Hayward CAT 2000 W3CATPP2000 User manual

\
USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
Hayward Pool Products
620 Division Street, Elizabeth NJ 07207
Phone [phone]
www.hayward.com
CAT 2000
Automated Controller
Owner’s Manual
092746 RevB
Contents
Introduction............................................3
Installation..............................................5
Pool Chemistry........................................9
Conguration..........................................9
DisplayFunctions...................................17
System Maintenance............................20
Troubleshooting....................................21
Warranty...............................................26
®
W3CATPP2000

USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
1
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.
SAVE THESE INSTRUCTIONS

USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
2
Foreword
Congratulations on your wise investment. The product you have selected from the CAT 2000 line
of automated controllers should provide you with substantially reduced chemical maintenance, im-
proved 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 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 and recording manual
water testing in conformance with your state or local health department regulations. 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.

USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
3
Introduction
Description
A pool operator typically checks and adjusts pool or spa water chemistry hourly at best. The CAT
2000 continuously monitors pH and sanitizer activity, 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 Health
Department chemistry standards, reduced burden on operating staff, and a reduction of chemical
usage and costs.
The following graph compares typical chlorine levels when chemistry is adjusted manually versus
automatically with the CAT 2000 controller.
What’s Included:
Description
The following is a description of the components incorporated in a typical CAT 2000 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 2000 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.
The Professional-Series ORP Sensor samples water from the filtration system and sends signals
to the controller indicating the oxidation-reduction potential (redox) of the water. ORP is an actual
measure of sanitizer activity (chlorine, bromine, ozone, etc.) and bacteriological water quality
rather than an expression of chemical residual levels. The CAT 2000 controller is preset from the
factory to maintain ORP at 650 millivolts.
Manual Control HCC Automated Control
CL2
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0.0
10:00 11:00 12:00 1:00 2:00 3:00 4:00 5:00 Time

USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
4
The Flow Sensor (required) monitors the rate of flow across the pH and ORP sensors and signals
the controller 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, ORP and Flow Sensor while
ensuring ideal hydraulic conditions to maximize sensor performance and life.
The CAT 2000 controller unit scans and interprets the signals from the pH and ORP probes,
displays water quality readings in digital format, and activates chemical feeders in proportion to the
demand required to maintain setpoint pH and ORP levels. 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 for either channel. The CAT 2000 controller unit also features an
internal micro-computer for unsurpassed accuracy, adaptability, and ease of use. All user-entries
and adjustments are made through the touch-screen 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 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 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.

USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
5
Installation
Installation Procedure With Flow Cell
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. 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 and ORP sensors from the plastic storage bottles and save bottles and storage
fluid for future use. Thread sensors into flow cell.
8. Remove BNC protective covers from left side of controller unit and store for future use. These
covers protect the controller unit from electro-static discharge (ESD) and should be used
whenever handling or transporting the controller unit.
9. Connect the pH, ORP 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
manufacturers 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.

USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
6
Typical CAT 2000 Installation Diagram With Flowcell
CAT Controllers
Flow
Main Drain
and Skimmer
Flow
Flow
Flow
Flow Cell / Flow Sensor Bypass Line
Solenoid
Flow Pressure
Differential
Solenoid
CAT CO2
pH Control
Erosion
Feeder
or
or
Chemical
Pump
Chemical Pump
Influent
(to Return Line)
Effluent (to Suction)
SUCTION LINE
PUMP
FILTER
WASTE
RETURN LINE
CAT PRO25
ORP
Sensor
CAT PRO15
pH
Sensor
pH
ORP
CAT 2000
ChemicalAutomation Technologies AutomatedController
pH / ORP
pH ORP
FEED ALARM
SetpointAdjustment
SET CALIBRATE
Channel Mode Selection
AUTO OFF MANUAL
FEED ALARM
SetpointAdjustment
SET BREAKPOINT
Channel Mode Selection
AUTO OFF MANUAL
POWER
Rotary Flow Sensor
pH ORP CAT 2000
CONTROLLER
Sample
Stream
ALL CHEMICALS MUST BE INJECTED DOWN STREAM FROM HEATER AND FLOW CELL

USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
7
Installation Procedure With Bypass Line
CAT recommends the use of a CAT Flowcell and Rotary Flow Sensor for all recreational water ap-
plications. The CAT Flowcell provides a controlled flow to maximize sensor life, convenient sample
port for manual water tests, integrated mounting of Rotary Flow Sensor, and fast professional
installation with flexible tubing and Tru-seal connectors.
Construction of a bypass line should only be performed by experienced technicians familiar with
the procedures for plumbing with PVC as well as the material used in the existing filtration system.
Refer to the Illustration on the following page for a typical bypass diagram.
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 unobstructed bypass line plumbing.
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 the CAT 2000 controller on a vertical wall.
4. Install one “reducing tee” or “saddle tee” fitting each on the incoming suction line to the pump
and the return line upstream from heater as shown in the illustration on the following page.
5. Install ball valves on bypass inlet and effluent immediately adjacent to tee fittings.
6. Install in-line filter (optional) immediately downstream from bypass inlet valve.
7. Install flow meter (optional) immediately downstream from in-line filter (if applicable) or bypass
inlet valve.
8. Install two tee fittings to accommodate ½” NPT Professional Series pH & ORP sensors as
shown in the illustration on the following page.
9. Install Rotary Flow Sensor in bypass line as shown in the illustration on the following page.
10. Remove pH and ORP sensor storage caps and save for future use.
11. Remove BNC protective covers from left side of controller unit and save for future use. NOTE:
These covers protect the controller 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 ½” tee fittings. Teflon tape may be used to seal
threads.
13. Carefully route sensor cables to the controller unit, and connect the sensor cables to the
controller unit as labeled. NOTE: Sensor cables are constructed from a specialized coaxial
material - never cut or splice sensor cables.

USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
8
14. Label and support all new piping. If new chemical feeders are to be used with the controller,
install according to instructions provided by the manufacturer.
15. Connect chemical feeders to the controller unit as labeled.
16. Resume operation of the filtration system and check for leaks.
Typical CAT 2000 Installation Diagram With Bypass Line
Flow
Main Drain
and Skimmer
Flow
Flow
Flow
Flow Cell / Flow Sensor Bypass Line (Plumbed On-Site)
Solenoid
Flow
Solenoid
CAT CO2
pH Control
Erosion
Feeder
or
or
Chemical
Pump
Chemical Pump
SUCTION LINE
PUMP
FILTER
WASTE
RETURN LINE
pH
ORP
CAT 2000
ChemicalAutomation Technologies Automated Controller
pH / ORP
pH ORP
FEED ALARM
SetpointAdjustment
SET CALIBRATE
ChannelMode Selection
AUTO OFF MANUAL
FEED ALARM
SetpointAdjustment
SET BREAKPOINT
ChannelMode Selection
AUTO OFF MANUAL
POWER
Flow Sensor
CAT 2000 CONTROLLER
CATPRO25
ORP
Sensor
CATPRO15
pH
Sensor
pH ORP
Sensor Adaptors

USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
9
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 2000.
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.
All CAT water quality controllers maintain sanitizer levels (chlorine, bromine, ozone, etc.) based
on ORP. Although ORP is a superior index of water quality compared to part per million sanitizer
residual levels, factors such as 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 alka-
linity, temperature, and cyanuric acid levels prior to initiating automated control of the pool or spa.
The ORP setpoint will need to be changed periodically as described later in this section if the goal
is to provide consistent sanitizer residual levels rather than consistent control of ORP.
Configuration
Overview
Once desired start up chemistry parameters have been established, you are ready to set the CAT
2000 to automatically maintain pH and sanitizer levels. Please refer to the Illustration on page 12
for controller unit button designations. Button designations appear in bold type.
Basic Configuration Options
Selecting Acid or Base Feed
The CAT 2000 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 facility 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:

USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
10
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 2000 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.
Changing the pH Setpoint
The CAT 2000 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.
Changing the ORP Setpoint
The CAT 2000 is preset from the factory to maintain ORP at 650 mV. This is the generally ac-
cepted world standard for safe drinking water. In order to meet Health Department standards for
a particular pool or spa, the ORP setpoint may be changed to maintain a desired sanitizer level by
performing the following:
1. Manually test pool or spa to confirm that the current sanitizer reading (chlorine, bromine,
etc.) is the level you wish to maintain.
2. Note the ORP reading displayed by the controller.
3. Press the ORP Setpoint Adjustment Button (#8) until the green “SET” LED is illumi-
nated.
4. Press the arrow-shaped ORP Channel Increase Button (#6) or ORP Channel Decrease
Button (#7) until the digital display matches the ORP reading previously noted.
5. The controller will automatically return to the normal operating mode after twenty sec-
onds, storing any changes.
The ORP setpoint should be changed as needed to maintain sanitizer residuals in conformance
with Health Department standards.

USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
11
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 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 chemical feeder will operate continuously for 30
minutes, and 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. So that
the user may have time to enter selections, the chemical feeding cycle will not be interrupted for
approximately ten seconds.
Manually Disabling ORP Feed
To manually prevent operation of the pH chemical feeder press the ORP Channel Mode Selection
Button (#9) until the red “OFF” LED is illuminated. Automatic ORP 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.
Automatically Controlling ORP Feed
For automated control of the ORP chemical feeder press the ORP Channel Mode Selection But-
ton (#9) 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 chemi-
cal feeding cycle will not be interrupted for approximately ten seconds.
About Proportional Feed
The CAT 2000 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, but should be disabled for use with salt chlorine systems.

USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
12
CAT 2000 Switch And Keypad Functions
Advanced Configuration Options
Beginning with the 2008 model year, the CAT 2000 controller incorporates an advanced program-
ming menu and enhanced features. 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 displays, in addition to activating both channel
Alarm indicators and sounding an audible alarm.
BUTTON DESIGNATION DESCRIPTION
POWER
1
2
3
4
5
6
7
8
9
pH Channel Decrease Button
Controller Unit Power Switch
Hidden Button (Located Behind “pH” Text)
pH Channel Increase Button
pH Channel Setpoint Adjustment Button
pH Channel Mode Selection Button
ORP Channel Increase Button
ORP Channel Decrease Button
ORP Channel Setpoint Adjustment Button
ORP Channel Mode Selection Button

USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
13
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 pH channel 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 (#6) and Down (#7) arrow buttons to scroll through programming options.
3. Press the Enter Button (#8) to make a selection.
P.Fd (pH Feed Mode)
Selects the condition under which the pH feed output is activated.
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.Pr (pH Priority)
Inhibits ORP feed when pH is not within .2 of setpoint.
Off: The pH feed and ORP feed decisions are independent of each other. This is the default
setting.
On: The pH Priority feature is enabled. Inhibits the ORP feed output when the measured pH
value differs from the pH setpoint by more than 0.2 pH units. For example, when the pH set-
point is 7.5, then the ORP feed output will be enabled when the measured pH value is in the
range 7.3 to 7.7; and inhibited when the measured pH is any value outside this range.
P.Ai (pH Interlock)
Inhibits ORP feed when the controller is in pH High Alarm.
OFF: The pH feed and ORP feed decisions are independent of each other. This is the default
selection.
On: The pH Priority feature is enabled. Inhibits the ORP feed output when the pH High Alarm is
triggered. ORP feed will resume when pH High Alarm stops.
A
3.17

USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
14
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.
P.OF (pH Overfeed Timer)
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 out-
put. 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.
7.0: 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 7.0 pH.

USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
15
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.
8.0: 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 8.0 pH.
O.PF (ORP Proportional Feed)
Selects either fixed setpoint or proportional control.
Off: The ORP feed output is activated based on a simple above or below setpoint decision.
When the measured ORP value is less than or equal to the ORP setpoint, the ORP output feed
is turned on. Otherwise, the ORP feed output is turned off.
On: The ORP feed output is activated based on the difference between the ORP setpoint and
the measured ORP value. As the difference increases, the duration the ORP feed output is
turned on increases to 20, 30, 40, and 50 seconds of the 60 second cycle, and then the ORP
feed output is turned on continuously. This is the default setting.
O.OF (ORP Overfeed Timer)
When Off is selected, the ORP feed output will remain activated as long as an ORP feed condition
is indicated. When any other selection is made, an overfeed limit timer is enabled on the ORP feed
output. After the ORP feed output has been turned on for a period of time greater than this limit,
the ORP channel is turned off and placed into an overfeed alarm condition which must be manually
reset.
If ORP Proportional Feed: On has been selected, the ORP feed output must be on continuously for
the overfeed time limit, rather than in the part of the proportional feed cycle in which the ORP feed
output is on for only a portion of the 60 second proportional feed cycle.
After the ORP feed channel is placed into the overfeed alarm condition, the ORP channel is turned
off and the ORP Feed Mode indicator flashes rapidly to indicate the alarm. Press the ORP Feed
Mode button to return the ORP channel to the off, manual or automatic feed mode. This will reset
the ORP overfeed alarm and restart the overfeed timer. The ORP overfeed alarm will also be reset if
the controller is powered off and then back on.
The ORP overfeed timer is disabled when the ORP Feed Mode button is used to place the ORP
channel in the manual feed state.
Off: The ORP 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

USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
16
O.AL (ORP Alarm Low Limit)
Sets the low alarm point for the ORP channel. When the measured ORP value is less than this
limit, the audible alarm will be activated and the ORP feed output will be disabled. The alarm will
be cleared and feed will resume automatically when the measured ORP value returns to within the
non-alarm range.
525: Use the UP and DOWN buttons to select a value between 200 and 995 pH. The value
must be less than the pH alarm high value. The default value is 525 mV.
r.AD (Remote Alarm Delay)
When using a remote alarm connected to the Alarm Output relay, you can select a delay time
between 0 and 10 minutes.
0: Use the UP and DOWN buttons to select a value between 0 and 10. The default value is 0.
O.AH (ORP Alarm High Limit)
Sets the high alarm point for the ORP channel. When the measured ORP value is greater than this
limit, the audible alarm will be activated and the ORP feed output will be disabled. The alarm will
be cleared and feed will resume automatically when the measured ORP value returns to within the
non-alarm range.
900: Use the UP and DOWN buttons to select a value between 400 and 995. The value must
be greater than the ORP alarm low value. The default value is 900 mV.
Clr (Clear All Programming and Restore Factory Defaults)
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 2000 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 min-
ute intervals. Data recorded includes pH and ORP measured values, and the feed output and
alarm status of both channels. 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.

USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
17
Display Functions
Please refer to the illustration on page 19 with reference to designations of the various LED
indicator lights on the front panel. Please note that for enhanced viewing the CAT 2000 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.
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.

USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
18
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.
ORP Alarm Indicator (#10)
Illumination of this red indicator is accompanied by an audible alarm and indicates that ORP is
outside of the safe operating range. Check that the ORP chemical feeder is functioning properly
and that an adequate supply sanitizer is available.
ORP Digital Display (#11)
The red digital numeric display of the ORP channel of the controller normally indicates the current
ORP (oxidation-reduction potential) of the pool or spa water passing through the filtration system.
Pressing the ORP Setpoint Adjustment Button until the red “SET” LED is illuminated causes the
ORP setpoint to be displayed.
ORP Setpoint Adjustment Mode Indicator (#12)
This green LED is illuminated whenever the controller is in the ORP setpoint adjustment mode.
ORP Automatic Control Indicator (#13)
This green LED is illuminated when ORP is under automated control.
ORP Manual Off Indicator (#14)
This red LED is illuminated when ORP feeding is manually disabled.
ORP Manual On Indicator (#15)
This green LED is illuminated when pH feeding is manually activated.

USE ONLY HAYWARD GENUINE REPLACEMENT PARTS
19
CAT 2000 Indicator Designations & Functions
ORP FEED MANUALLY DISABLED
DESIGNATION COLOR/TYPE DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
GREEN LED
RED LED
DIGITAL DISPLAY
pH SETPOINT ADJUSTMENT MODE INDICATORGREEN LED
GREEN LED
GREEN LED
RED LED
GREEN LED
GREEN LED
RED LED
DIGITAL DISPLAY
GREEN LED
GREEN LED
GREEN LED
RED 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
ORP FEED INDICATOR
ORP OUT OF RANGE ALARM
ORP INDICATOR/SETPOINT
ORP SETPOINT ADJUSTMENT MODE INDICATOR
AUTOMATIC ORP CONTROL INDICATOR
ORP FEED MANUALLY ACTIVATED