Henny Penny FlexFusion FPG-221 Manual

Read the Operating instructions before starting maintenance
FlexFusion® GAS
PLATINUM COMBI incl.
grease collection
FM08-901B en-US
Model
Maintenance
Instructions
FPG-221
FM08-901B • 2/22/2024

2
Maintenance instructions
Henny Penny Corporation
P.O. Box 60
Eaton, OH 45320
USA
Phone [phone]
Fax [phone]
Toll free in USA
Phone [phone]
Fax [phone]
www.hennypenny.com

Maintenance instructions
3
Directory of contents
1 Introduction .................................................................................. 5
1.1 About this manual ........................................................................................ 5
1.2 Personnel qualification ............................................................................ 5
2 Maintenance intervals ................................................................ 6
2.1 Required maintenance ............................................................................. 6
2.2 Recommended maintenance .................................................................. 6
3 Notes on safety ............................................................................. 7
4 Description of unit ........................................................................ 9
4.1 Flexi Fusion device overview .................................................................... 9
4.1.1 Tray trolley .................................................................................................10
4.1.2 Cooking chamber.......................................................................................11
4.1.3 Air inlet.......................................................................................................11
4.1.4 Gas screens...............................................................................................12
4.2 Unit and connection data ......................................................................... 12
5 Special tools, testing and measuring equipment ............... 17
6 Entering the order data and nameplate information .......... 18
7 Opening and closing the housing .......................................... 20
7.1 Removing and attaching the side wall ................................................. 20
7.1.1 Removing the side wall ..............................................................................20
7.1.2 Attaching the side wall................................................................................21
7.2 Opening and closing the control panel ................................................ 22
7.2.1 Opening the control panel ..........................................................................22
7.2.2 Closing the control panel............................................................................22
8 Performing maintenance ........................................................ 23
8.1 Complaints from the operator ................................................................. 24
8.2 Check all existing tray trolleys ............................................................... 24
8.2.1 Align combi steamer...................................................................................25
8.3 Check cooking chamber door and gasket ........................................... 26
8.3.1 Check Preheat strip ...................................................................................26
8.3.2 Door latch ..................................................................................................26
8.4 Checking the overall state of the unit ................................................... 27
8.4.1 Operating panel .........................................................................................27
8.4.2 Supply air electronics .................................................................................27
8.5 Check housing ........................................................................................... 28
8.6 Check cooking chamber ........................................................................... 28
8.6.1 Supply air supply cooking chamber............................................................28
8.6.2 Cooking chamber.......................................................................................29
8.6.3 Lighting ......................................................................................................29
8.6.4 Internal core temperature sensor................................................................29
FM08-901B

Directory of contents
4
Maintenance instructions
8.6.5 Cooking chamber sensor and protective guard.......................................... 30
8.6.6 Heat exchanger, fan wheel and water inlet ................................................30
8.7 Check water connection ........................................................................... 31
8.8 Check gas connection .............................................................................. 31
8.9 Check flexible hose lines ......................................................................... 31
8.10 Check waste water connection ............................................................ 32
8.11 Checking the condition of the electrical components ................... 32
8.12 Check components ............................................................................... 33
8.13 Check components gas .......................................................................... 34
8.14 Check software ...................................................................................... 36
8.15 Checking the power supply ................................................................... 36
8.16 Checking the controller .......................................................................... 37
8.16.1 Check date and time................................................................................37
8.16.2 Are there any current error messages?....................................................37
8.17 Clean and check Grease Collection on combi steamer ................ 38
8.17.1 Clean grease collection system................................................................38
8.17.2 Function test grease pump.......................................................................38
8.17.3 Function test Automatic flushing ..............................................................39
8.18 Restoring the unit to operability .......................................................... 39
9 Completing the maintenance .................................................. 41
10 Acceptance of maintenance .................................................. 44
FM08-901B

Maintenance instructions
5
Introduction
1 Introduction
1.1 About this manual
The maintenance instructions contain information about the safe
maintenance of the unit. Observe the following notes and adhere
to them:
• Read the maintenance instructions completely before starting
maintenance.
• Read the Operating instructions before operating the unit.
Target group: The target group for the maintenance instructions is trained specialist
personnel who are entrusted with the service, maintenance, and
operation of the unit.
Figures: All figures in this manual are intended as examples. Discrepancies
can arise between this and the actual unit.
Part replacement: The customer is informed about the need to replace parts and his
consent is obtained. Only original spare parts are used.
1.2 Personnel qualification
Explanation of qualification
Skilled personnel
• A skilled person is someone who, on the basis of
their technical training, knowledge and
experience as well as familiarity with the
applicable standards, can assess the assigned
work and recognize possible dangers.
Expert • An expert is a person, who has sufficient
professional knowledge based on training and
experience, and who is sufficiently familiar with
the relevant regulations, guidelines, and rules
covering specific technologies, that they can
assess the safe operating condition of the
system.
• The person must be named in writing by the
specialist company concerned, and the remit of
his authorized tasks must also be stated.
Type of activity Qualification
Electrical connection
• Electrician
• Specialized training
• Employee of the responsible technical company
Gas connection • Gas expert
• Specialized training
• Employee, who is named in writing, of the
specialist company concerned
FM08-901B

Maintenance intervals
6
Maintenance instructions
2 Maintenance intervals
2.1 Required maintenance
The manufacturer does not prescribe any mandatory maintenance of
the unit.
2.2 Recommended maintenance
The manufacturer recommends maintenance of the unit in
accordance with the following table.
FM08-901B
Overall state of the unit
Operating unit
Power supply
Electrical components
Water connection
Wastewater connection

Maintenance instructions
7
Notes on safety
3 Notes on safety
The maintenance personnel must be familiar with regional regulations
and observe them.
The maintenance personnel must observe the safety information in
these maintenance instructions.
The maintenance personnel must also observe the "Safety
information" chapter in the installation instructions and operating
instructions of the unit.
Organizational measures Risk of property damage and personal injury from lack of
organizational measures
• Inform the operators present prior to starting the maintenance
work.
• Discuss how to respond to an emergency prior to starting the
maintenance work.
• Use equipment and protective gear suitable for the activity.
Electrical connection Danger of electric shock from live components.
• Prior to working on the electrical system, switch off the unit,
disconnect the electrical system from the mains and prevent
power from being switched on again. Check to ensure the system
is dead.
• Use only insulated tools.
• Do not put a unit with damaged operating elements into service.
Gas connection Risk of explosion and fire from improper connection
• Observe applicable regional regulations of the gas utility.
• Ensure that only a tradesman licensed by the gas supplier
connects the unit to the gas supply.
• Prior to working on the gas system, switch off the unit, close the
gas supply from the gas system and secure it against being
reopened. When bleeding air or degassing, ensure that the air and
gas are discharged to the outside in a technically correct manner
and without creating a risk.
• Observe the information on the nameplate and Gas type
additional shield.
• Check for leaks.
• When working on the gas system and units in buildings, ensure
that a hazardous gas-air mixture cannot form in the rooms.
Risk of poisoning from exhaust gases
• Ensure that exhaust gases are discharged properly and that the
necessary amount of combustion air is supplied.
FM08-901B

Notes on safety
8
Maintenance instructions
• Ensure that a maximum CO content of < 0.1 vol. % or < 1000 ppm
is achieved in undiluted exhaust gas.
Risk of fire from combustion gases and hot surfaces
• Install the unit such that there is no contact with combustible
surfaces.
• Maintain an adequate distance from grease filters on ventilation
systems.
Improper maintenance Risk of physical damage and personal injury from improper
maintenance
• Service the unit only as specified in these maintenance
instructions.
• Use only original spare parts.
Concluding activities Risk of damage to property and personal injury from improper
connections
• Reactivate all safety devices and check that they function
properly.
FM08-901B

Maintenance instructions
9
Description of unit
4 Description of unit
4.1 Flexi Fusion device overview
Image: Device with tray trolley and Grease Collection
a Tray rack k Unit leg
b Insulating disk l Nameplate
c Door handle m Grease container
d Cooking chamber door n
Grease drain hose
e Guide rail (right) o
Operating unit
f Tray trolley p Housing
g Handlebar q Air inlet nozzle
h Guide rail (left) r Waste gas connection
i USB port (covered) s Steam outlet nozzle
j hand shower
FM08-901B
s
r
a
q
b
p
c
o
d
n
m
g
f
e
l
kj
i
h

Description of unit
10
Maintenance instructions
4.1.1 Tray trolley
Image: Rear of device
a Grease pump cover c Grease drain hose
b Guide sleeve d Grease container
Image: Tray trolley with retraction system EasyIn
a Holder cleaning cartridge f Caster with brake
b Slide-in frame (tray rack) g Handlebar
c Grease drip tray h Pan with quick release
d Sliding caster (ball bearing) right/
left
e Caster
iWarning
a b c d
a
b
c
d
e
i
g
h
f
FM08-901B

Description of unit
Maintenance instructions
11
d
c
a
b
4.1.2 Cooking chamber
4.1.3 Air inlet
Image: Cooking chamber
a Air diverter c Cooking chamber sensors
b Heat exchanger d
Protective guard
The two cooking chamber sensors are located on the rear right inner
side in the cooking chamber.
Image: Supply air openings
a Ventilation grille
b Ventilation shaft
b
a
FM08-901B

Description of unit
12
Maintenance instructions
4.1.4 Gas screens
Image: Gas fitting with gas orifice
a Gas orifice with gasket
4.2 Unit and connection data
Unit size 215 221
Emissions
Noise level (db(A)) < 70
Steam output (g/h (oz/h)) 8400 (296,3) 16140 (569,31)
Steam output (m³/h (cuft/h)) 14,2 (501,1) 27,4 (966,9)
Latent heat loss (W) 5706 10962
Sensible heat loss (W) 4755 9135
Operating environment
Temperature (°C (°F)) 5 (41 ) — 40 (104 )
Relative humidity (%)
non-condensing
95
Cooking chamber light
Illuminant Halogen oven lamp 20 W 12 V G4
Energy efficiency class C
Electrical connection
Protective system IPX5
Type of connection 1NPE / AC 50/60 Hz
Voltage (V) 120
Connected load (kW) 1.0
Recommended fuse (A) 16
Type of connection 1NPE / AC 50/60 Hz, 2PE / AC 50/60 Hz
Softened drinking water connection
Water type Softened drinking water, cold
Residual hardness CaCO3
(mmol/l (ppm))
< 1 (100 ppm)
FM08-901B
a

Description of unit
Maintenance instructions
13
Unit size 215 221
Chloride Cl (mg/l) < 100
Iron Fe (mg/l) < 0.2
Connection pressure (kPa (psi)) 200 (29) — 600 (87)
Diameter (") R 3/4
Drinking water connection
Water type Drinking water, cold
Carbonate hardness CaCO3
(mmol/l (ppm))
< 4 (400 ppm)
Connection pressure (kPa (psi)) 200 (29) — 600 (87)
Diameter (") R 3/4
Water consumption, steaming
Softened drinking water (l/h
(gal/h))
36 (9,51) 48 (12,68)
Water consumption, Combi Steaming
Softened drinking water (l/h
(gal/h))
8 (2,11) 10,6 (2,8)
Water consumption, WaveClean cleaning program
Softened drinking water (l (gal)) 3 l (0,79)
Drinking water (l (gal)) 32 l (8,45)
Waste water connection
Wastewater type Dirty water, maximum 80 °C (176 °F)
Diameter (mm (in)) 50 (1,97)
Maximum length (m (ft)) 1 (3,3) with downward slope of at least 5% or 3°
Temperature resistance (°C
(°F))
95 (203 )
Maximum flow rate (l/min (gal/
min))
10 (2,64)
Exhaust air connection
Diameter (mm (in)) 73 (2,87) 73 (2,87)
Maximum length (m (ft)) 2,5 (8,2)
Temperature resistance (°C
(°F))
180 (356)
Gas connection
Rated heat input (kW) 36 52
Gas type The gas type, for which the unit is set, is indicated on the gas type supplemental
label.
Diameter according to
EN10226-1 (")
R 3/4
Diameter (US version only) (") 3/4 NPT
Connection pressure (hPa (lbf/
sqft))
Natural gas 2H, 2E, 2L, 2LL *
20 (41,8)
FM08-901B

Description of unit
14
Maintenance instructions
Unit size 215 221
Connection pressure (hPa (lbf/
sqft))
Liquid gas 3B/P, 3P *
50 (104,4)
Natural gas E/H, G20 (m³/h
(cuft/h)) **
3,74 (132) 5,4 (190,6)
Liquefied gas P G31 (kg/h (lb/
h))
2,8 (6,17) 4,04 (8,91)
Combustion air (m³/h (cuft/h)) ** 45 (1587,9) 65 (2293,7)
Supply air and exhaust gas routing
required conveying pressure
B13BS (Pa)
0 — 5
Exhaust gas temperature B13BS
(°C (°F))
205 (401) 250 (482)
Exhaust gas mass flow B13BS
(kg/h (lb/h))
99 (218,3) 142 (313,11)
Diameter (mm (in)) 155 (6,1) x 1 (0,04) 155 (6,1) x 1 (0,04)
* Information is country-specific and applies in Germany; for further information, see "Checking the connection pressure"
** Data valid at 15 °C (59 °F) and 1013,25 hPa (2115,34 lbf/sqft)
Transformer voltage
Type of connection 1NPE / AC 50/60 Hz
Voltage range (V) 100 — 120
Transformer T1 T2 / T3
Wire identification or color blue red blue red
Voltage measured (V) Voltage at transformer (V)
90 — 100 0110 -20 120
101 — 110 0110 0120
111 — 120 0120 0120
Gas connection pressure
Gas type
Dynamic pressure (inch WC
(mbar))
Dynamic pressure range (inch WC
(mbar))
Natural gas A 8 (20) 6.8 - 10 (17 - 25)
LP Gas B/P gas E12 (30) 17 - 23 (42.5 - 57.5)
Gas blower speed
Unit size Gas blower speed (rpm)
High output (High) Low output (Low)
221 6700 2800
FM08-901B

Description of unit
Maintenance instructions
15
Exhaust gas values
Gas type CO
2
at high power (high) CO
2
at low power (low)
CO (ppm)
range
CO (ppm)
optimal
Natural gas 8.6 — 9.6 % 0.5 - 1.2% lower than at high
setting
0 — 1000 < 100
Liquefied petroleum gas
(LP)
10.0 — 11.0 %
Gas orifice size, natural gas
E/H LL/L L K 13A Gas A
NGN,
NG174
Test gas G20 G25 G25 G25.3 G21 G20 G20,
Wobbe index (kWh/
m3)*
15.0 12.4 12.4 12.5 16.1 15.0 15.0
Range Wobbe index
(kWh/m3)*
12.0 — 16
.1
10.1 — 13
.1
11.5 — 13
.1
12.7 — 13
.3
14.5
— 16.3
12.0 —
16.1
12.0 —
16.1
Connection pressure
(hPa (lbf/sqft))
20 (41,8) 20 (41,8) 25 (52,2) 25 (52,2) 20 (41,8) 20 (41,8) 20 (41,8)
Primary air gap (mm
(in))
30 (1,18) — 50 (1,97)
CO content (ppm) *** < 1000 (optimum < 100)
Unit size Aperture size (1/100 (mm (in)))
215 565
(22,24)
650
(25,59)
650
(25,59)
650
(25,59)
N/A** 590
(23,23)
565
(22,24)
221 565
(22,24)
640 (25,2) 640 (25,2) 640 (25,2) N/A** 580
(22,83)
565
(22,24)
* Upper Wobbe index, data apply at 0 °C (32 °F) and 1013,25 hPa (2115,34 lbf/sqft)
** For information on manually setting the rated heat input, (see "Adjusting the basic gas setting").
*** in undiluted exhaust gas
FM08-901B

Description of unit
16
Maintenance instructions
Gas orifice size, liquefied gas
B/P B/P P LP gas B/P
LP gas B/P
gas E
LP gas B/P
FL50, BP29,
PX275
Test gas G30/G31 G30/G31 G31 G30/G31 G30/G31 G30/G31,
Wobbe index (kWh/
m3)*
25.7 / 22.5 25.7 / 22.5 22.5 23.5 25.7 / 22.5 25.7 / 22.5
Range Wobbe index
(kWh/m3)*
21.4 — 25.7 21.4 — 25.7 21.4 — 22.5 21.4 — 25.7 21.4 — 25.7 21.4 — 25.7
Connection pressure
(hPa (lbf/sqft))
50 (104,4) 30 (62,6) 37 (77,2) 28 (58,5) 30 (62,6) 50 (104,4)
Primary air gap (mm
(in))
30 (1,18) — 50 (1,97)
CO content (ppm)** < 1000 (optimum < 100)
Unit size Aperture size (1/100 (mm (in)))
215 420 (16,54) 420 (16,54) 420 (16,54) 420 (16,54) 420 (16,54) 420 (16,54)
221 400 (15,75) 400 (15,75) 400 (15,75) 400 (15,75) 400 (15,75) 400 (15,75)
* Upper Wobbe index, data apply at 0 °C (32 °F) and 1013,25 hPa (2115,34 lbf/sqft)
** in undiluted exhaust gas
FM08-901B

Special tools, testing and measuring equipment
Maintenance instructions
17
5 Special tools, testing and measuring equipment
The following tools and measuring instruments are needed for
maintenance:
• Pressure gauge, measuring accuracy at least 0.1 mbar
• Exhaust gas measuring device (for CO² measurements)
• Voltmeter
• Amp meter
• Hex key, size 5 mm
• Bubble level
• Personal protective equipment
• Measuring cup with scale, capacity approx. 1 liter
• Floor jack (for aligning the device)
• USB stick with current software
FM08-901B

Entering the order data and nameplate information
18
Maintenance instructions
www.hennypenny.com
6 Entering The Order D ata and N ameplate I nformation
I. Henny Penny Service P rovider I nformation
Company: Company Phone:
Address: City:
State/Province: Postal Code:
Email Address:
II. Store Information
Store ID Number: Store Phone:
Address: City:
State/Province: Postal Code:
Email Address:
The nameplate contains important data and information regarding the unit.
It is attached to the outside of the unit's housing. A second nameplate is located inside the
unit behind the operating panel.
Image: Nameplate data
a Manufacturer h Barcode
b Electrical connected load i
Connection pressure for water
c Serial number j Year of manufacture
d Type of connection k
Gas connection value
e Type number l Test criteria
f Frequency m Manufacturer's web address
g Protective system n Certificate
Checking The D ata Plate
Test Criteria Yes No
•Does the unit have a data plate attached, and is it legible?
FM08-901B
a
b
c
d
e
Eaton,
Ohio / USA
f
n
g
m
l
k
j
i
h

Entering the order data and nameplate information
Maintenance instructions
19
Checking The Data Plate
Test Criteria
Remarks / values
If No,
Check if the data plate is present inside the device. If either
the data plate is not legible or not present, then:
1. Open the Service menu.
2. Display unit information.
3. Serial number and type designation are available.
General information
Enter serial number (c)
SN:
Enter type (e)
Type:
FM08-901B

Opening and closing the housing
20
Maintenance instructions
7 Opening And Closing the Housing
Risk of P ersonal I njury and P roperty D amage from E lectric S hock
• Before working on the unit’s housing, ensure that the unit is not connected to
an electrical outlet.
• Do not operate the unit with the housing open.
Risk of Property Damage from Damage to T he L ines
• Remove and attach housing components carefully.
7.1 Removing and Attaching the Side Wall
7.1.1 Removing the Side Wall
Image: Removing the side wall
1. Remove the screws on the trolley handle holder using a flat-head
screwdriver.
2. Remove trolley handle holder.
3. Remove the screws at the bottom of the side panel using a 7 mm
hexagon screwdriver.
4. Pull the bottom edge of the side wall forward.
5. Remove the side wall.
NOTICE
DANGER
FM08-901B
•Wear protective gloves.
CAUTION