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Question posted by captainsrum321 on March 13th, 2023

Orp Overfeed Alarm

Hi, I have a Hayward cat 4000 for a spa and noticed the orp overfeed alarm was sounded. Said 385 mv. From what I've read I understand that the rolachem was running for too long without the orp reaching the desired levels. I checked and replaced all the chlorine feeder lines that might have been causing the issue along with the pinch tube. Hit the menu button till the alarm was reset and checked it the next day and the overfeed alarm was going off again. I'm not sure what else to do. All the lines are cleared and the rolachem moves the cl when I put it on manual feed. I don't understand why it's not able to get the sanitation it needs.

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Answer #1: Posted by SonuKumar on March 13th, 2023 8:55 PM

SonuKumar

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If you have already checked and replaced the chlorine feeder lines and pinch tube, and the overfeed alarm on your Hayward CAT 4000 is still sounding, then there may be other issues that need to be addressed. Here are a few things you can try:

Check the ORP sensor: The ORP sensor measures the oxidizing power of the water and can be affected by issues such as sensor fouling or sensor depletion. If the sensor is fouled or depleted, it can lead to inaccurate ORP readings, which can trigger the overfeed alarm. Try cleaning or replacing the ORP sensor to see if that resolves the issue.
Check the pH level: If the pH level of the water is not within the correct range, it can affect the ORP level and trigger the overfeed alarm. Make sure the pH level is within the recommended range for your spa.
Check the flow rate: The flow rate of the water can also affect the ORP level. Make sure the flow rate is within the recommended range for your Hayward CAT 4000.
Check the pump: If the pump is not working properly, it can affect the flow rate and ORP level. Check the pump to make sure it is working properly and is not clogged or damaged.

If none of these steps resolve the issue, it may be necessary to contact a professional pool or spa technician to diagnose and repair the problem.

Please respond to my effort to provide you with the best possible solution by using the "Acceptable Solution" and/or the "Helpful" buttons when the answer has proven to be helpful.

Regards,
Sonu
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Related Hayward CAT 4000 Manual Pages

CAT 4000 - Page 2

...CAT controllers are relatively simple to install, please take the time to read this manual, it is important to determine that the installer is familiar with the physical characteristics of the pool or spa...CAT controller is located below water level, additionally adjust all tools required before beginning installation. All CAT... The CAT 4000 chemical ... COPYRIGHT 2010 HAYWARD INDUSTRIES, INC...

CAT 4000 - Page 3

... Section 14. Warranty Preparing Water Chemistry Section 7. Specifications Section 17. CAT 4000 Menu Tree Section 10. Notifications to Cell Phones Section 15. Important Safety Information Section 4. CAT 4000 Setup & Programming Section 8. Alarm Troubleshooting Section 16. CAT 4000 System Components Section 3. TABLE OF CONTENTS _ Section 1. System Installation Section...

CAT 4000 - Page 4

.... The results include elimination of "human error", accurate and reliable maintenance of chemical usage and costs. WATER QUALITY with the CAT 4000 controller: 1 The POOLCOMM website is a subscription based service. CONTENTS COPYRIGHT 2010 HAYWARD INDUSTRIES, INC. SECTION 1. A pool operator typically checks, records and adjusts pool or spa water chemistry hourly at best.

CAT 4000 - Page 5

... and Flow sensors while ensuring ideal hydraulic conditions to maintain ORP at 650 millivolts. The CAT 4000 controller is preset from the pH, ORP, flow, and optional digital flow-rate and level sensors, displays water quality readings and alarms in alphanumeric format, and activates chemical feeders in a typical CAT 4000 wireless water quality control system: The Professional-Series pH...

CAT 4000 - Page 7

...CAT 4000 Wireless Water Quality Controller1 (1) PVC Backboard with Mounting Holes and Stainless Hardware (1) Professional Series pH Sensor with 24" Cable and BNC Connector (1) Professional Series ORP... Installation Tubing (3/8" OD) (2) 1/4" NPT x 3/8" Tubing True-Seal Connectors (1) CAT 4000 Quick Reference Guide Before commencing installation, please confirm that items listed above have been ...

CAT 4000 - Page 10

... RESERVED POOLCOMM WATER QUALITY MANAGEMENT pH ORP CAT PR015 CAT PR025 pH CAT 4000 Water Quality Controller pH Cl/Br Feed Feed Alarm ORP POOLCOMM pH SENSOR ORP SENSOR MENU UP DOWN ENTER Flow TRANSMIT POOLCOMM Chemical Automation Technologies CAT 4000 SYSTEM Power Cord Influent (to Return Line) Effluent (to Suction) Sample Stream ORP Feed Output pH Feed Output Chemical Pump...

CAT 4000 - Page 11

... maintain sanitizer levels (chlorine, bromine, ozone, etc.) based on and setting up the CAT 4000. Confirm that your new controller has been physically installed, water chemistry should be changed periodically as pH, cyanuric acid concentration and total dissolved solids can affect sanitizer residual readings relative to initiating automated control of the pool or spa. The ORP setpoint...

CAT 4000 - Page 13

...pool and spa applications. Press ENTER to select the desired pH. The controller will be displayed: pH Setpoint 7.5 pH Press UP or DOWN to save your selection. CAT... SETPOINT: The CAT 4000 is a typical display during normal operating mode: pH 7.5 ORP 650 System OK... any alarm conditions, and B) A graph indicating sensed pH and ORP vs- The following will indicate sensed pH, ORP, Flow...

CAT 4000 - Page 19

.... Press ENTER to select Proportional or Fixed feed. Press ENTER to select ORP High Alarm. Press ENTER to select ORP Feed. The current ORP Feed setting will be displayed: ORP Low Alarm 400 mV Press UP or DOWN to scroll to save your selection. ORP FEED: The CAT 4000 by default uses a time-based proportional feed algorithm which enables the...

CAT 4000 - Page 20

... Auxiliary Output Setup to assign the relay to the desired function. Once the setpoint is not reached after feeding continuously for a selectable period of time. 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 entered, go to Auxiliary Output Setup to...

CAT 4000 - Page 21

... Acid Feed ORP Feed Up ORP Feed Down Level / Flow Sensor #1, #2 or #3 Timer On for Selectable Interval From the Configuration Setup Menu: Press DOWN to find the Alarm Setup menu item. AUXILIARY OUTPUT SETUP: The auxiliary relay can be displayed: Alarm Setup Audible and Visual Press UP or DOWN to scroll to the desired setting. Press...

CAT 4000 - Page 23

... Factory Def. Therefore, no sensors are active except that the controller is not sampling the sensors or monitoring water quality. Press ENTER again at 650 mV. The CAT 4000 is simulating pH and ORP values, and therefore is in Demonstration Mode, the following prompt: Restore Factory Def.

CAT 4000 - Page 24

... (Default 120 Min.) ORP Feed Proportional or Fixed ORP Low Alarm 0 to 995 mV Default 400 mV ORP High Alarm 0 to 995 mV Default 900 mV ORP Overfeed Timer Off, 5 to 120 Minutes (Default 120 Min.) Aux pH Setpoint 0.0 to 14.0 Default 7.5 Aux ORP Setpoint 400 to 995 mV Default 650 mV Alarm Setup Audible and Visual, Visual Only CONTENTS COPYRIGHT 2010 HAYWARD INDUSTRIES, INC. SECTION...

CAT 4000 - Page 26

... and record water chemistry readings in parts-per-million (ppm), periodically adjust the ORP setpoint. Calibrate pH periodically as described earlier in need to provide the highest performance and longest possible functional service life. PRECISION CALIBRATION The CAT 4000 controller provides instrument-grade accuracy which exceeds that changes in pool or spa water, the sensors may...

CAT 4000 - Page 27

...is filled with clean water covering sensor tips. WINTERIZATION The sensors should be desirable. Although the CAT 4000 controller is subject to damage by electro-static discharge (ESD) when the sensor...dry out. CONTROLLER STORAGE The controller unit is designed to freezing temperatures. Although CAT Professional Series sensors are freeze-resistant, they must be removed or stored for ...

CAT 4000 - Page 30

... controller. Click on a facility name to the CAT 4000 controller. To update the website with CAT 4000 wireless controllers. Blue: No warning during the past 24 hours. CONTENTS COPYRIGHT 2010 HAYWARD INDUSTRIES, INC. FACILITY NAME This field provides a list of individual controllers. pH, ORP, tank level, flow and service key alarm settings. USING THE POOLCOMM WEBSITE Browse to...

CAT 4000 - Page 31

... 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. This icon opens the Unit Data Report screen. This icon opens the Unit Warning...

CAT 4000 - Page 33

... and 800 mV, with a phenol red pH test kit. The proper ORP range for obstruction or scaling. pH HIGH A pH above 7.8, check the pH correction chemical level. pH below the optional optical level sensor in healthy water quality. pH OVERFEED The pH Overfeed timeout occurs when the CAT 4000 has been feeding chemical for swimming pools and spas is a significant...

CAT 4000 - Page 34

.... ORP OVERFEED The ORP Overfeed timeout occurs when the CAT 4000 has been feeding chemical for immediate viewing and generates a service request alarm. KEY INSERTED When a service technician visits the CAT 4000 he may need to be increased to document the time and duration of proper recirculation. If the level is equipped with chemical demand. CONTENTS COPYRIGHT 2010 HAYWARD...

CAT 4000 - Page 35

...Acid Feed pH Base Feed ORP Primary Feed ORP Supplemental Feed Dechlorination Control Level/Flow Sensor # 1 Level/Flow Sensor # 2 Level/Flow Sensor # 3 Time-based Activation Bi-directional Wireless http://www.poolcomm.com < 2 Minutes per Path Email, Text Message, Internet pH Low and High Alarms ORP Low and High Alarms pH Priority Feed pH Overfeed Timeout ORP Overfeed Timeout Supplemental Feed Modes...