Getinge 7800A Series User manual

7800A SERIES
FLOOR MOUNTED
CART & UTENSIL
WASHER
INSTALLATION INSTRUCTIONS
61301604981 Rev. B

7800A SERIES
FLOOR MOUNTED
CART AND UTENSIL
WASHER
INSTALLATION INSTRUCTIONS
Getinge USA, Inc.
1777 East Henrietta Road
Rochester, New York 14623-3133
Phone: [phone]
Facsimile: [phone]

ii
INSTALLATION INSTRUCTIONS 61301604981
Rev. A (12/18/01)
Rev. B (09/29/03)
Related Publication:
Operator Manual 61301604768
Service Manual 61301605323
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 USA, Inc. It shall
not be reproduced in whole or in part without the written permission of
Getinge USA, Inc.
• POSSIBILITY OF INJURY: Misuse of equipment may result
in personal injury.
• POSSIBILITY OF EQUIPMENT DAMAGE: Misuse of
equipment may result in equipment damage.
The 7800A Washer is designed to clean and dry case carts,
stands, utensils, containers, tote boxes, and similar bulk items.
This equipment is NOT intended for use other than expressly
stated.
If the 7800A Washer is used in a manner not specified by
Getinge USA, Inc., the protection provided by the equipment
may be impaired.
Getinge® is a registered trademark.
Copyright ©2003 by Getinge USA, Inc.
NOTE
CAUTION
WARNING
NOTE
CAUTION
WARNING

61301604981 iii
Table of Contents
SAFETY LABELS USED ON THE EQUIPMENT. . . . . . . . . . V
Section 1 Installation Requirements
GENERAL DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . 1–1
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
UTILITIES AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . 1–2
INSTALLATION ADVISORY . . . . . . . . . . . . . . . . . . . . . . . 1–3
WASHER OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Size (Load Length). . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Floor Mount vs. Pit Mount . . . . . . . . . . . . . . . . . . . . . . 1–3
Left Side vs. Right Side Controls . . . . . . . . . . . . . . . . . 1–3
Left Hand vs. Right Hand Door Mounting . . . . . . . . . . 1–3
Barrier Flanges and Service Enclosure . . . . . . . . . . . . 1–3
Electrical Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Vented vs. Non-vented . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Purified Water Rinse . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Seismic Anchoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
SHIPPING CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . 1–4
TOOLS AND MATERIALS REQUIRED . . . . . . . . . . . . . . . 1–5
Section 2 Installation
ASSEMBLE THE WASHER STRUCTURE . . . . . . . . . . . . 2–1
Install the Base/Sump Assembly . . . . . . . . . . . . . . . . . 2–1
Position the Mechanical Core . . . . . . . . . . . . . . . . . . . 2–3
Assemble the Washer Panels . . . . . . . . . . . . . . . . . . . 2–5
Channel Fillers and Threshold Assemblies . . . . . . . . 2–11
Door Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12
INSTALL COMPONENTS ON THE OUTSIDE OF THE
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–14
Return Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–15
Washer Light Assembly . . . . . . . . . . . . . . . . . . . . . . . 2–16
Spray Manifold Drive Motor . . . . . . . . . . . . . . . . . . . . 2–17
Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–18
Dispenser Float Switch Junction Box, Detergent
Dispenser, and Rinse Aid Dispenser. . . . . . . . . . . . . 2–19
Emergency Stop Switch. . . . . . . . . . . . . . . . . . . . . . . 2–21
Unload End Indicator Panel Box . . . . . . . . . . . . . . . . 2–22
Door Proximity Switches . . . . . . . . . . . . . . . . . . . . . . 2–23

iv
INSTALL COMPONENTS ON TOP OF THE WASHER . 2–24
Power Floor Tilt Pulley System . . . . . . . . . . . . . . . . . 2–25
Transformer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–27
Exhaust Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 2–28
Intake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–29
PLUMBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–30
ELECTRICAL WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . 2–32
INSTALL COMPONENTS ON THE INSIDE OF THE
WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–35
Drive Chain Tension Idlers and Idler Bearing . . . . . . 2–35
Chain Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . 2–36
Spray Manifold Supports and Spray Manifolds . . . . . 2–38
Manifold Cover, Manifold Guard Tubes, Wash Cart
Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–41
Emergency Stop Switch Cable . . . . . . . . . . . . . . . . . 2–43
FINAL INSTALLATION TASKS . . . . . . . . . . . . . . . . . . . . 2–44
Final Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 2–45
Dispenser Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–46
Barrier Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–48
Pit Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–49
Service Area Enclosure (Option). . . . . . . . . . . . . . . . 2–50
Ramps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–51
Exhaust Connection . . . . . . . . . . . . . . . . . . . . . . . . . 2–52
Plumbing System Connections . . . . . . . . . . . . . . . . . 2–52
Electrical Supply Connection. . . . . . . . . . . . . . . . . . . 2–52
Concluding Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–53
Section 3 Rough-In Drawings
Section 4 Seismic Anchoring Drawings

7800A Series Floor Mounted Cart and Utensil Washer
61301604981 v
Safety Labels Used on the Equipment
The following safety labels are used on the 7800A washer:
You must remove all power to the washer before removing the back cover
to the washer chamber light assembly.
High voltage is present inside the control box. You must remove all power to
the washer before opening the door to the control box.
If you change a fuse, you must use an equivalently rated replacement.
Refer to “Spare Parts”on page C-2 in the Operator Manual for a list of spare
fuses.
If you are inside the washer when someone closes the door, press firmly on
this label on the inside of either door to stop the washer, if applicable, and
open the door.
CAUTION
CAUTION

vi

61301604981 1–1
Section 1 Installation Requirements
General Description
The Getinge 7800A Series Floor Mounted Cart and Utensil Washer is a fully
automatic, large capacity, hydro-spray washer that is used to clean and dry
case carts, stands, utensils, containers, tote boxes, and similar bulk items.
The washer can be installed in a shallow pit or installed 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 of the chamber 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 at the load end door. After cleaning, the
items are removed from the unload end door at the opposite end of the
washer.
The washer is generally installed in a facility’s decontamination room with
the unload end door opening out into a clean-preparation area. The unit is
available in three sizes, which are determined by compartment length: 80"
(2032 mm), 98" (2489 mm), and 112" (2845 mm), and which correspond to
models 78003A, 78004A, and 78005A, respectively.
Treatment solutions are delivered by separate oscillating (back and forth)
wash and rinse manifolds equipped with spray nozzles. Detergent and rinse
aid solutions are dispensed automatically as a standard feature.
A standard cycle consists of the following sequential phases: wash,
standard rinse (or optional purified rinse), drying, and exhaust. The length of
a cycle’s phase can be adjusted at the touch control panel.
Figure 1–1. 7800A Series Floor Mounted Cart and Utensil Washer
HW-001

Installation Requirements
1–2
Model Identification
The rating plate for a 7800A washer is affixed to the inside of the control
box.
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, USA.
Figure 1–2. Rating Plate Location
Utilities and Specifications
Utility requirements and specifications are included on sheet 2 of the
appropriate rough-in drawing (pit mounted or floor mounted version). Refer
to “Rough-In Drawings”on page 3-1.

7800A Series Floor Mounted Cart and Utensil Washer
61301604981 1–3
Installation Advisory
A 7800A washer is assembled at the factory, tested, and 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.
Where applicable, installers should refer to specifications contained in the
product information documents, such as Assembly drawings, that have
been forwarded to local Getinge USA product support personnel. Rough-in
drawings can be found in “Rough-In Drawings”on page 3-1.
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.
Size (Load Length) There are three models of the 7800A washer, each corresponding to a
different compartment size, or load length (all models are the same width):
•78003A is 80" (2032 mm) long
•78004A is 98" (2489 mm) long
•78005A is 112" (2845 mm) long
All models have five or six side panels and three top panels. The middle
panel on the front (service) side, the end panels on the rear, and the top
panels at each end are common for all three washer lengths. The sizes of
the end panels on the front side, the middle panel on the rear side (if
applicable), and the middle top panel depend on the washer length.
Floor Mount vs. Pit Mount A floor mounted washer requires the installation of ramps to provide access
to the washer. The interior floor of a pit mounted washer is level with the
finished floor of the facility.
Left Side vs. Right Side
Controls
The location of controls on your washer also determines the location of the
service area, as well as the barrier flanges and service enclosure that may
be provided with your washer.
Left Hand vs. Right Hand
Door Mounting
The orientation of the load and unload door mountings determines the doors
and door panels for 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.
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.

Installation Requirements
1–4
Vented vs. Non-vented A vented washer has an automatic damper that connects directly to the
ventilation system of your facility. A non-vented washer has a condenser
(with associated electric and plumbing connections) mounted on the top of
the washer to remove moisture from the air that is exhausted from the
washer.
Purified Water Rinse An optional purified rinse phase uses water from the customer’s purified
water supply.
Printer If your washer has the printer option, the printer is already mounted on the
control box.
Seismic Anchoring If your washer has the seismic anchoring option, the sump assembly and
the mechanical core are secured to the floor.
Shipping Configuration
A disassembled 7800A washer is shipped on five pallets and one box of
various sizes. The maximum size of any one pallet may be as large as 130"
x 68", depending on the length of the unit. 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.

7800A Series Floor Mounted Cart and Utensil Washer
61301604981 1–5
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
USA.
Table 1–1. Tools Required
Table 1–2. Materials Required
Tool Quantity
Common Hand Tools Assorted
12' Pipe Clamp 2
C-Clamp 2
Johnson Bar 1
Pry/Pinch Bar 2
Caulking Gun 1
1/4-20 Tap, Short 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
Tape Measure 1
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 4" Stainless Steel Shims:
•12 ga
•14 ga
•16 ga
•18 ga
10
10
10
10

Installation Requirements
1–6
Four rigid 3/4" x 60" long pipes are recommended for use if a floor mounted
washer is to be assembled out-of-position, then moved to its intended
operational site. 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
Material Quantity

61301604981 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
•“Position the Mechanical Core”on page 2-3
•“Assemble the Washer Panels”on page 2-5
•“Channel Fillers and Threshold Assemblies”on page 2-11
•“Door Assembly”on page 2-12
Install the Base/Sump
Assembly
General Instruction
If the load or unload end of the base is not marked, check the configuration
of the sump against the rough-in drawing (page 3-1) 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
1. Move the base into its operating position.
Figure 2–1. Base/Sump Assembly
2. 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.
NOTE
SERVICE SIDE
SUMP

Installation
2–2
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, two 2 1/2" flanges (with anchor bolt holes)
must be bolted to the bottom frame of the base (one flange on each end of
the washer).
3. Drill holes for the anchors through the holes in the base
flange.
Table 2–1. Drilling Specifications
4. Secure the base to the floor using 1/2" bolt stud anchors
suitable for your floor structure.
Figure 2–2. Track/Frame Assembly
5. Lay the track/frame assembly into the base so that the floor
tilt weldments are on the non-service side of the washer.
6. Lay the floor grates in the track of the track/frame
assembly.
The 78003A model (88" long) has two 34" floor grates. The 78004A model
(106" long) has two 34" floor grates and one 16" floor grate. The 78005A
model (120" long) has two 34" floor grates and one 30 1/8" floor grate.
7. Lay the cardboard sheet over the floor grates to protect
from scratches while you complete the installation.
Drill Bit Size 1/2”
Embedment 2 1/4”minimum
Torque 50 ft.-lb.
CAUTION
TRACK/FRAME ASSEMBLY
FLOOR TILT
WELDMENTS
NOTE

7800A Series Floor Mounted Cart and Utensil Washer
61301604981 2–3
Position the Mechanical
Core
Objective
Position the mechanical core in its approximate location on the side of the
washer.
Installation
Refer to Figure 2–3. Mechanical Core.
Figure 2–3. Mechanical Core
Silicone primer (orange) is extremely flammable, harmful if
swallowed or inhaled, and harmful to eyes or skin. Wear
protective clothing, gloves, and eyewear 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 cosmetic
surfaces of the washer.
ADJUSTABLE LEGS
MOUNTING
BRACKET
HOLES
(4 PLACES
EACH SIDE)
(4 PLACES)
WARNING
CAUTION

Installation
2–4
1. Using a fork lift, move the mechanical core into place on
the service side of the washer, approximately one inch
away from where the washer side walls will be.
If your washer has a left-hand service area, one of the adjustable legs rests
on the pad on the right side of the sump box. If the washer has a right-hand
service area, one of the adjustable legs rests on the pad on the left side of
the sump box.
2. Clean mating surfaces on the dryer duct flange and around
the dryer duct cutout on the washer side panel with thinner,
and treat with silicone primer.
You will apply silicone caulk to the dryer flange after the washer walls are
assembled and just before you attach the mechanical core to the washer.
3. Set the washer light assembly on the dryer duct shelf.
•You will secure the light to the side panel after the washer panels are
assembled.
•If the return pump was shipped already attached to the sump, it may be
necessary to temporarily remove the pump until after the mechanical core
is positioned.
NOTE
NOTE
NOTES

7800A Series Floor Mounted Cart and Utensil Washer
61301604981 2–5
Assemble the Washer Panels Objective
Assemble the door, side, and top panels. Install the required number of
interior side panel seam cover strips.
The 7800A washers have five or six side panels and three top panels. The
middle panel on the front (service) side, the end panels on the rear, and the
top panels at each end are common for all three washer lengths. The sizes
of the end panels on the front side, the middle panel on the rear side (if
applicable), and the middle top panel depend on the washer length. The
service side middle panel provides the cutouts for the dryer air duct and for
the wash and rinse manifolds. The top panels at each end of the washer
provide the cutouts for the intake and exhaust assemblies.
Each side panel carries a number that matches the number on the base’s
frame. The width of a top panel is the width of the washer (52"). The side
panels have 7/16" diameter holes that carry 3/8" thru bolts (five on each
side of the washer) to hold the panels together. The top panels have holes
to carry two thru bolts.
There is no established order to follow for panel assembly. You can start
from the load or the unload end. You can assemble all the vertical panels
first, followed by the top panels; or you can add individual top panels as you
erect the vertical panels. The method illustrated below starts from the load
end and progressively adds top panels as the vertical panels are erected.
Installation
You must clean all mating surfaces with thinner, then treat with silicone
primer, and then apply a generous amount of silicone sealant. This includes
all instances where panels are secured to the washer base or to other
panels, as well as the seam cover strips inside the washer.
Silicone primer (orange) is extremely flammable, harmful if
swallowed or inhaled, and harmful to eyes or skin. Wear
protective clothing, gloves, and eyewear 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 cosmetic
surfaces of the washer.
NOTE
WARNING
CAUTION

Installation
2–6
1. Attach the load end door panels to the base.
There are two vertical panels, each with three mounting
holes at the top to attach to the horizontal panel.
a. Position a vertical panel and use a C-clamp to hold the
panel in place temporarily.
b. Secure the bottom of the panel to the base frame with
four 1/4-20 fasteners (1/2" hex head bolts and lock
washers) and remove the clamp.
c. Repeat steps a and b for the other vertical panel.
Figure 2–4. Door Panels
d. Secure the horizontal panel between the two vertical
panels with 1/4-20 fasteners (six each 1/2" hex head
bolts and lock washers).
e. Plumb and square the door opening.
2. Attach the load end rear (non-service side) side panel to
the base and to the load end door.
a. Position the load end side panel.
b. Partially insert five 3/8" diameter thru rods through the
7/16" diameter holes to stabilize and align the side
panel with the door panel.
c. Use pipe clamps to draw the panels tight.
d. Secure the bottoms of the side panel to the base frame
with 1/4-20 fasteners (1/2" hex head bolts and lock
washers).