CAT-1000-ORP Automated ORP Controller

Introduction

Congratulations on your investment in the Hayward CAT-1000-ORP Automated ORP Controller. This advanced microprocessor-based system is designed to provide substantially reduced chemical maintenance, improved water quality compliance, chemical cost savings, and years of reliable operation.

This manual provides comprehensive information on installation, operation, maintenance, and troubleshooting. Please read it thoroughly before beginning installation to ensure proper setup, avoid hazards, and prevent voiding the warranty.

It is assumed that the installer is familiar with pool or spa systems. Ensure all pumps, heaters, and related equipment are turned off and pressure is relieved before installation. If the filtration system is below water level, adjust valves to eliminate pressure.

Installation is comparable to a chemical feeder. Pool contractors or maintenance engineers should have the necessary tools and knowledge. Hayward's technical support is available for any questions.

Important Note: This controller is not a substitute for regular manual water testing. Never operate a water chemistry controller without a flow sensor, power interlock, or other safety measures to ensure chemicals are only fed when filtration is active.

Please complete and return your warranty registration.

Important Information

Chemical Automation with the CAT-1000-ORP

Unlike manual checks performed hourly at best, the CAT 1000 continuously monitors ORP (Oxidation Reduction Potential) and sanitizer activity. It automatically adjusts sanitizer feeding proportionally to demand, eliminating human error and inaccuracies. This ensures reliable chemical levels 24/7, compliance with safer water quality standards, reduced staff burden, and lower chemical usage costs.

Illustration 1: Manual vs. CAT Automated Control (Graph Description)

This graph illustrates the difference in water chemistry control. The 'Manual Control' line shows significant fluctuations in Chlorine (CL2) levels over a four-hour period, peaking and dropping sharply. In contrast, the 'CAT Automated Control' line demonstrates a stable, consistent level of Chlorine, maintained within a narrow, ideal range throughout the same period.

What is ORP?

Oxidation Reduction Potential (ORP) measures the quality and oxidizing capability of a water treatment component, such as chlorine, bromine, ozone, or hydrogen peroxide. Sanitizers are most effective in a properly balanced water body. ORP specifically quantifies the oxidizer's ability to react with contaminants, which is influenced by pH, alkalinity, dissolved solids, and temperature.

Oxidation is the loss of an electron by a substance. When a sanitizer interacts with unwanted substances, it steals an electron, altering the substance's chemical makeup. This process reduces the sanitizer's electrical energy, making it less effective.

Reduction occurs when a substance gains an electron. After oxidation, the sanitizer may lose its ability to oxidize further or combine with other substances, forming by-products or combined chlorine.

Potential refers to stored energy. In ORP, it relates to the sanitizer's potential to oxidize contaminants. This potential is measured in millivolts (mV). An oxidizer attempts to steal negatively charged electrons. When it steals an electron from an electrode (like an ORP sensor), the electrode generates positive energy, increasing the ORP reading. A higher ORP indicates a greater oxidizing potential.

Maintaining a proper balance is crucial. If the amount of reducers equals the oxidizers that have gained electrons, there is no potential for further oxidation, necessitating continuous sanitization.

pH is a critical factor. A lower pH (more acidic, 7.5 or below) increases the effectiveness of Hypochlorous Acid (HOCl), the stronger form of chlorine, thereby increasing ORP. Automated pH and ORP controllers monitor and adjust these levels to maintain safe water 24/7.

The standard ORP level for safe drinking water is designated as 650mV.

Components of the CAT-1000-ORP System

The CAT 1000 system comprises several key components:

• Professional-Series ORP Sensor: Samples water from the filtration system and transmits ORP (redox) signals to the controller. It measures sanitizer activity and water quality, not just chemical residual levels. The factory preset is 650mV.
• Flow Sensor (Required): Monitors water flow. It signals the controller to disable chemical feeding when the filtration system is off or flow is too low, ensuring safety and proper operation.
• Flow Cell: Provides a mounting location for the ORP sensor, ensuring optimal hydraulic conditions for performance and longevity.
• CAT 1000 Controller Unit: Scans and interprets signals from the ORP sensor, displays readings digitally, and activates the chemical feeder based on demand to maintain the setpoint. It features audible and visual alarms for out-of-range conditions and manual/disable feeding modes. An internal micro-computer ensures accuracy and ease of use via a touch-screen interface.

Installation

Package Contents

Upon unpacking, verify the following items are included:

• (1) CAT 1000 Water Chemistry Controller
• (1) Professional Series ORP Sensor with 24" Cable and BNC Connector
• (1) BNC Connector Protective Covers
• (1) Sensor Storage Container
• (1) CAT 1000 Owner's Manual
• (1) PVC Backboard with Mounting Holes and Stainless Hardware
• (1) Round Machined Acrylic Flow Cell assembled with:
• (2) 1/4" NPT x 3/8" Tubing Parker Ball Valves
• (1) Pressure Flow Switch with Cable
• (1) 30' Roll, Black Poly Installation Tubing (3/8" OD)
• (2) 1/4" NPT x 3/8" Tubing True-Seal Connectors

Report any shortages immediately to the factory.

Recommended Tools

• Drill (Cordless Preferred)
• 7/16" Drill Bit
• 1/4" NPT (National Pipe Tapered) Tap
• Masonry Drill Bit & Anchors (if required)
• 13/16" Wrench or Channel-Lock Pliers

Installation Procedures

Successful flow cell installation requires a pressure differential for water to pass through the cell and across the sensor. A pressure-suction "loop" line using a CAT Flow cell and fittings is recommended.

1. Turn off Heater, chemical feeders, pump, and all related equipment. Relieve pressure from the filtration system.
2. Select a convenient mounting location for the controller unit that meets these criteria:
   • Facilitates a combined (influent and effluent) tubing run of up to 30'.
   • Is at least ten feet from the pool or spa.
   • Has a GFI-protected power source available.
   • Is easily accessible to the pool or spa operator.
   • Is located away from corrosive materials and physical hazards.
3. Securely mount the Controller or PVC Backboard on a vertical wall.
4. Drill and tap a 1/4" NPT port downstream of the filter but upstream of any chemical injection point. Install a tubing connector and run the flex tubing to the influent flow cell port.
5. Drill and tap a 1/4" NPT port at a location subject to vacuum or reduced pressure. Install the remaining tubing connector and run flex tubing to the effluent flow cell port.
6. Remove the ORP sensor from its plastic storage bottle (save bottle and fluid for future use). Apply Teflon tape and thread the sensor into the flow cell.
7. Remove the BNC protective cover from the left side of the controller unit (store for future use). This cover protects against electro-static discharge (ESD).
8. Connect the ORP and Flow sensor cables to the controller unit as labeled. These cables are specialized and should never be cut or spliced.
9. If using new or additional chemical feeders, install them according to the manufacturer's instructions.
10. Connect the chemical feeder to the controller as labeled.
11. Check all electrical and mechanical connections. Resume filtration system operation and check for leaks.

Preparing Water Chemistry

Before powering on and setting up the CAT 1000, test and adjust water chemistry to conform to the following ranges:

CAT controllers maintain sanitizer levels based on ORP. While ORP is a superior indicator of water quality compared to parts-per-million sanitizer residuals, factors like pH, cyanuric acid, and total dissolved solids can affect sanitizer residual readings relative to ORP. Hayward recommends establishing desired levels for pH, sanitizer residual, calcium hardness, total alkalinity, temperature, and cyanuric acid before initiating automated control.

Operation

Once startup chemistry parameters are established, you can set the CAT 1000 for automatic ORP maintenance. Refer to Illustration 3 for button designations.

Changing the ORP Setpoint

The CAT 1000 is factory preset to maintain 650 mV, the standard for safe drinking water. To adjust the setpoint for specific pool/spa needs:

1. Manually test pool/spa sanitizer levels (chlorine, bromine, etc.) to determine the desired level.
2. Note the ORP reading displayed on the controller.
3. Press the ORP Setpoint Adjustment Button (#4) until the green "SET" LED illuminates.
4. Use the ORP Channel Increase (#2) or Decrease (#3) buttons to match the digital display to the previously noted ORP reading.
5. The controller will automatically return to normal operating mode after twenty seconds, saving the changes.

Adjust the ORP setpoint as needed to meet Health Department standards.

Manually Activating ORP Feed

To manually enable the ORP chemical feeder, press the ORP Channel Mode Selection Button (#5) until the green "MANUAL" LED illuminates. The feeder will operate for 30 minutes before reverting to "Auto" to prevent over-feeding.

Manually Disabling ORP Feed

To manually prevent ORP feeder operation, press the ORP Channel Mode Selection Button (#5) until the red "OFF" LED illuminates. Automatic ORP feeding will be disabled. The feeding cycle will not be interrupted for approximately ten seconds to allow user input.

Automatically Controlling ORP Feed

For automated control, press the ORP Channel Mode Selection Button (#5) until the green "AUTO" LED illuminates. The chemical feeder will operate automatically, proportional to the chemical demand. The feeding cycle will not be interrupted for approximately ten seconds to allow user input.

About Proportional Feed

The CAT 1000 uses an advanced proportional feed algorithm that analyzes chemical demand and initiates feeding in intervals based on the relationship between the setpoint and actual water sample values. This ensures precise water chemistry control.

CAT-1000-ORP Switch and Keypad Functions (Illustration 3 Description)

The controller features several buttons:

• Button 1: Hidden Button (behind "ORP" text)
• Button 2: ORP Channel Increase Button
• Button 3: ORP Channel Decrease Button
• Button 4: ORP Channel Setpoint Adjustment Button
• Button 5: ORP Channel Mode Selection Button

The front panel also includes indicators for FEED (Green LED #1), ALARM (Red LED #2), and a DIGITAL DISPLAY (#3) showing ORP or SETPOINT. Mode indicators include SETPOINT ADJUSTMENT (Green LED #4), AUTOMATIC (Green LED #5), MANUAL OFF (Red LED #6), and MANUAL ON (Green LED #7).

Advanced Setup Options

The CAT 1000 offers advanced features for various applications, typically configured during initial dealer setup.

Enhanced No-Flow Alarm

If the flow sensor detects no flow, the controller enters a "No-Flow" alarm. This triggers an audible alarm and disables controller operation until flow resumes. The LED display will show "no Flo".

Power on Display

Upon power-on, the controller displays its firmware version number on the ORP channel LED display (e.g., "6.12").

Entering Advanced Setup Mode

To access advanced settings:

1. Press and hold the Hidden Button (#1) for five seconds.
2. Use the Up (#2) or Down (#3) arrow buttons to scroll through programming options.
3. Press the Enter Button (#4) to make a selection.

ORP Proportional Feed (O.PF)

Selects between fixed setpoint or proportional control.

• OFF: ORP feed output is activated based on a simple above/below setpoint decision. Output turns OFF when ORP is >= setpoint, and ON when ORP is < setpoint.
• ON (Default): ORP feed output is activated based on the difference between the setpoint and measured ORP. The ON duration increases with the difference, cycling up to 50 seconds per 60-second cycle, and can become continuous.

ORP Overfeed Timer (O.OF)

Sets a time limit for the ORP feed output.

• OFF: ORP feed output remains active as long as an ORP feed condition is indicated.
• ON: An overfeed limit timer is enabled. If the feed output is active for longer than the set limit, the channel turns off and enters an overfeed alarm condition requiring manual reset. When set to ON, the feed output must be continuous for the overfeed time limit, rather than part of the proportional cycle.

The ORP overfeed timer is disabled when the ORP Feed Mode button is used to place the ORP channel in manual feed state.

Overfeed Timer Options:

• OFF (Unlimited time)
• 15 Minutes
• 30 Minutes
• 60 Minutes (1 Hour)
• 120 Minutes (2 Hours)
• 180 Minutes (3 Hours)
• 240 Minutes (4 Hours) - default

After an overfeed alarm, press the ORP Feed Mode button (#5) to return to off, manual, or automatic mode. This resets the alarm and timer. The alarm also resets if the controller is powered off and on.

ORP Low Alarm Limit (O.AL)

Sets the low alarm point. If measured ORP is less than this limit, an audible alarm sounds, and ORP feed is disabled. Feed resumes when ORP returns to the non-alarm range.

• Value Selection: 200 to 995mV (must be less than the high alarm value). Default: 525mV.

ORP Alarm High Limit (O.AH)

Sets the high alarm point. If measured ORP is greater than this limit, an audible alarm sounds, and ORP feed is disabled. Feed resumes when ORP returns to the non-alarm range.

• Value Selection: 400 to 995mV (must be greater than the low alarm value). Default: 900mV.

Clear All Programming and Restore Factory Defaults (C.Lr)

Resets all controller operating parameters to their factory default values.

Demonstration Mode (dEo)

Places the controller in Demo Mode for showroom displays or presentations.

Audible Alarm (Beeper) (bPr)

Enables or disables the audible alarm (default is enabled).

Serial Interface (Srl)

The CAT 1000 includes a standard RS232 serial interface. A header assembly and cable are required.

• Online Communications (Onl): For connection to a PC or building automation systems.
• Printer (Prn) (default): For connection to a CAT serial Printer, which records operating parameters (ORP, feed status, alarms) at 15-minute intervals.

After entering settings, press the Hidden Button or wait 30 seconds to return to default operating mode.

Display Functions

The CAT 1000 front panel features LED indicators and a digital display for status information.

• ORP Feed Indicator (#1): Illuminates when the ORP chemical feeder is automatically or manually activated.
• ORP Alarm Indicator (#2): Red illumination with an audible alarm signifies ORP is outside the safe operating range. Check feeder operation and chemical supply.
• ORP Digital Display (#3): Shows current ORP. Pressing the Setpoint Adjustment Button (#4) until the "SET" LED is lit displays the ORP setpoint.
• ORP Setpoint Adjustment Mode Indicator (#4): Green LED illuminates when in setpoint adjustment mode.
• ORP Automatic Control Indicator (#5): Green LED illuminates when under automated control.
• ORP Manual OFF Indicator (#6): Red LED illuminates when ORP feeding is manually disabled.
• ORP Manual On Indicator (#7): Green LED illuminates when ORP feeding is manually activated.

Maintenance

CAT 1000 Controller

The controller unit requires minimal maintenance. Clean the enclosure, front panel, and flow cell with a soft, damp cloth and mild soap or glass cleaner. Avoid abrasives or harsh chemicals, which can damage the unit.

Water Maintenance

Regularly test and record water chemistry readings using a quality manual test kit, adhering to Health Department requirements.

Sensor Maintenance

The ORP sensor must be clean and free from oil, chemical deposits, and contamination for proper function. Cleaning may be required weekly or monthly, depending on bather load and facility conditions. Slow response or inconsistent readings indicate the need for cleaning.

To clean the sensor: disconnect it from the controller, carefully remove it from the flow cell. Clean the reference junction (white Teflon ring) with a soft toothbrush and toothpaste, or mild liquid dishwashing detergent. Rinse with fresh water, replace Teflon thread-seal tape, and reinstall the sensor, hand-tightening only.

Never allow the ORP sensor to dry completely, as this will damage the reference junction and void the warranty.

Sensor Replacement

CAT Professional Series ORP sensors are engineered for high performance and longevity. If a cleaned sensor continues to provide unstable readings, it should be replaced with a genuine CAT Professional Series sensor.

Sensor Storage

Exposure to atmospheric conditions can dry out sensors. Always remove and store the ORP sensor in its provided soaking cap for periods longer than one hour. While freeze-resistant, sensors must be protected from freezing temperatures when not in use.

Ensure the soaking cap is filled with the original storage solution or clean water. If the cap is lost, use a small glass or plastic container with clean water covering the sensor tips.

Controller Storage

The controller unit is susceptible to electro-static discharge (ESD) damage when sensor cables are disconnected. Always reinstall the BNC protective covers before storing or transporting the unit.

Winterization

Prepare the ORP sensor for storage as outlined above and protect it from freezing temperatures. Although the CAT 1000 withstands a broad temperature range, secure winter storage is recommended.

Drain the flow cell and poly tubing before exposure to freezing temperatures. Purge water using compressed air or drain thoroughly through valve ports and tubing connections.

Troubleshooting

The CAT 1000 is built to high standards, but apparent malfunctions can often be resolved with these corrective actions.

No Lights Illuminated When Controller is Powered On

1. Check circuit breaker and/or receptacle for proper operation. Ensure connection to a functional ground-type GFCI protected power source.
2. Check for damaged power cord or connector.
3. Check controller fuses.

Alarm Light(s) and Tone Are Observed

1. Ensure the filtration system is functioning properly, flow is adequate, and water chemistry is balanced.
2. Ensure sensor and power cables are properly connected to the controller unit.
3. Check chemical feeders for proper operation.
4. Ensure the flow sensor is properly installed and connected.

ORP Chemical Feeder Is Not Activated as Expected

1. Ensure "Auto" ORP feed mode is selected.
2. Check the ORP setpoint and confirm the ORP reading is within range.

ORP Readings Are Inconsistent or Slow in Response

1. Ensure sensor cables are properly connected to their respective BNC connectors on the controller unit.
2. Clean the sensors as outlined in the maintenance section. If readings remain unstable after cleaning, replace the sensors.
3. Check that all electrical equipment in the facility pump room is properly bonded.

ORP Chemical Feeder Runs Continuously

1. Ensure "Auto" feed mode is selected.
2. Ensure chemical feeders are properly connected to their respective connectors on the control unit.

Chlorine or Bromine Residual Is Too High or Too Low

1. Factors such as pH, cyanuric acid concentration, total dissolved solids, and the use of additional or alternative sanitizers affect sanitizer residual levels relative to ORP. Consider chemicals recently added to the pool or spa.
2. Check and adjust the ORP setpoint.

ORP Is Overshooting the Setpoint

1. Ensure each chemical feeder is properly sized.
2. Check that the chemical feeder output is appropriate for the size of your body of water.
3. Verify you have the correct setpoint for your body of water.

ORP Feeding Does Not Reach the Setpoint

1. Ensure each chemical feeder is properly sized.
2. Check that the chemical feeder output is appropriate for the size of your body of water.
3. Verify you have the correct setpoint for your body of water.
4. Check chemical injection points for proper operation.

Your Display Is Flashing an Alarm Status

1. Check the flow sensor for damage or irregularities and ensure no dirt or debris is stuck on it.
2. Make sure you are getting adequate flow in your circulation.
3. Ensure there are no clogs or foreign objects in and around the flow cell.

Limited Warranty

Hayward Commercial Pool warrants the CAT 1000 automated controller to be free of defects in material and workmanship for a period of 5 years from the date of shipment from its factory or authorized distributors. Liability is limited to repair or replacement of defective components returned within 5 years of delivery to the original purchaser, shipping pre-paid.

Flow sensors, fittings, and accessories are warranted for one year. Professional Series ORP sensors are warranted for two years from the date of shipment. Liability is limited to repair or replacement of defective components returned within the warranty period, shipping pre-paid.

Hayward Commercial Pool disclaims liability for damage during transportation, consequential damage, damage due to handling, improper installation or operation, or for determining suitability for the purchaser's intended use. No representative has the authority to change this warranty.

For warranty claims, obtain a Return Merchandise Authorization form and direct inquiries to:

Hayward Commercial Pool
10101 Molecular Drive, Suite 200
Rockville, MD 20850 (USA)

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