Hayward CAT 4000 Water Quality Controller

Introduction

The CAT 4000 revolutionizes water quality monitoring and maintenance for pools and spas. Unlike manual checks, the CAT 4000 continuously samples pH and sanitizer activity, automatically adjusting chemical feeding based on demand. It transmits hourly readings, alarms, and service requests wirelessly to the POOLCOMM web server for remote management via the internet. The POOLCOMM website is a subscription-based service.

Subscribers can monitor water quality, print charts, graphs, and logs, change settings, and designate notification contacts. Optional digital flow and level sensors can monitor flow rate, chemical storage levels, and automate water level control.

Benefits include elimination of human error, accurate chemical levels 24/7, compliance with health standards, reduced staff burden, and lower chemical costs. The CAT 4000 and POOLCOMM website offer comprehensive control, access, and documentation.

A graph compares typical chlorine levels: Manual control shows fluctuations, while HCC Automated Control (CAT 4000) maintains a more stable level.

What's Included

The CAT 4000 Wireless Water Quality Control System package includes:

• 1 CAT 4000 Wireless Water Quality Controller
• 1 PVC Backboard with Mounting Holes and Stainless Hardware
• 1 Professional Series pH Sensor with 24” Cable and BNC Connector
• 1 Professional Series ORP Sensor with 24” Cable and BNC Connector
• 2 Sensor Storage Containers
• 1 Injection Molded Flow Cell
• 1 1/4" NPT x 3/8" Tubing True-Seal Ball Valve
• 1 Flow Switch with 24” Cable and Specialty Connector
• 2 BNC Connector Protective Covers
• 1 30' Roll, Blue Poly Installation Tubing (3/8” OD)
• 2 1/4" NPT x 3/8" Tubing True-Seal Connectors
• 1 CAT 4000 Quick Reference Guide

Tools Needed for Installation

Recommended tools include:

• Drill (Cordless preferred)
• 3/8" Drill Bit
• 1/4" NPT (National Pipe Tapered) Tap
• Masonry Drill Bit & Anchors (if required)
• 13/16" Wrench or Channel-Lock Pliers

Installation

Installation Procedure

Successful flow cell installation requires proper plumbing to create a pressure differential for water flow across sensors. A pressure-suction "loop" line using enclosed tubing and fittings is recommended.

1. Turn off heater, chemical feeders, pump, and related equipment. Relieve pressure from the filtration system.
2. Select a mounting location for the controller unit that meets these criteria: facilitates a 30' tubing run, is at least ten feet from the pool/spa, has a GFI protected power source, is easily accessible, and is away from corrosive materials and hazards.
3. Securely mount the PVC Backboard on a vertical wall.
4. Drill and tap a 1/4" NPT port downstream of the filter and 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" length of flex tubing and insert into the sample stream port.
7. Remove pH and ORP sensors from storage bottles, save bottles and fluid. Thread sensors into the flow cell.
8. Remove and store BNC protective covers from the controller unit for electrostatic discharge (ESD) protection.
9. Connect pH, ORP, and Flow sensor cables to the controller as labeled. Sensor cables are constructed from specialized material and should not be cut or spliced.
10. Install any new or additional chemical feeders according to manufacturer instructions.
11. Connect chemical feeders to the controller as labeled.
12. Check all electrical and mechanical connections. Resume filtration system operation and check for leaks.

Diagram illustrating the correct method for preparing, inserting, and releasing tubing using Tru-Seal Fluid Connections.

Diagram showing the typical installation of the CAT 4000 system, illustrating connections to the pump, filter, chemical feeders, and flow cell.

Pool Chemistry

Before activating the CAT 4000, test and adjust pool or spa water chemistry to conform to the following generally accepted guidelines. Always adhere to local or State Health Department standards.

CAT controllers maintain sanitizer levels based on ORP. While ORP is a superior indicator of water quality, factors like pH, cyanuric acid, and total dissolved solids can affect sanitizer residual readings relative to ORP. It is recommended to establish desired levels for pH, sanitizer residual, calcium hardness, total alkalinity, temperature, and cyanuric acid before automated control. The ORP setpoint may need periodic adjustment to maintain consistent sanitizer residual levels.

Configuration

Overview

The CAT 4000 features a bright, menu-driven vacuum-fluorescent display for simple setup and programming. The menu structure is divided into an Operating Menu for frequent adjustments and a Configuration Menu for advanced features.

Diagram of the CAT 4000 controller keypad with labels for MENU, UP, DOWN, ENTER, and TRANSMIT buttons.

Keypad Functions

• MENU: Enter menu mode and navigate back.
• UP: Increase values and navigate up.
• DOWN: Decrease values and navigate down.
• ENTER: Select or confirm a menu item.
• TRANSMIT: Send a Service Request alarm and current data to POOLCOMM.

Normal Operating Mode

In normal operation, the display shows sensed pH, ORP, Flow Rate (if applicable), and a status line alternating between "System OK" or alarms, and a graph of sensed pH/ORP vs. setpoint values.

Adjusting Display Brightness

While in normal operating mode:

• Press UP to increase display intensity.
• Press DOWN to decrease display intensity.

Operating Menu

Entering the Operating Menu

While in normal operating mode, press MENU to access the Operating Menu.

Changing the pH Setpoint

1. Press MENU.
2. Select "pH Setpoint" by pressing ENTER. The current setpoint will display.
3. Use UP or DOWN to select the desired pH.
4. Press ENTER to save. The controller returns to normal mode in 10 seconds.

Calibrating pH

1. Press MENU.
2. Press DOWN to find "pH Calibrate" and press ENTER. The current calibrated pH will display.
3. Use UP or DOWN to match your known standard.
4. Press ENTER to save. The controller returns to normal mode in 10 seconds.

Configuration Setup Menu

Entering the Configuration Setup Menu

While in normal operating mode, press MENU, then press DOWN to find "Configuration Setup" and press ENTER.

Selecting pH Feed Mode

The CAT 4000 defaults to automatic feed. Options include Off (disabled) and Manual On (fixed interval up to 25 minutes).

1. Press MENU.
2. Navigate to "pH Feed Mode" and press ENTER. The current mode will display.
3. Use UP or DOWN to select the desired mode.
4. Press ENTER to save. The controller returns to normal mode in 10 seconds.

Changing the ORP Setpoint

The default ORP setpoint is 650 mV. To set a specific ORP level for chlorine or bromine residual:

1. Ensure pH, calcium hardness, and total alkalinity are balanced. Manually feed chlorine or bromine to the desired residual and note the ORP value.
2. Press MENU.
3. Navigate to "ORP Setpoint" and press ENTER. The current setpoint will display.
4. Use UP or DOWN to select the noted ORP value.
5. Press ENTER to save. The controller returns to normal mode in 10 seconds.

Selecting ORP Feed Mode

The CAT 4000 defaults to automatic feed. Options include Off (disabled) and Manual On (fixed interval up to 25 minutes).

1. Press MENU.
2. Navigate to "ORP Feed Mode" and press ENTER. The current mode will display.
3. Use UP or DOWN to select the desired mode.
4. Press ENTER to save. The controller returns to normal mode in 10 seconds.

Advanced Configuration Options

pH Control Mode

The CAT 4000 defaults to acid feed mode. If pH decreases due to sanitizer or other factors, base feed mode may be necessary.

1. From the Configuration Setup Menu, navigate to "pH Control Mode" and press ENTER. The current mode will display.
2. Use UP or DOWN to select acid feed or base feed.
3. Press ENTER to save. The controller returns to normal mode in 10 seconds.

In unusual applications, pH correction may be required in both acid and base feed modes. The third relay can be programmed for this.

pH Priority

This setting inhibits ORP feed if pH is more than 0.2 pH from the setpoint, providing a safeguard with high-pH sanitizers.

1. From the Configuration Setup Menu, navigate to "pH Priority" and press ENTER. The current mode will display.
2. Use UP or DOWN to enable or disable pH Priority.
3. Press ENTER to save. The controller returns to normal mode in 10 seconds.

pH Interlock

When enabled ("On"), ORP Feed is disabled if pH is in a high alarm condition.

1. From the Configuration Setup Menu, navigate to "PH Interlock" and press ENTER. The current setting will display.
2. Use UP or DOWN to select the desired setting.
3. Press ENTER to save.

pH Feed

The CAT 4000 uses a time-based proportional feed algorithm. For some feeders, disabling proportional feed and using a fixed basis is beneficial.

1. From the Configuration Setup Menu, navigate to "pH Feed" and press ENTER. The current setting will display.
2. Use UP or DOWN to select Proportional or Fixed feed.
3. Press ENTER to save. The controller returns to normal mode in 10 seconds.

pH Low Alarm

Inhibits pH feed, sounds alarms, and sends a message to POOLCOMM during a low pH condition.

1. From the Configuration Setup Menu, navigate to "pH Low Alarm" and press ENTER. The current setting will display.
2. Use UP or DOWN to scroll to the desired setting.
3. Press ENTER to save. The controller returns to normal mode in 10 seconds.

pH High Alarm

Inhibits pH feed, sounds alarms, and sends a message to POOLCOMM during a high pH condition.

1. From the Configuration Setup Menu, navigate to "pH High Alarm" and press ENTER. The current setting will display.
2. Use UP or DOWN to scroll to the desired setting.
3. Press ENTER to save. The controller returns to normal mode in 10 seconds.

pH Overfeed Timeout

Inhibits pH feed, sounds alarms, and sends a message to POOLCOMM if the setpoint is not reached after continuous feeding for a selectable period.

1. From the Configuration Setup Menu, navigate to "pH Overfeed Timeout" and press ENTER. The current setting will display.
2. Use UP or DOWN to scroll to the desired setting.
3. Press ENTER to save. The controller returns to normal mode in 10 seconds.

NOTE: Overfeed Timers prevent dangerous chemical dispensing. It is recommended to keep "Overfeed Timeout" enabled.

ORP Feed

The CAT 4000 uses a time-based proportional feed algorithm. For some feeders, disabling proportional feed and dispensing chemicals on a fixed basis is beneficial.

1. From the Configuration Setup Menu, navigate to "ORP Feed" and press ENTER. The current setting will display.
2. Use UP or DOWN to select Proportional, Fixed, or Mixing time.
3. Press ENTER to save.

ORP Mixing Time On

This feature prevents inaccurate readings from chemicals passing sensors before injection into the return line, typically when feeding on the "suction side".

1. From the Configuration Setup Menu, navigate to "ORP Mixing Time On" and press ENTER. The current setting will display.
2. Use UP or DOWN to scroll to the desired setting.
3. Press ENTER to save.

ORP Mixing Time Off

This feature prevents inaccurate readings from chemicals passing sensors before injection into the return line after a feed cycle.

1. From the Configuration Setup Menu, navigate to "ORP Mixing Time Off" and press ENTER. The current setting will display.
2. Use UP or DOWN to scroll to the desired setting.
3. Press ENTER to save.

ORP Low Alarm

Inhibits ORP feed, sounds alarms, and sends a message to POOLCOMM during a low ORP condition.

1. From the Configuration Setup Menu, navigate to "ORP Low Alarm" and press ENTER. The current setting will display.
2. Use UP or DOWN to scroll to the desired setting.
3. Press ENTER to save.

ORP High Alarm

Inhibits ORP feed, sounds alarms, and sends a message to POOLCOMM during a high ORP condition.

1. From the Configuration Setup Menu, navigate to "ORP High Alarm" and press ENTER. The current setting will display.
2. Use UP or DOWN to scroll to the desired setting.
3. Press ENTER to save.

ORP Overfeed Timeout

Inhibits ORP feed, sounds alarms, and sends a message to POOLCOMM if the setpoint is not reached after continuous feeding for a selectable period.

1. From the Configuration Setup Menu, navigate to "ORP Overfeed Timeout" and press ENTER. The current setting will display.
2. Use UP or DOWN to scroll to the desired setting.
3. Press ENTER to save.

NOTE: Overfeed Timers prevent dangerous chemical dispensing. It is recommended to keep "Overfeed Timeout" enabled.

Auxiliary pH Setpoint

The auxiliary relay can be programmed for acid or base feed pH correction, or supplemental pH control with a second setpoint.

1. From the Configuration Setup Menu, navigate to "Auxiliary pH Setpoint" and press ENTER. The current setpoint will display.
2. Use UP or DOWN to scroll to the desired setting.
3. Press ENTER to save.

Auxiliary ORP Setpoint

The auxiliary relay can be programmed for supplemental ORP control with a second setpoint, or dechlorination.

1. From the Configuration Setup Menu, navigate to "Auxiliary ORP Setpoint" and press ENTER. The current setpoint will display.
2. Use UP or DOWN to scroll to the desired setting.
3. Press ENTER to save.

Alarm Setup

This allows disabling the audible alarm without affecting other safeguards or POOLCOMM alerts.

1. From the Configuration Setup Menu, navigate to "Alarm Setup" and press ENTER. The current option will display.
2. Use UP or DOWN to scroll to the desired setting.
3. Press ENTER to save.

Feed on Alarm

This feature allows the controller to override pH High Alarm and ORP Low Alarm by feeding chemicals while displaying the alarm.

1. From the Configuration Setup Menu, navigate to "Feed On Alarm" and press ENTER. The current setting will display.
2. Use UP or DOWN to scroll to the desired setting.
3. Press ENTER to save.

Auxiliary Output Setup

The auxiliary relay can be programmed for functions like Remote Alarm, pH Acid/Base Feed, ORP Feed Up/Down, Level/Flow Sensor input, Primary ORP Relay, or Time-based Activation.

1. From the Configuration Setup Menu, navigate to "Auxiliary Output Setup" and press ENTER. The current selection will display.
2. Use UP or DOWN to scroll to the desired setting.
3. Press ENTER to save.

Level/Flow Sensor Input #3 Setup

This input facilitates digital flow monitoring, water level control, and other features using optional sensors.

1. From the Configuration Setup Menu, navigate to "Input 3 Setup" and press ENTER.
2. Press DOWN to view options: Disabled, Digital Flow (select pipe size), or Level Sensor.
3. Press ENTER to confirm the selection. The controller reverts to the Configuration Setup Menu after 10 seconds.

Digital Flow Pipe Size

Select the pipe size and schedule to ensure proper flow rate display.

1. From the Configuration Setup Menu, navigate to "Digital Flow Pipe Size" and press ENTER. The current setting will display.
2. Use UP or DOWN to scroll to the desired setting.
3. Press ENTER to save.

Digital Flow Alarm

Sounds alarms and sends a message to POOLCOMM during a Low Flow condition, inhibiting chemical feed.

1. From the Configuration Setup Menu, navigate to "Digital Flow Alarm" and press ENTER. The current setting will display.
2. Use UP or DOWN to scroll to the desired setting.
3. Press ENTER to save.

Digital Flow Sensor Type

Select the type of digital flow sensor being used (e.g., Blue-White, Signet).

1. From the Configuration Setup Menu, navigate to "Digital Flow Sensor Type" and press ENTER. The current setting will display.
2. Use UP or DOWN to scroll to the desired setting.
3. Press ENTER to save.

Display System Information

View firmware revision number and system date/time acquired from the wireless link.

1. From the Configuration Setup Menu, navigate to "Display System Info" and press ENTER.
2. Press ENTER at the prompt to confirm. System information will display. The controller reverts to the Configuration Setup Menu after 10 seconds.

Update FW via BL

This feature updates controller firmware. Contact Hayward Commercial at 301-838-4001 for firmware issues.

Restore Factory Defaults

This function erases user settings and restores factory defaults.

1. From the Configuration Setup Menu, navigate to "Restore Factory Def." and press ENTER.
2. Press ENTER again at the prompt to restore. The display will blank, and settings will be restored. The controller reverts to Normal Operating Mode after 10 seconds.

Caution: User-modified settings must be reconfigured after restoring factory defaults.

Demonstration Mode

Enables the CAT 4000 for demonstration, training, or sales, simulating pH at 7.5 and ORP at 650 mV without sensors.

1. From the Configuration Setup Menu, navigate to "Demo" and press ENTER. The current status will display.
2. Use UP or DOWN to make a selection.
3. Press ENTER to save. The controller reverts to the Configuration Setup Menu.

Caution: Do not use Demonstration Mode when the CAT 4000 is connected to active feeders or controlling water quality.

System Maintenance

Cat 4000 Controller Package

The CAT 4000 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.

Water Maintenance

Regularly test and record water chemistry using a quality manual test kit, adhering to Health Department requirements. Calibrate pH periodically. Factors like pH, cyanuric acid, total dissolved solids, and alternative sanitizers affect ORP readings. Maintain total alkalinity for pH stability. Adjust ORP setpoint periodically to maintain consistent sanitizer residual.

Precision Calibration

The CAT 4000 offers instrument-grade accuracy, potentially exceeding that of liquid test kits. Calibrating pH with commercially available reference solutions may be preferable.

Sensor Maintenance

Sensors must be clean and free from oil, chemical deposits, and contamination. Cleaning may be needed weekly or monthly depending on usage. Slow response, increased calibration needs, or inconsistent readings indicate cleaning is required.

To clean sensors: disconnect from the controller, remove from the flow cell. Clean the reference junction (white teflon ring) with a soft toothbrush and toothpaste. Household liquid dishwashing detergent can remove oil. Rinse with fresh water, replace teflon thread-seal tape, and reinstall.

Sensor Replacement

For optimal performance and service life, replace pH and ORP sensors if they provide unstable readings or require excessive calibration. Use genuine CAT Professional Series sensors PRO15-2 and PRO25-2.

Sensor Storage

Atmospheric exposure can dry sensor tips. Store sensors in provided soaking caps filled with original storage solution or clean water. If caps are lost, store sensors individually in clean water. CAT Professional Series sensors are freeze-resistant but must be protected from freezing temperatures.

Controller Storage

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

Winterization

Prepare sensors for storage and protect from freezing temperatures. While the controller withstands a broad temperature range, winter storage in a secure location is advisable. Drain the flow cell and tubing before exposure to freezing temperatures, either by purging with compressed air or draining through valve ports.

Network Communications

Cell and Satellite

CAT controllers on Cell and Satellite networks are pre-activated for wireless communication. After installation and registration on www.poolcomm.com, devices will communicate. Local reception and antenna positioning affect capability. Contact technical support for communication issues.

WIFI

WIFI Controllers communicate via local WIFI networks and require configuration to connect. Consult the WIFI Connectivity Checklist for details.

Test w/ a CAT 4000

To check coverage, place a CAT 4000 unit where installation is planned and press the Transmit data button. A service request alarm will be generated within 2 minutes, visible on the POOLCOMM website and directed to your phone or device. Ensure your email address is entered under Notifications.

Activating Communications

To activate your CAT 4000 wireless controller on the POOLCOMM website, first register an account by calling 301-838-4001 or visiting www.poolcomm.com. Follow the prompts to register your account and then register your unit.

Using The POOLCOMM Website

Browse to www.poolcomm.com and log in with your username and password to access the Account Unit Management Screen. This screen displays all communicating units.

Status Symbol: Indicates 24-hour alarm status (Blue: No warning, Yellow: Warning corrected, Red: Warning exists).

Facility Name: Lists facilities automated with CAT 4000 controllers. Clicking a facility name opens the Unit Profile for online settings modification (facility name, location, time zone, pH/ORP setpoints, alarm settings, notification contacts).

Commands:

• Manage: Opens the Unit Profile page.
• Alarms: Opens the Unit Warning Alarms page.
• Graph: Opens the Unit Data Graph page.
• Data: Opens the Unit Data Report screen.

Screenshot of the POOLCOMM website login page.

Screenshot of the POOLCOMM Account Unit Management Screen, listing connected units and their status.

Screenshot of the POOLCOMM Unit Profile screen, showing detailed settings and commands for a specific unit.

Troubleshooting

pH Out Of Range

pH is measured on a scale of 0-14, with 7.0 being neutral. Below 7.0 is acidic, above 7.0 is alkaline. Proper pH for pools/spas is 7.2-7.8.

pH Low

A pH below 7.2 can cause corrosion and bather discomfort. Test with a phenol red kit. If the kit agrees with the controller and pH is below 7.2, check pH correction chemical levels. If they do not agree, clean the sensor.

pH High

A pH above 7.8 can cause scaling, cloudy water, inefficient sanitizer use, and bather discomfort. Test with a phenol red kit. If the kit agrees with the controller and pH is above 7.8, check pH correction chemical levels. If they do not agree, clean the sensor.

pH Overfeed

Occurs when the CAT 4000 feeds chemicals beyond the maximum time without reaching the setpoint. This prevents overfeeding if chemical supply is low or a feeder is clogged. Check chemical supply and feeder first. If issues persist, increase the Overfeed timeout setting.

pH Tank Low

The pH Tank Low alarm sounds when chemical levels fall below the optional optical level sensor. Check the chemical level. If the level is adequate, check the sensor for obstruction or scaling.

ORP Out Of Range

Oxidation Reduction Potential (ORP) measures oxidizing capacity. It's a more accurate indicator of water quality than DPD chlorine readings, regardless of pH, TDS, or cyanuric acid. The proper ORP range for pools/spas is 650-800 mV; values above 650 indicate healthy water quality.

ORP Overfeed

Occurs when the CAT 4000 feeds chemicals beyond the maximum time without reaching the setpoint. This prevents overfeeding if chemical supply is low or a feeder is clogged. Check chemical supply and feeder first. If issues persist, increase the Overfeed timer setting.

ORP Tank Low

The ORP Tank Low alarm sounds when chemical levels fall below the sensor in the tank. Check the chemical level. If adequate, check the sensor for obstruction or calcification.

No Flow

The CAT 4000 uses a flow sensor to prevent chemical feeding without recirculation. Ensure the filtration system is running and water is flowing through the flowcell. If the alarm persists with flow, check the flow sensor for obstruction.

With the optional Digital Flow Sensor, a "No Flow" alarm can be set for filter cleaning/backwashing based on gallons-per-minute.

Service Request

Pressing the Transmit button sends logged data to the POOLCOMM website and generates a service request alarm.

Key Inserted

An optional service key can be inserted by a technician, logging the time and duration of their visit.

Technical Specifications

Enclosure

Display

Components

Inputs

Outputs

Communications

Safety Systems

Optional Equipment

Sensor Output Signal Requirements

Warranty

Hayward warrants the W3CAT4000WIFI CAT 4000 automated controller, its sensors, flow switches, fittings, and accessories to be free from defects in material and workmanship for one year from the date of shipment. Liability is limited to repair or replacement of defective components returned to the factory, shipping prepaid, within one year of delivery.

Hayward disclaims liability for damage during transportation, consequential damage, damage due to handling, improper installation or operation, or suitability for intended use.

No representative can alter this warranty. For warranty claims, obtain a Return Merchandise Authorization form and direct claims to:

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

Extended Warranty & Support

Register your product with your smartphone to protect your investment and receive a 90-day extended warranty (parts only, labor not included). Visit Hayward.com/Warranty for details.

For further information or consumer technical support, visit www.hayward.com.