FFPR26/KL44

Overview

The Champion FFPR26/KL44 is a single tank rack conveyor dishmachine fitted with a 26" front feed prewash section. It is one of the configurations documented in Champion's service and parts manual P/N 112844 Rev. I (March 2005) for the single tank rack conveyor family — a manual that also lists the 44KB, 54KB, 44WS, 66WS and KL66 machines and their PR22, PR36 and FFPR26 prewash versions. In the model code, FFPR26 denotes the 26" front feed prewash arrangement, combined here with the KL44 single tank machine from the same family. The manual carries Champion's Winston-Salem, North Carolina address (P.O. Box 4149, 2674 N. Service Road) and its Jordan Station, Ontario, Canada location (L0R 1S0), and PartHubz provides this manual for FFPR26/KL44 owners and service technicians.

On machines beginning with serial number 88503 and above, the manual's control panel layout (Fig. 62) shows a prewash contactor and a wash contactor alongside the tank and booster contactors, motor overloads, fuse block, 24V transformer, bus bar, drive, power connector, terminal block and the machine electrical connection plate — the prewash section has its own place in the machine's electrical circuit.

Key Features

• 26" front feed prewash: the FFPR26 prewash section runs ahead of the wash tank, with its own prewash contactor shown on the control panel for machines from S/N 88503 and above.
• Single tank rack conveyor operation: the pumps stop automatically shortly after the last rack leaves the machine while the conveyor continues to run; a STOP button on the control cabinet stops the machine at any point in the cycle, and restarting fully washes and rinses the items inside.
• Chemical automation connections: a removable black plug in the load end side of the wash tank accepts the detergent conductivity cell, and the rinse aid/sanitizer signal is 120VAC with a 1 amp maximum load.
• Curtain system: J-hooks in the corners of each section accept curtain rods; the manual specifies four curtain sizes and shows the short flaps of the long curtains facing the load end, with the longest curtains on each end of the dishwasher.
• Scrap management: scrap screens sit on supports above the tanks, with scrap baskets where applicable, and are cleaned every 2 hours of operation.
• Conveyor protection: the manual highly recommends a table limit switch, because racks left on the unload dishtable can jam the conveyor and damage the machine.
• Documented parts support: the Champion 109588 curtain, 900837 vacuum breaker repair kit and 111026 magnet are all listed for the FFPR26/KL44.

Replacement parts referenced for this model

• Champion 900837 — 3/4" vacuum breaker repair kit listed for the FFPR26/KL44; listed dimensions 2.54 x 2.54 x 2.54 cm, item weight 454 g.
• Champion 111026 — large gray magnet from Champion - Moyer Diebel, listed for the FFPR26/KL44 and other Champion models including the KL44, KL66, IDH-200, MD-1000HT, MD-1000LT, MD18-1, MD18-2 and P5.

The family parts manual also documents shared hardware and control components, including the 109069 thermostat with capillary, 107967 grip nut (1/4-20) with nylon insert, 112296 chemical connections label, 112352 timer socket, 108615 machine electrical connection data plate, 109014 terminal block, 103310 ground lug, 104873 ground label, 108498 fuse amps label, 313744 control cabinet cover, 110920 sealtite connector (1" x 90°), 106482 split lock washer (1/4"), 100097 truss head screw (10-32 x 1/2"), 106460 truss head screw (6-32 x 1/4") and 100100 round head screw (8-32 x 1/4"). For the electrically heated configurations in the same manual, it documents electric booster (40°F/22°C rise) assemblies with 18 kW heater elements in 208V, 240V and 480V versions, and notes to check the kW rating and voltage stamped on the heater flange.

Specifications

• Model: Champion FFPR26/KL44
• Type: Single tank rack conveyor with front feed prewash
• Prewash section: 26" front feed (FFPR26)
• Service & parts manual: Champion P/N 112844 Rev. I, March 2005
• Required final rinse pressure: 20-22 psi [138-151 kPa]
• Required final rinse temperature: 180°F/82°C minimum
• High limit thermostat: bimetal snap design, not adjustable; red reset button pops out when temperature exceeds 210°F/99°C
• Rinse aid/sanitizer signal: 120VAC, 1 amp maximum
• Standard long curtain: 24" x 20-1/4" [610mm x 515mm]
• High hood long curtain: 24" x 22-3/4" [610mm x 578mm]
• Standard short curtain: 24" x 13-1/4" [610mm x 337mm]
• High hood short curtain: 24" x 20-1/4" [610mm x 515mm]
• Control panel (S/N 88503 and above): prewash contactor, wash contactor, tank contactor, booster contactor, motor overloads, fuse block, 24V transformer, bus bar, drive, power connector, terminal block, machine electrical connection plate

Installation & Requirements

Before racks go in: the manual warns not to insert racks into the machine before the tanks fill with water — operating the pumps dry causes pump seal damage and leakage that can result in motor failure.

Commissioning steps from the manual:

• Remove any foreign material from inside the machine.
• Check to ensure the drains and overflow pipes are operational and sealed.
• Position the scrap screens on supports above the tanks.
• After the plumbing and electrical connections are completed, fill the tank and wait 10 minutes, then check all plumbing connections for leaks.
• Drain the tank and check the drain lines for leaks.

Curtain installation: hang the curtains as shown in the manual's illustrations. J-hooks are located in the corners of each section to accept the curtain rods. Make sure the short flaps of the long curtains face the load end of the dishwasher, and put the longest curtains on each end of the machine.

Chemical connections: install the detergent conductivity cell through the removable black plug in the load end side of the wash tank. The rinse aid/sanitizer signal is 120VAC with a 1 amp maximum load, and the manual's connection diagram shows 120V signal-only connections for the detergent and rinse aid/sanitizer common.

Table limit switch: the manual highly recommends installing one — racks allowed to remain on the unload dishtable can jam the conveyor and damage the machine.

Operation

• Racks must not be inserted before the tanks fill with water; dry pumps cause pump seal damage and leakage that can end in motor failure.
• Racks must pass through the final rinse at 20-22 psi [138-151 kPa] with a final rinse temperature of 180°F/82°C minimum.
• The pumps stop automatically shortly after the last rack leaves the machine; the conveyor continues to run.
• The STOP button on the control cabinet stops the machine at any time during the cycle; when restarted, items inside the machine are fully washed and rinsed.
• Clean the scrap screens and scrap baskets (if applicable) and replace the tank water every 2 hours of operation or after each meal period, and check the chemical supply.
• Do not allow racks to remain on the unload dishtable — this can jam the conveyor and damage the machine.
• Do not leave water in the tanks overnight.

Cleaning & Maintenance

The manual ties the machine's efficiency and service life to regularly scheduled preventive maintenance, and directs that intervals be shortened whenever the machine faces abnormal working conditions, hard water, or multiple shift operations.

Daily — every 2 hours of operation

• Turn the power switch to OFF.
• Remove all scrap screens and scrap baskets (if applicable) and pull the drain lever(s) to drain the water; clean the inside of the tanks and flush with clean water; backflush the scrap screens until clean — do not strike screens against solid objects.
• Remove the spray pipes with a 1/4 turn counterclockwise, remove the end plug from each pipe, and flush the pipe and nozzles until clean; do not strike spray pipes against solid objects. Replace the end plugs, verify the rubber seals are in place on the manifolds, and reinstall the spray pipes with a 1/4 turn clockwise.
• Remove and clean the curtains; hang them off the dishtable to dry.
• Leave the doors open between operations to allow drying.
• Verify the final rinse nozzles are clean and free of internal hard water deposits; clean the rinse nozzle orifices with a small paper clip. Consult your chemical supplier for the proper use and kind of deliming chemical.
• Report any unusual conditions to your supervisor.

As required

• Check the temperature and pressure gauge readings.
• Inspect the machine and check the pump motor for leaks around the shaft.
• Check chemical supplies and refill as necessary.

Weekly

• Inspect all water lines for leaks and tighten at joints if required.
• Clean all detergent residue from the exterior of the machine.
• Check the drain/overflow tube for leaks.
• Clean accumulated scale from the heating element.
• Remove and closely inspect each spray arm for blockage.
• Straighten a paper clip and use it to clear each rinse nozzle.

Troubleshooting

Insufficient pumped spray pressure

• Clogged pump intake screen — clean.
• Clogged spray pipe — clean.
• Scrap screen full — must be kept clean and in place.
• Low water level in tank — check the drain and overflow tube.
• Pump motor rotation incorrect — reverse the connection between L1 and L2 in the control cabinet (3-phase only).
• Defective pump seal — contact a service agent.

Insufficient or no final rinse

• Faulty pressure reducing valve — clean or replace.
• Improper setting on the pressure reducing valve — set the flow pressure to 20-22 psi [138-151 kPa].
• Clogged rinse nozzle and/or pipe — clean with a paper clip/delime.
• Improper water line size — have the installer change to the proper size.
• Clogged 'Y' strainer — clean or replace.

Low final rinse temperature

• Low incoming water — the manual directs you to check that the booster thermostat is set to maintain 180°F/82°C (noted for the KB and KPRB models in the family) and to check the valve is clean and operating.
• Defective thermometer — check for proper setting or replace.

Poor washing results

• Detergent dispenser not operating properly — contact the detergent supplier.
• Insufficient detergent — contact the detergent supplier.

Temperature controls and resets

Electric tank heat in this family is controlled by two thermostats: a control thermostat, wired normally closed, with an adjustment screw that increases tank temperature when turned clockwise; and a non-adjustable high limit thermostat whose red reset button pops out when the tank exceeds 210°F/99°C. Press the red button in to reset the high limit, then determine the cause of the high temperature condition. The manual's troubleshooting chart also lists a defective solenoid valve among the items to check or replace.

Applications

The FFPR26/KL44 suits high-volume warewashing where racks flow continuously through the machine instead of being washed in batches: busy restaurant dish lines, hotel and banquet kitchens, institutional and healthcare cafeterias, school and university dining halls, and catering operations with sharp meal-period peaks. The 26" front feed prewash section handles the first wash stage ahead of the main wash tank, and the conveyor format lets operators keep loading while the machine runs — the pumps stop on their own shortly after the last rack leaves. The detergent conductivity cell connection and the 120VAC rinse aid/sanitizer signal let the machine run with automatically dispensed dishwashing chemicals, and the manual's every-2-hours cleaning rhythm lines up with meal-period changeovers. PartHubz supplies the documented replacement parts for this model — the 109588 curtain, the 900837 vacuum breaker repair kit and the 111026 magnet — along with the machine's service and parts manual.