Hayward CAT 2000 Automated Controller Owner's Manual

FOREWORD

Congratulations on your wise investment. The Hayward CAT 2000 line of automated controllers is designed to provide substantially reduced chemical maintenance, improved compliance with Health Department operating standards, chemical cost savings, and many years of reliable operation. All CAT controllers incorporate state-of-the-art microprocessor-based design technology for sophisticated control functions at an affordable price.

Although CAT controllers are relatively simple to install, please read this entire manual, compare package contents with the parts list, and gather all tools required before beginning installation. Improper installation may void the warranty and create unnecessary hazards. Proper preparation will also reduce facility down-time.

This manual presupposes the installer is familiar with the physical characteristics of the pool or spa to be automated. As with any filtration system component, all recirculating pumps and heaters must be turned off prior to installation. If the filtration system is below water level, adjust all valves to eliminate pressure from the system.

Physically, installing a CAT controller is no more challenging than installing a chemical feeder. Pool contractors or maintenance engineers should have the necessary tools and knowledge. Hayward's technical support line is available for any installation-related questions.

Remember that your CAT controller is not a substitute for performing and recording manual water testing in conformance with state or local health department regulations. Never operate a water chemistry controller without a flow sensor, power interlock, or other means ensuring chemicals are not fed without proper filtration system recirculation.

Congratulations on your purchase and welcome to chemical automation. Please complete and return your warranty registration card.

SECTION 1. CHEMICAL AUTOMATION WITH THE CAT 2000

A pool operator typically checks and adjusts water chemistry hourly. The CAT 2000 continuously monitors pH and sanitizer activity, adjusting chemical feeding proportionally to demand. This eliminates "human error", ensures accurate and reliable chemical levels 24 hours a day, promotes compliance with Health Department standards, reduces staff burden, and lowers chemical usage and costs.

Illustration 1 compares typical chlorine levels when chemistry is adjusted manually versus automatically with the CAT 2000 controller.

ILLUSTRATION 1. MANUAL -VS- CAT AUTOMATED CONTROL

Description of Illustration 1: A line graph showing Chlorine (CL2) levels over time. Two lines are plotted: 'Manual Control' (dashed red line) shows fluctuating chlorine levels, while 'CAT Automated Control' (solid blue line) shows much more stable chlorine levels within a target range. The X-axis represents Time, and the Y-axis represents CL2 concentration.

SECTION 2. COMPONENTS OF A CAT 2000 AUTOMATED SYSTEM

The CAT 2000 controller system incorporates the following components:

• Professional-Series pH Sensor: Samples water, sending acidity signals to the controller. The ideal pH range for pools and spas is 7.4 - 7.6. The CAT 2000 is preset to maintain pH 7.5. Low pH (<7.4) can cause eye irritation, equipment corrosion, and surface damage. High pH (>7.6) reduces sanitizer activity, can cause cloudy water, and eye irritation.
• Professional-Series ORP Sensor: Samples water, sending oxidation-reduction potential (redox) signals. ORP measures sanitizer activity (e.g., chlorine, bromine, ozone) and water quality, not just chemical residual levels. The CAT 2000 is preset to maintain ORP at 650 millivolts.
• Flow Sensor (required): Monitors water flow across the pH and ORP sensors. It signals the controller to disable automated chemical feeding when the filtration system is off or low recirculation flow is detected.
• Flow Cell: Provides a convenient mounting location for the pH, ORP, and Flow Sensors, ensuring ideal hydraulic conditions for optimal sensor performance and life.
• CAT 2000 Controller Unit: Scans and interprets sensor signals, displays water quality readings digitally, and activates chemical feeders proportionally to demand to maintain setpoint pH and ORP levels. It features audible and visual safeguard alarms, calibration adjustment for pH, and mode selections for manual feed or disabling feed. An internal micro-computer ensures accuracy, adaptability, and ease of use, with all adjustments made via the touch-screen interface.

SECTION 3. IMPORTANT SAFETY INFORMATION

IMPORTANT SAFETY INFORMATION

1. WARNING: Important safety information is contained throughout this manual. Read complete instructions prior to installation.
2. WARNING: Risk of Electric Shock. Connect controller only to a grounding-type receptacle protected by a ground-fault circuit interrupter (GFI). Installation to a dedicated GFI circuit breaker by a licensed electrician is recommended.
3. WARNING: Disconnect power before servicing. There are no user-serviceable parts inside the controller, other than fuses.
4. WARNING: Inspect all power cords frequently. Replace any damaged power cords immediately to reduce the risk of electric shock. Never operate a controller without functional flow protection.
5. WARNING: Installation requires a properly located GFI-protected receptacle. Never use an extension cord for electrical connections.
6. WARNING: Always mount the controller in a safe area not subject to damage by moving objects. Never bury controller power cords.
7. WARNING: Any person using, adjusting, or monitoring the controller must be at least 18 years of age and familiar with these instructions and the manual's contents.
8. WARNING: Always take and record manual water chemistry readings in conformance with Health Department requirements. Automated controllers aid water quality but are not a substitute for manual testing with an accurate test-kit.
9. WARNING: Always read and become familiar with Material Safety Data Sheets (MSDS) and safe handling instructions for all chemicals used with the controller.
10. Caution: The automatic controller should not be installed where it is accessible to the public.

SECTION 4. PACKAGE CONTENTS

Please unpack your new controller system carefully. Do not use a razor or sharp instrument to remove contents. Report any shipping or handling damage immediately to your shipping company. Enclosed in the packaging you should find all of the following:

• (1) CAT 2000 Water Chemistry Controller
• (1) Professional Series pH Sensor with 24" Cable and BNC Connector
• (1) Professional Series ORP Sensor with 24" Cable and BNC Connector
• (2) BNC Connector Protective Covers (Remove to Connect Sensors)
• (2) Sensor Storage Containers
• (1) CAT 2000 Owner's Manual

The CAT 2000 Pro-Pack includes the following additional items:

• (1) PVC Backboard with Mounting Holes and Stainless Hardware
• (1) Machined Acrylic Flow Cell assembled with:
• (3) 1/4" NPT x 3/8" Tubing Asahi Ball Valves
• (1) Rotary Flow Sensor with Cable and Specialty Connector
• (1) 30' Roll, Blue Poly Installation Tubing (3/8" OD)
• (2) 1/4" NPT x 3/8" Tubing True-Seal Connectors
• (1) Pro-Pack Quick Start Guide

Before commencing installation, please confirm that all listed items are included. Report any shortages immediately to the factory.

SECTION 5. INSTALLATION WITH FLOWCELL

The following tools are recommended for installation:

• 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

The key to a successful flow cell installation is in the plumbing. A pressure differential is required to allow clean, untreated water to pass through the cell and across the sensors. A pressure-suction "loop" line using a CAT Flowcell and fittings is recommended.

1. Turn off heater, chemical feeders, pump, and any other related equipment. Relieve pressure from the filtration system.
2. Select a convenient mounting location for the controller unit meeting these criteria:
   • Facilitates a combined (influent and effluent) maximum tubing run of 30'.
   • Located a minimum of ten feet from the pool or spa.
   • GFI protected power source available.
   • Easily accessible to the pool or spa operator.
   • 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 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. Cut a 3" to 6" length of flex tubing and insert into the sample stream port.
7. Remove pH and ORP sensors from their storage bottles, saving the bottles and storage fluid for future use. Thread sensors into the flow cell.
8. Remove BNC protective covers from the left side of the controller unit and store them for future use. These covers protect the unit from electro-static discharge (ESD) and should be used when handling or transporting the controller.
9. Connect the pH, ORP, and Flow sensor cables to the controller unit as labeled. Sensor cables are constructed from specialized material; never cut or splice them.
10. If new or additional chemical feeders are to be used, install them according to the manufacturer's instructions at this time.
11. Connect chemical feeders to the controller as labeled.
12. Check all electrical and mechanical connections. Resume filtration system operation and check for any leaks.

ILLUSTRATION 2. CAT 2000 INSTALLATION DIAGRAM WITH FLOWCELL

Description of Illustration 2: A schematic diagram showing the CAT 2000 controller connected to a pool filtration system. It illustrates the placement of the pH Sensor, ORP Sensor, and Rotary Flow Sensor within a Flow Cell, which is plumbed into the main water line after the filter. The diagram shows the suction and return lines, pump, filter, chemical pumps, and the flow path of water and chemicals. Key connections and components like the solenoid valve and erosion feeder are also depicted. Arrows indicate water flow.

SECTION 6. INSTALLATION WITH BYPASS LINE

CAT recommends using a CAT Flowcell and Rotary Flow Sensor for all recreational water applications. The CAT Flowcell provides controlled flow for maximum sensor life, a convenient sample port for manual water tests, integrated mounting for the Rotary Flow Sensor, and fast installation with flexible tubing and Tru-seal connectors.

Construction of a bypass line should only be performed by experienced technicians familiar with PVC plumbing and the existing filtration system. Refer to Illustration 3 for a typical bypass diagram.

1. Turn off heater, chemical feeders, pump, and any other related equipment. Relieve pressure from the filtration system.
2. Select a convenient mounting location for the controller unit meeting these criteria:
   • Facilitates unobstructed bypass line plumbing.
   • Located a minimum of ten feet from the pool or spa.
   • GFI protected power source available.
   • Easily accessible to the pool or spa operator.
   • Away from corrosive materials and physical hazards.
3. Securely mount the CAT 2000 controller on a vertical wall.
4. Install one "reducing tee" or "saddle tee" fitting on the incoming suction line to the pump and the return line upstream from the heater, as shown in Illustration 3.
5. Install ball valves on the bypass inlet and effluent immediately adjacent to the tee fittings.
6. Install an in-line filter (optional) immediately downstream from the bypass inlet valve.
7. Install a flow meter (optional) immediately downstream from the in-line filter (if applicable) or bypass inlet valve.
8. Install two tee fittings to accommodate 1/2" NPT Professional Series pH & ORP sensors, as shown in Illustration 3.
9. Install the Rotary Flow Sensor in the bypass line, as shown in Illustration 3.
10. Remove pH and ORP sensor storage caps and save for future use.
11. Remove BNC protective covers from the left side of the controller unit and save for future use. These covers protect the unit from electro-static discharge (ESD) and should be used whenever handling the controller unit.
12. Insert the pH and ORP sensors into the two 1/2" tee fittings. Teflon tape may be used to seal threads.
13. Carefully route sensor cables to the controller unit and connect them as labeled. Sensor cables are constructed from a specialized coaxial material; never cut or splice them.
14. Label and support all new piping. If new chemical feeders are to be used, install them according to the manufacturer's instructions.
15. Connect chemical feeders to the controller unit as labeled.
16. Resume operation of the filtration system and check for leaks.

ILLUSTRATION 3. CAT 2000 INSTALLATION DIAGRAM WITH BYPASS LINE

Description of Illustration 3: A schematic diagram illustrating the installation of the CAT 2000 controller using a bypass line. It shows the controller unit, pH and ORP sensors, and flow sensor integrated into a bypass loop connected to the main filtration system's suction and return lines. The diagram details the placement of tee fittings, ball valves, optional filters/flow meters, and the connection of chemical pumps. Arrows indicate water flow.

SECTION 7. PREPARING WATER CHEMISTRY

After the controller has been physically installed, water chemistry should be tested and adjusted before initiating automated control. Confirm that your pool or spa water conforms to the following ranges before powering on and setting up the CAT 2000:

The table above indicates generally accepted guidelines. Always maintain water chemistry according to standards set by your local or State Health Department.

All CAT water quality controllers maintain sanitizer levels based on ORP. While ORP is a superior index of water quality compared to part per million sanitizer residual levels, factors like pH, cyanuric acid concentration, and total dissolved solids can affect sanitizer residual readings relative to ORP.

CAT strongly recommends establishing desired pH, sanitizer residual, calcium hardness, total alkalinity, temperature, and cyanuric acid levels prior to initiating automated control. The ORP setpoint may need periodic adjustment to provide consistent sanitizer residual levels rather than consistent control of ORP.

SECTION 8. SETTING AND OPERATING THE CAT 2000

Once desired start-up chemistry parameters are established, you can set the CAT 2000 to automatically maintain pH and sanitizer levels. Refer to Illustration 4 for controller unit button designations (bold type indicates button names).

Selecting Acid or Base Feed

The CAT 2000 is preset to operate in acid feed mode (pH chemical feeder activates when pH exceeds setpoint). If your sanitizer causes pH to decrease, select base feed mode. To switch between modes:

1. Press and hold the Hidden Button (#1) for five seconds to enter advanced setup mode.
2. Scroll to pFD and press Enter. Scroll to select A for acid feed or B for base feed. Press Enter to set your selection, then press the Hidden Button (#1) again to return to normal operating mode.

Upon power-on, the digital pH readout will display "A" or "B" indicating the selected feed mode.

Calibrating pH

CAT 2000 readings are more accurate than most liquid test standards. To match manual water testing results or compensate for a depleted/unclean pH sensor, calibrate the pH channel as follows:

1. Press the pH Setpoint Adjustment Button (#4) twice, illuminating the green "CALIBRATE" LED.
2. Press the pH Channel Increase Button (#2) or pH Channel Decrease Button (#3) until the digital display matches your manual pH test reading.
3. The controller will automatically return to normal operating mode after twenty seconds, storing any changes.

Changing the pH Setpoint

The CAT 2000 is preset to maintain pH at 7.5. To set a different pH control level:

1. Press the pH Setpoint Adjustment Button (#4) until the green "SET" LED is illuminated.
2. Press the pH Channel Increase Button (#2) or pH Channel Decrease Button (#3) until the digital display matches your desired pH control level.
3. The controller will automatically return to normal operating mode after twenty seconds, storing any changes.

Changing the ORP Setpoint

The CAT 2000 is preset to maintain ORP at 650 mV, the world standard for safe drinking water. To meet specific pool/spa standards or maintain a desired sanitizer level:

1. Manually test pool or spa to confirm the current sanitizer reading (e.g., chlorine, bromine) is the desired level.
2. Note the ORP reading displayed by the controller.
3. Press the ORP Setpoint Adjustment Button (#8) until the green "SET" LED is illuminated.
4. Press the ORP Channel Increase Button (#6) or ORP Channel Decrease Button (#7) until the digital display matches the noted ORP reading.
5. The controller will automatically return to normal operating mode after twenty seconds, storing any changes.

The ORP setpoint should be changed as needed to maintain sanitizer residuals in conformance with Health Department standards.

Manually Activating pH Feed

To manually enable the pH chemical feeder, press the pH Channel Mode Selection Button (#5) until the green "MANUAL" LED is illuminated. The feeder will operate continuously for 30 minutes, then automatically revert to "Auto" to prevent accidental over-feeding.

Manually Activating ORP Feed

To manually enable the ORP chemical feeder, press the ORP Channel Mode Selection Button (#9) until the green "MANUAL" LED is illuminated. The feeder will operate continuously for 30 minutes, then automatically revert to "Auto" to prevent accidental over-feeding.

Manually Disabling pH Feed

To manually prevent operation of the pH chemical feeder, press the pH Channel Mode Selection Button (#5) until the red "OFF" LED is illuminated. Automatic pH feeding will be disabled. The chemical feeding cycle will not be interrupted for approximately ten seconds, allowing time for user entries.

Manually Disabling ORP Feed

To manually prevent operation of the ORP chemical feeder, press the ORP Channel Mode Selection Button (#9) until the red "OFF" LED is illuminated. Automatic ORP feeding will be disabled. The chemical feeding cycle will not be interrupted for approximately ten seconds, allowing time for user entries.

Automatically Controlling pH Feed

For automated control of the pH chemical feeder, press the pH Channel Mode Selection Button (#5) until the green "AUTO" LED is illuminated. The feeder will operate automatically in proportion to chemical demand. The chemical feeding cycle will not be interrupted for approximately ten seconds, allowing time for user entries.

Automatically Controlling ORP Feed

For automated control of the ORP chemical feeder, press the ORP Channel Mode Selection Button (#9) until the green "AUTO" LED is illuminated. The feeder will operate automatically in proportion to chemical demand. The chemical feeding cycle will not be interrupted for approximately ten seconds, allowing time for user entries.

About Proportional Feed

The CAT 2000 features an advanced proportional feed algorithm that constantly analyzes chemical demand and initiates feeding based on the relationship between setpoint and actual water sample values. This feature is valuable for precise water chemistry control in most applications but should be disabled for use with salt chlorine systems.

SECTION 9. ADVANCED (DEALER) SETUP OPTIONS

Beginning with the 2008 model year, the CAT 2000 controller includes an advanced programming menu and enhanced features, typically implemented during initial dealer setup and not requiring routine operator changes.

Enhanced No-Flow Alarm

The no-flow alarm displays "no Flo" on the LED displays and activates both channel Alarm indicators and the audible alarm.

Power On Display

At power-on, the controller displays the pH feed mode and firmware version number. The pH feed mode is shown on the pH channel LED display: A (Acid feed selected) or b (Base feed selected). The firmware version number is displayed on the ORP channel LED display (e.g., 3.17).

Entering Advanced Setup Mode

Locate the Hidden Button (#1) behind the large pH text over the pH digital display.

1. Press and hold the Hidden Button (#1) for five seconds to enter advanced setup mode.
2. Press the Up (#6) and Down (#7) arrow buttons to scroll through programming options.
3. Press the Enter Button (#8) to make a selection.

pH Feed Mode (Acid or Base Feed)

P.Fd pH Feed: Selects the condition under which pH feed output is activated.

• A (Acid, default): pH feed output activates when measured pH is greater than the setpoint, indicating the need to feed acid to decrease pH.
• b (Base): pH feed output activates when measured pH is less than the setpoint, indicating the need to feed base to increase pH.

pH Priority

P.Pr pH Priority: Inhibits ORP feed when pH is not within 0.2 of setpoint.

• OFF (default): pH feed and ORP feed decisions are independent.
• On: pH Priority is enabled. ORP feed output is inhibited if the measured pH differs from the setpoint by more than 0.2 pH units (e.g., for a 7.5 setpoint, ORP feed is enabled between 7.3 and 7.7 pH, and inhibited outside this range).

pH Proportional Feed

P.PF pH Proportional Feed: Selects either fixed setpoint or proportional control.

• OFF: pH feed output activates based on a simple above/below setpoint decision. Feed is turned off when measured pH is less than or equal to the setpoint (Acid feed) or greater than or equal to the setpoint (Base feed). Otherwise, feed is turned on.
• On (Default): pH feed output activates based on the difference between the pH setpoint and measured pH. As the difference increases, the duration the pH feed output is on increases (20, 30, 40, 50 seconds per 60-second cycle), eventually becoming continuous.

pH Overfeed Timer

P.OF pH Overfeed Timer: When Off, pH feed output remains activated as long as a feed condition is indicated. Any other selection enables an overfeed limit timer. After exceeding this limit, the pH channel turns off and enters an overfeed alarm condition requiring manual reset.

If pH Proportional Feed: On is selected, the pH feed output must be continuous for the overfeed time limit, not just a portion of the proportional cycle.

When the pH feed channel enters the overfeed alarm condition, the pH channel turns off, and the pH Feed Mode indicator flashes rapidly. Pressing the pH Feed Mode button returns the channel to off, manual, or automatic mode, resetting the alarm and timer. The alarm also resets upon power cycle.

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

• OFF: pH feed output remains on for an unlimited amount of time.
• 15: 15 Minutes.
• 30: 30 Minutes.
• 60: 60 Minutes (1 Hour).
• 120: 120 Minutes (2 Hours).
• 180: 180 Minutes (3 Hours).
• 240: 240 Minutes (4 Hours) - default.

pH Low Alarm Limit

P.AL pH Alarm Limit Low: Sets the low alarm point for the pH channel. When measured pH is less than this limit, an audible alarm activates, and pH feed output is disabled. The alarm clears and feed resumes when measured pH returns to the non-alarm range.

Use the UP and DOWN buttons to select a value between 6.0 and 9.0 pH. The value must be less than the pH alarm high value. The default value is 6.8 pH.

pH Alarm High Limit

P.AH pH Alarm Limit High: Sets the high alarm point for the pH channel. When measured pH is greater than this limit, an audible alarm activates, and pH feed output is disabled. The alarm clears and feed resumes when measured pH returns to the non-alarm range.

Use the UP and DOWN buttons to select a value between 6.0 and 9.0 pH. The value must be greater than the pH alarm low value. The default value is 8.2 pH.

ORP Proportional Feed

O.PF ORP Proportional Feed: Selects either fixed setpoint or proportional control.

• OFF: ORP feed output activates based on a simple above/below setpoint decision. Feed turns on when measured ORP is less than or equal to the ORP setpoint; otherwise, it turns off.
• On (Default): ORP feed output activates based on the difference between the ORP setpoint and measured ORP value. As the difference increases, the duration the ORP feed output is on increases (20, 30, 40, 50 seconds per 60-second cycle), eventually becoming continuous.

ORP Overfeed Timer

O.OF ORP Overfeed Timer: When Off, ORP feed output remains activated as long as an ORP feed condition is indicated. Any other selection enables an overfeed limit timer. After exceeding this limit, the ORP channel turns off and enters an overfeed alarm condition requiring manual reset.

If ORP Proportional Feed: On is selected, the ORP feed output must be continuous for the overfeed time limit, not just a portion of the proportional cycle.

When the ORP feed channel enters the overfeed alarm condition, the ORP channel turns off, and the ORP Feed Mode indicator flashes rapidly. Pressing the ORP Feed Mode button returns the channel to off, manual, or automatic mode, resetting the alarm and timer. The alarm also resets upon power cycle.

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

• OFF: ORP feed output remains on for an unlimited amount of time.
• 15: 15 Minutes.
• 30: 30 Minutes.
• 60: 60 Minutes (1 Hour).
• 120: 120 Minutes (2 Hours).
• 180: 180 Minutes (3 Hours).
• 240: 240 Minutes (4 Hours) - default.

ORP Alarm Low Limit

O.AL ORP Alarm Low Limit: Sets the low alarm point for the ORP channel. When measured ORP is less than this limit, an audible alarm activates, and ORP feed output is disabled. The alarm clears and feed resumes when measured ORP returns to the non-alarm range.

Use the UP and DOWN buttons to select a value between 200 and 995 mV. The value must be less than the ORP alarm high value. The default value is 525 mV.

ORP Alarm High Limit

O.AH ORP Alarm Limit High: Sets the high alarm point for the ORP channel. When measured ORP is greater than this limit, an audible alarm activates, and ORP feed output is disabled. The alarm clears and feed resumes when measured ORP returns to the non-alarm range.

Use the UP and DOWN buttons to select a value between 400 and 995 mV. The value must be greater than the ORP alarm low value. The default value is 900 mV.

Clear All Programming and Restore Factory Defaults

Clr Factory Clear: Returns all controller operating parameters to their default values.

Demonstration Mode

dEo: Places the controller in Demo Mode for showroom display, presentations, etc.

Audible Alarm (Beeper)

bPr: The Beeper setting allows the audible alarm to be enabled (default) or disabled.

Serial Interface

Srl: The CAT 2000 includes a standard Rs232 serial interface. A header assembly and cable are required for connection.

• Onl (Online Communications): Use this selection when the controller is attached to a PC or building automation system.
• Prn (Printer, default): Use this selection when the controller is attached to a CAT Serial Printer to make a hard-copy record of controller operating parameters. The printer is supplied with a cable. It prints one data record at 15-minute intervals, including pH and ORP measured values, and feed output and alarm status for both channels.

When all desired settings have been entered, press the Hidden Button or wait 30 seconds, and the controller will return to default operating mode.

SECTION 10. DISPLAY FUNCTIONS

Refer to Illustration 4 for designations of the various LED indicator lights on the front panel. The CAT 2000 features a "dead-front" display panel, meaning only illuminated indicators are visible. All lights and indicators activate during power-on.

pH Indicators

• pH Feed Indicator (#1): Green LED illuminated when the pH chemical feeder is automatically or manually activated.
• pH Alarm Indicator (#2): Red LED illuminated with an audible alarm, indicating pH is outside the safe operating range. Check the pH chemical feeder and chemical supply.
• pH Digital Display (#3): Red digital numeric display showing the current pH of the pool or spa water. Pressing the pH Setpoint Adjustment Button until the "SET" LED illuminates displays the pH setpoint.
• pH Setpoint Adjustment Mode Indicator (#4): Green LED illuminated when the controller is in pH setpoint adjustment mode. Adjustment is allowed only when this LED is illuminated.
• pH Calibrate Mode Indicator (#5): Green LED illuminated when the controller is in pH calibration mode. Calibration is allowed only when this LED is illuminated.
• pH Automatic Control Indicator (#6): Green LED illuminated when pH is under automated control.
• pH Manual Off Indicator (#7): Red LED illuminated when pH feeding is manually disabled.
• pH Manual On Indicator (#8): Green LED illuminated when pH feeding is manually activated.

ORP Indicators

• ORP Alarm Indicator (#10): Red LED illuminated with an audible alarm, indicating ORP is outside the safe operating range. Check the ORP chemical feeder and sanitizer supply.
• ORP Digital Display (#11): Red digital numeric display showing the current ORP (oxidation-reduction potential) of the pool or spa water. Pressing the ORP Setpoint Adjustment Button until the "SET" LED illuminates displays the ORP setpoint.
• ORP Setpoint Adjustment Mode Indicator (#12): Green LED illuminated when the controller is in ORP setpoint adjustment mode.
• ORP Automatic Control Indicator (#13): Green LED illuminated when ORP is under automated control.
• ORP Manual Off Indicator (#14): Red LED illuminated when ORP feeding is manually disabled.
• ORP Manual On Indicator (#15): Green LED illuminated when ORP feeding is manually activated.

ILLUSTRATION 4. CAT 2000 INDICATOR DESIGNATIONS & FUNCTIONS

Description of Illustration 4: A table listing designations (1-15), color/type (LED, Digital Display), and description for each indicator and button on the CAT 2000 controller's front panel. Below the table is a graphical representation of the controller's front panel, clearly labeling each indicator and button with its corresponding designation number and function (e.g., pH Feed Indicator #1, pH Channel Increase Button #2).

SECTION 11. MAINTENANCE

CAT 2000 CONTROLLER

The CAT 2000 controller unit is virtually maintenance-free. Clean the enclosure, front panel, and flow cell with a clean, soft cloth moistened with a mild soap and water solution or glass cleaner. Avoid abrasives or harsh chemicals, which can damage the enclosure and membrane switch panel.

WATER MAINTENANCE

Always test and record water chemistry readings according to Health Department requirements using a quality manual test kit. Calibrate pH periodically as described earlier in this manual.

Changes in pH, cyanuric acid concentration, total dissolved solids, and the use of additional or alternative sanitizers affect the primary sanitizer residual level relative to ORP. Maintaining total alkalinity regularly ensures pH stability. To maintain a consistent sanitizer residual (ppm), periodically adjust the ORP setpoint.

PRECISION CALIBRATION

The CAT 2000 controller offers instrument-grade accuracy exceeding most liquid-standard water testing kits. Calibrating pH using commercially available reference solutions may be preferable.

SENSOR MAINTENANCE

Sensors must be clean and free from oil, chemical deposits, and contamination to function properly. Depending on bather load and facility characteristics, sensors may need cleaning weekly or monthly. Slow response, increased need for pH calibration, and inconsistent readings indicate sensors need cleaning.

To clean sensors: disconnect from the controller, carefully remove them from the flow cell. Clean the reference junction (white Teflon ring at the bottom of the sensor body) with a soft toothbrush and toothpaste. Household liquid dishwashing detergent can remove oil. Rinse with fresh water, replace Teflon thread-seal tape, and reinstall sensors, tightening by hand only.

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

SENSOR REPLACEMENT

CAT Professional Series pH and ORP sensors are engineered for high performance and long service life. If properly cleaned sensors provide unstable readings or require excessive calibration, replace the pair. For optimum performance, use genuine CAT Professional Series sensors PRO15-2 and PRO25-2.

SENSOR STORAGE

Exposure to atmospheric conditions can dry sensor tips. Always remove and store sensors in their provided soaking caps if they will be removed or stored for one hour or longer. CAT Professional Series sensors are freeze-resistant but must be protected from freezing temperatures when not in use.

Store sensors in soaking caps, ensuring each container is filled with the original storage solution or clean water. If storage containers are misplaced, store sensors individually in small glass or plastic containers with clean water covering the sensor tips.

CONTROLLER STORAGE

The controller unit is susceptible to damage from electro-static discharge (ESD) when sensor cables are disconnected. Always reinstall the BNC protective covers prior to storing or transporting the CAT 2000 controller unit.

WINTERIZATION

Prepare sensors for storage as outlined above and protect them from freezing temperatures. While the CAT 2000 controller withstands a broad temperature range, winter storage in a secure location is advisable.

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

SECTION 12. TROUBLESHOOTING

Each CAT 2000 controller is manufactured to high standards and thoroughly tested. State-of-the-art design ensures years of trouble-free operation. Most malfunctions can be resolved with the following corrective actions:

No lights are illuminated when controller is powered on.

1. Check circuit breaker and/or receptacle for proper operation. Connect to a functional grounding-type GFCI protected power source.
2. Check for damaged power cord or connector.

Alarm light(s) and tone are observed.

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

Both pH and ORP digital readouts display illogical values.

1. Sensor cable connections may be reversed. Ensure sensor cables are properly connected to their respective BNC connectors on the controller unit.
2. Ensure the filtration system is functioning properly, flow is adequate, and water chemistry is in balance.

ORP chemical feeder is not activated as expected.

1. Make sure "auto" ORP feed mode is selected.
2. Check ORP setpoint.

pH chemical feeder is not activated as expected.

1. Ensure that acid/base feed mode is properly set for your chemical feeding requirements.
2. Make sure "auto" pH feed mode is selected.
3. Check pH Setpoint.

Chlorine or bromine residual is too high or too low.

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

pH requires frequent calibration.

1. Clean the sensors as outlined in the maintenance section. If sensors continue to provide unstable readings after cleaning, replace them.

pH or ORP readings are inconsistent or slow in response.

1. Ensure that 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 sensors continue to provide unstable readings after cleaning, replace them.
3. Check to ensure that all electrical equipment in the facility pump room is properly bonded.

pH or ORP chemical feeder runs continuously.

1. Make sure "auto" feed mode is selected.
2. Ensure that chemical feeders are properly connected to their respective connectors on the controller unit.

pH or ORP feeding overshoots the setpoint.

1. Ensure that each chemical feeder is properly sized.
2. Check concentration of sanitizer or pH chemical.

pH or ORP feeding does not reach the setpoint.

1. Ensure that each chemical feeder is properly sized.
2. Check concentration of sanitizer or pH chemical.
3. Check chemical feeders and injection points for proper operation.

SECTION 13. TECHNICAL SPECIFICATIONS

SECTION 14. WARRANTY

LIMITED WARRANTY

Hayward® warrants the CAT 2000 automated controller to be free of defects in material and workmanship for a period of five years from the date of shipment from its factory or an authorized distributor. Liability under this warranty is limited to the repair or replacement of any device or component returned to the factory within five years of delivery to the original purchaser, shipping prepaid, and found to be defective upon examination.

Hayward® warrants all flow sensors, fittings, and accessories to be free of defects in material and workmanship for a period of one year from the date of shipment. Professional Series pH and ORP sensors are warranted for a period of two years from the date of shipment. Liability under this warranty is limited to the repair or replacement of any device or component returned to the factory within the warranty period, shipping prepaid, and found to be defective upon examination.

Hayward® disclaims all liability for damage during transportation, for consequential damage of any nature, for damage due to handling, improper installation or operation, and for determining suitability for the use intended by the purchaser. Hayward® makes no warranties, either expressed or implied, other than those stated above. No representative has the authority to change or modify this warranty in any respect.

After obtaining a Return Merchandise Authorization form, any warranty claims should be directed to:

Hayward Commercial Pool Products
10101 Molecular Drive Suite 200
Rockville, MD 20850 (USA)
800-657-2287
301-838-4001