Henny Penny FPG-121 Installation Manual
INSTALLATION MANUAL
FlexFuison® PLATINUM GAS COMBI
FPG-615
FPG-621
FPG-115
FPG-121
FPG-215
FPG-221
Directory of contents
2
1
Introduction
5
1.1
About this manual
5
1.1.1
Explanation of signs
5
1.2
Use of the unit
7
1.3
Warranty
7
2
Safety information
8
3
Description of the unit
11
3.1
Overview of the unit
11
3.2
Planning drawing
13
3.3
Equipment and connection data
14
3.3.1
Connection pressure
16
3.3.2
Gas blower speed
17
3.3.3
Exhaust gas values
17
3.3.4
Gas orifice size
18
4
Transporting the unit
19
4.1
Transport information
19
4.2
Transporting to the installation site
19
4.2.1
Transporting on a pallet
20
4.2.2
Transporting without a pallet
20
4.2.3
Transporting by raising and lowering
22
4.3
Unpacking the unit
22
5
Setting up the unit
23
5.1
Lifting the unit off the pallet
23
5.2
Placing the unit on the equipment legs
24
Directory of contents
Directory of contents
3
5.3
Setting up the unit on a work surface
24
5.4
Aligning the unit
25
5.4.1
Aligning countertop units
26
5.4.2
Aligning floor-standing units
26
5.5
Maintaining minimum clearances
28
6
Connecting the unit
29
6.1
Opening and closing the housing
29
6.1.1
Removing and attaching the side panel
29
6.2
Checking the supply air and exhaust gas routing
30
6.2.1
Description of the supply air and exhaust gas routing
31
6.3
Making the electrical connection
33
6.3.1
Notes regarding the electrical connection
33
6.3.2
Connecting the electric power cable to the unit
34
6.3.3
Connecting to the potential equalisation circuit
36
6.4
Connecting the unit to the network
36
6.5
Making the basic control settings
37
6.5.1
Opening the Setting menu
38
6.5.2
Changing the basic control settings
39
6.6
Making the water connection
40
6.6.1
Connecting hard and soft water
40
6.6.2
Connecting soft water twice
42
6.7
Making the wastewater connection
42
6.7.1
Connecting the wastewater line to a permanent connection
43
6.8
Connecting the gas
44
6.8.1
Notes about the gas connection
44
6.8.2
Description of the gas connection
45
6.8.3
Connecting the gas connection line
46
6.8.4
Checking for leaks
47
Directory of contents
4
6.8.5
Checking the connection pressure
49
6.8.6
Checking the basic gas setting
51
6.8.7
Adjusting the basic gas setting
56
6.9
Converting the gas type
61
6.10
Making the exhaust air connection
63
6.11
Checking operation
64
6.11.1
Checking the exhaust gas routing for leaks
65
6.11.2
Checking the monitoring of the exhaust gas routing
65
6.11.3
Checking the ignition behaviour
66
6.11.4
Checking the flame pattern
66
6.11.5
Checking the flame monitoring
67
6.11.6
Checking the controls
68
6.11.7
Checking the monitoring of the cooking zone door
68
6.11.8
Running the self-diagnosis
68
7
Putting the unit into service
70
7.1
Filling out the commissioning report
70
Introduction
1
About this manual
5
DANGER
Imminent threat of danger
Failure to comply will lead to death or very severe injuries.
WARNING
Possible threat of danger
Failure to comply can lead to death or very severe injuries.
CAUTION
Dangerous situation
Failure to comply can cause minor or moderate injuries.
1
1.1
Target group
Figures
1.1.1
Introduction
About this manual
The instruction manual is part of the unit and contains information on safe
installation of the unit.
Observe and adhere to the following instructions:
▪ Read the instruction manual in its entirety prior to installation.
▪ Make the instruction manual available to the installer at the operating site
at all times.
▪ Preserve the installation manual throughout the service life of the unit.
▪ Insert any supplements from the manufacturer.
▪ Pass on the installation manual to any subsequent operator of the unit.
The target group for the installation manual is trained technical personnel
that is familiar with installing and operating the unit.
All figures in this manual are intended as examples. Discrepancies between
these and the actual unit can arise.
Explanation of signs
1
Introduction
About this manual
6
SAFETY INSTRUCTIONS
Material damage
Failure to comply can cause material damage.
NOTICE
Information
Notes for better understanding and operation of the unit.
Symbol / sign
Meaning
▪
Listing of information.
Action steps, which can be
performed in any sequence.
1.
2.
Action steps, which must be
performed in the prescribed
sequence.
Result of a listed action.
Introduction
1
Use of the unit
7
1.2
1.3
Use of the unit
This unit is intended to be used solely for commercial purposes, particularly
in commercial kitchens.
This unit is certified in the following:
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.
2
Safety information
8
2
Ensuring conformity with
standards
Improper installation
Transportation and storage
Fire prevention
Organisational measures
Safety information
Observe applicable international, European and national laws, regulations,
standards and directives for the unit when transporting, setting up and
connecting it.
Risk of property damage and personal injury from improper
installation
▪ Install the unit only as specified in these installation instructions.
▪ Do not add anything to the unit or modify the unit.
▪ Use only original spare parts.
Risk of personal injury and property damage from improper
transportation and improper storage.
▪ Store the unit in a dry, frost-free environment.
▪ Observe the safety regulations for the lifting gear used.
▪ Attach the unit to the lifting gear securely during transport and setup, and
prevent it from dropping.
▪ Transport the unit in an upright position, do not tilt or stack.
▪ Pay attention to protruding parts when transporting the unit without
packaging.
Risk of fire from combustible surfaces
▪ Observe general fire prevention regulations.
▪ When setting up the unit in close proximity to heat-sensitive substances
or substances that pose a risk of fire, observe fire prevention regulations.
▪ The room's ceiling above the unit must be non-combustible.
Risk of fire from objects
▪ Do not obstruct the exhaust gas duct.
Risk of property damage and personal injury from lack of
organizational measures
▪ Identify hazard areas when transporting, setting up and connecting the
unit.
Safety information
2
9
Setup
Electrical connection
Gas connection
▪ Prior to starting the installation work, notify any operators present about
the procedure.
▪ Prior to starting the installation work, discuss how to behave in an
emergency.
▪ Use equipment and protective gear suitable for the activity.
▪ Brace housing components to prevent them from falling over and
dropping.
Risk of property damage and personal injury from improper
setup
▪ Ensure that the installation area has adequate load-bearing capacity.
▪ Where safety shoes and protective gloves.
Risk of fire from improper connection
▪ Observe applicable regional regulations of the electrical utility.
▪ Ensure that only licensed electricians connect the unit.
▪ Ensure that the electrical system is earthed by a protective earthing
conductor.
▪ Note the information on the nameplate.
Risk 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 absence of voltage.
▪ Use only insulated tools.
Risk of explosion and fire from improper connection
▪ Observe applicable regional regulations of the gas utility.
▪ Ensure that only a licensed tradesman 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
label.
Gas type
supplemental
2
Safety information
10
Additional connection work
Commissioning
▪ 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.
▪ Ensure that a maximum CO value of < 0.1 vol. % or < 1000 ppm is
achieved in undiluted exhaust gas.
Risk of fire from combustion gases and hot surfaces
▪ Maintain an adequate distance from grease filters on ventilation systems.
Risk of physical damage and personal injury from improper
connection
▪ Prior to working on the unit, switch off the unit, disconnect the unit from
the mains and prevent power from being switched on again. Check to
ensure absence of voltage.
▪ Prior to working on the unit, switch off the unit, close the gas supply and
secure it against being reopened.
▪ Route connection lines such that they cannot be damaged from heat.
Risk of property damage and personal injury from improper
commissioning
▪ Read the operating instructions prior to commissioning. Observe the
safety instructions in this installation manual and in the "Safety
information" chapter of the operating instructions.
▪ Put the unit into service only after a successful function test following
assembly.
▪ Put the unit into service only after it has reached room temperature.
▪ Observe the units during operation.
Description of the unit
3
Overview of the unit
11
a
Cooking zone door
h
Wastewater connection
b
Door handle
i
Opening for power connection
c
Operating elements
j
Gas connection on unit
d
Hand shower
k
Potential equalization connection
e
Equipment leg, vertically
adjustable
l
Steam outlet connection fitting
f
Hard water connection
m
Waste gas connection
g
Soft water connection
n
Air intake connection fitting
3
3.1
Description of the unit
Overview of the unit
G-FlexFusion, unit size 10
3
Description of the unit
Overview of the unit
12
a
Cooking zone door
i
Opening for power connection
b
Door handle
j
Gas connection on unit
c
Operating elements
k
Potential equalization connection
d
Hand shower
l
Air intake connection fitting
e
Equipment leg, vertically
adjustable
m
Waste gas connection, burner 2
f
Hard water connection
n
Steam outlet connection fitting
g
Soft water connection
o
Waste gas connection, upper fanassisted gas burner
h
Wastewater connection
G-FlexFusion, size 20
Description of the unit
3
Planning drawing
13
Unit size
a b c d e f g h 6.15, 6.21
500 (20)
1020 (40)
50 (2)
50 (2)
799 (31)
790 (31)
850 (33)
1640 (65)
10.15, 10.21
500 (20)
1020 (40)
50 (2)
50 (2)
799 (31)
1060 (42)
580 (23)
1640 (65)
20.15, 20.21
500 (20)
1075 (42)
50 (2)
50 (2)
813 (32)
---
---
1960 (77)
a-h= mm (in)
3.2
Planning drawing
Unit sizes 6 and 10
Unit size 20
3
Description of the unit
Equipment and connection data
14
Unit size
6.15
6.21
10.15
10.21
20.15
20.21
Dimensions
Unpacked unit
Length x width x height
cm
(in)
102 x 80 x
79
(40 x 31 x
31)
102 x 80 x
79
(40 x 31 x
31)
102 x 80 x
106
(40 x 31 x
41)
102 x 80 x
106
(40 x 31 x
41)
108 x 82 x
196
(42 x 32 x
77)
108 x 82 x
196
(42 x 32 x
77)
Packaged unit
Length x width x height
cm
(in)
96 x 108 x
102
(38 x 43 x
40)
96 x 108 x
102
(38 x 43 x
40)
96 x 108 x
128
(38 x 43 x
50)
96 x 108 x
128
(38 x 43 x
50)
96 x 116 x
220
(38 x 46 x
87)
96 x 116 x
220
(38 x 46 x
87)
Weight
Unpacked unit kg (lbs)
137 (302)
142 (313)
167 (368)
187 (412)
355 (783)
355 (783)
Packaged unit kg (lbs)
170 (375)
170 (375)
195 (430)
195 (430)
375 (827)
375 (827)
Heat loss
Latent (W)
2200
3400
3600
5200
7200
10400
Sensible (W)
1700
2600
2700
3900
5400
7800
Noise level (db (A))
<70
Ambient climate
5 – 40 °C (5 – 104°F), 95 % relative humidity, non-condensing
Electrical connection
Type of connection
1NPE 220-240 V AC 50/60 Hz
2PE 220-240 V AC 50/60 Hz
1NPE 100 V AC 50/60 Hz
Protection class
IPX5
Connected load (kW)
0.6
1.0
3.3
Equipment and connection data
Description of the unit
3
Equipment and connection data
15
Unit size
6.15
6.21
10.15
10.21
20.15
20.21
Recommended fusing (A)
16
Soft water connection
Carbonate hardness CaCO3
(mmol/l)
<0.9
Chloride Cl (mg/l)
<50
Iron Fe (mg/l)
<0.1
Connection pressure (hPa),
(bar)
200 - 600, 2 - 6
Connection (inches)
R ¾", male thread
Hard water connection
Carbonate hardness CaCO3
(mmol/l)
<4
Connection pressure (hPa),
(bar)
200 - 600, 2 - 6
Connection (inches)
R ¾", male thread
Wastewater connection
Discharge temperature (°C)
<80 (176°F)
Connection (mm)
Connection fitting, 50 mm (2in) diameter
Gas connection
Rated heat input (kW)
11
17
18
26
36
52
Gas type
The gas type for which the unit is set is indicated on the gas type
supplemental label.
Gas connection (inches)
R ¾", male thread EN10226-1
Connection pressure (mbar)
Natural gas 2H, 2E, 2L, 2LL
**
20
3
Description of the unit
Equipment and connection data
16
Unit size
6.15
6.21
10.15
10.21
20.15
20.21
Connection pressure (mbar)
Liquefied gas (LPG) 3B/P, 3P
**
50
Natural gas E/H, G20 (m3/h) *
1.14
1.76
1.87
2.70
3.74
5.40
Natural gas LL/L, G25 (m3/h)
*
1.33
2.05
2.17
3.14
4.35
6.28
Liquefied gas (LPG) B, G30
(kg/h) *
0.87
1.34
1.42
2.05
2.84
4.10
Liquefied gas (LPG) P G31
(kg/h) *
0.85
1.32
1.40
2.02
2.80
4.04
Combustion air (m3/h) *
15.0
22.5
22.5
32.5
45.0
65.0
Supply air and exhaust gas routing
Required delivery pressure
B
13BS
(Pa)
0 - 5
Exhaust gas temperature
B
13BS
°C (°F)
170
(338)
230
(446)
195
(383)
240
(464)
205
(401)
250
(482)
Exhaust gas mass flow rate
B
13BS
(kg/h)
30
47
49
71
99
142
Primary air gap cm (in)
3 – 5 (1-2)
*) Information applies at 15 °C (59°F) and 1013.25 mbar
**) Information is country-specific and applies in Germany; for further information, see "Checking the
connection pressure"
Gas type
Connection pressure (mbar)
Connection pressure range (mbar)
Germany:
Natural gas 2H, 2E, 2L (LL)
20
17 (18) - 25
3.3.1
Connection pressure
Description of the unit
3
Equipment and connection data
17
Gas type
Connection pressure (mbar)
Connection pressure range (mbar)
Liquefied gas (LPG) 3B/P, 3P
50
42.5 - 57.5
Europe:
Natural gas 2E, 2H, (LL)
20
17 (18) - 25
Natural gas 2E+, (2L)
20/25 (25)
17 (20) - 30
Liquefied gas (LPG) 3B/P, 3P
50
42.5 - 57.5
Liquefied gas (LPG) 3B/P (3P)
29 (30)
25 - 35
Liquefied gas (LPG) 3+ (3P)
28 - 30/37 (37)
20 (25) - 45
Liquefied gas (LPG) 3B
29
20 - 35
Unit size
Gas blower speed (rpm)
High output (HI)
Low output (LO)
6.15
5050 *
4800
6.21
6700
4800
10.15
5050
2800
10.21
6700
2800
20.15
5050
2800
20.21
6700
2800
* In deviation from the table, for unit size 6.15 the gas blower speed at the described setting and upon
verification of the rated heat input is 5500 rpm.
Gas type
Output
Unit size
CO2 (vol. %) *
p
offset
(hPa) **
CO (ppm) ***
Range
optimal
Range
optimal
Range
optimal
Natural
HI
All units
8.6 - 9.6
9.2
---
---
0 - 1000
<100
3.3.2
3.3.3
Gas blower speed
Exhaust gas values
3
Description of the unit
Equipment and connection data
18
Gas type
Output
Unit size
CO2 (vol. %) *
p
offset
(hPa) **
CO (ppm) ***
Range
optimal
Range
optimal
Range
optimal
gas
LO
6.15, 6.21
0.5 - 1.0
0.6
-0.8 - 0
-0.55
LO
10.15, 10.21,
20.15, 20.21
0.5 - 1.0
0.6
-0.4 - 0
-0.15
Liquefied
gas,
propane
HI
All units
10.0 - 10.6
10.3
---
---
LO
6.15, 6.21
0.5 - 1.0
1.0
-0.8 - 0
-0.55
LO
10.15, 10.21,
20.15, 20.21
0.5 - 1.0
1.0
-0.4 - 0
-0.15
Liquefied
gas,
butane
HI
All units
11.5 - 12.5
11.8
---
---
LO
6.15, 6.21
0.5 - 1.0
1.0
-0.8 - 0
-0.55
LO
10.15, 10.21,
20.15, 20.21
0.5 - 1.0
1.0
-0.4 - 0
-0.15
* At low output (LO) 0.5 - 1.0 lower than at high output (HI)
** Adjustment aid, offset pressure applies only at low output (LO)
** Undiluted exhaust gas
Orifice table
Unit size
Orifice size (1/100 mm)
Natural gas LL/L
Natural gas E/H
Liquefied gas, propane /
butane
6.15
720
650
470
6.21
650
565
420
10.15
650
565
420
10.21
680
600
460
20.15
630
565
420
20.21
630
565
420
3.3.4
Gas orifice size
Transporting the unit
4
Transport information
19
WARNING
Risk of property damage and personnel injury from tipping equipment
a) Do not linger next to or behind raised equipment.
b) Move raised equipment carefully.
SAFETY INSTRUCTIONS
Risk of physical damage from improper transport
a) Transport the unit upright.
b) Do not tilt or stack the unit.
c) Pay attention to protruding parts when transporting the unpacked unit.
4
4.1
4.2
Transporting the unit
Transport information
Crossing a grate with the tray trolley
Prior to transporting the unit to the installation site, ensure that:
▪ The route has adequate load-bearing capacity; place rails or metal plates
underneath if necessary.
▪ Wall openings are large enough. Removing the packaging reduces the
clear width required (see "Equipment and connection data").“
Transporting to the installation site
4
Transporting the unit
Transporting to the installation site
20
SAFETY INSTRUCTIONS
Risk of physical damage from improper lifting of the unit
a) Lift size 6 and size 10 units only with the aid of wooden beams placed
underneath.
4.2.1
4.2.2
Requirement
Transporting on a pallet
a) Move the pallet truck under the pallet.
b) Raise the unit on the pallet.
Transporting the unit on a pallet
c) Move the unit to the installation site.
Transporting without a pallet
Unit sizes 6 and 10
➢ Packaging removed except for the pallet
a) Move the pallet truck under the unit from the right.
b) Place the wooden beams on the lift forks and slide under the unit.
c) Lift the unit off the pallet.
Transporting the unit
4
Transporting to the installation site
21
Requirement
Transporting unit sizes 6 and 10 without a pallet
d) Move the unit to the installation site.
Unit size 20
➢ Packaging removed except for the pallet
a) Move the pallet truck under the guide rails of the unit from the right.
b) Lift the unit off the pallet.
Transporting unit size 20 without a pallet
c) Move the unit to the installation site.
4
Transporting the unit
Unpacking the unit
22
DANGER
Risk of fatal injury from falling unit
a) Do not linger under a suspended load.
b) Cordon off hazard area in compliance with regulations.
SAFETY INSTRUCTIONS
Risk of physical damage from tightened lifting straps
a) Always lift the unit with lifting straps and a spreader bar.
WARNING
Risk of injury from sharp edges
a) Wear protective gloves.
NOTICE
When unpacking the unit, inspect it for transport damage. Do not install
damaged units or put into service. Enter the information from the
nameplate into the commissioning report.
4.2.3
4.3
Transporting by raising and lowering
a) Guide the lifting straps under the pallet and attach them to the spreader
bar.
b) Brace the unit to prevent tipping.
c) Carefully lift the unit onto the pallet.
Unpacking the unit
a) Remove the packaging.
b) Pull the protective film off the unit.
c) Remove the packaging material from the cooking zone completely.
d) Lift the unit off the pallet and place in position.
e) Clean the unit (see "Cleaning and maintaining the unit").
f) Separate and dispose of the packaging material.
Setting up the unit
5
Lifting the unit off the pallet
23
WARNING
Risk of burns from spraying hot fat
a) Set up deep fat fryers outside the range of the hand shower.
CAUTION
Risk of crushing from improper setup
a) Protect the unit and work area during setup and alignment.
WARNING
Risk of fire from failure to observe applicable regional fire prevention
regulations
a) Observe applicable regional fire prevention regulations.
SAFETY INSTRUCTIONS
Risk of physical damage from overheating of the unit
a) Do not set up the unit close to heat sources.
CAUTION
Risk of property damage and personnel injury from tipping equipment
a) Do not linger next to or behind raised equipment.
b) Move raised equipment carefully.
SAFETY INSTRUCTIONS
Risk of physical damage from lifting the unit incorrectly
a) Place the forks of the lift truck next to the waste trap.
5
5.1
Requirement
Setting up the unit
The supply air and exhaust gas openings in the unit must not be obstructed
or closed.
Lifting the unit off the pallet
➢ Unit unpacked
➢ Protective film removed
➢ Unit cleaned
5
Setting up the unit
Placing the unit on the equipment legs
24
5.2
Requirement
5.3
Requirement
Lifting the unit off the pallet
a) Slide the forks of the pallet truck under the unit and to the right of the
waste trap.
b) Lift the unit off the pallet.
Placing the unit on the equipment legs
➢ The floor must carry the weight of the unit
a) Lift the unit with the pallet truck.
b) Move the unit to the installation site.
c) Place the unit on the floor.
d) Set up the unit in accordance with the planning drawing Planning
drawing .
Setting up the unit on a work surface
➢ The base frame must carry the weight of the unit
➢ Base frame levelled
➢ Base frame set up in accordance with the planning drawing Planning
drawing
a) Lift the unit.
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