CAT 4000 WATER QUALITY CONTROLLER OWNER'S MANUAL INSTALLATION OPERATION MAINTENANCE SPECIFICATIONS
FOREWORD _ Congratulations on your wise investment and welcome to the world of wireless, web-enabled water quality management. The CAT 4000 chemical automation system has been engineered to provide you with substantially reduced chemical costs and maintenance, improved water quality, increased compliance with Health Department operating standards, and many years of reliable operation.
TABLE OF CONTENTS Section 1. Water Quality Control with the CAT 4000 Section 2. CAT 4000 System Components Section 3. Important Safety Information Section 4. Package Contents Section 5. System Installation Section 6. Preparing Water Chemistry Section 7. CAT 4000 Setup & Programming Section 8. Advanced Configuration Options Section 9. CAT 4000 Menu Tree Section 10. Maintenance Section 11. Testing for Network Coverage Section 12. Activating Wireless Communications Section 13.
SECTION 1. WATER QUALITY with the CAT 4000 The CAT 4000 revolutionizes the manner in which water quality can be monitored and maintained. A pool operator typically checks, records and adjusts pool or spa water chemistry hourly at best. The CAT 4000 continuously samples pH and sanitizer activity, adjusting the feeding of chemicals on a basis proportional to the demand.
SECTION 2. CAT 4000 SYSTEM COMPONENTS The following is a description of the components incorporated in a typical CAT 4000 wireless water quality control 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 4000 controller is preset from the factory to maintain pH 7.5. If pH is maintained below 7.
SECTION 3. IMPORTANT SAFETY INFORMATION IMPORTANT SAFETY INFORMATION 1. WARNING - Important safety information is contained throughout this manual. Read complete instructions prior to installation. 2. WARNING - Risk of Electric Shock. Connect controller only to a grounding type receptacle protected by a ground-fault circuit interrupter (GFI). CAT Controllers recommends installation to a dedicated GFI circuit breaker performed by a licensed electrician. 3. WARNING - Disconnect power before servicing.
SECTION 4. 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.
SECTION 5. SYSTEM INSTALLATION 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. INSTALLATION PROCEDURES 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.
. 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.
CONTENTS COPYRIGHT 2010 HAYWARD INDUSTRIES, INC.
SECTION 6. PREPARING WATER 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 4000. TEST MINIMUM IDEAL MAXIMUM pH 7.2 7.5 7.
SECTION 7. CAT 4000 SETUP & PROGRAMMING The CAT 4000 features a bright, menu-driven vacuum-flourescent display which makes setup and programming simple in any lighting conditions. The menu structure is divided into two sections; the Operating Menu is intended for the enduser to manage settings which are accessed on a frequent basis, while the Configuration Menu is used to setup advanced features which truly customize the controller to meet the individual requirements of the application.
NORMAL OPERATING MODE: During normal operating mode, the display will indicate sensed pH, ORP, Flow Rate (with optional digital flow sensor) and a status line which alternates between: A) “System OK” or a list of any alarm conditions, and B) A graph indicating sensed pH and ORP vs- setpoint values. The following is a typical display during normal operating mode: pH 7.
TO CALIBRATE pH: The CAT 4000 is far more accurate than most liquid test standards, but pH calibration is necessary to match manual water testing results, compensate for a depleted or unclean pH sensor, and confirm proper operation of the system. While in normal operating mode: Press MENU. Press DOWN to find the pH Calibrate menu item. Press ENTER to select pH Calibrate. The sensed pH value as currently calibrated will be displayed: pH Calibrate 7.5 pH Press UP or DOWN match your known good standard.
TO CHANGE THE ORP SETPOINT: The CAT 4000 is programmed at the factory to maintain ORP at 650 mV by default. This is the generally accepted world standard for safe drinking water. In order to maintain a given chlorine or bromine residual in conformance with Health Department standards for a particular body of water, perform the following: Check and balance pH, calcium hardness and total alkalinity. Manually feed chlorine or bromine to desired ppm residual. Note the displayed ORP value.
SECTION 8. ADVANCED CONFIGURATION OPTIONS TO ENTER THE CONFIGURATION SETUP MENU: The configuration setup menu contains features which enable the CAT 4000 to be customized to the unique characteristics of the application. Optional accessories such as the digital flow meter are also activated through this menu. While in normal operating mode: Press MENU. Press DOWN to find the Configuration Setup menu item. Press ENTER to select Configuration Setup.
pH PRIORITY: The CAT 4000 features a pH Priority setting which will inhibit ORP feed whenever pH is greater than .2 pH from the setpoint. This feature provides an important safeguard when sanitizers with a high pH (such as liquid chlorine) are used. From the Configuration Setup Menu: Press DOWN to find the pH Priority menu item. Press ENTER to select pH Priority. The current pH Priority Mode will be displayed: pH Priority Off Press UP or DOWN to enable or disable pH Priority.
pH LOW ALARM: The pH Low Alarm inhibits pH feed, sounds audible and visual alarms, and sends a message to the POOLCOMM website during a low pH condition. From the Configuration Setup Menu: Press DOWN to find the pH Low Alarm menu item. Press ENTER to select pH Low Alarm. The current pH Low Alarm Setting will be displayed: pH Low Alarm 7.0 pH Press UP or DOWN to scroll to the desired setting. Press ENTER to save your selection. Press MENU to return to the Operating Menu.
ORP FEED: The CAT 4000 by default uses a time-based proportional feed algorithm which enables the precise control of virtually any body of water. With some types of chemical feeders, however, it is beneficial to disable proportional feed and dispense chemicals on a fixed basis. From the Configuration Setup Menu: Press DOWN to find the ORP Feed menu item. Press ENTER to select ORP Feed.
ORP OVERFEED TIMEOUT: The ORP Overfeed Timeout inhibits ORP feed, activates audible and visual alarms, and sends a message to the POOLCOMM website when the ORP setpoint is not reached after feeding continuously for a selectable period of time. From the Configuration Setup Menu: Press DOWN to find the ORP Overfeed Timeout menu item. Press ENTER to select ORP Overfeed Timeout.
ALARM SETUP: The Alarm Setup allows the audible alarm to be disabled without interfering with any other safeguards or alerts to the POOLCOMM website. From the Configuration Setup Menu: Press DOWN to find the Alarm Setup menu item. Press ENTER to select Alarm Setup. The current Alarm Setup option will be displayed: Alarm Setup Audible and Visual Press UP or DOWN to scroll to the desired setting. Press ENTER to save your selection.
LEVEL/FLOW SENSOR INPUT # 3 SETUP: The third Level/Flow Sensor input is provided to facilitate, digital flow monitoring water level control, other features using optional sensors. From the Configuration Setup Menu: Press DOWN to find the Input 3 Setup menu item. Press ENTER to select Input 3 Setup. Press DOWN to view the following options: Disabled Digital Flow (ENTER to select pipe size). Level Sensor Press ENTER to confirm the selection.
RESTORE FACTORY DEFAULTS: The Restore Factory Defaults function erases all user-modified settings from memory and restores all factory default settings and values. From the Configuration Setup Menu: Press DOWN to find the Restore Factory Def. menu item. Press ENTER to select Restore Factory Def. Press ENTER again at the following prompt: Restore Factory Def. ENTER to Restore.... The display will go blank, and all default settings will be restored.
SECTION 9. CAT 4000 MENU TREE Default Operating Mode pH Setpoint 7.0 to 8.0 (Default 7.5) pH Calibrate Plus or Minus 2.0 pH pH Feed Mode Automatic Off On for Specified Time ORP Setpoint 400 to 900 mV (Default 650 mV) ORP Feed Mode Automatic Off On for Specified Time Configuration Setup Menu pH Control Mode Acid Feed Base Feed pH Priority Off pH Feed ProportionalFixed pH Low Alarm 0.0 to 14.0 Default 7.0 pH pH High Alarm 0.0 to 14.0 Default 8.
Default Operating Mode Configuration Setup Menu AUX Output Setup Disabled Remote Alarm pH Base Feed pH Acid Feed ORP Feed Up ORP Feed Down pH Level/Flow Sensor ORP Level/Flow Sensor Level/Flow Sensor #3 On for Specified Time 1 to 30 Minutes Level/Flow Input #3 Setup Disabled, Digital Flow, Level Digital Flow Pipe Size 3/8" to 12", 50mm to 315mm Digital Flow Alarm Select Alarm Flow Rate Display System Information ENTER to Display Hard Reset ENTER to Reset Restore Factory Defaults Enter to Restor
SECTION 10. MAINTENANCE CAT 4000 CONTROLLER PACKAGE The CAT 4000 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 requirements using a quality manual test kit.
SENSOR STORAGE Exposure to atmospheric conditions will cause the sensor tips to dry out. Always remove and properly store sensors in the soaking caps provided if sensors are 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 sensors in the soaking caps provided, making sure that each container is filled with the original storage solution or clean water.
SECTION 11. TESTING FOR NETWORK COVERAGE Check the Coverage Map CAT can provide a printed or electronic copy of the Reflex coverage map in your state. Please contact the POOLCOMM Program Administrator. Check the Web Site Visit the Sky-Tel web site and enter the exact address of the facility to be monitored. The web site will pin point that address on a custom coverage map. Start by entering www.skytel.com into your web browser.
SECTION 12. ACTIVATING COMMUNICATIONS To activate your first CAT 4000 wireless controller on the POOLCOMM web site you must first register an account. Call 800-657-2287 and ask for the POOLCOMM Program Administrator if you need assistance. Visit www.poolcomm.com from any internet-connected computer. Click on Register Account and complete all requested account information. Click on Register Account again to register with the system.
SECTION 13. USING THE POOLCOMM WEBSITE Browse to www.poolcomm.com. At the Login screen type your username and password, then click on Login. This will bring up the Account Unit Management Screen, which allows you to view all of your communicating units: STATUS SYMBOL The status symbol indicates the 24 hour alarm status of individual controllers. Blue: No warning during the past 24 hours. Yellow: A warning condition has been corrected during the past 24 hours. Red: A warning condition currently exists.
The following screen capture shows the settings which can be modified from the Unit Profile screen: SITE LOCATION This field is used to identify the specific asset being monitored (main pool, lap pool, spa, etc.) within the facility. LAST WARNING This field provides a timestamp of the last warning received. COMMANDS This icon opens the Unit Profile page (shown above). This icon opens the Unit Warning Alarms page. This icon opens the Unit Data Graph page. This icon opens the Unit Data Report screen.
SECTION 14. NOTIFICATIONS TO CELL PHONES The POOLCOMM website can provide email alerts through every major cell phone provider. You can set up your Poolcomm account to alert you with a text message any time an alarm is activated at any of your CAT 4000 locations. Just follow each company's e-mail to text message instructions. AT&T Your cell phone's e-mail address: 10-digit cell phone number@mobile.att.net Motorola's MX2000 and T721, Samsung's V206, and Panasonic's GU87 are all text message compatible.
SECTION 15. ALARM TROUBLESHOOTING pH OUT OF RANGE pH is measured on a scale ranging from 0 to 14, with pH 7.0 considered neutral. pH below 7.0 is considered acidic and above 7.0 is alkaline. pH is a significant variable in determining water quality as it affects sanitizer activity, color, and human compatibility with the water. The proper pH range for swimming pools and spas is between 7.2 and 7.8. pH LOW A pH below 7.
ORP OVERFEED The ORP Overfeed timeout occurs when the CAT 4000 has been feeding chemical for a time greater than the selected maximum feed time and has not reached its set point. A properly selected Overfeed timeout prevents the unit from continuing to feed chemicals when the chemical supply has been diminished or a chemical feeder has become clogged or broken. First, check the chemical supply and chemical feeder.
SECTION 16. TECHNICAL SPECIFICATIONS Enclosure Type Enclosure Properties Flame Resistance Display Front Panel Key Type Flowcell Flow Sensor Backboard Inputs Outputs 7" x 7" x 2.
WARRANTY ® Hayward warrants the CAT 4000 automated controller to be free of defects in material and workmanship for a period of five years 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 five years of delivery to original purchaser, shipping prepaid, and which is found to be defective upon examination.
