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.

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Power On Display
At power on, the controller displays the pH feed mode and firmware version number. The pH feed
mode is displayed on the LED display:
A: Acid feed selected.
b: Base feed selected.
The firmware version number is displayed on the ORP channel LED display:
Firmware version number (or later).
Entering Advanced Setup Mode
Find the Hidden Button (#1) located 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 (#2) and Down (#3) arrow buttons to scroll through programming options.
3. Press the Enter Button (#4) to make a selection.
P.Fd (pH Feed Mode)
Selects the condition under which the pH feed output is activated. This can be set to either acid or
base feed.
A: Acid (default). pH feed output is activated when the measured pH is greater than the pH
setpoint, indicating the need to feed acid to decrease the pH of the water.
b: Base. pH feed output is activated when the measured pH is less than the pH setpoint,
indicating the need to feed base to increase the pH of the water.
P.PF (pH Proportional Feed)
Selects either fixed setpoint or proportional control.
Off: The pH feed output is activated based on a simple above or below setpoint decision.
When the measured pH value is less than or equal to the pH setpoint (pH Feed: Acid selected)
or greater than or equal to the pH setpoint (pH Feed: Base selected) the pH output feed is
turned off. Otherwise, the pH feed output is turned on.
On: The pH feed output is activated based on the difference between the pH setpoint and the
measured pH value. As the difference increases, the duration the pH feed output is turned on
increases to 20, 30, 40, and 50 seconds of the 60 second cycle, and then the pH feed output
is turned on continuously. This is the default setting.
AA
6.126.12

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P.OF (pH Overfeed Timer)
Overfeed Timers prevent potentially dangerous, unintentional dispensing of chemicals. Hayward
recommends always having the “Overfeed Timeout” functions enabled as a precautionary mea-
sure. By disabling the “Overfeed Timeout” the overfeeding of chemicals could occur and create
unsafe water chemistry conditions. Overfeeding chemicals is dangerous and could potentially harm
patrons.
When Off is selected, the pH feed output will remain activated as long as a pH feed condition is
indicated. When any other selection is made, an overfeed limit timer is enabled on the pH feed
output. After the pH feed output has been turned on for a period of time greater than this limit,
the pH channel is turned off and placed into an overfeed alarm condition which must be manually
reset.
If pH Proportional Feed: On has been selected, the pH feed output must be on continuously for
the overfeed time limit, rather than in the part of the proportional feed cycle in which the pH feed
output is on for only a portion of the 60 second proportional feed cycle.
After the pH feed channel is placed into the overfeed alarm condition, the pH channel is turned off
and the pH Feed Mode indicator flashes rapidly to indicate the alarm. Press the pH Feed Mode
button to return the pH channel to the off, manual or automatic feed mode. This will reset the
pH overfeed alarm and restart the overfeed timer. The pH overfeed alarm will also be reset if the
controller is powered off and then back on.
The pH overfeed timer is disabled when the pH Feed Mode button is used to place the pH
channel in the manual feed state.
Off: The pH feed output will remain 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
P.AL (pH Low Alarm Limit)
Sets the low alarm point for the pH channel. When the measured pH value is less than this limit,
the audible alarm will be activated and the pH feed output will be disabled. The alarm will be
cleared and feed will resume automatically when the measured pH value returns to within the non-
alarm range.
6.8: 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.

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P.AH (pH Alarm High Limit)
Sets the high alarm point for the pH channel. When the measured pH value is greater than this
limit, the audible alarm will be activated and the pH feed output will be disabled. The alarm will
be cleared and feed will resume automatically when the measured pH value returns to within the
non-alarm range.
8.2: 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.
Clr (Clear All Programming and Restore Factory Defaults)
Factory Clear. Returns all controller operating parameters to their default values.
dEo (Demonstration Mode)
Places the controller in Demo Mode for showroom display, presentations, etc.
bPr (Audible Alarm)
The Beeper setting allows the audible alarm to be enabled (default) or disabled.
Srl (Serial Interface)
The CAT 1000 includes a standard RS232 serial interface. A header assembly and cable are
required to connect.
Onl: Online Communications. Use this selection when the controller is attached to a PC or
building automation system.
Prn: Printer. 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
to connect it to the controller. The CAT Serial Printer prints one data record at 15 minute
intervals. Data recorded includes pH measured values, and the feed output and alarm status.
This is the default setting.
When all desired settings have been entered, press the Hidden Button or wait 30 seconds and the
controller will return to default operating mode.
Display Functions
Please refer to Illustration 4 with reference to designations of the various LED indicator lights on the
front panel. Please note that for enhanced viewing the CAT 1000 features a “dead-front” display
panel, so only illuminated indicators will be visible to the user. All lights and indicators are activated
during power-on.
pH Feed Indicator (#1)
This green LED is illuminated whenever the pH chemical feeder is automatically or manually
activated.

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pH Alarm Indicator (#2)
Illumination of this red indicator is accompanied by an audible alarm and indicates that pH is
outside of the safe operating range. Check that the pH chemical feeder is functioning properly and
that an adequate chemical supply is available.
pH Digital Display (#3)
The red digital numeric display of the pH channel normally indicates the current pH of the pool or
spa water (as calibrated) passing through the filtration system. Pressing the pH Setpoint Adjust-
ment Button until the red “SET” LED is illuminated causes the pH setpoint to be displayed.
pH Setpoint Adjustment Mode Indicator (#4)
This green LED is illuminated whenever the controller is in the pH setpoint adjustment mode.
Setpoint adjustment is allowed only when this LED is illuminated.
pH Calibrate Mode Indicator (#5)
This green LED is illuminated whenever the controller is in the pH calibration mode. Calibration of
the pH display is allowed only when this LED is illuminated.
pH Automatic Control Indicator (#6)
This green LED is illuminated when pH is under automated control.
pH Manual Off Indicator (#7)
This red LED is illuminated when pH feeding is manually disabled.
pH Manual On Indicator (#8)
This green LED is illuminated when pH feeding is manually activated.
CAT 1000 Indicator Designations & Functions
DESIGNATION COLOR/TYPE DESCRIPTION
1
2
3
4
5
6
7
8
GREEN LED
RED LED
DIGITAL DISPLAY
pH SETPOINT ADJUSTMENT MODE INDICATORGREEN LED
GREEN LED
GREEN LED
RED LED
GREEN LED
pH FEED INDICATOR
pH OUT OF RANGE ALARM
pH INDICATOR/SETPOINT/CALIBRATION
pH CALIBRATION MODE INDICATOR
AUTOMATIC pH CONTROL INDICATOR
pH FEED MANUALLY DISABLED
pH FEED MANUALLY ACTIVATED

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System Maintenance
CAT 1000 Controller
The CAT 1000 controller unit is virtually maintenance free. Cleaning of the enclosure, front panel
and flow cell can be performed using a clean, soft cloth moistened with mild soap and water
solution or glass cleaner. Use of abrasives or harsh chemicals may damage the enclosure and
membrane switch panel.
Water Maintenance
Always test and record water chemistry readings in compliance with Health Department require-
ments using a quality manual test kit. Calibrate pH periodically as described earlier in this manual.
Precision Calibration
The CAT 1000 controller provides instrument-grade accuracy which exceeds that of most liquid-
standard water testing kits. Therefore, it may be preferable to calibrate pH using commercially
available reference solutions.
Sensor Maintenance
The sensor must be clean and free from oil, chemical deposits and contamination to function
properly. After saturation in pool or spa water, the sensor may need to be cleaned on a weekly or
monthly basis depending on bather load and other facility-specific characteristics. Slow response,
increased need to calibrate pH, and inconsistent readings are indications that the sensor is in need
of cleaning.
CAT 1000 pH CONTROLLER
pH
FEED ALARM
SETPOINT ADJUSTMENT
SET CALIBRATE
pH FEED MODE
AUTO OFF MANUAL
21
3
4 5
6 7 8

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To clean the sensor, disconnect from the controller and carefully remove them from the flow cell.
Clean the reference junction (the white teflon ring at the bottom of sensor body) with a soft tooth
brush and regular tooth paste. A household liquid dishwashing detergent may also be used to
remove any oil. Rinse with fresh water, replace teflon thread-seal tape, and reinstall sensor. Hand
tighten only.
Never allow a pH sensor to dry completely. Drying will damage the reference junction and void the
sensor warranty.
Sensor Replacement
CAT Professional Series pH sensors are engineered to provide the highest performance and longest
possible functional service life. If a properly cleaned sensor provides unstable readings or requires
excessive calibration, the sensor should be replaced. For optimum controller performance, replace
with genuine CAT Professional Series sensor PRO15-2.
Sensor Storage
Exposure to atmospheric conditions will cause the sensor tips to dry out. Always remove and
properly store pH sensor in the soaking cap provided if sensor is to be removed or stored for one
hour or longer. Although CAT Professional Series sensors are freeze-resistant, they must be
protected from freezing temperatures when not in use.
Store sensor in the soaking cap provided, making sure that the container is filled with the original
storage solution or clean water. If the storage container has been misplaced, store sensors indi-
vidually in small glass or plastic containers with clean water covering sensor tips.
Controller Storage
The controller unit is subject to damage by electro-static discharge (ESD) when the sensor cables
are disconnected. Always reinstall the BNC protective covers prior to storing or transporting the
CAT 1000 controller unit.
Winterization
The pH sensor should be prepared for storage as outlined above and protected from freezing tem-
peratures. Although the CAT 1000 controller is designed to withstand a broad temperature range,
winter storage in a secure location is desirable.
The flow cell and poly tubing must be drained prior to exposure to freezing temperatures. Either
purge all water using compressed air or thoroughly drain through the valve ports and tubing con-
nections.
Troubleshooting
Each CAT 1000 controller is manufactured to the highest quality standards and then thoroughly
tested before leaving the factory. State of the art design and fabrication technology ensure years of
trouble free operation. Most apparent malfunctions can be solved through the following corrective
actions:

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No lights are illuminated when controller is powered on.
1. Check circuit breaker and/or receptacle for proper operation. Connect to functional
grounding-type GFCI protected power source.
2. Check for damaged power cord or connector.
Alarm light(s) and tone are observed.
1. Ensure that filtration system is functioning properly, flow is adequate, and water chemis-
try is in balance.
2. Ensure that sensor and power cables are properly connected to their respective connec-
tors on the controller unit.
3. Check chemical feeders for proper operation.
4. Ensure that flow sensor is properly installed and connected.
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.
pH requires frequent calibration.
1. Clean the pH sensor as outlined in the maintenance section. If sensor continues to
provide unstable readings after cleaning, replace sensor.
pH 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 sensors.
3. Check to ensure that all electrical equipment in the facility pump room is properly
bonded.
pH 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 feeding overshoots the setpoint.
1. Ensure that each chemical feeder is properly sized.
2. Check concentration of sanitizer or pH chemical.
pH 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.

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Technical Specifications
Display Range: pH 0.0 - 9.9
Setpoint Range: pH 7.0 - 8.0
Default Settings: pH 7.5
Calibration Range: pH 2.0 pH +/-
Control Accuracy: pH 0.1 pH
Mode Selections: pH Feed Auto/Off/Manual
pH Selection Acid/Base
pH Mode Auto/Set/Calibrate
Safety Systems: pH Audible & Visual Alarms
Controller Unit Diagnostic Self Test
Required Flow Sensor
Optional Remote Alarm
pH & Sensor: Casing Material Molded ABS
Junction Type Teflon Reference
Wet End ½” NPT
Connector Shielded BNC
Sensor Output Signal
Requirements: 0-14 pH
Power Input: 120/240 Volt AC, 10 AMP, 50/60 Hz
Outputs: pH Feed 4 Amp / 120 VAC
4 Amp/ 240 VAC
1 Amp / Dry Contact
1 Amp / Dry Contact
Remote Alarm 1 Amp / Dry Contact
Optional Equipment RS232 Computer Interface Cable
Thermal Printer
Three-Year Professional Series Sensor

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WARRANTY
Hayward®warrants the CAT 1000 automated controller to be free of defects
in material and workmanship for a period of five years from date of ship-
ment from our factory or authorized distributor. Liability under this warranty
is limited to the repair or replacement of any device or component which
is returned to the factory within five years of delivery to original purchaser,
shipping prepaid, and which is found to be defective upon examination.
Hayward®warrants all sensors, flow switches, fittings and accessories to be
free of defects in material and workmanship for a period of one year from
date of shipment from our factory or authorized distributor. Liability under this
warranty is limited to the repair or replacement of any device or component
which is returned to the factory within one year of delivery to original pur-
chaser, shipping prepaid, and which is found to be defective upon examina-
tion.
Hayward®disclaims all liability for damage during transportation, for conse-
quential damage of whatever 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 authority to change or modify this
warranty in any respect. After obtaining a Return Merchandise Authorization
form, any warranty claims should be directed to the following address:
Hayward Commercial Pool Products
10101 Molecular Drive Suite 200
Rockville, MD 20850 (USA)
800-657-2287
301-838-4001

USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
For further information or consumer
technical support, visit our website at
www.hayward.com
Hayward is a registered trademark and CAT 1000 is a
trademark of Hayward Industries, Inc. © 2019 Hayward Industries, Inc.
All other trademarks not owned by Hayward are the property of their respective owners.
Hayward is not in any way affiliated with or endorsed by those third parties.