Henny Penny FlexFusion FPG-221 Operating and maintenance instructions

Maintenance
instructions
FM08-901A • 2/3/2023
FM08-901A en-US
Read the Operating instructions before starting maintenance
FlexFusion® GAS
PLATINUM COMBI incl.
grease collection Model
FPG-221

Manufacturer
MKN Maschinenfabrik Kurt Neubauer GmbH & Co. KG
Halberstädter Strasse 2a
38300 Wolfenbüttel
Germany
Phone [phone]
Fax [phone]
Internet www.mkn.com
Copyright
All rights concerning texts, graphics or images in this documentation remain property of MKN
Maschinenfabrik Kurt Neubauer GmbH & Co. KG. Any reproduction or distribution without prior written
consent of MKN is prohibited.
Copyright by MKN Maschinenfabrik Kurt Neubauer GmbH & Co. KG
2 Maintenance instructions

Directory of contents
3Maintenance instructions
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.............................................................................  20
7.2Opening and closing the control panel........................................ 21
7.2.1Opening the control panel .......................................................................  21
7.2.2Closing the control panel.........................................................................  21
8Performing maintenance ................................................. 22
8.1Complaints from the operator....................................................... 23
8.2Checking the overall state of the unit .......................................... 23
8.2.1Operating panel.......................................................................................  23
8.2.2Supply air supply cooking chamber.........................................................  23
8.2.3Supply air electronics ..............................................................................  24
8.3Check all existing tray trolleys...................................................... 24
8.3.1Align combi steamer................................................................................  25
8.4Check housing................................................................................ 25
8.4.1Cleaning the steam outlet........................................................................  26
8.5Check cooking chamber................................................................ 27
8.5.1Cooking chamber ....................................................................................  27
8.5.2Lighting....................................................................................................  27
8.5.3Internal core temperature sensor ............................................................  28
8.5.4Cooking chamber sensor and protective basket .....................................  28
8.5.5Fan wheel, heating element and water inlet............................................  28
FM08-901A

Directory of contents
4 Maintenance instructions
8.6Check oven door ............................................................................ 29
8.6.1Check Preheat strip.................................................................................  29
8.6.2Door latch ................................................................................................  30
8.7Check water connection ................................................................ 30
8.8Check gas connection ................................................................... 31
8.9Check flexible conduits ................................................................. 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 ............................................................... 36
8.16.1Check date and time .............................................................................  36
8.16.2Are there any current error messages?.................................................  37
8.17Clean and check Grease Collection ........................................... 37
8.17.1Clean grease collection system.............................................................  37
8.17.2Function test grease separator..............................................................  38
8.17.3Function test Automatic flushing ...........................................................  38
8.18Restoring the unit to operability ................................................. 39
9Completing the maintenance .......................................... 40
10Acceptance of maintenance.......................................... 43
FM08-901A

Introduction
5Maintenance instructions
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 experi-
ence 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 profes-
sional knowledge on the basis of his training and
experience, and who is sufficiently familiar with
the relevant regulations, guidelines and rules cov-
ering the particular technology, that he can as-
sess the safe operating condition of the system.
•The person must be named in writing by the spe-
cialist 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 spe-
cialist company concerned
FM08-901A

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.
After 12 months, after 6 months under heavy workload (more than 12 hours
per day)
•Overall state of the unit
•Operating unit
•Power supply
•Electrical components
•Water connection
•Waste water connection
FM08-901A

Notes on safety
7Maintenance instructions
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.
FM08-901A

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.
FM08-901A

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

Description of unit
10 Maintenance instructions
a b c d
Image: Rear of device
a Grease pump cover c Grease drain hose
b Guide sleeve d Grease trap
4.1.1 Tray trolley
a
i
c
h
g
b
d
e
f
Image: Tray trolley with retraction system EasyIn
a Holder cleaning cartridge f Roller with brake
b Slide-in frame (tray rack) g Handle bar
c Grease guide plate h Tub with drain
d Sliding roller (ball bearing) right/
left
i Warning
e Roller
FM08-901A

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

Description of unit
12 Maintenance instructions
4.1.4 Gas screens
a
Image: Gas fitting with gas orifice
a Gas orifice with seal
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)
FM08-901A

Description of unit
13Maintenance instructions
Unit size 215 221
Chloride Cl (mg/l) < 100
Iron Fe (mg/l) < 0.2
Connection pressure (kPa (psi)) 200 (29) — 600 (87)
Connection size (") 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)
Connection size (") R 3/4
Water consumption, steaming
Softened drinking water (l/h
(gal/h))
36 (9,51) 48 (12,68)
Water consumption, combisteaming
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
Waste water type Dirty water, maximum 80 °C (176 °F)
Dimension (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
Dimension (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.
Connection dimension in
accordance with EN10226-1 (")
R 3/4
Dimension (only US version) (") 3/4 NPT
Connection pressure (hPa (lbf/
sqft))
Natural gas 2H, 2E, 2L, 2LL *
20 (41,8)
FM08-901A

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)
Dimension (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 0 110 -20 120
101 — 110 0 110 0 120
111 — 120 0 120 0 120
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 E 12 (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
FM08-901A

Description of unit
15Maintenance instructions
Exhaust gas values
Gas type CO2 at high power (high) CO2 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
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)
FM08-901A

Description of unit
16 Maintenance instructions
B/P B/P P LP gas B/P LP gas B/P
gas E
LP gas B/P
FL50, BP29,
PX275
* upper Wobbe index, data apply at 0 °C (32 °F) and 1013,25 hPa (2115,34 lbf/sqft)
** in undiluted exhaust gas
FM08-901A

Special tools, testing and measuring equipment
17Maintenance instructions
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
•Exchange mirror
•Voltmeter
•Clamp-on ammeter
•Hex key, size 5
•Spirit level
•Personal protective equipment
•Measuring cup with scale, capacity approx. 1 litre
FM08-901A

Entering the order data and nameplate information
18 Maintenance instructions
6 Entering the order data and nameplate information
Order data
Date:
Name and location of customer:
Company performing the work:
Order number:
The nameplate contains all important data and information about the
present unit.
It is attached to the outside of the unit's housing. A second nameplate
is located inside the unit behind the operating panel.
BTU/h 100000
Gas Food Service Equipment
ANSI Z83.11b / CSA 1.8b - 2009
SN: XXXXXX
0,60 kW 120 V 1NPE AC 60 Hz
Water pressure 29-87 lbs/sq.in. IPX5D
Typ: XXXXXX
www.hennypenny.com
Eaton, Ohio / USA
Build: 2020 - 11
b dc e
f
g
ih
a
n
ml k j
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 nameplate
Test criteria Remarks / values Yes No
•Present.
•Legible.
In case of no.
Check if the nameplate is present inside the device.
Nameplate not legible or not present: Do not carry out any further work and contact customer service.
FM08-901A

Entering the order data and nameplate information
19Maintenance instructions
General information Yes No
Enter serial number (c)
SN:
General information Yes No
Enter the data of the type plate
SN: Type:
Heat load (calorific value):
Electrical connection:
Item no.: (if available)
FM08-901A

Opening and closing the housing
20 Maintenance instructions
7 Opening and closing the housing
DANGER Risk of personal injury and property damage from electric shock
• Before working on the unit, ensure that the unit is dead.
• Do not operate the unit with the housing open.
CAUTION Risk of injury from sharp edges
• Wear protective gloves.
NOTICE Risk of property damage from damage to the lines
• 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. Unscrew the screws on the holder.
2. Remove holder.
3. Unscrew the screws at the bottom of the side panel.
4. Pull the bottom edge of the side wall forwards.
5. Remove the side wall.
7.1.2 Attaching the side wall
NOTICE Risk of property damage from leaky housing
• Check seals when attaching the housing parts.
FM08-901A