Service Manual

CascadaTM Lab Water Systems

SERVICE MANUAL
Cascada RO Lab Water Systems
100 to 240 VAC
50 to 60Hz RO-water
Model
INTRODUCTION
This service manual has been prepared for the Cascada™
RO-water system originally introduced in 2005.

This manual is intended to be used by properly trained and

authorized service engineers in conjunction with the
Cascada Lab Water RO-water System Operation Manual
(PAL-MANU37991 Version 1 March 05).

INTRODUCTION 2
TABLE OF CONTENTS
SAFETY INSTRUCTIONS 4
Electrical 4
Pressure 4
Ultraviolet Light 5
Sanitization Chemicals 5
Control of Substances Hazardous to Health (COSHH) 5
PAL-CT1 Sanitization Tablet - Safety Information 5

ROUTINE SERVICE 6

TROUBLESHOOTING 7

ELECTRICAL CONNECTIONS 8

CALIBRATION PROCEDURE 9

CASCADA™ RO-WATER 11
SYSTEM PARTS LIST
Cascada RO-water System With Front Door 13
and All Covers Removed

SYSTEM WIRING DIAGRAM 14

KEY TO CONTROL PANEL 15

REMOTE ALARM OUTPUT CONNECTION 16

www.pall.com/lab 3 TABLE OF CONTENTS

SAFETY INSTRUCTIONS
Do not attempt to operate or maintain the system The Cascada™ RO-water system has been designed
without first reading this manual. to be safe; however, it is important that personnel
The basic rules of safety set forth in this manual are working on these units understand any potential
intended as a guide for safe operation of Pall Corporation dangers. All safety information in this manual is
equipment. This general safety information, along with highlighted as WARNING and CAUTION instructions.
explicit service, maintenance and operational materials for These are as follows:
the specific machine, make up the complete instruction
manual. All personnel who will operate, service or be WARNING! WARNINGS ARE GIVEN WHERE
involved with this equipment in any way should be totally FAILURE TO OBSERVE THE
familiar with this information prior to start-up. It is the user’s INSTRUCTION COULD RESULT IN
responsibility to make certain that the procedures set forth INJURY OR DEATH TO PERSONS.
are followed.

CAUTION! Cautions are given where failure to

observe the instruction could result in
damage to the equipment, associated
equipment, and processes.

Electrical
It is essential that the power switch on the Cascada Lab
Water system is turned off before any items are changed Main Power Supply
or maintenance work performed.
The ON/OFF switch is located at the left-hand side of Fuses
the unit. The main power cord is located just behind the On/Off Power switch
Power socket
ON/OFF switch.
WARNING! THIS APPLIANCE MUST BE
GROUNDED. PLUG INTO A PROPERLY Power cord
GROUNDED (GFCI) WALL OUTLET.

Pressure
The main water supply valve should be turned off and
residual pressure released prior to removal of any cartridges
or carrying out work on the unit.
CAUTION! Switching off the electrical power will
isolate the source of pressure, but
pressure trapped within the unit should
be released.

SAFETY INSTRUCTIONS 4
Ultraviolet Light
WARNING! UNDER NO CIRCUMSTANCES
SHOULD THE LAMP BE CONNECTED Cascada with UV Lamp
AND ACTIVATED WHEN OUTSIDE
THE HOUSING.
The Cascada™ RO-water system is fitted with an ultraviolet
lamp. The UV lamp is enclosed in a stainless steel chamber
ensuring that the operator will not be exposed to UV light.

UV lamp

Sanitization Chemicals
During the sanitization cycle, a PAL-CT1 sanitization tablet
is used and relevant safety information is included in this
handbook. A safety data sheet conforming to COSHH
and/or OSHA regulations is also provided with the tablets
and should be read before a tablet is used.

Control of Substances Hazardous to Health (COSHH)

Material safety data sheets covering the various replaceable
Purification Packs are available upon request. Contact your
local Pall supplier or distributor.

PAL-CT1 Sanitization Tablet - Safety Information

General description - white solid tablet which rapidly
dissolves in water, used for sanitization applications.
Hazard assessment - contains sodium
dichloroisocyanurate dihydrate and is toxic by inhalation,
ingestion, and skin contact.
Properties - soluble in water and pH6, non-combustible.
Keep container tightly closed in a dry place and wear
protective clothing when handling.
Spillages - if tablets are dry and uncontaminated, collect
up and place in heavy duty plastic bag. Do not return to
original container. Wash away any residues with copious
amounts of water.
Toxicity - serious risk of poisoning by inhalation or
ingestion. Irritating to skin, eyes, and respiratory system.
First Aid
Eyes: thoroughly wash out with clean water for at least
15 minutes. Seek medical advice.
Inhalation: remove from exposure, rest, and expose to
fresh air. In severe cases, obtain medical attention and treat
for acute chlorine poisoning.
Skin: drench the skin with plenty of water. Remove
contaminated clothing and wash before reuse. In severe
cases, obtain medical advice.
Mouth: wash out the mouth thoroughly with water and give
large quantity of milk to drink. Obtain medical advice.
Note: A comprehensive data sheet is available on request
and is supplied with each packet of tablets.

www.pall.com/lab 5 SAFETY INSTRUCTIONS

ROUTINE SERVICE
• Purpose and Scope:
To ensure full and correct servicing of Pall equipment
by Pall approved service engineers.
• References:
Cascada™ RO-water System Operation Manual
Calibration Procedure – see section 5
• Instructions:
1. View the equipment with the client and discuss any
operational difficulties which may have occurred since
the last service visit.
2. Inspect the installation for leaks and check, clean,
lubricate, or replace any ancillary items.
3. Complete a fouling index test and a free chlorine test
on the feed water and report.
4. Investigate and replace from the client’s stock as
necessary any system filters and consumables.
5. Measure and record concentrate flow. This should be
1.1 liters per minute.
6. Measure and record RO permeate flow. This should
be 15 liters per hour (+/- 10% at 15ºC).
7. Measure and record permeate conductivity from each
RO module.
ROUTINE SERVICE
8. Measure and record feed water conductivity.
9. From 5.7 and 5.8, calculate performance of each
RO cartridge and advise client accordingly.
Note: If ion rejection is < 90%, the PAL-LC143 cartridges
should be replaced.
10. Check operation of level controls on the reservoir tank.
11. Inspect and clean line cell. Check calibration of unit
(refer to Section 5).
12. Check frequency of PAL-LC140 pre-treatment
cartridge replacement. Advise client of recommended
replacement frequency (maximum 6 months).
13. Disinfect unit as required by client. (See page 23 in
the Cascada RO-water System Operation Manual.)
14. Wipe down equipment and leave in clean, tidy condition.
15. Fill out service report and detail any follow up
action required. Discuss report with client and
obtain signature.
6
TROUBLESHOOTING
The table below gives guidance on what action to take should any problems arise. This section should be used
in conjunction with the Cascada™ RO-water System Operation Manual.

PROBLEM CAUSE ACTION

Low RO permeate flow
No RO permeate flow
Noisy boost pump or delivery pump
Leaking John Guest fittings
Blocked inlet strainer.
Pre-treatment cartridge blocked.
Drain solenoid valve not
closing properly.
Inlet solenoid valve not opening.
Faulty raw water boost pump.
Faulty treated water reservoir
level controls.
There is a stainless steel strainer
immediately in front of both pumps
If this becomes blocked the pump
gets very noisy.
High feed water pressure.
Leaks from around the stem may
occur if a stem adaptor is disturbed.
Leaks from around the tube may
occur if an adaptor is disturbed.
Clean strainer as per instructions in
the Operation Manual (pg. 22)
Replace PAL-LC140 cartridge and
carry out FI test on feed water. (High
FI may require additional pre-
treatment or more frequent
PAL-LC140 changes.)
Check for correct operation and
replace if faulty with VALV36854.
If solenoid valve is OK, replace main
PC board with PAL-PCBS37987.
Check operation of inlet solenoid
valve. Replace if faulty with
VALV36853.
If solenoid valve is OK, replace main
PCB with PAL-PCBS37987.
Replace raw water boost pump with
PN PUMP36858.
Check level switch assembly.
Replace with new SP744 if faulty.
Clean the strainer.
Fit an LA512 pressure regulator.
If feed water pressure is > 2 bar, this
will result in a noisy boost pump.
Replace any leaking stem adaptors.
If disturbed they should be replaced
where possible. They are not
designed to be continuously re-used.
Cut the end 5 mm from the tube
before pushing it into the adaptor.
Make sure the tube is cut square and
not at an angle.

www.pall.com/lab 7 TROUBLESHOOTING
ELECTRICAL CONNECTIONS
For electrical connections, please see Wiring Diagram near
end of this manual.
Level control assembly circuit – fitted to all Pall reservoirs as
supplied.

R1
S1 220Ω
N/C 0.25W

R2
S2 220Ω
N/C 0.25W
1
R3 2
220Ω
Phone
0.25W
jack 3.5 mm
S3 connects to
N/C Cascada
R4
220Ω RO-water
0.25W system

S5 Phone jack 1/4" connects

N/C to Cascada BIO- or AN-water
polishing unit. T2 & 3 normally
closed & open below 10%

1
2
3

ELECTRICAL CONNECTIONS 8
CALIBRATION PROCEDURE
To carry out a calibration of the Cascada™ RO-water 4. Set SUB-03 box to 5 and wait for a steady displayed
system, switch off main power. Remove electrical cover by value and PF1 icon to appear as follows: → ϖ ← .
removing single screw and sliding cover forward to 5. Press PF1 button and the icon fades for approximately
disengage securing clips. Locate electrical cover in the slot two seconds and then reappears indicating the
to the left of the electrical compartment. calibration setting is accepted. The display will change
80.0
to the exact value: HHHH .
TH10 TH9
6. Press PF2 button and the display changes to
"calibration 80 µS/cm".
TH12 TH10 TH9 TH8 7. Set SUB-03 box to 2 and wait for a steady displayed
::
:: value → ϖ ← .
JH1 Install
:: calibration 8. Press PF1 button and the icon fades approximately
Graphics
:: link
display for two seconds and then reappears indicating the
PAL-PCBS37987 calibration setting is accepted. The display will
80.0
change to the exact value: HHHH .
JH3
Touch
panel
TH TH TH TH TH TH TH
7 6 5 4 3 2 1
TH11
. 80 µS/cm
→ϖ← 80.2
Proceed as follows: HHHH
1. Install calibration link and connect SUB-07 setting
box to TH10 and SUB-03 setting box to TH9. PF1 PF2

2. Switch on main power and screen displays

Calibration routine.
Icon changes to Then
→ϖ←

Cascada RO 9. Press PF2 button and the display changes to

"calibration 24 µS/cm".
×
10. Set SUB-03 box to position 3 and wait for a steady
displayed value → ϖ ← .
PF1 PF2 11. Press PF1 button and the icon fades for
approximately two seconds and then reappears
indicating the calibration setting is accepted and
24.2
stored. The displayed value remains unchanged HHHH .
3. Press PF2 button to calibrate outlet quality line cell.
(8 µS/cm)

Calculated quality
reading before 24 µS/cm
calibration
→ϖ← 24.2
HHHH
8µS/cm
→ϖ← 08.2
HHHH
PF1 PF2
Indicates
hexadecimal
PF1 PF2 A/D reading
Icon changes to Then
→ϖ←
Icon changes to Then
→ϖ←

www.pall.com/lab 9 CALIBRATION PROCEDURE

Calibration Procedure (continued)

12. Press PF2 button and the display changes to 18. Press PF2 button to return to PROCESS OFF.
"calibration 1ºC". 19. Switch off main power. Remove calibration link, SUB
13. Set SUB-07 box to position 1 and wait for a steady 03 and 07 setting boxes and reconnect transducers.
displayed value → ϖ ← . 20. Refit electrical cover taking care that the securing
14. Press PF1 button and the icon fades for approximately clips are properly engaged at the rear before replacing
two seconds and then reappears indicating the screw removed at the start of this procedure.
calibration setting is accepted and stored. The display 21. Switch on main power and revert to normal
changes to the exact value. operation.

1 ºC
→ϖ← 01.2
HHHH

PF1 PF2

Icon changes to Then

→ϖ←

15. Press PF2 button and the display changes to

01.0
"calibration 35ºC" HHHH .
16. Set SUB07 box to position 35 and wait for a steady
displayed value → ϖ ← .
17. Press PF1 button and the icon fades for approximately
two seconds and then reappears indicating the
calibration setting is accepted and stored. The
35.2
displayed value remains unchanged HHHH .

35 ºC
→ϖ← 35.2
HHHH

PF1 PF2

Icon changes to Then

→ϖ←

CALIBRATION PROCEDURE 10
CASCADA™ RO-WATER SYSTEM PARTS LIST
Part Number Description Quantity Part Number Description Quantity
ADAP32798 Adaptor straight 8 mm 1 PAL-PLAT37941 Plate – Door 1
OD tube x 1/4" BSP
PINS36834 Pin dowel 4 mm dia x 1
ADAP35438 Adaptor straight 6 mm 1 14 mm (bottom door
OD tube x 1/4" BSP hinge)
CABL36864 Ribbon connector 1 POWE34241 Power inlet module 1
microprocessor to display 240V 6A
CONN32791 Connector bulkhead 3 POWE35964 65W switch mode 1
8 mm OD power supply (SMPS)
COVR36773 Cover rear 1 PUMP36858 Diaphragm pump 1
(boost pump)
COVR38020 Cover dust – EMI/RFI 1
shielded REDU35441 Reducer 8 mm OD 5
stem x 6 mm OD
DISP36777 Display LCD 1
RING36843 ‘O’ ring 1
ELBW30903 Elbow stem 5/16" OD 1
RIVT35962 Rivet snap 5 mm dia x 2
ELBW34263 Elbow swivel 6 mm 2 12 mm long
OD x 1/8" BSP
RIVT36352 Rivet snap 4 mm dia x 4
ELBW35604 Elbow stem 6 mm 2 11 mm long
OD x 6 mm OD tube
SP713 Thermistor assembly 1
ELBW35957 Elbow stem 3/8" 2
OD x 5/16" OD tube SP714 Line cell 380 mm
with plug 1
ELBW36122 Elbow swivel 8 mm 3
OD x 1/4" BSP SPRI36849 Spring 3.7 mm dia. x 1
9.5 mm (bottom door pin)
ELBW36616 Elbow swivel 6 mm 2
OD x 1/4" BSP (para) STRA20564 Strap cable small black 6
FANS36899 Fan ball bearing 24 volt 1 STRA30673 Strap cable releasable 2
black
FOOT36782 Foot rubber, self adhesive 4
SUPP36850 Support vessel 2
FUSE36107 Fuse semi-delay
20 mm 3.15A 2 TEES31702 Tee equal 6 mm OD tube 2
HOUS35913 Line cell housing 1 TEES36857 Tee swivel 6 mm OD 1
tube x 1/4" BSP off-set
HOUS36787 Housing disinfection port 1
TUBE31957 Tube hipure 8 mm OD 0.3 mtr
PAL-COVR37937 Cover front 1 x 5 mm ID
PAL-COVR37942 Cover top 1 TUBE35949 Tube 6 mm OD LDPE 2.0 mtr
PAL-DOOR37936 Door front 1 natural

PAL-HOUS38021-02 Housing RO disinfect 1 VALV36853 Valve solenoid 24v dc 1

2 way
PAL-LC140 Pre-treatment cartridge 1
VALV36905 Drain solenoid valve with 1
PAL-LC143 RO cartridge 2 1.1 mm orifice

PAL-MANU37991 Operation Manual 1

Version 1 March 05
PAL-PANL37938 Touch fascia 1
PAL-PANL37984-03 Panel touch 1
PAL-PCBS37987 Microprocessor board 1

www.pall.com/lab 11 PARTS LIST

Cascada™ RO-water System Parts List (continued)

Sanitization Cap LA634 Installation Kit

Part Number Description Quantity Part Number Description Quantity

CAPS36763 Cap disinfection port – 1 ADAP20175 Adaptor hose ABS 1/2" 1
blue BSP(M) x 1/2" hosetail
HOLD36786 Tablet holder 1 ADAP22508 Adaptor straight 5/16" 1
disinfection port OD tube x 1/4" BSP(M)
RING36843 O-ring 1 BEND30108 Bend flow clip-on 5/16" 4
OD tube
Stainless Steel Filter Assembly COUP31006 Coupling 1/2" BSP(F) x 1
1/4" BSP(F)
BUSH36141 Bush reducing 1/2" – 1
1/4" BSP PAL-PACK32541 Pack starter tablets 1
disinfection
COUP31006 Coupling 1/2" BSP female 1
x 1/4" BSP female STEM31763 Stem 5/16" OD x 3/16" 1
ID hose
ELBW36122 Elbow swivel 8 mm OD 2
x 1/4" BSP TAPE10110 Tape PTFE 1/2" wide 1

FILT36123 Filter 1/2" st/steel 1 TEES22504 Tee equal 5/16" OD tube 1

WASH10534 Washer 19 mm OD 1 TUBE31957 Tube Hipure 8 mm OD x 5.0 mtr

x 11 mm ID 5 mm ID
NOTE: The installation kit is included in the packaging with
the unit.

PARTS LIST 12
Cascada™ RO-water System With Front Door and All Covers Removed

PAL-LC143
ELBW34263 x 3

SUPP36850

REDU35441
PUMP36858

ELBW35957
REDU35441

REDU35441

VALV36853 CONN32791
ELBW36616
ELBW36122

TUBE35949

VALV36905
CONN32791 ADAP32798
ELBW36616
FILT36123
BUSH36141 PAL-LC140
COUP31006 ELBW36616
ELBW36122 x 2 ADAP35438
WASH10534

SP714

CAPS36763 HOUS35913
HOLD36786
RING36843
TEES36857
HOUS36787
ELBW34263 x 2
SP713

Sanitization port

www.pall.com/lab 13 PARTS LIST

 black
black Outlet temperature probe
yellow
brown
blue RO quality sensor

Test links:
Top pair = calibration
DISP6777 TH10 TH12 TH8 TH9 2nd pair =

1
JH1
SYSTEM WIRING DIAGRAM

Graphics Processor

SYSTEM WIRING DIAGRAM

On board fuses:
display chip FS1 = 5A slow blow 20 mm
13 FS2 = 630mA slow blow 20 mm

1 PAL-PCBS37987
JH3
Touch panel TB1 alarm output connections:
6 1 = common
TO 2 = common
PAL-PANL37984-03 3 = normally open - closed when
3
unit alarms.

14
2 TB1
1
red
F2 black
TH7 TH6 TH5 TH4 TH3 TH2 TH1
1 8
TH11 F1 65 watt SMPS
POWE35964
blue
Fan N L
black brown Aurorinse sol. valve
red
Boost pump (optional) black brown 1 Power inlet
brown blue 2 module
Inlet sol. valve blue fused at 3.15A
Earth wire to be
soldered to SMPS
KEY TO CONTROL PANEL
Icons Alarm Conditions
Icon Description Icon Alarm Conditions

Mute Alarm UV Lamp Failure

(Flashing)

Accept Sanitization Tablet Reminder

(Flashing)

Scroll Bypass Fitted - Warning

(Flashing)

Auto Restart Purification Pack Not in Place

(Flashing)

Manual Restart Reinstall Purification Pack

(Flashing)

Set Up Menu Clock Stopped

(Flashing)

Cursor Option Choice Reservoir Level –

Disconnect Fault
(Flashing)

Cursor Selection Choice Incorrect Password

(Flashing)

Cancel Open UF Flush Valve

(Flashing)

Reset Closed UF Flush Valve

(Flashing)

Printer
Quality Alarms
Screen Description
Intermittent Recirculation
Outlet Purity Alarm

Replacement Date

Temperature Alarm

www.pall.com/lab 15 KEY TO CONTROL PANEL

REMOTE ALARM OUTPUT CONNECTION
An alarm outlet is available for connection to a building
management system.
This consists of a set of normally open volts-free contacts
TB1-1 and TB1-3 on the main Processor PCB. These
contacts will close when any alarm condition occurs and
will not open again until all alarms have been cancelled.
NOTE: Pressing the MUTE button on the graphics display
will mute the audio alarm but will not reset the relay contacts.

www.pall.com/lab 16 REMOTE ALARM OUTPUT CONNECTION

www.pall.com/lab 17
Copyright Note
The written text, technical information, and illustrations
contained in this document are the property of ELGA
LabWater, a division of Veolia Water Systems Ltd, and
protected by copyright law. Permission for this information
to be reproduced in this Service Manual has been duly
authorized by ELGA LabWater under the terms of the
supply and distribution agreement with Pall Corporation.
The information is supplied without liability for errors or
omissions. No part of the Manual may be copied,
reproduced, transmitted in any form or by any means
electronic, mechanical, magnetic, or manual including
photocopying, recording, information storage and retrieval
systems, disclosed to third parties, or used for any purpose
other than the purchaser's personal use, without the
express written permission obtained from ELGA LabWater.
ELGA LabWater, as exclusive supplier to Pall Corporation,
reserves the right to alter, without notice to the purchaser,
the text, technical information, and illustrations contained in
this Service Manual.

Australia – Lane Cove, NSW India – Mumbai Singapore

Tel: 02 9424-3000 Tel: 91 (0) 22 55995555 Tel: (65) 389-6500
1800 635-082 (in Australia) Fax: 91(0) 22 55995556 Fax: (65) 389-6501
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Tel: 00 1 49 192 0 Fax: 02-47796 394 Tel: +27-11-2662300
Fax: 00 1 49 192 400 or 02-4122 985 Fax: +27-11-3253243
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Tel: 86-10-8458 4010 Tel: +64 7 957 9510 Tel: 886 2 2545 5991
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Tel: 01 30 61 39 92 Tel: 22 510 2100 Tel: 66 2937 1055
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Tel: 06103-307 333 Fax: 5 01 787 76 15 Tel: 02392 302600
Fax: 06103-307 399 Fax: 02392 302601
Lab-DE@pall.com Lab-UK@europe.pall.com

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E-mail us at Lab@pall.com

© 2005, Pall Corporation. Pall, , and Cascada are trademarks of Pall Corporation.
is a service mark of Pall Corporation. ELGA® LabWater is the global laboratory
water brand of Veolia Water.

7/05, GN05.1187