Getinge Castle 7900 User manual

7900
FLOOR MOUNTED
CART WASHER
Castle
®
INSTALLATION INSTRUCTIONS
61301604805 Rev. A

7900 FLOOR LOADING
CART WASHER
Castle
®
INSTALLATION
INSTRUCTIONS
Getinge/Castle, Inc.
1777 East Henrietta Road
Rochester, New York 14623-3133
Phone: [phone] USA
Facsimile: [phone]

ii
INSTALLATION INSTRUCTIONS 61301604805
Rev. A (12/27/01)
Related Publication:
Operator Manual 61301604804
DESCRIPTION OF SYMBOLS AND NOTES IN MANUAL
The following symbols with related notes appear in this manual.
“Warning” notes alert the user to the possibility of personal injury.
“Caution” notes alert the user to the possibility of damage to the equipment.
“Notes” alert the user to pertinent facts and conditions.
This manual contains proprietary information of Getinge/Castle, Inc. It shall
not be reproduced in whole or in part without the written permission of
Getinge/Castle, Inc.
is a registered trademark.
Copyright ©2001 by Getinge/Castle, Inc.
WARNING
NOTE
CAUTION
NOTE
Castle
®

61301604805 iii
Table of Contents
Section 1 Installation Requirements
GENERAL DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . 1–1
MODEL IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . 1–2
UTILITIES AND SPECIFICATIONS. . . . . . . . . . . . . . . . . . 1–3
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Hot Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Cold Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Steam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Condensate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Overall Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
INSTALLATION ADVISORY . . . . . . . . . . . . . . . . . . . . . . . 1–4
WASHER OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Floor Mount vs. Pit Mount . . . . . . . . . . . . . . . . . . . . . . 1–4
Left Side vs. Right Side Controls. . . . . . . . . . . . . . . . . 1–4
Barrier Flanges and Service Enclosure . . . . . . . . . . . . 1–4
Electrical Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Seismic Anchoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
SHIPPING CONFIGURATION. . . . . . . . . . . . . . . . . . . . . . 1–5
TOOLS AND MATERIALS REQUIRED . . . . . . . . . . . . . . . 1–6
Section 2 Installation
ASSEMBLE THE WASHER STRUCTURE . . . . . . . . . . . . 2–1
Install the Base/Sump Assembly . . . . . . . . . . . . . . . . . 2–1
Assemble the Washer Panels . . . . . . . . . . . . . . . . . . . 2–5
Door Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
Trim Panels (Non-Service Side) . . . . . . . . . . . . . . . . 2–12
INSTALL COMPONENTS ON TOP OF THE WASHER . 2–13
Dryer and Condenser Assemblies. . . . . . . . . . . . . . . 2–13
Power Floor Tilt Pulley System . . . . . . . . . . . . . . . . . 2–17
Transformer and Emergency Stop Switch
Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–19
Rear Emergency Stop Switch . . . . . . . . . . . . . . . . . . 2–20
Plumbing Mounting Brackets. . . . . . . . . . . . . . . . . . . 2–21

iv
INSTALL COMPONENTS ON THE OUTSIDE
OF THE WASHER. . . . . . . . . . . . . . . . . . . . . . . . . . . 2–22
Spray Manifold Drive Motor. . . . . . . . . . . . . . . . . . . . 2–23
Exhaust Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–25
Washer Light Assembly. . . . . . . . . . . . . . . . . . . . . . . 2–26
Front Dryer Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–27
Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–29
Junction Box Assembly . . . . . . . . . . . . . . . . . . . . . . . 2–30
Dispenser Float Switch Junction Box . . . . . . . . . . . . 2–31
Front Emergency Stop Switch. . . . . . . . . . . . . . . . . . 2–32
Detergent and Rinse Aid Dispensers . . . . . . . . . . . . 2–33
Unload End Indicator Panel Box . . . . . . . . . . . . . . . . 2–34
Door Proximity Switches . . . . . . . . . . . . . . . . . . . . . . 2–35
Sump Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–36
Return Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–37
Circulation Tank Assembly . . . . . . . . . . . . . . . . . . . . 2–38
Wash Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–39
Tank Drain Valve, Tank Overflow, and Tank
Water Level Indicator . . . . . . . . . . . . . . . . . . . . . 2–40
Booster Heater Assembly . . . . . . . . . . . . . . . . . . . . . 2–41
Rinse Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–42
PLUMBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–43
Stainless Steel Plumbing. . . . . . . . . . . . . . . . . . . . . . 2–43
Black Iron (Steam) Plumbing. . . . . . . . . . . . . . . . . . . 2–44
Hot Water (Copper) Plumbing. . . . . . . . . . . . . . . . . . 2–44
Cold Water (Copper) Plumbing . . . . . . . . . . . . . . . . . 2–45
ELECTRICAL WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . 2–46
Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–46
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–46
INSTALL COMPONENTS ON THE INSIDE OF
THE WASHER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–49
Rear Dryer Ducts. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–49
Drive Chain Tension Idlers and Idler Bearings . . . . . 2–51
Chain Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . 2–52
Spray Manifold Supports and Manifold Assembly. . . 2–54
Manifold Cover and Spray Guard, Manifold Guard
Tubes, Wash Cart Tubes . . . . . . . . . . . . . . . . . . 2–56
Emergency Stop Switch Cables . . . . . . . . . . . . . . . . 2–58
FINAL INSTALLATION TASKS . . . . . . . . . . . . . . . . . . . . 2–60
Final Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 2–61
Dispenser Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–62
Sanitary Barrier Flanges . . . . . . . . . . . . . . . . . . . . . . 2–64
Pit Covers (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . 2–65
Service Area Enclosure (Option). . . . . . . . . . . . . . . . 2–66
Base Shrouds (Floor Mounted Option) . . . . . . . . . . . 2–67
Ramps (Floor Mounted Option). . . . . . . . . . . . . . . . . 2–68

7900 Floor Loading Cart Washer
61301604805 v
Exhaust Connection. . . . . . . . . . . . . . . . . . . . . . . . . . 2–68
Plumbing System Connections . . . . . . . . . . . . . . . . . 2–68
Electrical Supply Connection. . . . . . . . . . . . . . . . . . . 2–69
Concluding Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–69

vi

61301604805 1–1
Section 1 Installation Requirements
General Description
The Castle 7900 Floor Loading Cart Washer is a fully automatic, floor
loading, hydro-spray cart washer with dual side-by-side wash compartments
that is used to clean and decontaminate case carts, stands, utensils,
containers, tote boxes, and similar bulk items.
Processing cycles are set up using a programmable controller equipped
with a touch screen interface (touch control panel). Four cycle definitions
are possible. The operator needs only to select and start a cycle.
A standard cycle consists of the following sequential phases: wash, rinse,
exhaust, and drying. The length of a cycle’s phase can be adjusted at the
touch control panel.
The washer can be installed in a shallow pit or at floor level. When installed
in a pit, the floor of the washer’s chamber is level with the room floor, which
allows the direct loading and unloading of carts. When the washer is
installed at floor level, the floor is higher than the room floor. Ramps are then
provided as standard equipment to facilitate loading and unloading.
The washer is designed for pass-through operation. Items to be cleaned are
placed in the washer’s compartment through one of the load end doors.
After cleaning, the items are removed from the opposite end of the washer
through the unload end doors.
The washer is generally installed in a facility’s decontamination room with
the unload end doors opening out into a clean-preparation area. The unit is
110" (2794 mm) wide and 108" (2743 mm) high. The washer is currently
available in only one compartment size: 98" (2489 mm).
Figure 1–1. 7900 Floor Loading Cart Washer
HW-006

Installation Requirements
1–2
Model Identification
The rating plate for a 7900 washer is affixed to the inside of the control box
door.
Record the model type and serial number (S/N) from the rating plate.
TYPE: _________________________________
SERIAL NO: ____________________________
Include the model type and serial number when communicating with
Getinge/Castle.
Figure 1–2. Rating Plate Location

7900 Floor Loading Cart Washer
61301604805 1–3
Utilities and Specifications
Electrical 208 V, 60 Hz, 3 phase, 100 A, 5-wire with neutral and ground
240 V, 60 Hz, 3 phase, 60 A, 4-wire with ground
380 V, 50 Hz, 3 phase, 60 A, 4-wire with ground
415 V, 50 Hz, 3 phase, 60 A, 4 wire with ground
480 V, 60 Hz, 3 phase, 30 A, 4-wire with ground
600 V, 60 Hz, 3 phase, 30 A, 4-wire with ground
Hot Water 1" IPS (25.4 mm)
40–60 PSI (276–414 kPa)
780 gal/hr (2953 l/hr) demand rate
12 gal/cycle (47 l/cycle) consumption
120°F min. (49°C)
Cold Water 3/4" IPS (19 mm)
40–60 PSI (276–414 kPa)
600 gal/hr (2271 l/hr) demand rate
10 gal/cycle (38 l/cycle) consumption
Steam 1-1/2" IPS
40–50 PSI (276–345 kPa)
1200 lb/hr demand rate
85 lb/cycle consumption
Condensate 3/4" IPS (19 mm)
Drain 3" IPS (76.1 mm) minimum
45 gal/cycle (170 l/cycle)
Exhaust 12" square flanged (304.8 mm)
800 ft3/hr (22.7 m3/hr)
1/4" static pressure
Weight 1800–2200 lb (811–991 kg) approximate
Overall Size 108" high x 110" wide x 106" long (2743 mm x 1321 mm x 1829 mm)

Installation Requirements
1–4
Installation Advisory
A 7900 washer is assembled at the factory, tested, then disassembled for
shipment. Extensive on-site reassembly is required. The installation
instructions in this manual are intended as the primary reference for
accomplishing this reassembly. Every effort has been made to make this
information as accurate as possible. No two washers are exactly alike,
however.
Each washer is uniquely configured to meet the demands of its operational
site. These demands most often necessitate variances in the location of a
washer's exterior components. These variances, in turn, impact the
configuration of related plumbing and electrical wiring assemblies.
For this reason, some instructions or illustrations carried here may not
reflect the actual location or configuration of selected component
assemblies for a specific site. Where applicable, installers should refer to
specifications contained in the product information documents, such as
Rough-In and Assembly drawings, that have been forwarded to local
Getinge/Castle product support personnel.
Washer Options
There are a number of options that may be included with your washer.
These options affect the procedures that apply to your specific installation.
Floor Mount vs. Pit Mount A floor mounted washer will require the installation of ramps to provide
access to the washer. The two options may have different plumbing
specifications.
Left Side vs. Right Side
Controls The location of controls on your washer will also determine the location of
the service area, as well as the barriers flanges and service enclosure that
may be provided with your washer.
Barrier Flanges and Service
Enclosure Your installation may have barrier walls at the load or unload end of the
washer, or both, as well as have a service enclosure. These structures will
be designed specifically for your site.
Electrical Service The electrical service at your facility determines the specific high voltage
devices (motors, pumps, etc.), transformer, and control box provided with
your washer.
Printer If your washer has the printer option, the printer will already be mounted on
the control box.
Seismic Anchoring Washers with the seismic anchoring option have base/sump assemblies
that are mounted differently.

7900 Floor Loading Cart Washer
61301604805 1–5
Shipping Configuration
A disassembled 7900 washer is shipped on 4 to 8 pallets of various lengths.
The maximum size of any one pallet may be as large as 10' x 5'
(approximate). For stability during transit, selected pallets are often pegged
(with nails) to the floor of the truck.
Moving the disassembled washer from the truck to the installation site
requires the use of any available combination of the following:
•fork lift
•pallet jack
•dollies
•Johnson bars
A sufficient supply of commonly used fasteners (#10-32 and 1/4-20, for
example) is bagged for shipment. Speciality hardware and fasteners (door
latches and hinges, for example) are labeled and bagged separately for
shipment.
Many disassembled items, such as plumbing and panel sections, are
marked with handwritten numbers with black grease pen to identify their
location, orientation, or connection points. Take care not to inadvertently
smudge or erase these identifying marks.

Installation Requirements
1–6
Tools and Materials Required
The following tables list the specific tools and materials required at the
installation site. Items marked with an asterisk * are supplied by Getinge/
Castle.
Table 1–1. Tools Required
Table 1–2. Materials Required
Tool Quantity
Common hand tools Assorted
Bar clamp 2
C-clamp 2
Johnson bar 1
Pry/pinch bar 2
Caulking gun 1
1/4-20 tap, short 1
1/4-20 tap, long 1
10-32 tap, short 1
10-32 tap, long 1
#7 drill bit 2
#21 drill bit 2
Torpedo level 1
4’ level 1
Scratch awl 2
Material Quantity
* Silicone adhesive 8 tubes
* Silicone primer 1 pt
* Thinner 1 pt
* Polish 1 container
* Stainless steel nuts, bolts,
washers, lock washers Assorted
* Wire nuts, tie wraps Assorted
* 3" x 6" stainless steel shims:
•12 ga
•14 ga
•16 ga
•18 ga
12
12
12
12

7900 Floor Loading Cart Washer
61301604805 1–7
The following items are recommended for use if a floor mounted washer is
to be assembled out-of-position, then moved to its intended operational site:
The Masonite protects the floor during assembly. The pipe is used to roll the
washer into position after assembly.
1" x 4" x 6" wood block 2
2" x 4" x 52" wood block 4
* 4’x 8’x 1/8" Masonite, smooth 2 to 3
Pipe, rigid 3/4" x 60" L 4
Material Quantity

Installation Requirements
1–8

61301604805 2–1
Section 2 Installation
Assemble the Washer Structure
This section contains procedures for assembling the basic structure of the
washer compartment. Refer to the following sections.
• “Install the Base/Sump Assembly” on page 2-1
• “Assemble the Washer Panels” on page 2-5
• “Door Assembly” on page 2-10
• “Trim Panels (Non-Service Side)” on page 2-12
Install the Base/Sump
Assembly General Instruction
The base/sump assembly is shipped in two halves that you must assemble
on the site. If the load or unload ends of the base are not marked, check the
configuration of the base’s sump against the rough-in drawing to determine
the correct orientation.
Some installation sites may have an existing wall in close proximity to the
non-service side of the washer that could interfere with the assembly of the
washer's side panels. If this situation exists, you will have to seat the base
temporarily out-of-position until the side, top, and non-service side trim
panels are assembled. You can then maneuver the unit to its operating
position, where you can level and anchor it, if required.
Installation
Silicone primer (orange) is extremely flammable, harmful if
swallowed or inhaled, and harmful to eyes or skin. Wear
protective clothing, gloves, and eye wear when using this
product. Keep it away from heat, sparks, and flames. Store
upright in a cool place (less than 30°C (85°F). Keep the
container closed when not in use. Use only in a well-ventilated
area. Avoid breathing vapors.
Silicone Primer stains/discolors clothing, stainless steel surfaces, flooring,
etc. Avoid accidental spills. Avoid spreading this substance onto exterior
surfaces of the washer.
NOTE
WARNING
CAUTION

Installation
2–2
1. Clean all mating surfaces where the two halves of the base
meet with thinner, treat with silicone primer, and then apply
a generous amount of silicone sealant.
2. Move the two halves of the washer base together and
attach the halves together:
a. At each end, secure the front and rear halves together
with 1/4-20 fasteners (four each 1/2" hex head bolts
and lock washers) as shown in Figure 2–1.
Figure 2–1. Attaching Ends of Base Assembly
b. Use a fork lift to raise one end of the assembly.
Make sure that the base/sump assembly is properly supported
and secured before getting underneath the assembly.
c. Underneath the sump, secure the halves together with
5/16-18 fasteners (1-1/2" hex head bolts and lock
washers), two each at six places, as shown in Figure
2–2.
1/4-20 FASTENERS
(4 PLACES EACH END)
REAR BASE HALF FRONT BASE HALF
WARNING

7900 Floor Loading Cart Washer
61301604805 2–3
Figure 2–2. Attaching Base Assembly Underneath
3. Move the base assembly into its final operating position.
4. Check the base for level.
Use the 4' level to check from all sides of the base and in
all directions. Adjust the level if necessary using the
stainless steel shims that are provided.
Failure to critically level the base will result in the misalignment of mounting
holes and will make assembly of the washer panels difficult.
If seismic anchoring is required, a 3" flange (with anchor bolt holes) is
welded to the bottom frame of the base for this purpose.
5. Drill holes for the anchors through the holes in the base
flanges.
Table 2–1. Drilling Specifications
6. Secure the base to the floor using the 1/2 x 4-1/2" stud
anchor bolts provided.
Drill Bit Size 1/2"
Embedment 1 1/4"to 3 1/2"
Torque 50 ft.-lb.
5/16-18 FASTENERS
(2 EACH AT 6 PLACES) WOOD SUPPORT FORK LIFT
CAUTION

Installation
2–4
7. Lay the two track/frame assemblies into the base so that
the floor lift weldments are toward the center of the washer,
as shown in Figure 2–3. Base/Sump Components
Figure 2–3. Base/Sump Components
8. Lay the six floor grates in the tracks into the track/frame
assemblies.
9. Lay the masonite sheets over the floor grates to protect
from scratches while you complete the installation.
10. Position the four channel fillers (two on each end of the
washer) in the floor and secure each with two #10-32 x 3/8"
phillips head screws.
11. Install the four threshold assemblies in the floor.
There are two sizes: the longer threshold is installed on the rear (non-
service side) of the washer, one on each end. The shorter threshold is
installed on the front (service side) of each end.
a. Position one threshold assembly in its appropriate
location with the gasket facing toward the inside of the
washer.
b. Secure the assembly to the washer base with two #10-
32 x 3/8" phillips head screws.
FLOOR LIFT WELDMENTS
TRACK/FRAME ASSEMBLY FLOOR GRATES (6)
CHANNEL FILLERS THRESHOLD ASSEMBLIES
(2 PLACES AT EACH END) (2 PLACES AT EACH END)
NOTE