Hayward HCC 2000 User manual

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HCC 2000
Automated Controller
Owner’s Manual
092460 RevG
HCC2000
HCC2000-AQ
HCC2000-AU
W3HCC2000
Contents
Introduction............................................3
Installation..............................................5
Pool Chemistry .......................................7
Conguration..........................................8
Display Functions..................................15
System Maintenance.............................17
Troubleshooting....................................19
Warranty...............................................22
®
Hayward Industries
400 Connell Drive, Suite 6100
Berkeley Heights, NJ 07922
Phone: [phone]
www.hayward.com

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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 recepta-
cle protected by a ground-fault circuit interrupter (GFI). Hayward 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

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Foreword
Congratulations on your wise investment. The product you have selected from the Hayward®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. Hayward®controllers incorporate state of the art microprocessor-based
design technology to provide sophisticated control functions at an affordable price.
Although Hayward®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
beginning installation. Improper installation may void the warranty and create unnecessary haz-
ards. 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 Hayward®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 Hayward®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.
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 HCC
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 HCC 2000 controller:
What’s Included:
Description
The following is a description of the components incorporated in a typical HCC 2000 controller
system:
The pH Sensor samples water from the filtration system and sends signals to the controller indi-
cating the acidity of the water. The ideal pH range for pools and spas is 7.4 - 7.6. The HCC 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.
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

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The ORP Sensor samples water from the filtration system and sends signals to the controller indi-
cating 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 HCC 2000 controller is preset from the factory to maintain ORP at
650 millivolts.
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 HCC 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 HCC 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 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) HCC 2000 Water Chemistry Controller
(1) PVC Backboard with Mounting Holes and Stainless Hardware
(1) Flow Cell with Flow Sensor and Valves
(1) pH Sensor with 24” Cable and BNC Connector
(1) ORP Sensor with 24” Cable and BNC Connector
(1) 30’ Roll, Poly Installation Tubing (3/8” OD)
(2) 1/4” NPT x 3/8” Tubing True-Seal Connectors
(2) BNC Connector Protective Covers (Remove to Connect Sensors)
(2) Sensor Storage Containers
(1) HCC 2000 Owner’s Manual
(1) HCC 2000 Quick Start Guide
NOTE: 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)
3/8” 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 sensors. We recommend using
the enclosed tubing and fittings to create a pressure-suction “loop” line.
Follow the directions below for installation and refer to the Installation Diagram on page 6.
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 and 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 electrostatic discharge (ESD) and should be used when-
ever 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
manufacturer’s instructions at this time.
11. Connect chemical feeders to the controller as labeled (See diagram on following page).
12. Check all electrical and mechanical connections. Resume filtration system operation and
check for any leaks.

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Typical HCC 2000 Installation Diagram:
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
HCC 2000 CONTROLLER
Sample
Stream
ALL CHEMICALS MUST BE INJECTED DOWN STREAM FROM HEATER AND FLOW CELL
CAT PRO25
ORP
Sensor
CAT PRO15
pH
Sensor
pH
ORP
Flow
pH ORP
pH/ ORP CONTROLLER
HCC 2000
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 Cord
pH Feed Output
ORP Feed Output

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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 HCC 2000.
The table below indicates generally accepted guidelines. Always maintain water chemistry accord-
ing to standards set by your local or State Health Department.
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
Hayward 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.
Hayward strongly recommends establishing desired pH, sanitizer residual, calcium hardness, total
alkalinity, 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.

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Configuration
Overview
Once desired start up chemistry parameters have been established, you are ready to set the HCC
2000 to automatically maintain pH and sanitizer levels. Please refer to the illustration below for
controller unit button designations. Button designations appear in bold type.
Power: Controller Unit Power Switch
1: Hidden Button (Located Behind “pH” Text)
2: pH Channel Increase Button
3: pH Channel Decrease Button
4: pH Channel Setpoint Adjustment Button
5: pH Channel Mode Selection Button
6: ORP Channel Increase Button
7: ORP Channel Decrease Button
8: ORP Channel Setpoint Adjustment Button
9: ORP Channel Mode Selection Button
Basic Configuration Options
Selecting Acid or Base Feed
The HCC 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.
Press and hold the Hidden Button (#1) for five seconds to enter advanced setup mode.
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.

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Calibrating pH
Readings from the HCC 2000 are far more accurate than those obtained from most liquid test
standards. To match manual water testing results or compensate for a depleted or unclean pH sen-
sor, the pH channel of the controller may be calibrated as follows:
Press the pH Setpoint Adjustment Button (#4) twice, illuminating the green “CALIBRATE”
LED.
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.
The controller will automatically return to the normal operating mode after twenty seconds,
storing any changes.
Changing the pH Setpoint
The HCC 2000 is preset from the factory to maintain pH at 7.5. To set pH control at a different
level, perform the following:
Press the pH Setpoint Adjustment Button (#4) until the green “SET” LED is illuminated.
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.
The controller will automatically return to the normal operating mode after twenty seconds,
storing any changes.
Changing the ORP Setpoint
The HCC 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:
Manually test pool or spa to confirm that the current sanitizer reading (chlorine, bromine, etc.)
is the level you wish to maintain.
Note the ORP reading displayed by the controller.
Press the ORP Setpoint Adjustment Button (#8) until the green “SET” LED is illuminated.
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.
The controller will automatically return to the normal operating mode after twenty seconds,
storing any changes.
The ORP setpoint should be changed as needed to maintain sanitizer residuals in conformance
with Health Department standards.