Service
Manual
Cascada TM Lab Water Systems
IX-water Model LS-water Model
SERVICE MANUAL
Cascada IX and LS Lab Water Systems
100 to 240 VAC 50 to 60Hz
Foreword
This service manual has been prepared for the Cascada?Array
IX-water and LS-water Systems.
Part Number Description Country
PAL-CAXXXIXM2Cascada IX-Water Americas,
System China, Asia PAL-CASXXIXM1Cascada IX-Water Europe, Japan
System
PAL-CAXXXLSM2Cascada LS-Water Americas.
System China, Asia PAL-CASXXLSM1Cascada LS-Water Europe, Japan
System
This manual is intended to be used by properly trained and authorized service engineers in conjunction with the Cascada Lab Water System Operation Manual for
the IX-water and LS-water models (PN MANU38437 Version 2, November 2006).
SAFETY INSTRUCTIONS1 User’s Responsibility1 Electrical1 Pressure1 Ultraviolet (UV) Light2 Sanitization Chemicals2 Control of Substances Hazardous to Health (COSHH)2 PAL-C100 Sanitization Tablet – Safety Information2
ROUTINE SERVICE3
TROUBLESHOOTING4
CALIBRATION PROCEDURE5 Microprocessor PCB - Location of Test and 6 Level Control Links
CASCADA? IX-WATER AND LS-WATER 8 SYSTEM PARTS LIST
Inlet Parts Location, Front View - 10 Cascada IX-water System
Parts Location Nearest the Pump - 11 Cascada IX-water System
Inlet Parts Location, Front View12 Cascada LS-water System
Parts Location Nearest the Pump - 13 Cascada LS-water System
Dispense Assembly13 Cartridge Connector14 Line Cell and Thermistor14 Inlet Sub-assembly14 UV and UF Locations15SYSTEM WIRING DIAGRAM16
KEY TO CONTROL PANEL17 Icons17 Alarm Conditions17 Quality Alarms17
REMOTE ALARM OUTPUT CONNECTION18 WARRANTY/CONDITIONS OF SALE19
Table of Contents
Do not attempt to operate or maintain the system without first reading this manual.
The basic rules of safety set forth in this manual are
intended as a guide for safe operation of Pall Corporation equipment. This general safety information, along with explicit service, maintenance, and operational materials for the specific machine, make up the complete instruction manual. All personnel who will operate, service, or be involved with this equipment in any way should be
completely familiar with this information prior to start-up. It is the user’s responsibility to make certain that the procedures set forth are followed.
The Cascada? Lab Water Systems have been designed to be safe; however, it is important that personnel working on these units understand any potential dangers. All safety information in this manual is highlighted as WARNING and CAUTION instructions. These are as follows:WARNING!
WARNINGS ARE GIVEN WHERE FAILURE TO OBSERVE THE
INSTRUCTION COULD RESULT IN INJURY OR DEATH TO PERSONS.
CAUTION!
Cautions are given where failure to observe the instruction could result in damage to the equipment, associated equipment, and processes.
User’s Responsibility
It is essential that the power switch on the Cascada Lab Water System is turned off before any items are changed or maintenance work performed.
The On/Off switch is located at the left-hand side of the unit. The main power cord is located just behind the On/Off switch.WARNING!
THIS APPLIANCE MUST BE
GROUNDED. PLUG INTO A PROPERLY GROUNDED (GFI) WALL OUTLET.
Electrical
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.
During the sanitization cycle, a PAL-C100 sanitization tablet is used and relevant safety information is included in this manual. 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.
Sanitization Chemicals
Ultraviolet (UV) Light
WARNING!
UNDER NO CIRCUMSTANCES
SHOULD THE LAMP BE CONNECTED AND ACTIVATED WHEN OUTSIDE THE HOUSING.
The Cascada? LS-water unit is fitted with a UV lamp. The UV lamp is enclosed in a stainless steel chamber ensuring that the operator will not be exposed to UV light.The Cascada IX-water unit does not contain a UV lamp.
PAL-C100 Sanitization Tablet - Safety Information
General description:
White, solid tablet which rapidly dissolves in water and is used for sanitization applications.
Hazard assessment:
Contains sodium dichloroisocyanurate dihydrate and is toxic by inhalation, ingestion, and skin contact.Properties:
Soluble in water and pH 6, non-combustible. Handling precautions:
Keep container tightly closed in a dry place and wear protective clothing when handling.
Spillages:
If tablets are dry and uncontaminated, gather 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 chemical exposure, rest, and expose self 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. Obtain medical advice in severe cases.
Mouth -wash out the mouth thoroughly with water and give a 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.
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.
Purpose and Scope
To ensure full and correct servicing of Pall equipment
by Pall approved service engineers.
References
Cascada? IX-water and LS-water System
Operation Manual (PAL-MANU38437 Version 2, November 2006)
Calibration Procedure – see page 5 in this
Service Manual
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.Investigate and replace from the client’s stock as
necessary any system filters and consumables.
4.Check the feed water quality. If pressure fed, ensure
pressure is regulated to 0.7 bar (10 psi) max.
5.Switch on unit and press Process button. Check
for correct sequence and operation of solenoid valves, UV,and pump.
6.If unit is fed from a reservoir, check operation of low
level protection by unplugging the level control lead.
7.Check operation of dispenser and record dispense flow.
8. Inspect and clean quality sensors (line cells). Check
calibration of unit.
9.Check that consumable items are being replaced at
the correct intervals.
10.Advise client of recommended replacement frequency:
PAL-C195 Ion Exchange maximum 6 months Cartridge (Americas, China
Asia)
PAL-C295 Ion Exchange maximum 6 months Cartridge (Europe, Japan)
PAL-C151 UV Lamp (if fitted)maximum 12 months PAL-C184 UF cartridge maximum 24 months (if fitted)
PAL-C166 POU filter (if fitted)maximum 6 months PAL-C169 Composite maximum 6 months Vent Filter
11.Check alarm set points.
12.Carry out sanitization of the unit. (See page 27
of the Cascada IX-water and LS-water System
Operation Manual.)
13.Wipe down equipment and leave in clean,
tidy condition.
14.Fill out service report and detail any follow up action
required. Discuss report with client and obtain
client’s signature.
Routine Service
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? IX-water and LS-water System Operation Manual.
PROBLEM
ACTION
No display message
Check main power supply and lead.
Check that the main power is switched on.
Check fuses in power inlet module and replace if blown.
Alarm and flashing Mute alarm. Check alarm set quality value
value is correct (see Operation Manual, page 13). Dispense approximately 10 liters of water to drain.
Check UF cartridge (if fitted).If problem persists, replace
purification pack (see Operation Manual, page 20).
=== M ?-cm
Feature out of measurement range. Allow unit to recirculate. Replace purification pack
(see Operation Manual, page 20).Check quality sensor and calibrate.
High water
Check correct alarm point is set temperature alarm
(see Operation Manual, page 13).Check feedwater temperature has not risen suddenly.Dispense some water to allow cold water to be drawn into the unit.Check temperature sensor and calibrate.
Purification pack Mute alarm. Replace purification change reminder pack (see Operation Manual, alarm
page 20).
UF change reminder Mute alarm. Replace UF filter alarm
(see Operation Manual, page 21).UV change reminder Mute alarm. Replace UV filter alarm
(see Operation Manual, page 23).Sanitization reminder Mute alarm. Initiate sanitization alarm
procedure (see Operation Manual, page 27).
Reservoir low level Mute alarm. Ensure unit is fed alarm
from a reservoir and the correct feature has been set (see Operation Manual, page 14).Check feed to the reservoir is operational and that the reservoir is filling.
Reservoir level
Mute alarm. Ensure control lead disconnect fault alarm
from reservoir is properly
connected. Note:Unit must be powered down to clear alarm.Reduced flow from Check inlet water strainer. dispenser
Replace POU filter or replace UF cartridge (if fitted).
Check pump and replace if worn.
Unit noisy
Open front door and secure pipework to stop vibration.Unit will not operate
Ensure that the correct
purification pack is correctly installed.
Ensure purification pack has a valid consumable date and that the reminder has not been overrun by 12 months.
Calibration Procedure
1.Make sure main power is off.
2.Remove top cover by first removing two screws from
the under side of the dispense gallery and one screw
from the underside by the On/Off switch.
3.Ease cover forward to release catches at rear and
carefully lift cover 90o. Do not disturb encoder, display, or push button connectors. Cover can be temporarily
secured by locating in top left-hand bracket.4.Locate Test Link 1-2 on processor PCB and insert
calibration link (see diagram).
5.Disconnect quality sensor from TH12 and connect
SUB-08 box in its place.
6. Disconnect temperature sensor from TH15 and
connect SUB-07 box in its place.
7.
Switch the main power on. The unit will automatically enter an extended flush – press Process button once to escape the flush and enable the calibration screen.
8.
Press calibration button.
9.
Press left-hand "scroll" button to scroll between
IX-water and LS-water System. Select correct version and press to confirm.
10.Screen will change to "Calibration – 0 Mohm-cm" as shown.
11.Select 0 M ?-cm on SUB-08 box and wait for a steady reading on display.
12.
icon to appear.
13.
This indicates that the calibration is accepted into software memory and the display will change to the exact value of 00.0.
14.Press button to confirm.
15.Screen will change to "Calibration – 1 Mohm-cm" as shown.
16.Repeat #11-15 for further values of 1, 10, and 18 Mohm-cm.
17.
After accepting the 18 Mohm-cm calibration, the screen will change to “Calibration – 40 Mohm-cm”.
Note:The components required for calibrating this value are mounted onto the PCB.
18.
icon to appear.
19.
software memory and the display will change to the exact value of 40.0.20.Press button to confirm.
Note:If this step is skipped, the calibration will be incorrect.
Microprocessor PCB – Location of Test and Level Control Links
Microprocessor PCB – Location of Test and Level Control Links (continued)
21.Screen now changes to "Calibration – Fixed R"
as shown.
22.PRESS button to confirm.
Note:This is a reference screen and the indicated value should be 1 +/- 0.2.
23.Screen now changes to "Calibration - 1 oC" as
shown.
24.Select 1 oC on SUB-07 box.
25.
icon to appear.
26.
27.PRESS button to confirm.
28.The screen changes to “Calibration - 35 oC”.
29.Repeat #24-27.
30.The display will now revert to the initial
calibration screen. The calibration is complete.
31.Turn main electricity off.
32.Remove the calibration link.
33.Disconnect the SUB boxes and reconnect the quality
and temperature sensors.
Note:Ensure that the connectors on the unit are clearly identified with the socket identification and that they are reinstalled in the correct position.
34. Replace the top cover and secure the two screws
underside of dispense gallery and one screw on
underside by the On/Off switch.
Quantity Part Number Description IX LS ADAP31299Adaptor straight –1
8mm x 1/8" BSP
ADAP32798Adaptor straight 12
8mm x 1/4" BSP
ADAP36233Stem adaptor 8 mm 22
stem to 3/8" BSP(P)M
ADAP37236Adaptor 1/4" BSP 11
dispense nozzle
BEND301085/16" clip-on flow bend–1 BLAN36761Blank (SBP) disinfection 11
port
CABL37257Cable display11 CAPS37232Cap for UF PU050014–2 CLIP36136Clip spring UV housing–2 CLIP36526Clip cartridge retainer22 CONN32791Connector bulkhead 8 mm–1 CONN35914Connector cartridge11 COVR36773Cover rear – SBP11 DISP36777Display LCD (SBP)11 ELBW30106Elbow equal 5/16" 23
OD tube
ELBW30903Stem elbow 5/16"16 ELBW34263Elbow swivel 6 mm OD x 11
1/8" BSP
ELBW34304Elbow swivel 8 mm OD x 22
1/8" BSP
ELBW35604Stem elbow 6 mm11 ELBW35957Stem elbow 5/16" tube x 22
3/8" stem
ELBW35960Reducing elbow 8 mm 11
to 6 mm
ELBW36122Elbow swivel 8 mm OD 24
tube x 1/8" BSP
FOOT36782Foot rubber,self-adhesive44 FUSE36904Fuse semi-delay 20 mm 22
6.3A
HOUS35913Housing line cell11 HOUS36124Housing flow restrictor–1
Quantity Part Number Description IX LS PAL-C15114 Watt UV tube –1
(185 nm)
PAL-KNOB37995Dispense knob – Cascada 1–
IX-water System
PAL-KNOB37996Dispense knob – Cascada –1
LS-water System
MANI37789Manifold block – dispense11 MANI37791Manifold inlet valve11 PAL-COVR37937Cover front11 PAL-COVR38000Cover top11 PAL-DOOR37936Door front11 PAL-LA638Sanitization by-pass block11 PAL-C184UF cartridge–1 PAL-MANU38437Operation manual 11 Version 2,
November 06
PAL-PANL37938Panel facia11 PAL-PANL37943-03Panel touch11 PAL-PCBS37191-02Display Board PCB11 PAL-PCBS37986-02Microprocessor PCB11 PCBS35976PCB electronic ballast–1 PINS36834Pin dowel (door hinge)11 PLAT37243Plate mounting–1 PLUG32649Plug bottom end cap11 PLUG35945Inlet solenoid valve 11
electrical plug
POWE34241Power inlet module – 11
240v 6A
POWE36842110 watt switch mode 11
power supply
PU010448Connector UF membrane–1 PU050037UF membrane bottom cap–1 PU195020Splash ring – dispense11 PUMP37223Pump diaphragm bypass 11
set at 80 psi
RING22023O-ring BS010 11
(dispense manifold)
RING30750O-ring (dispense nozzle)11
Cascada? IX-Water and LS-Water System Parts List
Cascada? IX-Water and LS-Water System Parts List (continued)
Quantity Part Number Description IX LS RIVT35963Rivet snap 5 mm dia x 22
10.5 mm
RIVT37234Rivet snap 5 mm dia x 22
8.5 mm
RIVT37252Rivet snap 4.7 mm dia x 44
5/16"
SP713Thermistor assembly11 SP714Line cell 11 SP724185 nm UV housing –1
assembly
SP727Encoder assembly11 SP734Fan assembly UV/14W –1
ballast
SPRI36849Door pin spring11 SPRI37227Spring contact data tag 22
(DI pack)
STRA20564Strap cable small22 STRA37233Strap cable11 TEES22504Equal tee 5/16" OD tube11 TEES36857Swivel tee off-set leg 11
6mm x 1/4" BSP
TUBE31957Tube hipure 8 mm OD 22
x5mm id (meters)
TUBE35949Tube 6 mm LDPE natural 22
(meters)
UXD-92272Clamp pipe pp grey–2 VALV32039Valve shut-off 5/16"–1 VALV35944Valve solenoid 1/4" (inlet)11 VALV37258Valve non-return 3/8"11
BSPF 1 bar SP724 185 nm UV Assembly
Part Number Description Quantity CAPS32084Cap end PVC 185 nm 2
UV housing
COVR22510Cover collet grey 5/16" OD2
DISC32086Disc sealing 185 nm 2
UV housing
ELBW30106Elbow equal 5/16" OD tube1 HOUS37216Housing 185 nm UV tube 2" 1
stainless steel
PLUG36206Plug 8 mm x 22 mm long 1
PVDF – UV tell tale
RING32087O-ring BS115 red silicon2
RING32088O-ring BS119 red silicon2 SCRW32089Screw M4 x 10 mm csk.4
TEES22504Tee equal 5/16" OD tube1
TUBE32085Tube synthetic silica (quartz) 1
185nm UV housing
PAL-A675 Installation Kit
Part Number Description Quantity AAB1381Screw hook nylon coated2
AAB1384Screw M6 x 30 mm1
ADAP32798Adaptor straight 8 mm OD 1
tube x 1/4" BSP(M)
ADAP35438Adaptor straight 6 mm x
1/4" BSP
PU010093Union nut1
PU10468Elbow reducing 3/8"-5/16"1
PU160049Polypropylene fitting 1
connection insert R 1/4"
PU220048Tube 8 mm od. x 6 mm ID 2 mtr PU220051Tube 6 mm od. x 4 mm ID 2 mtr PU280021Flat packing1
PXA-95399Cable wrap 98 mm x 2.5 mm2
PXC-100890Dowel nylon type S83
Inlet Parts Location, Front View - Cascada? IX-water System
CONN35914
ELBW35957
ELBW30903
ELBW35960
C
Inlet Parts Location, Front View - Cascada? LS-water System
CONN35914
PU010448
ELBW36122
VALV32039
HOUS36124
ADAP31299
PAL-C184
ELBW30106
COVR22510
CAPS37232
ELBW36122
RIVT37234 x 2
Line Cell and Thermistor - Cascada LS-water and IX-water System
Inlet Sub-assembly - Cascada LS-water and IX-water System
PLUG32802
ELBW36122
UV and UF Locations - Cascada? LS-water System
System Wiring Diagram
Key to Control Panel
Icons
Icon
Description Mute Alarm
Accept
Scroll
Auto Restart
Manual Restart
Set-up Menu
Cursor Option Choice
Cursor Selection Choice
Cancel
Reset
Printer
Intermittent Recirculation
Replacement Date
Alarm Conditions
Icon
Alarm Conditions
UV Lamp Failure
(Flashing)
Sanitization Tablet Reminder
(Flashing)
By-pass Fitted - Warning
(Flashing)
Purification Pack Not in Place
(Flashing)
Reinstall Purification Pack
(Flashing)
Clock Stopped
(Flashing)
Reservoir Level –Disconnect Fault (Flashing)
Incorrect Password
(Flashing)
Open UF Flush Valve
(Flashing)
Closed UF Flush Valve
(Flashing)
Quality Alarms
Screen
Description Outlet Purity Alarm
Temperature Alarm