Gross Star

0

REV. ECN NO. DATE BY APPD. DESCRIPTION OF REVISION TOTAL #OF PAGES

PSS # xxxx-xxx-xxxGross Star sink top and final assembly

Model Numbers

= TQC (Touch Quality Control) = CTQ (Critical to Quality)

MATERIALSB10037 – Rinse bar (2 needed)

C1001428 – Spray nozzle (12 needed)

TOOLSPliers

Gross Star sink top and final assembly 0000-000-000

PAGE 2

B10037 C1001428

B10037

B10037

C1001428C1001428

Fig. 1

Fig. 3

Fig. 2


C1001428 – Spray nozzle (12 needed)1300712 = Teflon tape

PROCEDURESInstalling the spray nozzles to the rinse bar (continued)

Set the 2 rinse bars side by side. All 10 nozzles should face each other. If they do not, adjust the nozzles until they do (Fig. 1 and Fig. 2).

Apply Teflon tape to the threaded ends of the 2 rinse bars. Starting at the second thread wrap clockwise 4 complete turns, unless otherwise noted (Fig. 3).

TOOLSPliers


PAGE 3

B10037

C1001428

1300712

B10037

B10037C1001428

C1001428 Fig. 1

Fig. 3

Fig. 2


TOOLSSmall section of threaded pipe12” adjustable crescent wrench


PAGE 4

Threaded pipe

B10037B10037

Fig. 1

Fig. 3

Fig. 2



TOOLS12” adjustable crescent wrench


Page | 5

Position nozzle slightly down

Aim jets toward crease

C1001428

B10037 Crease

C1001428B10037

B10037

C1001428

Fig. 1

Fig. 3

Fig. 2


C1001428 – Spray nozzle (12 needed)B100-63 – Rinse bar bracket — rightB100-64 – Rinse bar bracket — left

C1000300 – 5/16” nyloc nuts (2 needed)

PROCEDURESAttaching rinse bars to sink (continued)

Slide the bracket over the open end of the rinse bar and attach it to the 2 studs (Fig. 1).

Thread on 2 nyloc nuts to secure the bracket (Fig. 2).

Tighten using a nut driver then install the other bracket (Fig. 3).

TOOLS7/16” nut driver


Page | 6

B10037

B10037B10037

B100-64

B100-64B100-64

C1000300

C1000300

Fig. 1

Fig. 3

Fig. 2



TOOLS


Page | 7

B10037

C1001428

B10037

B10037

Threaded hole

C1001428

Fig. 1

Fig. 3

Fig. 2

MATERIALSB1003115 – Disposal basket strainer

Plumber’s putty

PROCEDURESInstalling a basket strainer (for units with a disposal)

Remove the basket strainer from the disposal unit (Fig. 1).

Disassemble the basket strainer (Fig 2).

Apply a rope of plumber’s putty around the inside ring of the sink flange (Fig. 3).

TOOLSPower drill

¼” Phillips head bit


Page | 8

B1003115

B1003115

Sink flange

Fig. 1

Fig. 3

Fig. 2


Sink flangePlumber’s putty

PROCEDURESInstalling a basket strainer (for units with a disposal) (continued)

Flatten the plumber’s putty and spread it around the complete inner ring on the sink flange (Fig. 1).

Orient the sink flange so you will be able to read the writing when looking down from the front of the sink. Remember, the sink is positioned on its back so the writing should be upside down (Fig. 2).

Insert the sink flange into the drain hole on the sink, pressing firmly so the sink flange seats properly (Fig. 2).

TOOLS


Page | 9

Sink flange

Sink flange

Sink flange

Fig. 1

Fig. 3

Fig. 2


PROCEDURESInstalling a basket strainer (for units with a disposal) (continued)

Slide the backup ring over the mounting ring and hand tighten the 3 screws. Position the assembly over the base of the sink flange on the underside of the sink (Fig. 1).

Pull the snap ring open slightly and press it around the outside flange of the mounting ring. Work it onto the mounting ring until it snaps into place (Fig. 2).

Tighten the screws a little at a time working your way around each screw maintaining an even pressure. Continue tightening until each screw is firmly against the backup flange. Once tightened, remove any excess plumber’s putty from around the sink flange, top and bottom (Fig. 3).

TOOLSPower drill

¼” Phillips head bit


Page | 10

Backup ring

Mounting ring

Mounting ringMounting ring

Backup ring

Backup ring

Fig. 1

Fig. 3

Fig. 2

MATERIALSB105972 – Basket strainer

PROCEDURESInstalling a basket strainer (for units without a disposal)

Slide the brass nut over the tailpipe so it rests on the flange (Fig. 1).

Place the plastic washer inside the brass nut (Fig. 2).

Hand tighten the brass nut around the basket strainer (Fig. 3).

TOOLS


Page | 11

Brass nut

Tailpipe Brass nut

Brass nut

Tailpipe

Plastic washer

Tailpipe

Basket strainer

Fig. 1

Fig. 3

Fig. 2

MATERIALSB105972 – Basket strainer assembly

B10125 – Sink strainer stainless steel washerPlumber’s putty

PROCEDURESInstalling a basket strainer (for units without a disposal) (continued)

Place the assembly inside a vice, tailpipe up, and tighten the brass nut securely (Fig. 1).

Wrap a bead of plumber’s putty around the inside flange of the basket strainer, then flatten the putty around the flange (Fig. 2).

Insert the basket through the drain hole in the sink. Press firmly so the basket strainer seats properly (Fig. 3).

TOOLSVice

Channel lock pliers


Page | 12

Tailpipe

Tailpipe

Brass nutBasket strainer

Brass nut

Basket strainer

Basket strainer

Fig. 1

Fig. 2

Fig. 3


B10125 – Sink strainer stainless steel washer


Slide the rubber gasket over the tailpipe and fit it onto the bottom of the sink flange (Fig. 1).

Attach the fiber gasket over the rubber gasket (Fig. 2).

Slide on the stainless steel gasket (Fig. 3).

TOOLSSpanner wrench


Page | 13

Rubber gasket

Brass nut

Fiber gasket Rubber gasket

Sink flange

Fiber gasket

B10125

Rubber gasket

Sink flange Brass nut

Tailpipe

Tailpipe Fig. 1

Sink flange

Fig. 3

Fig. 2


B10125 – Sink strainer stainless steel washer


Thread the locking nut over the 3 gaskets (Fig. 1).

Tighten the locking nut with a spanner wrench. Once tight, remove any excess plumber’s putty that may have squeezed out during assembly (Fig. 2).

TOOLSSpanner wrench


Page | 14

Sink flange

Locking nut

Locking nut

Spanner wrench

Sink flange

Brass nut

Tailpipe

B10125

Brass nutTailpipe

Fiber gasket

Fig. 1

Fig. 2

MATERIALSB10095 – Trash exhaust hookup

B10072 – BlankB108355 – 8-32 x 3/8” Phillips head screws

PROCEDURESInstalling a trash exhaust hookup

If the unit uses a trash exhaust, you will need to install a trash exhaust hookup. It fits over the hole on the plumbing side of the unit. Before installing, make sure it has a rubber gasket attached. Do not use it without the gasket (Fig. 1).

Set the trash exhaust hookup in place and attach it with 3 screws (Fig. 2).

Install a blank on the other side of the unit using the same screws; again, making sure it has a rubber gasket. If the unit is not equipped with a trash exhaust, install a blank on both sides of the unit (Fig. 3).

TOOLSPower drill

¼” Phillips bit


Page | 15

Rubber gasket

B10095

B10095

B10072

B108355

Fig. 1

Fig. 2

Fig. 3

MATERIALSB1001088 – Fresh formulin faucet

B1001045 – Plastic ¾” x ½” male to female reducerB1001047 – Swivel end hose barb

C1001232 – ¾” plastic barbB1003246 – ¾” plastic 90° barb

7285011 – Hose clamp (2 needed)100319 – Braided clear hose — 4” section

1300712 – Teflon tape

PROCEDURESInstalling a fresh formulin faucet

Starting at the formulin plumbing side, remove the nut and washer from the threaded end of a fresh formulin faucet (Fig. 1).

Wrap Teflon tape around all male fittings. Starting on the second thread, wrap 4 complete turns clockwise. Do not tape the threaded end of the faucet yet (Fig. 2).

Position the faucet valve on the right side of the faucet, which when facing toward the front of the sink, would be on your left, and slide it through the hole in the unit (Fig. 3).

TOOLS


Page | 16

B1001088

B1001047

B1003246

B1001045B1001088

B1001088

Valve positioned on right

Fig. 1

Fig. 3

Fig. 2

MATERIALSB1001088— Fresh formulin faucet


PROCEDURESInstalling a fresh formulin faucet (continued)

Slide on the washer you removed earlier and thread on the nut (Fig. 1).

Using a deep wall socket, tighten the nut. Be careful not to over tighten on the plastic threads (Fig. 2).

Wrap Teflon tape to the threaded fitting on the faucet shaft. Starting on the second thread, wrap 4 complete turns. Cover about ½” of the threaded fitting (Fig. 3)

TOOLSRatchet

1 1/8” deep well socket


Page | 17

B1001088

1300712

B1001088

B1001088 Fig. 1

Fig. 3

Fig. 2

MATERIALSB1001045 – Plastic ¾” x ½” male to female reducer

B1001047 – Swivel end hose barb100319 – Braided clear hose — 4” section

3M Silicone Lubricant


Thread the barbed fitting onto the reducer. You will use this to temporarily hold the barbed fitting upright, making it easier to attach the 4” braided hose (Fig. 1).

Using a heat gun, heat 1 end of the braided hose (Fig.. 2)

Spray silicone inside the heated end of the 4” braided hose to lubricate it (Fig. 3).

TOOLSHeat gun


Page | 18

B1001045

B1001047

100319

100319Fig. 1

Fig. 3

Fig. 2

MATERIALSB1001047 – Swivel end hose barb

B1001045 – Plastic ¾” x ½” male to female reducer100319 – Braided clear hose — 4” section


Work the braided hose onto the plastic barb (Fig. 1).

With the hose secured, remove the reducer from the bottom of the barb (Fig. 2).

Thread the reducer onto the taped faucet shaft and tighten the fitting using an adjustable wrench (Fig. 3).



Page | 19

B1001045

B1001047

100319

B1001047

100319

B1001088B1001045

Fig. 1

Fig. 3

Fig. 2


B1001045 – Plastic ¾” x ½” male to female reducerC1001232 – ¾” plastic hose barb

100319 – Braided clear hose — 4” section7285011 – Hose clamps (2 needed)B1001047 – Swivel end hose barb



Thread the ¾” plastic hose barb into the formulin collar closest to the back of the sink and tighten using an adjustable wrench (Fig. 1).

Slide 2 hose clamps onto the open end of the hose (Fig. 2).

Thread the hose barb and hose onto the reducer. Finger tighten only (Fig. 3).



Page | 20

Fig. 1

Fig. 3

C1001232 B1001088

B1001045

B1001047

7285011

100319

B1001045B10010477285011

100319

Fig. 2


B1001045 – Plastic ¾” x ½” male to female reducerB1001047 – Swivel end hose barb

C1001232 – ¾” plastic barb7285011 – Hose clamp (2 needed)

100319 – Braided clear hose — 4” section


Bend the hose and work it onto the barb (Fig. 1).

Work the hose onto the barb until the hose is straight with no kinks and adjust the clamps so that 1 clamp is over each barb (Fig. 2).

Tighten each clamp with a nut driver (Fig. 3).

TOOLS¼” nut driver


PAGE 21

C1001232100319

7285011

B1001047

B1001045

B1001088

C1001232

100319B1001047

B1001045

B10010887285011

C1001232

7285011

100319

Fig. 1

Fig. 3

Fig. 2

MATERIALSB1002998 – 1” hole plug

B1001041 – Threaded plug

PROCEDURESInstalling hole plugs

If the unit does not take a fresh formulin faucet, press a 1” hole plug into the formulin faucet hole on the base of the sink (Fig. 1).

Also, screw a threaded plug into the formulin collar (Fig. 2).

Tighten the threaded plug using an adjustable wrench (Fig. 3).



PAGE 22

B1002998 B1001041

B1001041

Fig. 1

Fig. 1

Fig. 1

MATERIALSB1003246 – Plastic ¾” 90° barbed elbow

PROCEDURESInstalling fresh formulin fittings

For units that take a fresh formulin faucet, thread a 90° barbed elbow into the bottom threaded hole on the underside of the sink. If the unit does not take fresh formulin, leave this hole open. It will be blocked by the threaded plug in the sink top (Fig. 1).

Tighten the fitting using an adjustable wrench (Fig. 2).

Make sure the barb points towards the plumbing side of the sink (Fig. 3).



PAGE 23

B1003246

B1003246

B1003246

Fig. 1

Fig. 3

Fig. 2

MATERIALSB10077 – Stainless 1” x 4¾” pipe, long threaded on one end

B1001041 – Plastic threaded plugSoft cloth

PROCEDURESInstalling waste plumbing

If the unit accepts waste, thread a Teflon-taped section of stainless pipe into the waste collar on the top side of the sink (Fig. 1).

To keep from marking the pipe during tightening, lay a section of cloth over the pipe. Using channel lock pliers grasp the pipe firmly and tighten the pipe (Fig. 2).

If the unit does not accept waste, attach a threaded plug into the waste collar and tighten using an adjustable wrench (Fig. 3).

TOOLSChannel lock pliers

12” adjustable crescent wrench


PAGE 24

Fig. 1

B10077

B10077B1001041

Fig. 3

Fig. 2

MATERIALSB1003246 – Plastic ¾” 90° barbed elbow

PROCEDURESInstalling waste plumbing fittings

If the unit accepts waste, thread a barbed elbow into the waste collar, which is the top threaded hole when looking at the sink basin. If the unit does not accept waste, leave this fitting open. It will be blocked by a threaded plug on the sink side (Fig. 1).

Tighten the fitting with an adjustable wrench (Fig. 2).

Position the elbow so it is facing left, away from the plumbing, and slightly up (Fig. 3).



Page | 25

B1003246

B1003246B1003246Fig. 1

Fig. 3

Fig. 2

MATERIALSB1002690 – Pre-rinse hand sprayer kit

1300712 –Teflon tape

PROCEDURESInstalling a pre-rinse hand sprayer

Remove the threaded adapter from the end of the flexible hose. Make sure the black washer remains in the hose (Fig. 1).

Wrap Teflon tape around one end of the threaded adapter, clockwise, 2 complete turns, and thread the taped end into the hose (Fig. 2).

Tape the other end of the adapter, clockwise, 2 complete turns (Fig. 3).

TOOLS


Page | 26

Washer

1300712

1300712

Fig. 1

Fig. 2

Fig. 3

MATERIALSB1002690 – Pre-rinse hand spray kit

1300712 –Teflon tape

PROCEDURESInstalling a pre-rinse hand sprayer (continued)

Remove the hand sprayer assembly from the other end of the hose (Fig. 1).

Thread the adapter end of the hose through the bottom of the sink to the plumbing section (Fig. 3).

Connect the adapter to the open female connector under the sink (Fig.3).



Page | 27

Fig. 1

Fig. 3

Hand sprayer

1300712Adapter

Fig. 2

MATERIALSB1002690 – Pre-rinse hand sprayer kit


Tighten the connection using a pair of adjustable wrenches. Use 1 wrench to hold the female connector and the other to turn the hose fitting with adapter (Fig. 1).

Feed the open end of the hose up through the Gross Star unit and out the hand sprayer hole at the top of the sink (Fig. 2).

If necessary, insert the washer into the hand sprayer end of the hose (Fig. 3).

TOOLS2 adjustable crescent wrenches


Page | 28

Sink top

Sink top

Flexible hose

Fig. 1

Fig. 3

Fig. 2

MATERIALSB1002690 – Pre-rinse hand spray kit


Slide the metal ring washer over the base of the hand sprayer (Fig. 1).

Thread the hose fitting onto the hand sprayer, hand tighten only (Fig. 2).

To keep the hose away from potential pinch points when you mount the sink to the bottom section, wrap the hose around the faucet and vacuum breaker assembly (Fig. 3).

TOOLS


Page | 29

Fig. 1

B1002690B1002690

Fig. 3

Fig. 2

MATERIALS107554 – Parker hose — cut to lengths of 28” (supply hose), 25” (cold water hose), and 23” (hot water hose)

B1002690 – Pre-rinse hand spray kit

PROCEDURESInstalling the sink top to its base

Slide the faucet hose ends into the drain to keep them out of the way (Fig. 1).

Using 2 people carefully set the unit on its base (Fig. 2).

Unwrap the hand sprayer and slide the hose through the hole until the sprayer is firmly seated into the sink top (Fig. 3).

TOOLS


Page | 30

B1002690Fig. 1

107554

Fig. 3

Fig. 2

MATERIALSC1000584 – 3/8”-16 x 5/8” bolt (4 needed)1075973 – 3/8” crush washer (4 needed)

PROCEDURESInstalling the sink top to its base (continued)

Thread the bolts and lock washers through the 4 mounting brackets and into the tapped holes in the bottom section (Fig. 1).

Tighten the bolts using a ratchet with a deep well socket (Fig. 2).

To tighten one bolt, you will need to use a ratchet extension (Fig. 3).

TOOLSRatchet

11/16” deep well socketRatchet extension


Page | 31

C1000584

1075973

Fig. 1

Fig. 2

Fig. 2

MATERIALS107554 – Parker hose — cut to lengths of 28” (supply hose), 25” (cold water hose), and 23” (hot water hose)

3M Silicone Lubricant

PROCEDURESConnecting the hoses

Remove the 3 measured and cut lengths of hose from the drain hole and separate the lengths (Fig. 1).

Spray a silicone lubricant inside each hose (Fig. 2).

Starting with the shortest hose and working to the longest, slide each hose onto the barbed fitting on the solenoid valve. If the unit is equipped with a disposal, you will also need to thread the disposal’s braided hose end onto the threaded solenoid valve. The disposal hose is the only threaded fitting (Fig. 3).

TOOLS


Page | 32

107554

107554

107554

23”25”

28”

Fig. 1

Fig. 3

Fig. 2

MATERIALS100319 – Braided clear hose

B1003246 – Plastic ¾” 90° barbed elbow

PROCEDURESConnecting the hoses (continued)

If the unit uses a carboyd waste container, spray lubricant inside braided hose end leading from the carboyd waste unit and work the hose onto the barbed 90° fitting leading from the waste collar (Fig. 1 and Fig 2).

For units equipped with a carboyd fresh formulin, attach the braided hose leading from the fresh formulin container to the 90° barbed fitting leading to the fresh formulin faucet (Fig. 3).

TOOLS


Page | 33

B1003246 100319

100319

B1003246

Fig. 1

Fig. 3

Fig. 2

MATERIALS187086 – Cable ties

PROCEDURESReadying the unit for wiring

Pull the stored electrical wires through the openings on both sides of the unit (Fig. 1).

Place the wires in the sink until you are ready to attach them to their corresponding switches (Fig. 2).

Use cable ties to secure all loose wires in the base of the unit (Fig. 3).

TOOLS


Page | 34

187086

Fig. 1

Fig. 3

Fig. 2

MATERIALSB10081 – Hand spray deflector

C-1003056 – Double-backed tape

PROCEDURESWiring the Gross Star unit

Cut 3 strips of double-backed tape and apply them to the bottom of the hand spray deflector (Fig. 1).

Remove the double-sided tape backing from the hand spray deflector (Fig. 2).

With the tape on the bottom of the deflector, push the wires to the left and work the deflector through the slot on the right-sided front of the unit. Push the deflector as far back as it will go and press down on the bottom for the tape to adhere to the unit (Fig. 3).

TOOLS


Page | 35

B10081

B10081

C-1003056

C-1003056

B10081

Fig. 1

Fig. 2

Fig. 3

MATERIALSB10049 – Receptacle plate cover

B1005177 – Blank switch

TOOLS


Page | 36

B10049

B1005177

B10049

B1005177

Fig. 3

Fig. 1

Fig. 2

MATERIALSB10049 – Receptacle plate cover

B1005177 – Blank switch236036 – 6-32 screws (4 needed)

1000665 – Terminal connectors (3 needed)

PROCEDURESWiring the Gross Star unit (continued)

Attach the cover to the base of the unit (Fig. 3).

Measure about 6” of wire from the slot in the plate and cut off the excess wire (Fig. 2).

Remove about 4” of the outside protective cover to expose the 3 wires and cut off the stringy insulation (Fig. 3).

Strip off about ½” of plastic insulation from the 3 wires and using a crimping tool, add terminal connectors to the ends (Fig. 4)

TOOLS¼” Phillips head screwdriver

Wire cutterWire stripperCrimping tool


Page | 37

Fig. 2

B10049B10049

B10049

B1005177B1005177

B10049

B1005177

1000665Fig. 3

Fig. 4

Fig. 1

MATERIALS105932 – Receptacle

1000665 – Terminal connectors (3 needed)


Attach the brown wire to the gold screw on a receptacle (Fig. 1).

Attach the blue wire to the silver screw (Fig. 2).

Attach the green and yellow striped ground wire to the receptacle’s green screw (Fig. 3).

TOOLS¼ “ Phillips head screwdriver


Page | 38

Fig. 1

1059321000665

1000665

1000665105932

105932

Fig. 2

Fig. 3

MATERIALS1001237 – Receptacle cover plateB10049 – Receptacle plate cover

B1005177 – Blank switch105932 – Receptacle

1000665 – Terminal connectors (3 needed)236036 – 6-32 Phillips head screws (2 needed)


Fit a receptacle cover over the front of the receptacle (Fig. 1).

Slide the assembly over the slot, lining up the screws with the holes (Fig. 2).

Tighten the screws to secure the receptacle and cover (Fig. 3).



Page | 39

1001237

1000665

105932

B10051771001237

1001237

B10049

B10049B10049

Fig. 1

Fig. 2

Fig. 3

MATERIALSB10050 – Switch/alarm cover plate

B1001158 – Red light alarmB1001135 – Alarm reset button

B1001025 – Audible alarmB1005196 – Disposal buttonB1002999 – 7/8” hole plug


A 5-switch/alarm plate cover can control up to 5 devices. Install the specific switches or alarms for the unit you are building. Attach a hole plug in any slots not used. For example, this unit is not equipped with a disposal or a fresh formulin option. So we will insert a hole plug in the slot and ready the connections for future use (Fig. 1 and Fig. 2).

On the right side of the unit, select the wire marked COM ALARM SIREN (Fig 3).

TOOLS


Page | 40

B1001025

B10050

B1002999

B1001025

B1001135

B1001158

B1005196

B10050Fig. 1

Fig. 2

Fig. 3

MATERIALS106483 – Ring terminals (2 needed)


Measure about 6” of wire and cut off the excess (Fig. 1).

Strip away about 4”, remove the insulation, and separate the blue, brown, and ground wire. The ground wire is not needed, so cut it off (Fig 2).

Using a crimping tool, install ring terminals to the blue and brown wires (Fig 3).

TOOLSWire cutter

Wire stripperCrimping tool


Page | 41

106483

Fig. 1

Fig. 2

Fig. 3


B1001025 – Audible alarm106483 – Ring terminals (2 needed)


Using a Phillips head screwdriver, remove the 2 screws from the audio alarm terminals and attach the brown wire to the plus or positive side and the blue wire to the minus or negative sign (Fig. 1).

Select the wire marked COM AUDIBLE ALARM SILENCE (Fig. 2).

Cut the wire to length, expose the blue, brown, and ground wire, and cut off the ground wire (Fig. 3).


Wire cutterWire stripper


Page | 42

Fig. 1

B1001025

106483

B10050

Fig. 2

Fig. 3

MATERIALS

B10050 – Switch/alarm cover plateB1001158 – Red light alarm

B1001135 – Alarm reset buttonB1001025 – Audible alarm

B1005196 – Disposal buttonB1002999 – 7/8” hole plug


Strip the ends of the brown and blue wires. Insert the brown wire into the slot on the #4 side and blue into the slot on the #3 side of the alarm reset button (Fig. 1).

Tighten the connections with a Phillips head screwdriver (Fig. 2).

Select the wire labeled DISPOAL SWITCH (Fig. 3).



Page | 43

Fig. 2

B1001025

B1005196

B1001135

B1001158 Fig. 1B1001158

B1002999

B1001025

B1001135B1005196

Fig. 3




235094 – Female terminal connectors107087 – Cable tie


Measure and cut the length of disposal wire needed to reach the switch, remove all insulation, and cut off the ground wire (Fig. 1).

Strip the wires and using a crimping tool, install female terminal connectors to both wires. Slide the brown wire over the disposal terminal marked 5B (Fig. 2).

If the unit is not currently equipped with a disposal, do not connect the blue wire. Instead, use a cable tie to keep it out of the way. So, if the customer ever decides to add a disposal to the unit, the wiring is ready (Fig. 3).

TOOLSWire cutter

Wire stripperCrimping tool


Page | 44

B1005196B1001025

235094

235094

B10050 Fig. 1

Fig. 2

Fig. 3

MATERIALSB1001158 – Red light alarm


Select the wire labeled WASTE FORM ALARM (Fig. 1).

Measure, cut, separate, and strip the 3 wires, and cut off the green wire. The waste formulin alarm light has one terminal marked X1 and another terminal marked X 2. Insert the brown in the X1 terminal and tighten the screw (Fig. 2).

Insert the blue wire into the terminal marked X2 and tighten the screw to hold the wire in place (Fig. 3)

TOOLSWire cutters

Wire strippers¼” Phillips head screwdriver


Page | 45

X2 – for blue wire

Fig. 2

B1001158

B1001158

X1 – for brown wire

Fig. 1

Fig. 3





Select the wire labeled FRESH FORM LEVEL ALARM (Fig. 1).

Measure and cut the wire to length (Fig. 2).

If the unit is not equipped with the fresh formulin option, use a section of electrical tape to secure the cut end of the wire (Fig. 3).

TOOLSWire cutter

Electrical tape


Page | 46

Fig. 1

Fig. 2

Fig. 3




107087 – Cable tiesB108355 – 8-32 screws (4 needed)


Use a cable tie to hold the taped wire in place (Fig. 1).

Set the cover in place being careful not to pinch any wires between the plate and unit (Fig. 2).

Add the 4 screws and tighten (Fig. 3).

TOOLSElectrical tapeWire cutters

¼” Phillips head screwdriver


Page | 47

B10050

Fig. 1

Fig. 2

Fig. 3

MATERIALS

Waste, Alarm, Reset, and Audible decalsB10050 – Switch/alarm cover plate




Spray the panel with alcohol and wipe with a soft lint-free cloth to remove any excess grease, oil, or dirt that may prevent the decals from sticking (Fig. 2).

Carefully apply the decals identifying each, button, switch, or alarm (Fig. 2 and Fig. 3).

TOOLSIsopropyl alcohol in a spray bottle

Soft lint-free cloth


Page | 48

B10050B10050

B10050

Fig. 1

Fig. 2

Fig. 1

MATERIALSWeldment sink section

PROCEDURESMounting the top to the Gross Star

Mount the weldment sink section to the back of the sink (Fig. 1).

Once set in place, mark the screw mount areas on the back panel and remove the top and back again (Fig. 2).

Use a center punch on the marked area to either enlarge an existing hole or to make a new one (Fig. 3).

TOOLSMarker

Center punch


Page | 49

Fig. 1

Fig. 2

Fig. 3

MATERIALS108115 – 10-32 x 3/8” pan head screws

PROCEDURESMounting the top to the Gross Star (continued)

Remount the top and back section, and attach screws to the back of the unit to secure the top (Fig. 1).

Align the access panel with the studs on the sink top and slide it in place (Fig. 2).

Lock the access panel in place with the thumb screws (Fig. 3).



Page | 50

Stud

Fig. 1

Fig. 2

Fig. 3

MATERIALS1000452 – 3/8” NPT chrome union (2 needed)

SS16 pipe sealant

PROCEDURESAssembling the vacuum breaker

Separate the top and bottom sections of 2 unions (Fig. 1).

Apply pipe sealant to the end of the male threads on the 2 union’s top sections (Fig. 2 and Fig. 3).

TOOLS


Page | 51

1000452

1000452

Top section with male and female fittings

Bottom section with female fitting

1000452

Pipe sealant applied to union’s end threads

Fig. 1

Fig. 2

Fig. 3

MATERIALS1000452 – 3/8” NPT chrome union (2 needed)

PROCEDURESAssembling the vacuum breaker (continued)

Thread the union’s top end into its bottom end (Fig. 1).

Working on 1 union at a time, lock the reassembled union in a vice (Fig. 2).

Using an adjustable wrench, tighten the top end into its bottom (Fig. 2).

TOOLSVice



Page | 52

Fig. 2

1000452

1000452

1000452Fig. 1

Fig. 3

MATERIALS101918 – 3/8” NPT nipple 2¾” long (2 needed)

1300712 – Teflon tape1000452 – 3/8” NPT chrome union (2 needed)

Loctite 290

TOOLS


Page | 53

1019181300712

1000452

1019181000452

1300712

Fig. 1

Fig. 3

Fig. 2

MATERIALS1000492 – 3/8” NPT nipple 7¼” long (2 needed)

1300712 – Teflon tape1000452 – 3/8” NPT chrome union (2 needed)

105119 – Vacuum breaker1001917 – 3/8” NPT nipple1¾” long

101918 – 3/8” NPT nipple 2¾” long (2 needed) Loctite 290


After applying Loctite to the union’s bottom end, thread a 7¼” nipple, taped at both ends, into the union (Fig. 1).

Apply Loctite to the 2 female threaded fittings in the vacuum breaker and attach the open end of the taped 7¼” nipple into the breaker’s bottom end (Fig. 2).

Thread a 1¾” nipple, taped on both ends, into the threaded side of the vacuum breaker (Fig. 3).

TOOLS


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101918 1000452

10004921300712

1000492

1300712

1300712

105119

100492

105119

1001917

Fig. 1

Fig. 2

Fig. 3

MATERIALS1000492 – 3/8” NPT nipple 7¼” long (2 needed)1000452 – 3/8” NPT chrome union (2 needed)


101918 – 3/8” NPT nipple 2¾” long (2 needed)1000450 – 90° elbow fitting

1300712 – Teflon tapeLoctite 290


Apply Loctite to both ends of a 90° elbow and thread 1 end of the elbow onto the open end of the 1¾” nipple (Fig. 1).

Thread a second 7¼” nipple, taped on both ends, into the 90° elbow fitting (Fig. 2).

After applying Loctite to both female ends of a second union, thread the bottom of the union (you will see pipe sealant in the top end) onto the the 7¼” nipple (Fig. 3).

TOOLS


Page | 55

Fig. 2

Fig. 1

1300712

105119

1000450

1001917

100049210004921000492

1300712

1300712105119

10019171000450

1000452

Fig. 3






Thread the taped end of the second 2¾” nipple into the union (Fig. 1).

Attach a pair of soft jaw adapters to a vice (Fig. 2).

Place the assembly with the vacuum breaker down, inside the vice. Make sure the vacuum breaker is positioned just outside the vice jaws and tighten for a secure fit (Fig. 3).

TOOLSVice

Soft jaw adapters


Page | 56

Fig. 1Soft jaw adapters

101918

1000452

1000492

101918

1000452

1000492

1001917

105119

Fig. 2

Fig. 3



101918 – 3/8” NPT nipple 2¾” long (2 needed)1075903 – Brass nuts (4 needed)

1000450 – 90° elbow fitting1300712 – Teflon tape

Loctite 290


Thread 2 brass nuts onto both 2¾” nipples. The top nut should be about 1” down the threads. Position the nuts so they are about even on the threads (Fig. 1).

Use an adjustable wrench to tighten the nuts together. This way the nuts will act like jam nuts. So as you tighten the nuts all the fittings on that side of the assembly will also tighten. Try to keep both sides even (Fig. 2).

Tighten the bottom end of the unions to snug up the threaded connections (Fig. 3)

TOOLSVice

Soft jaw adapters12” adjustable crescent wrenches


Page | 57

Fig. 1

1075903

101918

1000452

1000492

1075903

1075903101918

101918

100049210004521000452

Fig. 2

Fig. 3




1000450 – 90° elbow fittingB100100-10 – Vacuum breaker mounting plate



With the fittings snug, loosen the brass nuts with an adjustable wrench and remove them from the nipple. Remove the vacuum breaker assembly from the vice (Fig. 1).

Lock the vacuum breaker mounting plate into the vice. Do not remove the protective film at this time (Fig. 2).

Rotate both sides of the vacuum breaker assembly in opposite directions. This will tighten the fittings on both ends of the 1¾” nipple (Fig. 3).


Vice Soft jaw adapters


Page | 58

Fig. 1

1075903

1019181000452

B100100-10

1000452

10004501001917105119

1000492

B100100-10

Fig. 2

Fig. 3




B100100-10 – Vacuum breaker mounting plate106347 – Escutcheon (2 needed)

1000450 – 90° elbow fitting1300712 – Teflon tape


Make sure both sides of the vacuum breaker assembly fits through the holes in the plate. If they do not fit, you may need to loosen or tighten the 1¾” fittings (Fig. 1).

Slide the 2 escutcheons over both ends of the assembly (Fig. 2).

Thread 1 brass nut onto each side of the assembly and tighten until they are even with the bottom of the escutcheon (Fig. 3).

TOOLSVice

Soft jaw adapters


Page | 59

Fig. 1

1000452101918

B100100-10

101918

106347

1000452106347

1075903

1000452

101918

Fig. 2

Fig. 3




106349 – Escutcheon (2 needed)B100100-10 – Vacuum breaker mounting plate

1075903 – Brass nuts (4 needed)


Lock the vacuum breaker assembly into the vice with the vacuum breaker down and just outside the vice jaws (Fig. 1).

Remove the protective film from the mounting plate and slide the plate over the 2¾” nipples on each side of the assembly (Fig. 2).

Make sure the plate is even when resting on the brass nuts. If necessary, adjust the nuts until the plate is even (Fig. 3).

TOOLS12” adjustable crescent wrenches

ViceSoft jaw adapters


Page | 60

1000452106347

1000492105119

101918106347

1000452B100100-10

1000492B100100-10

1075903

Fig. 1

Fig. 2

Fig. 3

MATERIALSVacuum breaker assembly

1075903 – Brass nuts (4 needed)B1002926 – Coupling (2 needed)



Attach the remaining 2 brass nuts to the nipples and tighten with an adjustable wrench (Fig. 1).

Wrap Teflon tape to the end of each nipple. Wrap clockwise 4 complete turns (Fig. 2).

Apply Loctite to each female end of a coupling, and thread it onto each taped nipple (Fig. 3).

TOOLSVice



Page | 61

B100100-10

10759031075903

1075903

B100100-10

1300712

101918

B100100-10

B1002926

Fig. 2

Fig. 1

Fig. 3


B1002926 – Coupling (2 needed)109289 – Hose bard with hose gasket (2 needed)



Apply Teflon tape, 4 complete turns wrapped clockwise, to the threads on the 2 barbed fittings and attach the barbs to the couplings (Fig. 1).

Tighten the fittings using a deep well socket (Fig. 2).

Slide the yellow hose gasket, with the lip facing up, onto each barb (Fig. 3).

TOOLSVice


½” ratchet11/16” socket


Page | 62

Fig. 1

B1002926

B1002926

109289

109289

B1002926

109289

Fig. 2

Fig. 3

MATERIALS1001243 – Hose end swivel (2 needed)

104233 – Reducer (2 needed)109289 – Hose barb with hose gasket (2 needed)

1300712 = Teflon tape

TOOLS12” adjustable crescent wrenches


Page | 63

104233 1001243104233 1001243109289 1001243

104233

109289

Fig. 1

Fig. 2

Fig. 3

MATERIALSB1005214 – Filter washer

1001243 – Hose end swivel 104233 – Reducer

109289 – Hose barb with hose gasket3M Silicone Lubricant


Place a filter washer inside the hose end swivel and straighten it so it lies flat (Fig. 1).

Slide a yellow barb gasket, lip side up, onto the barb (Fig. 2).

Spray silicone lubricant into both ends of the 110” hose section and in 1 end on the 53” hose section you cut during an earlier procedure (Fig. 3).

TOOLS


Page | 64

1001243

B1005214

1001243109289

104233

1075554

Fig. 1

Fig. 3

Fig. 2



With the vacuum breaker lying flat, work the 110” hose section onto the barb on the vacuum breaker side of the assembly. Work the lubricated end of the 55” section over the barb on the elbow side of the assembly (Fig. 1).

Work the open end of the vacuum breaker 110” hose section onto a barb with a hose end swivel connection (Fig. 2).

Position the vacuum breaker so it will be closest to the edge of the Gross Star unit and feed the 2 hoses from the vacuum breaker assembly through the open panel at the top of the unit (Fig. 3)

TOOLS


Page | 65

Vacuum breaker hose

Elbow hose

1075554

1075554

Fig. 1

Fig. 3

Fig. 2


3M Silicone Lubricant 108115 – 10-32 x 3/8” screws


Fit the vacuum breaker cover plate over the opening and secure it with 4 screws (Fig. 1).

Spray silicone lubricant through the open end of the 55” elbow hose (Fig. 2).

Work the elbow hose end onto the lower barb at the back of the unit (Fig. 3).



Page | 66

Fig. 1Vacuum breaker assembly

1075554

1075554

Fig. 3

Fig. 2

MATERIALS3M Silicone Lubricant

PROCEDURESAssembling and connecting the hot water hose

Spray silicone lubricant into both ends of the 66” hose section you cut during an earlier procedure (Fig. 1).

Work 1 end of the 66” hose onto the barb on a second hose end swivel connection (Fig. 2).

Work the open end of the 66” hose onto the upper barb for the hot side on the back of the unit, just above the 55” elbow hose connection (Fig. 3).

TOOLS


Page | 67

1075554

10755541075554

Fig. 1

Fig. 3

Fig. 2

MATERIALSB10067 – Plumbing service cover

1001113 – Cabinet handleB108355 – 8-32 x 3/8” screws

PROCEDURESFinishing the Gross Star assembly

Pull both the 110” cold vacuum breaker hose and the 66” hot hose from the back of the unit to verify they are both approximately the same length. If necessary shorten one or the other hose. Once verified roll both hoses and store them in the back of the unit (Fig. 1).

Remove the protective film and install the plumbing service cover to the plumbing side of the unit (Fig. 2).

Snap the 2 handles into the slots on the front of the unit (Fig. 3).

TOOLSPhillips head screwdriver


Page | 68

1075554

1001113

B10067

Fig. 1

Fig. 3

Fig. 2

MATERIALSHot and Cold foot pedals

PROCEDURESSetting up the Gross Star unit

Remove the plug stored in the back of the unit and insert it into an electrical outlet (Fig. 1 and Fig. 2).

Connect the Hot and Cold water foot pedals to their slots at the bottom of the unit (Fig. 3).

TOOLSPower supply


Page | 69

Fig. 1

Fig. 2

Fig. 3

MATERIALS


(continued)

Use a laptop to setup the Gross Star unit (Fig. 1).

Open the unit’s cabinet doors and turn on the 2 switches on the electrical cabinet door. The center panel will light (Fig. 2).

Using a flat head screwdriver turn the 3 screwdriver slots to unlock the electrical cabinet door. Open the panel (Fig 3).

TOOLSLaptop computerConnecting cord

Flat head screwdriver


Page | 70

Fig. 1

Fig. 3

Fig. 2

MATERIALS


(continued)

Attach the laptop to the control board inside the unit (Fig. 1).

Using the Gross Star setup sheet as a guide, the laptop will walk you through the complete setup procedure (Fig. 2).

Once setup is complete, reach inside the unit and slide the switch on the control board from PROG to RUN (Fig 3).

With the control board set on run, disconnect the laptop from the control board. Also unplug the unit from the power supply and store plug in the back of the unit (Fig. 4).

TOOLSLaptop computerConnecting cable


Page | 71

Fig. 2Fig. 3

Slide switch from PROG to RUN

Cable from laptop

Laptop connection

Laptop connection

Fig. 1

Fig. 3

MATERIALSFlexible drain hose

PROCEDURESLeak testing the Gross Star unit

To water test the unit, connect the 66” hot hose to the hot water valve and the 110 “ vacuum breaker hose to the cold water valve (Fig. 1).

Attach a drain hose to the drain in the unit and to a floor drain (Fig. 2).

Open the valves for the hot and cold water (Fig. 3).

TOOLSHot and cold water supply


Page | 72

1075554

Drain hose

Water valve

Fig. 1

Fig. 2

Fig. 3

MATERIALSHot and Cold foot pedals


(continued)

After plugging the unit into a power outlet, verify that the hot and cold water foot pedals work properly. Step on both pedals. You will hear an audible click as the water flows. Verify there is hot water with the Hot pedal and cold water with the Cold pedal. Step on each pedal again to shut off the water (Fig. 1).

Check each faucet and hand spray to verify hot and cold water (Fig. 2).

Turn on the star handle check valve to verify all the spray nozzles work (Fig. 3).

TOOLS


Page | 73

Hot and Cold foot pedals

Fig. 1

Fig. 2

Fig. 3


C1001428 – Spray nozzle (12 needed)B10063 – Rinse bar bracket — rightB10064 – Rinse bar bracket — left

C1000300 – 5/16” nyloc nuts (2 needed)


(continued)

Verify, too, that the water from the spray nozzles is aimed toward the creases in the back and front of the sink and not the sink wall (Fig. 1).

If necessary, adjust the rinse bar to aim the nozzles properly (Fig. 2).

Let the water run through the hole at the end of the rinse bars for a few minutes. This will flush out any metal shavings or other debris inside the rinse bar (Fig. 3).

TOOLSWater supply



Page | 74

B10037C1001428

B10037

B10037

C1001428

B10063

C1000300

Fig. 1

Fig. 2

Fig. 3

MATERIALSB10077 – Stainless 1” pipe — 4¾” long

B1001088 – Fresh formulin faucet


(continued)

If the unit is equipped with waste or fresh formulin plumbing, verify that they are operating properly and that the carboyd waste and carboyd fresh formulin are working (Fig. 1 and Fig. 2).

With the water still flowing, check the plumbing inside the cabinet for leaks (Fig. 3).

TOOLSWater supply

Flexible drain hose


Page | 75

B10077

B1001088

Fig. 1

Fig. 2

Fig. 3

MATERIALS1075061 – ¼”-20 x ½ bolt


(continued)

Once the rinse bars are flushed, turn off the water and add a Teflon-taped bolt (4 complete turns, clockwise) to the end of each bar (Fig. 1).

Tighten the bolts until snug (Fig. 2).

If necessary, tighten any leaking or loose fittings or connections and leak test again (Fig. 3).

TOOLSRatchet

11M socketAdjustable crescent wrenches


Page | 76

B10037

1075061

B10037

1075061

Fig. 1

Fig. 2

Fig. 3

MATERIALS


(continued)

With the system leak tested, close the hot and cold water valves at the main supply and open the hot, cold, and star handled check valve on the sink top (Fig. 1).

Open compressed air valves for both the hot and cold to flush out any residual water from the hot and cold lines. This also helps to dry the sink (Fig. 2 and Fig. 3).

Once the unit is dry and completely tested, complete any final prep work to prepare it for shipping.

TOOLSWater supply

Compressed air supply


Page | 77

Compressed air valve

Fig. 1

Fig. 2

Fig. 3

Gross Star

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