the Big Dipper also helps reduce or eliminate pumping and disposal costs associated
with conventional grease traps or interceptors. The recovered grease & oils are substantially
water-free and are suitable for recycling by local rendering and/or biodiesel companies.

The Big Dipper system is an automatic, self-cleaning device. As greasy kitchen efuent drains
from kitchen xtures, the unit traps the grease & oils. These separate from the efuent and rise
to the surface of the separator tank. The unit automatically skims the trapped grease & oils and
transfers the grease & oils to a collection container. A digital timer controls the self cleaning op­eration, activating the skimming wheel at a user-set time. Only the “cleaned” water exits the unit
and ows into the facility drain lines.

PROPERLY
DISPOSE OF
CONTENTS

DAILY

Incidental food solids less than 1” (25 mm) in diameter (W-250-AST) and 1.5” (38 mm) in diam­eter (W-750-AST & W-1250-AST) are separated and ushed out of the system automatically by
the Automatic Solids Transfer component. These incidental solids are typical of those that are
rinsed off of plates before going to a dishwasher. The Eductor Pump of the AST is not designed
to handle non-food products such as plastic, rubber or metal items.

The Big Dipper system’s compact footprint allows installation directly at the source, where grease
problems originate. The system design also allows easy maintenance and operation requiring
only a minimal amount of daily and weekly maintenance to maintain peak operating performance.

The Big Dipper system design allows for maximum installation exibility. Reversing the system
operation is as simple as rotating the cover assembly of the unit.

Grease interceptors, grease traps, automatic recovery units, grease removal devices and other
similar plumbing devices receiving kitchen ows from sinks, oor drains, woks and other food
bearing sources may generate odors. There are many factors inuencing odor evolution and dis­semination. These include room ventilation, kitchen menu, ambient temperatures, ware washing
practices, grease/oil input, daily input uid volume, sanitizers, installation plumbing design and
product maintenance/upkeep. Odors are usually prevented by good area ventilation, frequent
uid inputs, good product maintenance practices and proper product installation. Additional steps,
including aeration, chlorination, improved area ventilation and additional maintenance control,
may be needed at some sites.

©2015 Thermaco, Inc. All rights reserved • Patented/Patents Pending • Specications subject to change without notice

Thermaco, Inc. • 646 Greensboro St. • Asheboro, N. C. 27204-2548 • Phone [phone]

MNL-AST40000 3

40000 Series

Big Dipper® Automatic Solids Transfer

(AST) System Maintenance

Big Dipper® Automatic Solids Transfer (AST) System Maintenance

*CAUTION! DASTCONNECT POWER TO UNIT BEFORE CLEANING

to prevent damage to the unit and personal injury

*NOTE: Before energizing unit after cleaning, ll tank with water

to protect wipers and heater from damage

Daily Maintenance:

(A) Empty the clear plastic grease/oils collection container (located beside the unit) prior to its
becoming full once each day. The Big Dipper recovers grease and oil virtually water-free so that
they can be recycled. The collector container should be washed periodically so as to maintain
the easy viewing translucent characteristic of the collector.

Weekly Maintenance:

(A) Check the collection trough and the wiper blades for any solids build-up. Wipe off any accu­mulated deposits and assure the wiper blades are clipped in place properly.

(B) Press the Jog Switch button (on the side of the center module) momentarily to ensure that
the motor and skimming wheel are still operating correctly.

(C) Remove & spray down the strainer assembly to remove any accumulated solids. Be sure to
spray down both the inside and outside surfaces of the strainer assembly.

(D) Check the thickness of the grease layer at the top of the unit. If there is more than a 1/2” (12
mm) thick layer of grease after the skimming cycle, this indicates a need to increase the skim­ming time. Increase the digital control settings accordingly until a clean unit appearance is obtained

after the automatic skimming cycle. A simple guide is to change to the next higher setting (Light [I] to
Moderate [II] or Moderate [II] to Heavy [III]) and run for a period of time until enough grease is being
skimmed from the tank.

Quarterly Maintenance:

(A) The internal strainer assembly in the unit is designed to remove incidental solids from the
wastewater. Over a period of time, sediment consisting of very ne 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 bafe. To prevent this from occurring, remove the lid and stir the bottom of the unit with
a long handled spatula while water is owing to ush out the sediment. Occasionally drain and
clean the unit thoroughly. Properly used, a wet vac may be appropriate for this purpose.

©2015 Thermaco, Inc. All rights reserved • Patented/Patents Pending • Specications subject to change without notice

Thermaco, Inc. • 646 Greensboro St. • Asheboro, N. C. 27204-2548 • Phone [phone]

MNL-AST40000 4

40000 Series

REVISIONS

ZONE REV DESCRIPTION DATE APPROVED

Big Dipper® AST System

Digital Control Operation

Digital Control Operation (Default Modes)

Timed Skimming Default

Through the “User Interface” three
levels of skimming may be selected in
the “default” mode. By selecting one of
the skimming buttons – I, II, or III - the
skimming cycle (see table below) is
activated. The LED associated with
the selected button is illuminated

continuously as an indicator of the

selected skim cycle and as a “power
on” indicator. If the skimming level is
changed during an active skimming
cycle, the next active skim cycle will be
at the new setting (The LED associated
with the newly selected level will change
immediately). If the skimming cycle
is changed between active skimming
cycles the next skim cycle will be at the
new level.

Motor Exercising

For all default mode skimming levels, the
motor will be energized for 30 seconds
every 9.5 hours. Only the motor will be
energized (no heater operation) at these
exercising times.

Start Button Operation

Any time the start button is depressed the “time between skims” the digital control goes to its maximum time and
operation begins for the selected skim level. After this skimming cycle the normal time delay to the next skim cycle
is used (skim cycle resets when the start button is depressed).

Light Setting:

Recommended for

Light Grease Output

(Small Cafes, Coffee/

Ice Cream shops***)

Moderate Setting:

Recommended for

Moderate Grease Output

(Quick and Full-Service

restaurants***)

Heavy Setting:

Recommended for

Heavy Grease Output

(Steakhouses, Buffets,

producing sites***)

Start Button: Press

to begin a cycle early

or to test operation..

Heavy Grease

Heater Operation

The heater operates under Thermistor control any time the skimmer motor is energized and anytime the liquid
temperature drops to 40º F to prevent liquid from freezing. Contact Thermaco for programming alternative heater
settings.

Default Modes - Normal Operation*

Button Selected Skim Time Delay Between Skims**

Light (I) 15 Minutes 76 Hours

Moderate (II) 30 Minutes 19 Hours

Heavy (III) 60 Minutes 19 Hours

* For Extreme Conditions see next page.
** Delay between Skims is the time from the start of the 1st skim to the start of the next skim.
*** Only examples, actual mode needed will vary depending upon menu, warewashing procedures, etc.

©2015 Thermaco, Inc. All rights reserved • Patented/Patents Pending • Specications subject to change without notice

Thermaco, Inc. • 646 Greensboro St. • Asheboro, N. C. 27204-2548 • Phone [phone]

MNL-AST40000 5

40000 Series

REVISIONS

ZONE REV DESCRIPTION DATE APPROVED

Big Dipper® AST System

Digital Control Operation

Digital Control Operation (Extreme Modes)

Extreme Operation

For Food Service Operations which produce more grease and need additional run-time, the 40000 Series Big Dipper
provides additional modes for extreme operation. In order to access these modes:

1. Remove power from CLA by unplugging unit or lifting it to disengage the safety switch (found on
underside of the back of assembly).

2. Reapply power while holding down the Heavy Mode (III) Button.

3. The button (III) will blink temporarily, indicating which operation level has been selected.

4. Select desired mode at skim times/frequencies listed below.

Extreme Modes

Button Selected Skim Time Delay Between Skims*

Light (I) 90 Minutes 19 Hours

Moderate (II) 120 Minutes 19 Hours

Heavy (III) 120 Minutes 9.5 Hours

* Delay between Skims is the time from the start of the 1st skim to the start of the next skim.

To return to Default Modes, follow the instructions above, but press the Light Mode (I) Button instead of the Heavy
Mode (III) Button. The Light Mode (I) Button will temporarily blink to indicate this operational level has been
selected.

Hold down Light

Mode (I) Button

when connecting

power to unit to

switch back to

default modes.

Hold down Heavy

Mode (III) Button

when connecting

power to unit to

switch to extreme

modes.

©2015 Thermaco, Inc. All rights reserved • Patented/Patents Pending • Specications subject to change without notice

Thermaco, Inc. • 646 Greensboro St. • Asheboro, N. C. 27204-2548 • Phone [phone]

MNL-AST40000 6