Hayward CAT 1000 User manual

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USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
Hayward Industries
400 Connell Drive, Suite 6100
Berkeley Heights, NJ 07922
Phone: [phone]
www.hayward.com
CAT 1000
Automated pH Controller
Owner’s Manual
092429A RevD
CAT-1000-PH
CAT-1000-CO2
CAT-1000-PTC
CAT-1000ORPPTC
Contents
Introduction............................................3
Installation..............................................5
Pool Chemistry........................................7
Conguration..........................................7
Display Functions..................................12
System Maintenance.............................14
Troubleshooting....................................15
Warranty...............................................18
®
CAT-1000-PH-UL
CAT-1000-CO2-UL
CAT-1000-PTC-UL
CAT-1000-ORP-UL
CAT1000ORPPTCUL

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IMPORTANT SAFETY INSTRUCTIONS
When using this electrical equipment, basic safety precautions should always be followed, includ-
ing the following:
• READ AND FOLLOW ALL INSTRUCTIONS
• WARNING: Risk of Electric Shock. Connect controller only to a grounding type recep-
tacle protected by a ground-fault circuit interrupter (GFI). CAT Controllers recommends
installation to a dedicated GFI circuit breaker performed by a licensed electrician.
• WARNING: Disconnect power before servicing. Other than the fuses, there are no user
serviceable parts inside the controller.
• WARNING: All power cords should be inspected frequently. Any damaged power cords
must be replaced immediately to reduce the risk of electric shock. Never operate a
controller without functional flow protection.
• WARNING: Installation requires a properly located GFI protected receptacle. Never use
an extension cord for electrical connections to the controller.
• WARNING: Always mount controller in a safe area not subject to damage by moving
objects. Never bury controller power cords.
• WARNING: Any person using, adjusting, or monitoring the controller must be at least 18
years of age and be familiar with these instructions and the contents of this manual.
• WARNING: Always take and record manual water chemistry readings in conformance
with Health Department requirements. Although automated controllers are a great aid in
maintaining healthy water quality, controllers are not a substitute for manual water test-
ing with an accurate test-kit.
• WARNING: Always read and become familiar with Material Safety Data Sheets (MSDS)
and safe handling instructions for all chemicals used with the controller.
• Caution: The automatic controller should not be installed where it is accessible to the
public.
• Overfeed Timers prevent potentially dangerous, unintentional dispensing of chemicals.
Hayward recommends always having the “Overfeed Timeout” functions enabled as a
precautionary measure. By disabling the “Overfeed Timeout” the overfeeding of chemi-
cals could occur and create unsafe water chemistry conditions. Overfeeding chemicals is
dangerous and could potentially harm patrons.
SAVE THESE INSTRUCTIONS

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Foreword
Congratulations on your wise investment. The product you have selected from the CAT 1000 line
of automated controllers should provide you with substantially reduced chemical maintenance,
improved compliance with safe water quality standards, chemical cost savings, and many years
of reliable operation. All CAT controllers incorporate state of the art microprocessor-based design
technology to provide sophisticated control functions at an affordable price.
Although CAT controllers are relatively simple to install, please take the time to read this entire
manual, compare package contents with the parts list, and gather all tools required before begin-
ning installation. Improper installation may void the warranty and create unnecessary hazards.
Properly preparing for installation will also reduce facility down time.
For the purposes of this manual, it is presupposed that the installer is familiar with the physical
characteristics of the pool or spa to be automated. As is the case when installing any filtration
system component, all recirculating pumps, heaters, etc. need to be turned off prior to installation
of the controller. If the filtration system is located below water level, additionally adjust all valves
required to eliminate pressure from the system.
Physically, installation of a CAT controller is no more challenging than installation of a chemi-
cal feeder. Any swimming pool contractor or maintenance engineer should have the tools and
knowledge to perform the installation. Our technical support line can also be used to answer any
questions pertaining to controller installation.
Remember that your new CAT controller is not a substitute for performing regular manual wa-
ter chemistry testing. Never operate a water chemistry controller without a flow sensor, power
interlock, or other means of ensuring that chemicals will not be fed without proper filtration system
recirculation.
Congratulations on your purchase and welcome to the world of chemical automation. Please
complete and return your warranty registration card today.

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Introduction
Description
A pool operator typically checks and adjusts pool or spa water chemistry hourly at best. The
CAT 1000 continuously monitors pH, constantly adjusting the feeding of chemicals on a basis
proportional to the demand. The results include elimination of “human error”, accurate and reliable
maintenance of chemical levels twenty-four hours a day, compliance with safe water chemistry
standards, reduced burden on operating staff, and a reduction of chemical usage and costs.
The following graph compares typical pH levels when chemistry is adjusted manually versus auto-
matically with the CAT 1000 controller.
What’s Included
Description:
The following is a description of the components incorporated in a typical CAT 1000 controller
system:
The Professional-Series pH Sensor samples water from the filtration system and sends signals to
the controller indicating the acidity of the water. The ideal pH range for pools and spas is 7.4 - 7.6.
The CAT 1000 controller is preset from the factory to maintain pH 7.5. If pH is maintained below
7.4 (too acidic), eye irritation, corrosion of equipment, and damage to the pool or spa surface can
occur. If pH is maintained above 7.6 (too alkaline), sanitizer activity is reduced, water may become
cloudy, and eye irritation may result.
Manual Control CAT Automated Control
7.8
7.7
7.6
7.5
7.4
7.3
7.2
7.1
pH
10:00 11:00 12:00 1:00 2:00 3:00 4:00 5:00
Time

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The Flow Sensor (required) monitors the rate of flow across the pH sensor and signals the control-
ler to disable automated chemical feeding during periods when the filtration system is off or low
recirculation flow is detected.
The Flow Cell provides a convenient location for mounting the pH sensor while ensuring ideal
hydraulic conditions to maximize sensor performance and life.
The CAT 1000 controller unit scans and interprets the signals from the pH sensor, displays water
quality readings in digital format, and activates chemical feeder in proportion to the demand re-
quired to maintain the pH setpoint level. The unit incorporates audible and visual safeguard alarms
for out of range conditions, calibration adjustment for pH, and mode selections to manually feed or
disable feeding. The CAT 1000 controller unit also features an internal micro-computer for unsur-
passed accuracy, adaptability, and ease of use. All user entries and adjustments are made through
the touchscreen interface front panel.
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 1000 Water Chemistry Controller
(1) Professional Series pH Sensor with 24” Cable and BNC Connector
(1) BNC Connector Protective Covers (Remove to Connect Sensor)
(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
Before commencing installation, please confirm that items listed above have been included. Please
report any shortages immediately to the factory.
What You Will Need:
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.

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Installation
Installation Procedure:
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 sensor. We recommend
using a CAT Flowcell and fittings to create a pressure-suction “loop” line.
1. Turn off heater, chemical feeders, pump, and any other related equipment. Relieve pressure
from filtration system.
2. Select a convenient mounting location for the controller unit which will meet the following
criteria:
A. Facilitates a combined (influent and effluent) maximum tubing run of 30’.
B. Located a minimum of ten feet from pool or spa.
C. GFI protected power source available.
D. Easily accessible to pool or spa operator.
E. Away from corrosive materials and physical hazards.
3. Securely mount Controller or PVC Backboard on vertical wall.
4. Drill and tap a 1/4” NPT port at a location just downstream of the filter, but upstream from 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 sensor from the plastic storage bottle and save bottle and storage fluid for future
use. Apply teflon tape and thread sensor into flow cell.
8. Remove BNC protective cover from left side of controller unit and store for future use. This
cover protects the controller unit from electro-static discharge (ESD) and should be used
whenever handling or transporting the controller unit.
9. Connect the pH and Flow sensor cables to the controller unit as labeled. Sensor cables are
constructed from a specialized material - never cut or splice.
10. If new or additional chemical feeders are to be used with the controller, install according to
manufacturer’s instructions at this time.
11. Connect chemical feeder to the controller as labeled.
12. Check all electrical and mechanical connections. Resume filtration system operation and
check for any leaks.

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Flow
Main Drain
and Skimmer
Flow
Flow
Flow
Flow Cell / Flow Sensor Bypass Line
Flow Pressure
Differential
Solenoid
CAT CO2
pH Control
or
Chemical
Pump
SUCTION LINE
PUMP
FILTER
WASTE
RETURN LINE
CAT PRO15
pH
Sensor
pH
pH Feed Output
Influent
(to Return Line)
Effluent (to Suction)
pH CAT 1000
Controller Package
CAT Controllers
CAT 1000
pH Controller
pH
FEED ALARM
SETPOINT ADJUSTMENT
CALIBRATE
SET
AUTO OFF MANUAL
pH FEED MODE
Typical CAT 1000 Installation Diagram:

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Pool Chemistry
Now that your new controller has been physically installed, water chemistry should be tested and
adjusted prior to initiating automated control of the pool or spa. Confirm that your pool or spa water
conforms to the following ranges before powering on and setting up the CAT 1000.
Test Minimum Ideal Maximum
pH 7.2 7.5 7.8
Free Chlorine (PPM) 1 2 3
Bromine (PPM) 2 3 4
Cyanuric Acid (PPM) 0 - 100
ORP (mV) 650 - -
Total Alkalinity 80 - 120
Calcium Hardness 200 - 400
The above table indicates generally accepted guidelines. Always maintain water chemistry accord-
ing to standards set by your local or State Health Department.
CAT strongly recommends establishing desired pH, sanitizer residual, calcium hardness, total alka-
linity, temperature and cyanuric acid levels prior to initiating automated control of the pool or spa.
Configuration
Overview
Once desired start up chemistry parameters have been established, you are ready to set the CAT
1000 to automatically maintain pH. Please refer to the chart below and the illustration on the fol-
lowing page for controller unit button designations. Button designations appear in bold type.
BUTTON DESIGNATION DESCRIPTION
1
2
3
4
5
pH Channel Setpoint Adjustment Button
Hidden Button (Located Behind “pH” Text)
pH Channel Increase Button
pH Channel Decrease Button
pH Channel Mode Selection Button

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Basic Configuration Options:
Selecting Acid or Base Feed
The CAT 1000 is preset from the factory to operate in the acid feed mode (when pH exceeds the
setpoint, the pH chemical feeder is activated). If the sanitizer used at your pool or spa causes the
pH to decrease you must select base feed mode. To switch the controller between acid feed and
base feed modes, perform the following steps.
1. Press and hold the Hidden Button (#1) for five seconds to enter advanced setup mode.
2. Scroll to pFD and press the enter key. Scroll to select A for acid feed or B for base feed.
Press the Enter key to set your selection, then press the Hidden Button (#1) again to
return to normal operating mode.
As the unit powers on, the digital pH readout will display an “A” or “B” indicating whether acid feed
or base feed mode has been activated.
Calibrating pH
Readings from the CAT 1000 are far more accurate than those obtained from most liquid test stan-
dards. To match manual water testing results or compensate for a depleted or unclean pH sensor,
the pH channel of the controller may be calibrated as follows:
1. Press the pH Setpoint Adjustment Button (#4) twice, illuminating the green “CALI-
BRATE” LED.
2. Press the arrow-shaped 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 the normal operating mode after twenty sec-
onds, storing any changes.
CAT 1000 pH CONTROLLER
pH
FEED ALARM
SETPOINT ADJUSTMENT
SET CALIBRATE
pH FEED MODE
AUTO OFF MANUAL
1
23
4
5

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Changing the pH Setpoint
The CAT 1000 is preset from the factory to maintain pH at 7.5. To set pH control at a different
level, perform the following:
1. Press the pH Setpoint Adjustment Button (#4) until the green “SET” LED is illuminated.
2. Press the arrow-shaped 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 the normal operating mode after twenty sec-
onds, storing any changes.
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 chemical feeder will operate continuously for 30
minutes, and then automatically revert to “Auto” to prevent accidental overfeeding.
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. So that
the user may have time to enter selections, the chemical feeding cycle will not be interrupted for
approximately ten seconds.
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 chemical feeder will operate automatically in
proportion to chemical demand. So that the user may have time to enter selections, the chemical
feeding cycle will not be interrupted for approximately ten seconds.
About Proportional Feed
The CAT 1000 features an advanced proportional feed algorithm which constantly analyzes
demand for chemicals and initiates feeding in intervals based on the relationship between setpoint
and actual water sample values. This feature is highly valuable in maintaining precise control of
water chemistry in most applications.
Advanced Configuration Options
The CAT 1000 offers a host of advanced options to ensure compatibility with a wide variety of
applications. The advanced programming menu contains features which are usually implemented
during initial dealer setup and do not need to be routinely changed by the operator.
no Flo (Enhanced No-Flow Alarm)
The no-flow alarm displays the prompt on the LED display, in addition to activating the pH Alarm
indicator and sounding the audible alarm.