Henny Penny FlexFusion FPG-221 Operating instructions

Model
FPG-221
Service-in-
structions
FlexFusion® GAS
PLATINUM COMBI incl.
grease collection
Translation from the original document • FM06-143A • 2/3/2023
FM06-143A en-US

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
2 Service-instructions

Directory of contents
3Service-instructions
1Password overview ............................................................ 7
2Introduction......................................................................... 8
2.1About this manual ............................................................................ 8
2.2Warranty............................................................................................ 8
3Safety instructions ............................................................. 9
4Description of operation.................................................. 10
4.1DynaSteam...................................................................................... 10
4.2WaveClean ...................................................................................... 11
5Opening and closing the unit.......................................... 13
5.1Control panel .................................................................................. 13
5.2Side wall .......................................................................................... 14
6Component overview ....................................................... 15
6.1Operating panel / control............................................................... 15
6.2Left side........................................................................................... 16
6.3Right side ........................................................................................ 19
6.4Rear side ......................................................................................... 20
7Service menu - appliance test......................................... 21
7.1Service menu .................................................................................. 21
Accessing the Service menu ...........................................................................  21
Service menu overview ...................................................................................  22
7.2Appliance information.................................................................... 23
7.3Status information.......................................................................... 24
7.4CombiDoctor................................................................................... 27
7.5Relay test ........................................................................................ 30
7.6WaveClean Test.............................................................................. 32
7.7100°C + core temperature calibration........................................... 33
7.8DynaSteam test .............................................................................. 36
7.9Emptying the water ........................................................................ 37
7.10Data and time................................................................................ 37
7.11Installation height......................................................................... 38
7.12Audio settings .............................................................................. 38
7.13Select signal tones....................................................................... 39
7.14Exporting log data........................................................................ 39
7.15Software update ........................................................................... 40
7.16Importing additional content....................................................... 40
7.17Importing manufacturer's cookbook .......................................... 41
7.18Load OEM settings....................................................................... 41
7.19Restoring data .............................................................................. 41
FM06-143A

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4 Service-instructions
7.20Backing up data............................................................................ 41
7.21Water filter maintenance.............................................................. 42
7.22Importing contact data................................................................. 42
7.23Setting units.................................................................................. 42
7.24Backup relay ................................................................................. 43
7.25Settings parameters..................................................................... 45
7.26Backing up the SD card ............................................................... 47
7.27Restoring the SD card.................................................................. 47
7.28Background lighting..................................................................... 48
7.29Hour meter .................................................................................... 48
7.30Status overview direct access .................................................... 48
7.31Favorites mode settings .............................................................. 49
7.32Select the cookbook .................................................................... 49
8Sam's Club settings ......................................................... 50
8.1Access service area ....................................................................... 50
8.2Loading settings............................................................................. 50
8.2.1Enter OEM code......................................................................................  50
8.2.2Select the cookbook ................................................................................  51
8.3Importing the manufacturer's cookbook...................................... 52
9Software ............................................................................ 53
9.1Software update ............................................................................. 53
9.2Importing additional content......................................................... 55
10Trade show mode........................................................... 57
11Electronics ...................................................................... 58
11.1Overview of the controller ........................................................... 58
11.2Layout of the control board......................................................... 59
11.3Configuration of the control board............................................. 60
11.4Safety overview ............................................................................ 62
12Gas technology .............................................................. 64
12.1Basic principles............................................................................ 64
12.2CO2 setting ................................................................................... 65
12.3Converting the gas type .............................................................. 71
12.4Checking the connection pressure ............................................ 74
12.5Checking the offset pressure...................................................... 75
13Grease collection system .............................................. 77
13.1Description of operation.............................................................. 77
13.2Component overview grease collection system ....................... 78
13.3Circuit diagram overview grease collection system................. 80
13.4Cleaning and maintenance.......................................................... 80
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5Service-instructions
14Fault messages & troubleshooting............................... 82
14.1Overview ....................................................................................... 82
14.2Symbols for errors ....................................................................... 84
14.3Emergency operation................................................................... 85
14.4Temperature sensor area ............................................................ 86
Cooking chamber sensor defective (694, 695)................................................  86
Top cooking chamber sensor defective (696, 728) .........................................  87
Bottom cooking chamber sensor defective (697, 729)  ...................................  88
Core temperature sensor defective (699, 700)................................................  89
Internal core temperature sensor defective (714, 716) ...................................  89
Water vapor sensor defective (710) ................................................................  90
Siphon temperature very high (SOF_ID20, ID21) ...........................................  91
Risk of frost (TMP_ID72, MMI_ID51)...............................................................  91
Excess temperature in the cooking chamber (ID18, ID73)..............................  92
14.5Motor area ..................................................................................... 93
Fan defective or temperature limiter triggered (702) .......................................  94
Fan defective. Cooking program was cancelled (701) ....................................  96
Top fan defective. Automatic switching to emergency operation (703, 705) ..  96
Bottom fan defective. Automatic switching to emergency operation (704, 706)....
96
FAN_ID23: Fan error: Attempt to restart .........................................................  99
FAN_ID24: Upper fan fault: Attempt to restart.................................................  99
FAN_ID25: Lower fan fault: Attempt to restart.................................................  99
14.6Water area ................................................................................... 101
Water pressure too low (709) ........................................................................  101
Water pressure during WaveClean too low...................................................  103
14.7Electronics / control area .......................................................... 104
Overtemperature control (TMP_ID2) .............................................................  104
Critical temperature in the electronics (MMI_ID50) .......................................  105
Failure to access external EEPROM (SOF_ID12).........................................  106
Faulty CAN connection..................................................................................  106
5007: Not enough storage space for software update ..................................  106
5008: No new version found..........................................................................  106
5009: The application could not be started. Application is restarting. ...........  107
5010: The application could not be started. Restore configuration backup?.  109
5013: Application could not be restored! Restore to factory settings with OK.......
109
Unit was restarted after power failure............................................................  109
Door is open - cooking program was stopped...............................................  110
14.8Gas area ...................................................................................... 111
No gas (OTH_ID1).........................................................................................  111
No gas (top)(OTH_ID2) .................................................................................  112
No gas (bottom)(OTH_ID3) ...........................................................................  112
No flame (OTH_ID4)......................................................................................  112
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6 Service-instructions
No flame (top)(OTH_ID5) ..............................................................................  112
No flame (bottom)(OTH_ID6) ........................................................................  113
Error gas blower (OTH_ID7)..........................................................................  113
Error gas blower (top)(OTH_ID8) ..................................................................  113
Error gas blower (bottom)(OTH_ID9) ............................................................  113
Communication fault between I/O and ignition module (OTH_ID25).............  114
Communication fault between I/O and ignition module (top)(OTH_ID26) .....  114
Communication fault between I/O and ignition module (bottom) (OTH_ID27) ......
115
GAS_ID12: Gas error ....................................................................................  116
GAS_ID13: Flame fault during operation.......................................................  116
14.9Testing the gas components..................................................... 116
Checking the electrodes................................................................................  116
Inspection of the gas solenoid valve .............................................................  118
Testing the heat exchanger...........................................................................  119
14.10Grease collection system ........................................................ 120
Grease pump.................................................................................................  120
Solenoid valve flushing..................................................................................  121
FM06-143A

Password overview
7Service-instructions
1 Password overview
Range Password Description Described in
Service menu incl.
CO2 Gas calibration
1967 Service range for authorized
service technicians.
Service instructions
Installation /
commissioning
2100 Setting all basic parameters (for
example time / date).
Installation instructions
CO2 gas calibration 999 Verification and calibration of
exhaust emissions. Only for
energy type - gas.
Service manual
Installation manual
Network settings 2000 Input network addressing. Only
for units with touchscreen control.
Installation instructions
Basic settings / user 111 Setting of basic values for the
user, functions, software update.
Operating instructions
Lockscreen 369 Deactivating the lockscreen in
cooking mode. Only for units with
touchscreen control.
Operating instructions
Trade show mode 888 Activation / deactivation for
exhibition mode.
Service instructions
FM06-143A

Introduction
8 Service-instructions
2 Introduction
2.1 About this manual
This service manual contains information needed by the service
technician for professional and correct fault isolation, repair and
maintenance of the unit. The service technician must also observe
the contents of the installation instructions and the user manual.
Target group Target group for this service manual is qualified personnel who are
familiar with the technical functioning and operation of the unit and
have been trained to work on electrical units.
Figures All figures in this service manual are intended as examples.
Discrepancies can arise between this and the actual unit.
Spare parts To ensure the reliability of the unit and the individual components, it is
essential that only genuine OEM parts be used.
Spare parts can be identified exactly with the aid of the online
database.
2.2 Warranty
The warranty is void and safety is no longer assured in the event of:
•Modifications or technical changes to the unit,
•Improper use,
•Incorrect startup, operation or maintenance of the unit,
•Problems resulting from failure to observe these instructions.
FM06-143A

Safety instructions
9Service-instructions
3 Safety instructions
For servicing tasks, the service technician must be familiar with and
observe regional regulations.
In addition, the notes in the service manual must be observed.
DANGER Danger to life due to electric current
üDisconnect power prior to performing gas and electrical work.
• Disconnect unit from the mains supply and secure it against restart.
• Check to ensure absence of voltage.
DANGER Risk of fatal injury from gas
üDisconnect the unit from gas supply prior to performing gas installation
tasks.
• Lock site gas supply and secure it against restart.
FM06-143A

Description of operation
10 Service-instructions
4 Description of operation
4.1 DynaSteam
Overview
a
b
c
de
a Steaming appliance with pressure
switch
d Reduction
b Magnetic valve water vapor
elimination
e Water supply pipe
c Heat exchanger (up to approx.
50°degrees)
Description • The electronics control the DynaSteam steaming appliance. They
regulate the water quantity for generating steam. DynaSteam
guarantees, regardless of the water pressure, the precise supply
of the required quantity of water. The prerequisite for this is a
customer-supplied water flow pressure between 2 and 6 bar. The
water pressure is monitored using a pressure switch.
•The DynaSteam steaming appliance cannot be calibrated and is
completely electronically controlled.
•The heat exchange heats the water in advance up to 50°C. The
heat from the exhaust pipe is used for this.
•The water comes through the water supply pipe to the fan impeller
in the cooking chamber. The fan impeller creates small water
drops, which evaporate in the hot oven atmosphere. The water
evaporates in the cooking chamber and on the fan impeller. The
tapering of the hose stabilizes the water flow of the pulsing
steaming unit.
FM06-143A

Description of operation
11Service-instructions
4.2 WaveClean
Functional overview
a b c
a Magnetic valve K12 c Pump G24
b Pump G16
The following purification stages are available on the fully automatic
cleaning WaveClean:
•Short: duration of about one hour
•Normal: duration about two hours
•Extra: duration approximately three hours
Description 1. Testing the cooking chamber temperature.
Automatic cooling of the cooking chamber, if > 55°C.
2. Inserting the WaveClean cartridge.
3. Water exchange of siphon content by the siphon pump G24 and
solenoid valve K12.
4. Circulation of water by means of pump G16. Thus pre-cleaning of
the cooking chamber. Then anew siphon water exchange.
The heater heats the oven to 55°C.
5. Start cleaning.
Fan motor and WaveClean pump G16 active.
Heating active. Heating the cooking chamber to about 70°C.
The first layer of wax melts in the WaveClean cartridge. The
cleaner falls into the cooking chamber and mixes with water.
The fan motor operates in both directions of rotation and at
different speeds.
The cleaning phase duration depends on the selected
program.
FM06-143A

Description of operation
12 Service-instructions
6. A new water exchange of siphon content by means of the siphon
pump G24 and solenoid valve K12.
7. Start of rinsing.
Identical to step 5 (cleaning).
Differences: Heating of the cooking chamber to 92°C. The
second layer of wax melts in the WaveClean cartridge. The
rinse agent drops into the cooking chamber and mixes with
water.
Final rinse to bring the pH value to the normal level.
8. In the programs "normal" and "extra" additional drying of the
interior occurs by means of hot air.
9. Finally, an indicator for withdrawing the WaveClean cartridge
appears, and has to be confirmed.
INFORMATION Despite different cleaning durations, all cleaning steps require the same
amount of water.
During the cleaning process about 3 liters of water are provided by the steam-
ing unit into the oven.
WaveClean termination
INFORMATION WaveClean forced rinsing
The WaveClean forced rinse is automatically started by the operator in case of
failure or premature termination. The duration is 12 minutes. An entry is made
into the HACCP and in the diagnostic memory.
FM06-143A

Opening and closing the unit
13Service-instructions
5 Opening and closing the unit
5.1 Control panel
a
c
b
Image: Opening the control panel
a Lock (cam) b Operating panel
c Hex key
Opening the control panel
1. Insert hex key (5 mm ) into screw and turn it clockwise.
The operating panel is now unlocked.
The operating panel pops up automatically.
2. Withdraw the hex key.
Closing the control panel
NOTICE Damage due to vapor / moisture
There should be no gap between the control panel and housing.
1. Press and hold operating panel on the left.
Repeat as many times as necessary.
The operating panel snaps in audibly.
The operating panel is secured against unauthorized opening.
FM06-143A

Opening and closing the unit
14 Service-instructions
5.2 Side wall
BA
Image: A Sizes 6.x and 10.x; B Size 20.x
Removing the side wall
1. Unscrew the screws in the side wall.
2. Pull the bottom edge of the side wall forwards.
3. Remove the side wall.
Attaching the side wall
NOTICE Risk of property damage from leaky housing
• Check seals when attaching the housing parts.
• Replace damaged seals.
1. Insert top edge of side wall.
2. Carefully push the bottom of the side wall inward.
3. Secure the bottom of the side panel with screws.
4. Check that the side wall is in contact with the unit on all sides.
FM06-143A

Component overview
15Service-instructions
6 Component overview
6.1 Operating panel / control
A2
S0
A3
B1
B15
A1
B20
E1
SD
Image: Touch operating panel area - FKE/ FKG
A1 Control board A2 Operating panel
A3 Digital memory B1 Core temperature sensor
B15 Reed contact switch B20 Loudspeaker
E1 Insert with LED lighting S0 On / Off switch
SD SD card
FM06-143A

Component overview
16 Service-instructions
6.2 Left side
Upper area
A10
K50
B11
G10
B100
E10
M10
F1 Q1
M8
G9
F2 F4 K40
B13
B0
A10 Ignition module B0 Thermoswitch 158°F NC
B11 Safety temperature limiter B13 Thermoswitch 122°F NO
B100 Glow electrode E10 Ionization electrode
F1 Fuse 10A, slow-blow F2 Fuse 10A, slow-blow
F4 Fuse 6A, slow-blow G9 Cooling fan (119 x 119mm)
G10 Gas fan K40 Relay
K50 Gas magnetic valve M8 Lift magnet
Q1 Main contactor
FM06-143A

Component overview
17Service-instructions
Lower area
T2
R1 X1
G8
T1
B4
T10
B14
K20 K12/ K41
G24
G16
T3
K30
G7
M20 T20
A20
K60
E20
G20
B200 B12
X2
FM06-143A

Component overview
18 Service-instructions
A20 Ignition module B4 Vapor sensor
B12 Safety temperature limiter B14 Pressure switch
B200 Glow electrode E20 Ionization electrode
G7 Cooling fan (180 x 180 mm) G8 Cooling fan (180 x 180 mm)
G16 Circulation pump G20 Gas fan
G24 Drain pump K12
K41
Solenoid valve Steam
Solenoid valve Flushing Grease
system
K20 DynaSteam unit with
pressure switch
K21 DynaSteam unit without
pressure switch
K60 Gas magnetic valve M20 Fan motor
R1 Filter T1 Transformer (supply)
T2 Transformer for glow
electrode (top)
T3 Transformer for glow electrode
(bottom)
T10 Power supply for fan motor
(top)
T20 Power supply for fan motor
(bottom)
X1 Power connection terminal X2 Ethernet port
FM06-143A

Component overview
19Service-instructions
6.3 Right side
E3
B2
B3
E4
FKE/ FKG – View of right side
B2 = To cooking chamber sensor
B3 = Bottom cooking chamber sensor
E3 = Cooking chamber light
E4 = Cooking chamber light
FM06-143A

Component overview
20 Service-instructions
6.4 Rear side
G40
C40
Image: Grease collection system
C40 Capacitor G40 Pump grease system
FM06-143A