TRENT CaterSense-02 Installation and operation manual

CaterSense the Intelligent answer
CS-INST2-0.002
Model: CaterSense 02 Page 1 07-11
CaterSense -02
GAS SUPPLY CONTROL with
GAS PRESSURE PROVING
AND INTELLIGENT FLOW DETECTORS
INSTALLATION and COMMISSIONING
INSTRUCTIONS

CaterSense the Intelligent answer
CS-INST2-0.002
Model: CaterSense 02 Page 2 07-11
Product Overview
The CaterSense system is based on a range of products and ancillary equipment designed to meet the
ever changing requirements of the catering industry and associated regulations.
The system comes in four basic modes, you have selected
CaterSense -02 intelligent controller C/W current monitoring (on board
or remote) and optional Gas Pressure Proving
The controller has a unique “self-set” system which makes for easy system commissioning.
Contents
1.0 General Info
1.01 Opening the unit
1.02 Fixing details
1.03 Cable entry
1.04 Electrical connections
1.05 System mode and set-up (locations)
2.0 Set-up and commissioning
2.01 Initial Set-up
2.02 Mode Set-up
2.03 Functional Operation
2.04 Troubleshooting
2.05 System Checking
1.0 General Information
1.01 Opening the unit
The CaterSense unit is made up of the following component parts. Please ensure that all
components are present before proceeding.
Product code
Quantity
Description
CS-02-PCB-B1 1 CaterSense-02 enclosure base including main PCB
CS-02-F1 1 CaterSense-02 enclosure facia including PCB
CS-CABLE 1 200mm ribbon cable
CS-SP-01 1 CaterSense enclosure side panel (left)
CS-SP-02 1 CaterSense enclosure side panel (right)
CS-SP-03 2 CaterSense enclosure side panel restraining clip
SCR-03 4
CaterSense facia fixing screw
(No 8 x 3/4")

CaterSense the Intelligent answer
CS-INST2-0.002
Model: CaterSense 02 Page 3 07-11
1) To open the enclosure, first remove the snap-in clips at the bottom of the two side
panels: using a flat bladed screwdriver push the clip from below away from each side
panel.
2) Press the release pad on each side at the bottom of the enclosure and lift off each
side panel in turn by first pulling the bottom towards you. This will reveal the four
facia plate fixing screws.
3) Unscrew these four screws and lift the facia plate from the back box (3), ensuring that
the ribbon cable between the two PCBs has been unplugged at the main PCB end.
Place the screws, snap-in clips, side panels and facia plate in a safe place until the back box
has been fixed, wired and is ready for reassembly and set-up.
1.
3.
2.
x 2

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CS-INST2-0.002
Model: CaterSense 02 Page 4 07-11
1.02 Fixing details
The CaterSense unit has six (6) mounting holes
which can be used (as shown below)
Note: Ensure that the enclosure is mounted on a clean
and level surface away from the direct cooking area and
potentially wet areas.
1.03 Cable entry
The CaterSense unit has two knock-out
slots in the back of the enclosure (located at
the top) to enable back entry. The enclosure
has an area 190 x 25 mm which can be
drilled for conduit entry on the top edge of
the enclosure.
1.04 Electrical connections
The CaterSense system has two sets of terminals all mounted along the top edge of the main
PCB circuit board.
Terminals 1 to 22 are the smaller terminals (1.5 mm² cable) and are used for the
sensors (Screened cable must be used).
Terminals 29 to 34 are the larger terminals (4 mm² cable) and are for the power
connections for the fans, gas valve and power supply to the unit.
The terminals are of the rising clamp type protection.
All cabling should be kept to the top of the unit within the designated area. No cables should
be placed or laid across the PCBs as they may cause damage.
SENSOR 1 SENSOR 2 FIRE
ALARM
REMOTE
KOPB
GAS VALVE
OUTPUT
POWER
SUPPLY
E NL
E N
L
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
REMOVE JUMPER LINK TO ACTIVATE DEVICE
J27 J26 J23 J25
4 Amp Max
24v 0vS+ S- 24v 0vS+ S-
NOT USED
168
230
244
BOTTOM
TOP
12
3
4
56
41mm
60mm
41mm
22mm
DETAIL OF SLOT KNOCK-OUTS
60mm

GAS SOLENOID
VALVE
GSV-1
UNIT POWER
SUPPLY (240 Vac)
N
L
E
24v SIG
0v
LINK SHOWN FOR 3 WIRE SENSOR
FIRE ALARM
ONTA T
REMOTE
KNO K-OFF
OPTION
DIL SWIT H
SCHEMATIC WIRING
EQUIPMENT SCHEMATIC
LINK SHOWN FOR 3 WIRE SENSOR
GAS PRESSURE
SENSOR
GPS-1
USE N/O VOLT-FREE ONTA T
OFF
ON
1 4
24v SIG
0v
INTELLIGENT FLOW
DETE TOR
IFD01
DRAWN BYDRAWING No:DATE:
0 1 2 3 4 5 6 7 8 9
NOTES:
1) LO AL ISOLATION MUST BE PROVIDED IN A ORDAN E
WITH THE URRENT EDITION OF THE IEE REGULATIONS.
2) HE K MANUFA TURER'S WIRING DETAILS FOR ORRE T
ONNE TIONS AND SET-UP REQUIREMENTS.
3) ENSURE THAT THE SWIT HED POWER IS ORRE TLY FUSED
TO THE LOADING OF THE ATERSENSE AND PLANT ITEMS.
N L E
E
L
N
LO AL 240Vac
SWIT HED FUSED
POWER SUPPLY
(See Note: 3)
POWER SUPPLY
N L E
OUT
GAS VALVE
N L E
LO AL
ISOLATOR
(See Note: 1)
GAS VALVE
GAS VALVE OUTPUT
WITH POWER SUPPLY FROM CATERSENSE
CATERSENSE UNIT POWER SUPPLY
CIRCUIT BOARD LAYOUT
19/04/12 ST
ATERSENSE -2 IFD01 +GPP
FANS WIRING & ONNE TION DIAGRAM
Tel: 01782 - 844688 Fax: 01782 - 844772
IF IN DOUBT, ASK
1 2 3 4 5 6 7 8 9
10 11 12
29 30 31 32 33 34
SENSOR 1 SENSOR 2
FIRE ALARM KNO K-OFF ENGINEERS PIN
31 30 29
GSV-1
EXTRA T FAN
EXTRA T ANOPY
OOKING APPLIAN E
GAS SOLENOID
VALVE
34 33 32
N
N
LL
EE
GAS PRESSURE
SENSOR
GPS-1
N L E
29 30 31 1 3 2 E
GAS VALVE OUTPUT WITH POWER SUPPLY
FROM CATERSENSE VIA CS-GVJB-01
CS-GVJB-01
RED
BLA K
WHITE
PRESSURE
SENSOR
GPS-1
GAS VALVE
red
white black
red
white black
S-02-IFD01+GPP

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CS-INST2-0.002
Model: CaterSense 02 Page 6 07-11
1.05 System mode and set-up
The CaterSense unit is a number of intelligent control solutions in one controller. Each of the
solution types has a “Mode Code” which is set via a DIL switch mounted on the main PCB
circuit board. The CaterSense also has a unique “Self-set” system commissioning tool which
makes for easy system commissioning.
These devices are located on the left hand side of the main PCB, under the side cover, as
detailed below.
Follow the instructions in the next section for your model of CaterSense.
OFF
ON
1 2 3 4
SENSOR 1
SENSOR 2
KNOCK-OFF
FIRE ALARM
SET-UP
CONTROLLER
MODE DIL SWITCH
INPUT SELECTION
JUMPERS
ENGINEERS SYSTEM
SELF-SET BUTTON
MAIN PCB
SINGLE FAN
RIBBON CABLE
SOCKET
J27
J26
J25
J23
J13
J5J3

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Model: CaterSense 02 Page 7 07-11
2.0 Set-up and Commissioning
The set-up and commissioning of your CaterSense system is in two parts, Initial and Mode.
2.01 Initial Set-up
Once all of the wiring has been completed and tested and the system is ready to be set-up
and commissioned, the following sequence MUST be followed to ensure the CaterSense and
system operate correctly.
a) DIL Mode switch, Ensure the correct system code has been selected on the DIL
switch. This code is detailed on the wiring diagram for your installation.
b) Input Jumpers, Ensure that the correct input jumpers have been removed as
detailed on the System Mode page for your installation.
c) Sensor Links, If you are using four wire sensors in place of three wire type, remove
Link J3 & J5 as detailed on the System Mode page for your installation.
d) Ensure that fire alarm and knock-off
switches (if fitted) are all in the operational
position.
When all of the above stages have been completed,
re-assemble the CaterSense unit by reversing the
sequence described above in section 1.01.
NOTE: Ensure the ribbon cable is plugged in
correctly with the key pin (red stripe) at the top on
the main PCB, and at the bottom on the facia (see
diagram).

CaterSense the Intelligent answer
CS-INST2-0.002
Model: CaterSense 02 Page 8 07-11
2.02 Mode Set-up
Once the above has been carried out, the system is now ready to be powered up.
The CaterSense-02 unit is pre-set to close the gas solenoid valve if it detects gas pressure
below 12 mbar. The unit also tests the integrity of the pipework during every start up by
opening the gas valve for 10 seconds, and then closing it for 30 seconds. If a significant drop
in pressure is detected during this time, the CaterSense unit will not open the valve. The
CaterSense-02 has an inbuilt facility to open the gas valve for a maximum of 5 minutes to
allow for system checking.
The gas valve will open for a maximum of 5 minutes to allow for system checking. The
internal gas pressure test can then be activated.
Ensure the fans are running at the lowest speed. Allow system to run and settle.
If the fan is monitored via an external source, and the "fan healthy" signal is provided from a
volt-free contact, ensure that the contact is closed.
4) PRESS SYSTEM CONDITION
GAS VALVE
FAN
All other LEDs
3) PRESS GAS VALVE
GAS VALVE
SYSTEM CONDITION
GAS PRESSURE
START
RESET / GPT
10 sec
30 sec
2) PRESS GAS VALVE
START
RESET / GPT
1) PRESS SYSTEM CONDITION
(Hold for 3 secs) GAS VALVE
GAS PRESSURE
FAN
All other LEDs

CaterSense the Intelligent answer
CS-INST2-0.002
Model: CaterSense 02 Page 9 07-11
The system will produce a short beep. Change the speed of the fans to the highest speed
IMPORTANT – allow system to run and settle.
If the fan is monitored via an external source, and the "fan healthy" signal is provided from a
volt-free contact, ensure that the contact is closed.
The set-up is now complete and the system is ready to run.
Note: Please refer to section 2.05 (System Checking) before starting the CaterSense
unit to ensure that it has been successfully commissioned.
5) PRESS SYSTEM CONDITION
GAS VALVE
FAN
All other LEDs
6) PRESS GAS VALVE
All other LEDs

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Model: CaterSense 02 Page 10 07-11
2.03 Functional Operation
The operation of the CaterSense unit and system in this Mode is as follows:
In the event of a system fault (i.e. gas pressure fault, fan failure, knock-off button depressed,
fire alarm detected) the system must be reset by pressing SYSTEM STOP, or for systems
with remote start/stop, opening and closing the enable contact.
On systems with remote start/stop, if the local SYSTEM STOP pad is pressed, the system
stops immediately. This can be reset by either pressing SYSTEM STOP again, or by opening
and then closing the enable contact.
PRESS
GAS VALVE
GAS VALVE OPENS
GAS PRESSURE
All other LEDs
GAS VALVE GAS VALVE CLOSES
SYSTEM CONDITION
GAS VALVE
GAS PRESSURE
All LEDs GAS VALVE OPENS
START
RES
ET
/
GPT
10 sec
30 sec
1 min
OR CLOSE "ENABLE"
CONTACT
PRESS
GAS V
ALVE
GAS VALVE CLOSES
All other LEDs
SYSTEM
STOP
GAS SHUT OFF
OR OPEN "ENABLE"
CONTACT

CaterSense the Intelligent answer
CS-INST2-0.002
Model: CaterSense 02 Page 11 07-11
2.04 Troubleshooting
2.041 - SYSTEM STOPPED
Cause: - The system has been stopped
Solution: - Press "Start" key to begin startup sequence
2.042 - FIRE ALARM
Cause: - The link between terminals 9 and 10 has been broken (fire alarm
activated).The fan and gas valve outputs will be deactivated.
Solution: - Ensure fire alarm is not activated. Check wiring to fire alarm interface panel.
The system must be reset by pressing "STOP" before it can be restarted.
2.043 - KNOCK OFF BUTTON
Cause: - The link between terminals 11 and 12 has been broken (knock off
pressed). The gas valve output will be deactivated.
Solution: - Ensure remote knock off button has been released. Check wiring to remote
knock-off button. The system must be reset by pressing "STOP"
before it can be restarted.
2.044 – FAN – LOW AIRFLOW
Cause: - The indicated fan is drawing less airflow than the minimum airflow
established during commissioning.
Solution: - Ensure fan is working correctly.
Use the diagnosis mode to establish any problems with set-up.
The system must be reset by pressing "STOP" before it can be restarted.
POWER ON GAS VALVE
SYSTEM CONDITION
REMOTE KNOCK OFF GAS PRESSURE
FIRE ALARM FAN
POWER ON GAS VALVE
SYSTEM CONDITION
REMOTE KNOCK OFF GAS PRESSURE
FIRE ALARM FAN
POWER ON GAS VALVE
SYSTEM CONDITION
REMOTE KNOCK OFF GAS PRESSURE
FIRE ALARM FAN
POWER ON GAS VALVE
SYSTEM CONDITION
REMOTE KNOCK OFF GAS PRESSURE
FIRE ALARM FAN

CaterSense the Intelligent answer
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Model: CaterSense 02 Page 12 07-11
2.045 - FAN – HIGH AIRFLOW
Cause: - The indicated fan is drawing more airflow than the maximum airflow
established during commissioning.
Solution: - Ensure fan is working correctly.
Use the diagnosis mode to establish any problems with set-up. The system
must be reset by pressing "STOP" before it can be restarted.
2.046 - GAS PRESSURE FAULT 1
Cause: - The system has failed its initial gas pressure test.
Solution: - Ensure all gas appliances are off. Check wiring to gas pressure sensor.
Check gas pressure. The system must be reset by pressing "STOP" before it
can be restarted.
2.047 - GAS PRESSURE FAULT 2
Cause: - The gas pressure has dropped below 12mbar during normal running.
Solution: - See above.
2.048 - EMERGENCY STOP
Cause: - The system has been manually stopped by pressing SYSTEM STOP
Solution: - Reset the system by pressing SYSTEM STOP a second time.
If the above does not solve your problem, contact Trent Products.
POWER ON GAS VALVE
SYSTEM CONDITION
REMOTE KNOCK OFF GAS PRESSURE
FIRE ALARM FAN
POWER ON GAS VALVE
SYSTEM CONDITION
REMOTE KNOCK OFF GAS PRESSURE
FIRE ALARM FAN
POWER ON GAS VALVE
SYSTEM CONDITION
REMOTE KNOCK OFF GAS PRESSURE
FIRE ALARM FAN
POWER ON GAS VALVE
SYSTEM CONDITION
REMOTE KNOCK OFF GAS PRESSURE
FIRE ALARM FAN
* Only on modes with gas pressure proving

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Model: CaterSense 02 Page 13 07-11
2.05 System Checking
As an aid to system commissioning, CaterSense has a diagnostic tool which can be used to
quickly check that the stored settings are suitable for correct operation.
To access this tool,
In this mode, the FAN 1 and FAN 2 LEDs will instantly react to the current being drawn by the
attached motors. By slowly adjusting the speed control for the motors and observing the
LEDs, the parameters can be quickly checked and problems identified.
If the current is at a "fault" level for longer than 30s, a system fault would occur during normal
operation. It is normal for current draw to fall outside normal levels for a few seconds whilst
changing speeds. Allow fan to settle at each speed. IF IN DOUBT, ASK.
Diagnostic mode also allows the manual opening of the gas valve for testing purposes, for a
maximum of 5 minutes.
To leave diagnostic mode, press .
PRESS
GAS VALVE
GAS VALVE OPENS
GAS VALVE GAS VALVE CLOSES
START
RESET / GPT
5 mins
FAN 1 or FAN 2 LED: Low Airflow Fault
Low Airflow Warning
Fan Healthy
High Airflow Warning
High Airflow Fault
PRESS GAS VALVE
SYSTEM CONDITION
All other LEDs
SYSTEM
STOP
GAS SHUT OFF

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Notes:

CaterSense the Intelligent answer
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Model: CaterSense 02 Page 15 07-11
Notes:

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FOR FURTHER TECHNICAL ASSISTANCE, PLEASE CONTACT US BY
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
Web site: www.trentproducts.com
Note: i) Ensure that the electrical installation has been installed in
accordance with the current edition of the IEE regulations.
ii) Ensure that the gas installation has been installed in
accordance with the current gas regulations (GAS SAFE).
iii) If in doubt, ask! (contact us on or by any of the above).
iv) Ensure that the client has been shown how to operate the
system and that they have been handed the users guide
TRENT PRODUCTS
Trent House
Dewsbury Road
Fenton
Stoke-on-Trent
Tel: [phone] Fax: [phone]
This symbol on this product or the package indicates that disposal of this
product after its lifecycle could harm the environment.
DO NOT dispose of this product (or batteries if used) as unsorted municipal
waste. It should be disposed by a specialised company for recycling.
This product should be returned to your distributor or to a local recycling
service.
Respect the local environment rules.