BIOSED

KENZA 240
Random Access Analyzer

Service Manual
Clinical Chemistry Automatic and Diagnostic Analyzers
The photographs contained in this manual have only an explanatory function; therefore, some non-functional features
may not correspond to the device in question.
 KENZA 240
Service Manual

1 - General Description pg. 1

1. 1. Introduction pg. 3
1. 2. Readout system pg. 5
1. 3. Robotic system pg. 6
1. 4. Control system pg. 8
1. 5. Power supply unit pg. 12
1. 6. Hydraulic system pg. 12
1. 7. Technical specifications pg. 14

2 - Maintenance pg. 17

2. 1. Cuvette CK pg. 19
2. 2. Washing the cuvettes pg. 21
2. 3. Prime function pg. 21
2. 4. Setting the instrument pg. 21
2. 5. Sample/ Reagent level detector pg. 21
2. 6. Setting the barcode reader pg. 23
2. 7. Preventive maintenance pg. 24

3 - Replacing the components pg. 25

3. 1. Removing the cover pg. 27

3. 2. Replacing the lamp pg. 28
3. 3. Replacing the Readout cuvettes pg. 29
3. 4. Replacing the drying pad pg. 30
3. 5. Replacing the syringe piston pg. 31
3. 6. Replacing the probe washing device pg. 32
3. 7. Replacing the Photodiode Pre-amplifier board pg. 33
3. 8. Replacing the filtre wheel bearings pg. 35
3. 9. Rear view of the worktop pg. 36
KENZA 240
Index

4 - Checks and adjustments pg. 37

4. 1. General recommendations pg. 39

4. 2. Switching power supply control pg. 41
4. 3. Lamp power supply adjustment pg. 41
4. 4. Reagent cooling system power supply pg. 41
4. 5. Stepper motors reference voltages pg. 42
4. 6. Reagent & sample level detector adjustments pg. 42
4. 7. Robotic alignments pg. 43
4. 8. Sampling probe height pg. 44
4. 9. Cuvette positioning pg. 44
4. 10. Washing arm horizontal and vertical alignment pg. 45
4. 11. ADC board pg. 46
4. 12.+15v/-15v adjustment pg. 46
4. 13. Filtre wheel speed pg. 47
4. 14. Gain and Offset adjustment pg. 48
4. 15. Temperature adjustment pg. 49
4. 16. KENZA 240 troubleshooting table pg. 51
4. 17. KENZA Analyser Flags pg. 54
4. 18. Hardware error messages pg. 55

5 - Spare parts pg. 57

5. 1. Spare parts pg. 59

5. 2. Hydraulic system pg. 71

6 - Communication protocol pg. 73

6. 1. On-Line communication protocol and data format pg. 75

7 – Spare parts list pg. 79
General 1
Description
 KENZA 240
1
Service
Manual

1.1 Introduction

G KENZA 240 is an automatic analyser with microprocessor control, for clinical chemistry and
imunotur- bidimetry analysis, available in the table-top version. The “Random Access” operation
mode allows
rapidly running all the tests on a patient and printing the report, without having to wait the routine
to be completed. Moreover, you can add new patients, even with STAT priority, whilst running the
tests and, if necessary, repeat calibrations. KENZA analyser has been designed to achieve a
throughput of
240 tests/hour.

The graphical interface has been designed to make all the functions of this appliance simple and
intuiti-
ve, as well as to provide flexibility as required by every laboratory. KENZA 240 is composed of the
parts described in the following page.

3
1 KENZA 240
General Description

Pos. Name
1 Protection cover
2 Diluter module access panel
3 Distilled water and water drainage containers+level detector sockets unused 25-pin
con- nector junction nozzles
4 Halogen lamp housing access panel
5 power supply housing ventilation grid
6 Reagent cooling system forced ventilation socket
7 Switch+fuses+network filter unit
8 Voltage selector
9 Serial communication port
10 Sample and reagents tray
11 Cuvette tray
12 Cuvette washing arm
13 Sampling arm

4
 KENZA 240
1
Service
Manual

1.2. Readout system

This system is composed of a photometer equipped with a rotor containing a set of interference
filters;
an optic fibre connection and of a carousel containing 50 plastic optical cuvettes. It is also equipped
with
an automatic optical cuvette washing-rinsing and drying station for their next use.
The interference filters are installed on a rotor, which turns at a constant speed during the readout,
than-
ks to a DC motor. At the photometer outlet, a series of monochromatic pulses are transmitted via the
op-
tic fibre connection to the cuvette carousel, where the rays of light pass through each optical cuvette.
It is important to notice that each cuvette is crossed by a series of monochromatic light pulses,
which allows measuring transmittance at various wavelengths. These measurements are then
selected accor- ding to the test parameters.
Once the transmitted light reaches the solid-state detector located on the opposite side of the
selected cuvette, it is converted into an electrical signal, which is then amplified and sent to the
A/D Conversion circuit.

1.2.1. Photometer module

The KENZA 240 photometer provides a series of light pulses with different wavelengths, thanks to
a rotor onto which are installed a set of interference filters. The used light source is a halogen
quartz lamp po- wered at 5.8 V. The produced light is concentrated into a converging beam by a
convex and plain-convex lenses unit and passes through the filters, which turn at a constant
speed; the train of light pulses is then transmitted to the reading cuvettes via an optic fibre. The
rotation of the filter carousel occurs by means
of a DC motor, while the rotation control and the synchronisation for the readout of every single filter
are obtained via two pulse signals that result from the passage of the specially shaped filter wheel
through
a pair of optical couplers.

The photometer is composed of the following components:

1. A halogen quartz lamp with an adjusted and stabilised power supply, which emits light in the
visible,
UV and near Infrared regions.
2. A filter carousel that contains a set of 9 narrow band interference filters. By continuously
rotating during the readout, this filter carousel emits a train of monochromatic light pulses. This
way, it is pos- sible to have a readout of the cuvettes with all the available wavelengths.
Moreover, the continuous rotation of the filter carousel allows dissipating the heat absorbed by
each filter, thus increasing their average life. The rotation phase and speed are electronically
controlled.

5
1 KENZA 240
General Description

The carousel contains the following interference filters:

Pos. 2 340 nm Pos. 6 570

nm Pos. 3 405 nm Pos. 7
620 nm Pos. 4 505 nm Pos. 8
380 nm Pos. 5 546 nm Pos. 9
450 nm Pos. 10 700 nm

Position 1 is also used for controlling the Offset i.e., the amplifier output voltage in the absence of
light

Position 1 (Offset) is closed in order to prevent the light from passing and allow the readout of
the rest current of the amplifier.

1.2.2. Readout cuvettes

The train of light pulses deriving from the photometer is transmitted to the readout cuvette tray
via an optic fibre. This rotating tray contains 50 plastic cuvettes with a 0.6 cm optical path, in
which chemical reactions occur, after which the readout of the absorbencies related to the
intensity of the colours de- veloped during the reactions is performed. A resistive system with
electronic temperature control heats
the air around the cuvette tray, so that the induced temperature stabilises the cuvette temperature
at
37°C.
The rotating movement of the loader is due to a stepper motor with a 360° rotation.
When in idle state, the cuvette tray is positioned so that cuvette 21 in front of the ray of light.

1.3. Robotic system

The KENZA 240 robotic system involves all the mechanical parts related to fluid sampling operations
and
to the placement of the reagents and samples necessary for running the tests. The readout
module is also integral part of this system.

6
 KENZA 240
1
Service
Manual

1.3.1. Sampling arm

KENZA 240 is an instrument that operates in SIP & DIP mode; therefore, is uses one single
sampling arm for the aspiration and dispensing of the sample and reagent. The arm is
equipped with two bipolar stepper motors and it can move vertically as well as rotating by 320° in
order to place itself on samples, internal and external reagents, on the readout cuvettes and on
the drain and washing sump. The arm is also provided with a capacitative level detector for
detecting reagents and samples.

The rotating movement is performed according to the number of steps from an initial position
detected
by an optical sensor and a metal disc with reference slit. The vertical movement of the arm is
performed
in the same manner, only in this case, the reference position is indicated by a flag on the conveyor
belt that interrupts the photo-coupler.

When the level detector does not detect any sample, the appliance emits a sound to warn
the operator that the sample is insufficient or missing.

1.3.2. Sample tray

The sample tray can operate in two different configurations. The tray contains 40 samples that
can be arranged in 3ml secondary cups or in 12x100 primary tubes. In both cases there are 10
further positions available for calibrators and control sera.
Thanks to a bipolar stepper motor, the tray rotates clockwise and anticlockwise by 360° and it moves for
a preset number of steps, starting from the reference position indicated by a photo-coupler and a
flag.
A barcode reader detects the samples arranged in the primary tubes. The tray can be removed
from its housing by loosening the two fixing knobs.

1.3.3. Reagent tray

The reagent tray is provided with 30 positions for the insertion of as many plastic containers containing
the reagents necessary for running the tests. There are two different types of containers, the
single ones, which can contain 60 ml of reagent the double ones, with two separate
compartments, which can contain 17 ml and 40 ml respectively.
The reagent tray is provided with a cooling system, which is constantly in operation, even when
the appliance is off.
The stepper motor and the movement control system is the same as those used for the sample tray.

7
1 KENZA 240
General Description

1.3.4. Washing arm

The washing arm is a device located on the side of the readout module, which only performs a
vertical movement thanks to a stepper motor. The movement control is carried out via two
photo-couplers that detect the two extreme positions “high” and “low”.
On the head of the washing arm there are some tubes for introducing and sucking the washing
water,
as well as a teflon pad for drying the cuvette.

1.4. Control system

Most of the KENZA 240 electronic control system is located at the back of the appliance, while all the
robotics, temperature, conversion and digital signal and computer interface control boards are
located
on the upper part, beneath which is located the power supply unit. The micronotrollers that
are on some electronic boards can be identified by a yellow plate bearing the microcontroller
number and the software version.
Microcontroller 0 (PCB interface) communicates with all the other microcontroller in a
unidirectional manner, since it can require performing robotic movements or activating
solenoid valves and suction pumps. Only with micro 5 is there a bidirectional communication.
For an easy identification of these devices, please see the following table, which shows the
microcontrollers on each board and the associated command functions.

8
 KENZA 240
1
Service
Manual

PCB MICROCONTROLLER
interface U22/micro 0
board unidirectional
920104 and bidirectio-
nal communi-
cation with the
other micro-
controllers
motor control U6/micro U7/micro 1 U12/micro 4 U13/micro 3 U14/micro 2
board 1 13 cuvette cuvette tray diluter + sole- sampling arm sampling arm
920098 wa- shing noid valve vertical horizontal
arm move- ment mo- vement

motor control U6/micro 10 U7/micro 6 U12/micro 9

board 2 cuvette wa- sample probe
920099 shing dilute + and washing
solenoid reagent device di-
valve tray scharge
ADC board U3/micro 5 pump
920096 filter carousel
and AD con-
version control

temperature
and level
de- tector
control
board

9
1 KENZA 240
General Description

1.4.1. Interface board

This board is used for interfacing the instrument with an external management computer. The
instrument operates by means of three different managing software. The first and highest level is
represented by
the Windows management software, which includes the user interface. This software
communicates through the serial port with the interface board, which decodes the various
instructions via an interme- diate software and manages the motor and cycle control processes
of the instrument. The lowest level software is represented by the firmware configured in the
microcontrollers, which provide to the direct management of the electro-mechanical parts and
of each stepper motor. Micro 0 located on the Inter- face board directly controls some solenoid
valves, the suction pump, the drain sump and the vacuum pump.
Upon switching the instrument on, the management software receives all the settings
regarding the positioning of the robotic assemblies, as well as the various pre-set functions
stored in an EEprom of the interface board. The screen will briefly show the data reception and
then the main menu will appear. In case some of the settings have not been carried out, the
screen image below will appear, with the list of
all the instrument’s settings: those already made and those yet to be done.

10
 KENZA 240
1
Service
Manual

1.4.2. ADC board

This board allows amplifying the electric signal coming from the photodiode pre-amplifier located
in
the readout module and converting the analogue signal in a digital one, which will be processed
by the external management software.
The amplifier rest current gain level and offset level adjustments, as well as the filter carousel
motor ro- tation speed adjustment are carried out on this board. Moreover, this board also
houses some solenoid valve and discharge pump drivers.

1.4.3. Motor driver board

There are two motor control boards onto which the microcontrollers and the stepper motor
drivers are installed. These boards use two PBL 3717 bipolar motor drivers for each motor. Each
board is provided with a quartz oscillator circuit for producing the clock signal, which is necessary
for a correct microcon- troller operation.

1.4.4. Temperature & Level detector control board

This board includes all the electronic circuits that control the temperature in the various sections of
the instrument.
The control system used is always based on the same circuit configuration i.e., an operational
amplifier with a reference threshold connected to a temperature detection device. The control
actuation systems,
on the other hand, vary according to the used heating or cooling
elements. The temperature control functions of this board are carried out
as follows:

• a circuit controls the temperature of the readout module, i.e., of the cuvettes; in this case, an electri-
cal resistance powered with 30V AC is also used as a heating element.
• another part of the circuit controls the cooling system of the reagent tray; in this case, a Peltier cell
cools a metal tray onto which the reagent vials are arranged.

Finally, part of the electronic system controls the reagent pre-heating. Also in this case, a Pertier cell, in
contact with a teflon tube on a round support, heats the reagent during the sampling phase.
This board also houses the level detector control circuit to check the presence of the reagent and
the sample and, in the case of reagents, to measure their volume.

11
1 KENZA 240
General Description

1.5. Power supply unit

The power supply unit is located under the board rack and it is composed of two switching
power sup- plies and one conventional stabilised power supply. The latter provides the
necessary voltage for powe- ring the Photodiode Amplifier and ADC boards, as well as the 30V AC
for the readout module temperature control.
One of the two switching power supply, which is always in operation once the cable is connected,
pro- vides the +24V DC voltage for the operation of the cooling module and of some fans.
The other switching power supply, on the other hand, provides the +5V, +12V, -12V e +24V DC
voltages
for all the other parts of the instrument.

1.6. Hydraulic system

The KENZA analyser hydraulic system can be divided into:

• a sampling system
• a washing/drainage system

1.6.1. Sampling system

The sampling system is based on a dilution module with a 1ml syringe powered by a bipolar stepped
mo-
tor, a solenoid valve installed onto the module itself and a pre-heating device installed on the
sampling arm.

This sampling system operates in SIP & DIP mode. The sampling arm places itself on the
required rea- gent and the sampling probe lowers itself and withdraws the established volume of
reagent. The probe then it rises up, while the arm rotates and places itself on the sample tray
in correspondence of the sample to be analysed. The probe lowers itself and withdraws the
established volume of the sample and then it rises up again.
Once this stage has been completed, the sampling arm rotates and places itself on the readout
carousel
in the dispensing position. The probe descends in the cuvette and dispenses the sample with
the rea- gent and then, to make the solution even, it aspirates part of the liquid again to dispense
it in the readout cuvette.
The pre-heater located on the sampling arm, raises the temperature of the reagent up to
approximately
35°C, thus allowing the sample-reagent mixture to quickly reach 37°C.
After each procedure, a cleaning system washes the external surface sampling probe with a
mixture of water and air, preventing any contamination of the sampling system.

12
 KENZA 240
1
Service
Manual

1.6.2. Washing/Drainage system

The washing/drainage hydraulic system can be divided into two subsystems:

• A hydraulic system for washing the internal and external surface of the sampling probe and recove-
ring waste liquids.
• A hydraulic system for washing the readout cuvettes and recovering waste liquids.

The first hydraulic circuit carries out the following functions:

• Internal washing of the sampling probe and recovery of the waste liquid dispensed in the drain
sump
during the washing cycles;
• control of the water flow in the probe washing device for the external washing of the sampling probe
with the help of a pair of solenoid valves and a membrane suction pump.
The two solenoid valves are connected in parallel and are inactive during the washing phase
and activated when emptying the drain sump.

The readout cuvettes are washed by means of a mechanical arm that, when lowered, introduces
some
probes in the cuvettes that fill them with water and then aspirate it. The filling phase is carried out throu-
gh a water suction and dispensing cycle, which involves the use of a syringe with a metal piston control-
led by a plexiglass support and a solenoid valve. The drainage phase is based on the use of a
membrane suction pump and a solenoid valve that selects the cuvette to be emptied. A specially
shaped teflon pad, connected to the vacuum pump, dries the cuvettes that have been washed.

13
1 KENZA 240
General Description

1.7. Technical specifications

Operation principle Random Access

Readout mode Absorbance (extinction)
STAT Function Possible addition of urgent samples at any time
Type of analysis End Point with Continuous Monitoring.
Linear Regression for Kinetic Tests.
Initial Rate Reactions (2 points
Kinetic). Bichromatic Reactions.
Differential Reactions (with Sample Blank).
Type of calculation Counter factor with calibration curve
Sample tray 40 positions for samples in secondary cups or 40 positions for
primary tubes 12x100 (16x100 upon request). Primary tube barcode
identification available upon request. 10 positions for standards
and checks
Reagent tray Each positionfor
30 positions can housereagent
single a STAT (60ml)
sample.
or double reagent
containers
(17ml+40ml) .
60 positions for single
Readout carousel reagents. Reagent(0.6
50 optical cuvettes cooling
mm path).
system.
3-step automatic washing station.
Temperature controlled at 37°C +0.5°c -0°C
Optical System Interference Filter Photometer with wavelengths from 340 to 700nm
(340-380-405-450-505-546-570-620-700) bandwidth +/- 2nm with filters
340 and 380 and +/- 10nm with the remaining filters.
Linear Absorbance from 0.0005 Abs to 2.5000 Abs
Throughput Max. 240 tests/hour
Sampling system SIP & DIP sampling with capacitative level
detector. Reagent pre-heating
Sampling accuracy 1% for 1µl steps.
Peripherals External printer for A4 formats, RS232 serial port for connection to
the management system
User interface Indication on Display regarding the sample loading
list. Troubleshooting diagnostic system.
Help on Line
Sample volume 2-100ul

14
 KENZA 240
1
Service
Manual

External tanks distilled water, waste liquids

Operating environment Working temperature from 15° to 32°
Relative humidity Max. 70% at 32%
Power supply Voltage 115/230 AC+/- 6% 240 AC upon request
Frequency 50/60Hz
Power 350 VA
Dimensions and weight 79(L)x 58(D) x 54 (H)cm-45 Kg
Otions Barcode reader (for primary tubes
only) Sample tray for primary tubes
16x100

15
Maintenance 2
 KENZA 240
2
Service
Manual

T his section describes the various preventive and corrective maintenance operations for the
optimal operation of the analyser. The table at the end of this chapter includes a list of spare
parts subject
to wear, which must be replaced periodically.

The diagnostic routines available to the maintenance technician allow carrying out the
following operations:

• Ordinary maintenance interventions for keeping the instrument efficient.

• Stimulating and controlling the movements of the mechanical parts in case of malfunction.
• Mechanical and electronic adjustments following the replacement or removal of a mechanical
unit or of an electronic device.

2.1. Cuvette CK

This function of the maintenance menu fills the cuvettes with distilled water first and then
checks each test-tube, reading the optical density (OD) with each interference filter.

This function is very useful to verify the condition of the cuvettes and, indirectly, the state of
the photometer and of the washing system, since it carries out a voltage control in relation to
the cuvette transmittance. This value is expressed in volts for cuvette 1, while for the remaining
49 cuvettes it is expressed as the voltage differential compared to the voltage obtained through
cuvette 1.

While performing the cuvette CK, close the cuvette compartment cover in order to prevent
any influence from external light.

19
2 KENZA 240
Maintenance

To activate this function, click on “Cu-

vette CK” in the main menu. To start
up the function, click on “Execute”.
The instrument will fill the cuvettes
with di- stilled water first, and then it
will read the transmittance of each
one of them. After a few minutes, the
following table will be displayed:

The relation with the obtained results will be displayed on screen; column 01 shows the absolute
vol-
tages read through cuvette 1, while columns 02-50 indicate the voltage differential of the
remaining cuvettes compared to cuvette 1.

The voltage values measured through cuvette 1 must be within 8.5V-3.5V. The difference
with the other cuvettes is usually below 0.100 V. For higher values, we recommend
washing the
cuvettes with the appropriate solutions.

The Cuvette CK function cannot be considered as an autozero function that will be later used
for calculating the results. It is only a function to verify the integrity of the readout cuvettes and of
the
entire measuring system. The autozero of each cuvette is always carried out during the
routine
before use.

20
 KENZA 240
2
Service
Manual

2.2. Washing the cuvettes

Each time the readout cuvettes are replaced, we recommend performing at least 3 washing cycles
with Ipocleaning and Extracleaning solutions, in order to accurately clean the new cuvettes and
prevent the formation of air microbubbles that would affect the OD readout.

This function is considered as ordinary preventive maintenance and it allows washing the readout
cu- vettes. Please see Chapter 6 of the User Guide for detailed instructions.

2.3. Prime function

This function allows carrying out a series of washing cycles using the dilution syringe.
We recommend carrying out a few Primes every day, before starting the routine, to fill the
hydraulic circuit completely.
Moreover, the Prime function can be useful for verifying the hydraulic sealing of the piston
also fol- lowing its replacement. The reason of the possible presence of air bubbles in the
syringe may be found by checking the elements composing the sampling circuit in the following
order:
syringe, sampling tube, pre-heater, dilutor solenoid valve, syringe plexigas
support. Please see Chapter 6 of the User Guide for detailed instructions.

2.4. Setting the instrument

You can access this function from the Service Menu by clicking on “Set Steps”. This function
allows carrying out a series of adjustments regarding the mechanical parts positioning. These
adjustments
are stored by the system and then used when counting the phases. These adjustments are
described in detail in the Chapter “Checks and Adjustments”.

2.5. Sample/ Reagent level detector

The menu service allows the operator to access a series of

functions regarding the sampling arm capacitative level detector.
Contact with the sampling probe occurs by means of a metal
contact located on the rea- gent pre-heater screw connector (see
red arrow). It is important to keep this metal contact perfectly clean
with no oxidation to ensure a per- fect conductivity between the
probe and the electronic board. A small part of the electronic
system that controls this function is located in the reagent pre-
heater board, while the most part of it is contained in the
Temperature board.

21
2 KENZA 240
Maintenance

This detector allows verifying the

presence of reagents and samples
and automatically calculating the
volume of reagent in the container.
To activate the level detector, click on
“Set Steps” :

On the bottom right of the screen there are keys that allow activating the following functions:

(Reagent detector): Activates or deactivates the level detector. The green

LED
indicates that the function is ON

(Automatic volume Ck): Activates the automatic detection of the reagent

volume before starting the analysis routine. It can only be activated when
the reagent level detector is active

The activation of the “Reagent detector” key allows measuring the volume of reagent inside the vial
and detecting the sample inside the cup. The subsequent activation of the “Automatic volume Ck”
verifies
the reagent volume before starting the routine. If the level detector is activated, it controls the
sample
and reagent levels during the patient routine and it emits a sound alarm in case these volumes
are insuf- ficient. The ”Volume Test” and “Volume Calibration” keys on the lower right of the
screen, are used to carry out the volume verification and the volume calibration, respectively.
Click on the key and follow the instructions that appear on the screen.

Do not use distilled water to calibrate the volume detector. Since it is a capacitative detector
and
the distilled water has a very low capacity, being poor in electrolytes, we recommend using
a
protein-based reagent.

22
 KENZA 240
2
Service
Manual

2.6. Setting the barcode reader

The barcode reader is an optional accessory; therefore, its activation obviously depends on its
actual presence. The “Barcode Reader” key, located on the right of the “Set Step” menu, turns
green when enabled.

(Barcode Reader) Allows setting the barcode reader if present on the analyser. An
error message will appear if it is activated though not installed on the instrument.

By clicking on “Set Reader”, the menu for the barcode reader setup will appear.

Here you can select the type of barcode, according to the used label. For a correct operation, it is
im- portant to also set the Length ID and Position ID. Each code has its amount of digits, usually
more than
16, although KENZA actually uses only some of them. For this reason, it is important to indicate how
many digits of the entire barcode are actually used, as well as the position of the first digit read. In
short, the
ID length indicates the number of digits used to identify the samples, while the Position ID indicates
the position of the first digit used in the entire code.

23
2 KENZA 240
Maintenance

2.7. Preventive maintenance

This table shows the maintenance interventions that need to be carried out periodically, according
to the frequency of replacement of the parts subject to wear.

Component
Pos. Operazioni di controllo, sostituzione, allineamento code 6 months 1 year 18 months

2 Cuvette tray replacement 13-0055 √ √ √

Filter check, Gain & Offset adjustment √ √ √
1 Lamp replacement 13-0003 √
Diluter syringe sealing check √ √ √
4 Syringe glass replacement 001006 √
3 Syringe piston replacement 001007 √
5 Probe washing device replacement MA000140 √ √ √
6 Sampling probe replacement 3-0021 √ √ √
cuvette washing system efficiency check √ √ √
8 Cuvette pad replacement 13-0052 √
Hydraulic circuit check √ √ √
7 Tube replacement 13-0030 √
Mechanical parts cleaning and lubrication √ √ √
Cooling fans operation check √ √ √
Reagents cooling temperature check √ √ √
Cuvette temperature check √ √ √
Reagents pre-heating temperature check √ √ √
Robotic units alignment check √ √ √
Instrument accuracy and reproducibility check √ √ √

24
Replacing the 3
Components
 KENZA 240 3
Service Manual

3.1. Removing the cover

T he external cover needs to be removed to access the internal parts of the instrument, unless
other- wise specified.

To remove the KENZA 240 cover, proceed as follows:

1. Disconnect the power cable from the instrument.
2. Starting from the bottom, remove the 9 screws that fix the cover to the metal frame
3. Before lifting the cover completely from the instrument, make sure that the safety switch connection
cable is disconnected.

When lifting the external cover, the safety switch cable located at the centre front of the
analyser must be disconnected.

27
3 KENZA 240
Replacing the components

3.2. Replacing the lamp

To replace the photometer lamp, remove the protection

cover. Replace the lamp following the instructions below:

1. Deactivate the instrument following the proper procedure.

2. Remove the 4 fixing screws on the cover (see red arrow).
3. Disconnect the lamp Faston plugs from the power socket.
4. Remove the 3 fixing screws on the lamp and remove it from its hou-
sing.
5. Insert a new lamp, avoiding to modify the bulb alignment and to
touch it with your fingers. Reinsert the 3 fixing screws.
6. Connect the lamp Faston plugs to the power socket.
7. Please see the flow chart in Chapter 4 for any verification or
adjustment.

If during the lamp replacement you accidently touch

the lamp bulb with your fingers, remove any impurity
with ace- tone or ethyl alcohol.

28
 KENZA 240 3
Service Manual

3.3. Replacing the Readout cuvettes

This operation should be carried out every six months, although this lapse of time can vary according
to the daily volume of work.
To replace the readout cuvettes, proceed as follows:

1. Remove the readout tray cover and move the sampling arm so that it
does not obstruct the removal of the cuvette carousel.
2. To remove the readout carousel, loosen the 4 fixing screws (red ar-
rows) in the centre and lift with caution. When removing, make
sure that the carousel does not come into contact with the
washing sy- stem probes.
3. Insert a new carousel with the relative cuvettes inside the container
and fix the four screws beck on. Make sure that each cuvette is
com- pletely lowered and fixed to the plastic wheel.
4. Make sure that the carousel can rotate freely before putting the cover
back on.

Carry out a few washing cycles with Ipocleaning ed

Extracle- aning solutions to degrease the newly installed
cuvettes thus
preventing the formation of micro air bubbles.
5. Carry out the readout of the filters several times to verify readout
reproducibility and range. As for the Gain and Offset
adjustments, please refer to paragraph 4.14.

29
3 KENZA 240
Replacing the components

3.4. Replacing the drying pad

The cuvette drying pad must be replaced every 12 months depending on the planned ordinary
maintenance. Should the pad not remove the water from the cuvette completely, it could result
in the sample dilution which is the cause of inaccuracy and low result reproducibility.

To replace the drying pad, proceed as follows:

1. Remove the washing arm protection cover.

2. Disconnect the pad suction tube.
3. Loosen the two fixing screws from the pad (red arrow).
4. Remove the pad from its housing.
5. Insert the new pad in the washing arm head and connect the suc-
tion tube.
6. Manually lower the washing arm until the pad enters in the cuvet-
te.
7. Align the washing arm as described in paragraph 4.10

8. Put the washing arm protective cover back into place.

30
 KENZA 240 3
Service Manual

3.5. Replacing the syringe piston

The sampling system piston and syringe need to be replaced

periodically. Proceed as follows:

1. Remove the cover that allows accessing the dilutor module.

2. Use the diagnostic routine to lower the dilutor piston.
3. Loosen the screws (detail 3) and push the piston (detail 1) upwards
to disconnect it from the fixing collar.
4. Remove the anchor (detail 2) and the syringe rotating the upper me-
tal part (detail 4) clockwise.
5. Remove the teflon O’ring from the syringe housing in the Plexiglas
unit (detail 5) using a pointed tool.
6. Install a new Teflon O’ring.
7. Insert a new piston in a new syringe dipping its tip in distilled water
to make the movement more fluid, then screw the syringe and
the piston back on in the housing in the plexiglas unit (detail 5)
(pay the utmost attention to the inclination of the syringe,
since the piston must centre the fixing collar without being
forced. detail 3)
8. Manually lower the syring piston (detail one 1) until it enters in the
collar.
9. Turn the Analyser on and carry out a mechanical reset of the dilu-
tor.
10. Manually push the piston downwards and then upwards, leaving
less than 2mm distance between the upper part of the
plexiglas support and the tip of the piston.
11. Tighten the screw that fixes the piston to the lifting lever (detail 3).

Pay attention when tightening the screw; an excessive force

could break the head of the screw.

31
3 KENZA 240
Replacing the components

3.6. Replacing the probe washing device

The sampling probe washing device is subject to wear; therefore, it should be replaced at least
every six months according to the planned preventive maintenance. In case of a high number of
samples analysed daily, this lapse of time can be even lower. A poor sealing of the washing
device gasket causes an unsu- itable washing of the sample probe, which could lead to
contamination of the samples with an alteration
of the results and a possible loss of liquid during the sampling operations as a consequence.

To replace the probe washing device, proceed as follows:

1. use the hexagonal key to loosen the washing device grub screw.
2. Disconnect the two tubes from the probe washing device.
3. Connect the tubes to the new probe washing device.
4. Insert a new probe washing device from the bottom, making sure not to bend the sampling
probe.
The device can slightly force the probe, since it has a little O’ring inside.
5. Tighten the grub screw with a hexagonal key.
6. Carry out a few probe washing cycles through the special function in the Service Menu.

Pay attention to the tube connection to the probe washing device.

The water inlet must be connected to the lower connector, while the
drain
tube must be connected to the upper connector of the device (see figure).

32
 KENZA 240 3
Service Manual

3.7. Replacing the Photodiode Pre-amplifier board

The Photodiode Pre-amplifier board is located inside the readout carousel in correspondence with
the optical fibre. Usually, it does not need to be replaced; however, a leak from the cuvettes could
damage
the circuit. Since the replacement is quite difficult, to make sure that the board is acually faultes,
carry out the following verifications:

Carry out an ADC readout and if the voltages appear unstable or equal to
0V, check if the problem depends on the ADC system.
This verification can be made by connective the positive pole of a
1.5V standard battery to the blue cable and the negative pole to the
brown ca- ble of the connector shown in the figure.

This connector is part of the cabling and connects the amplifier photodio-
de board to the ADC board. It is located in the lower compartment
under the readout unit (red arrow).
The total absence or the instability of the signal despite the
insertion of the battery indicates a malfunction of the ADC board.
If, on the other hand, the fault is due to the photodiode pre-
amplifier board, the filter readouts would have all equal value and
be stable; therefore, the fault that was pointed out would disappear.

33
3 KENZA 240
Replacing the components

To access the photodiode pre-amplifier board, proceed as follows:

1. Turn the amplifier off, disconnect the power supply cable and remove
the external cover.
2. Remove the optical fibre from its housing by loosening the fixing grub
1
screw on the cylindrical support (fig.1).
3. Remove the four screws that fix the readout unit to the metal base of
the instrument (fig.2).
4. Lift the unit and disconnect the ground connection cable together with
the photocoupler connectors of the Amplifier Photodiode board and of
the heating element (fig.2). 2

5. Remove the eight screws that fix the cuvette tray support to the unit
and remove both the cuvettes and the support (fig.3).
6. Remove the collar and the cylindrical support of the optical fibre
(fig.4).
3
7. Remove the three screws that fix the external band to the base of the
readout unit and remove the band (fig.5).
8. Remove the three fixing screws and carefully lift the heating ring. For
an easier movement, remove the cabling fixing bands (fig.6).
9. Remove the two fixing screws and remove the lphotodiode pre-ampli-
fier board. (fig.7) 4

10. Insert the photodiode of the new board in its housing, making sure that
the surface is clean. If necessary, use a soft cloth to clean the lenses
(fig.7).
11. Reassemble the readout module, repeating the previous actions in re-
verse order.
5
12. Carry out the checks and adjustments provided for following this repla-
cements. For this purpose, please refer to the Checks & Adjustments
flow chart in Chapter 4.

34
 KENZA 240 3
Service Manual

3.8. Replacing the filter wheel bearings

1. Turn the amplifier off and disconnect the power supply cable
1. Remove the external cover
2. Remove the 4 screws that fix the photometer unit to the frame
1
3. Remove the two optical sensors (red arrows fig.1)
4. Disconnect the connector from the filter wheel motor, remove the lamp
connection terminal board and the ground connection (yellow arrows
fig.1)
5. Once free, lay the photometer on the table 2
6. Remove the 3 screws that fix the filter wheel motor to the unit
(fig.2)
7. Remove the 4 screws that fix the optical unit to the filters (fig.3)
8. Remove the fan and the filter wheel cover (fig.3)
9. Remove the filter wheel fixing screw by locking the rotation axis 3
with a screwdriver (fig.4)
10. Extract the filter wheel, the rotation axis, the two bearings and the
spacer in this order (fig.5)
11. Replace the faulted bearings with new ones of the same type and reas- 4
semble the photometer by carrying out the same operations in
reverse order.
12. With the replacement of the bearings, we recommend checking
and, if necessary, replacing the filter wheel motor.
5
13. Once the bearings have been replaced, carry out the checks and
adjustments as in paragraph 4.13

35
3 KENZA 240
Replacing the components

3.9. Rear view of the worktop

Remove the external cover of the analyser to access the components located under the worktop.
Remove the fixing screws and lift the worktop fixing it with its special bracket.

1. sample tray rotary movement

2. Sample and reagent tray hub
3. Sampling arm horizontal movement
4. Sampling arm vertical movement
5. Sampling arm robotic cable
6. Vacuum pump
7. Cuvette washing diluter
8. Sampling diluter
9. Reagent cooling module
10. Photometer cooling fan
11. Cuvette washing arm vertical movement

36
Checks and 4
Adjustments
 KENZA 240 4
Service
Manual

4.1. General recommendations

R emove the external cover to access the internal parts of the analyser.
Check the power supply voltage values and stability before carrying out any adjustment.
If necessary, use the extension boards p/n 920085 to carry out electronic adjustments and tests.

1. Motor driver 1
2. Motor driver 2
3. Interface board (between an external PC and the analyser)
4. ADC board
5. Temperature and level detector control board

To access the power supply compartment, disconnect the flat cable (red
arrow) from the interface board and remove the worktop fixing screws.

Lift the worktop and fix it on the special rod.

39
4 KENZA 240
Checks and adjustments

4.1.1. Flow chart

Checks and alignment flow chart to be carried out following removal or replacement of a
component or
a unit.

Lamp Filt ers out of range?

Carry out ADC
replacement Adjust Gain
par. 3.2
readout par. 4.14

Cuvette tray Wash w ith Carry out ADC Filt ers out of range?
replacement Adjust Gain
Ipo+Extra readout par. 4.14
par. 3.3

Photodiode Cuvette tray Pad aligned?

replacement Carry out ADC
aligned? Check Check
par. 3.7 par. 4.9
readout
par. 4.10

Filt ers wheel Filters wheel s peed

Checks & Carry out ADC
bearings replacement ok? Check
Regulations par. 3.8 par. 4.13
readout

Syringe
Carry out some
replacement
Prime cycles
par. 3.5

Probe was hing Check probe

device height
replacement par.3.6 par. 4.8

Pad Align pad Cuvette was hing Check Cuvette

replacement with water
par. 4.10 drying
par. 3.4

40
 KENZA 240 4
Service
Manual

4.2. Switching power supply control

Connect a voltmeter to the ground frame and the points indicated in the picture, making sure that
the measured voltages coincide with those in table.

Position Voltage
1 Dddd
Ground
2 + 5 V ± 0.2V
3 + 12 V ± 0.2V
4 - 12 V ± 0.2V
5 + 24 V ± 0.3V

4.3. Lamp power supply adjustment

To adjust the lamp voltage, connect the two voltmeter probes in parallel
to the lamp cables. Adjust the voltage by turning the
potentiometer shown in the picture.

All adjustments must comply with the specifications contained in the following table:

Uni Test Specifications

t
PCB 920080 P1 LampPoint
connector + 5.8V ± 0.2V

4.4 . Reagent cooling system power supply

The power supply shown in the picture is automatically

powered whenever the power cord is connected to the socket,
without having
to activate the main switch. This allows the cooling system to
operate permanently. The 24V provided by this switching power
supply power both the cooling system and the Temperature board
control circuit.

The 24V can be controlled on the connector shown in

the picture.

41
4 KENZA 240
Checks and adjustments

4.5. Stepper motors reference voltages

This adjustment determines the reference voltage of the stepper motors used to move the
mechanical units.

To check the reference voltage, connect the digital voltmeter between ground and the voltage
regulator heatsink.

Uni Test Specifications

PCB t920097 Point
P1 U1 (heatsink + 10.6 V ± 0.1V
P2 screw) U2 + 7.0 V ± 0.1V
P3 (heatsink screw) + 9.6 V ± 0.1V
U3 (heatsink
screw)

4.6. Reagent & sample level detector adjustments

Whenever enabled, the level detector function is active during both the sample and the
reagent aspiration. The control circuit of this function is located in part in the reagent pre-heater
and in part in
the temperature board.
All checks and adjustments must be carried out according to the specifications contained in the
table below:

Uni Test Specifications

t
PCB 920102 P7 Point
TP1 + 300 mV ± 10 mV

42
 KENZA 240 4
Service
Manual

4.7. Robotic alignments

These alignments determine the

correct placement of the robotic
mechanisms composing the
analyser. These settings are stored
in the EEprom located on the
interface board and uploaded in the
me- mory each time the software is
activated. To carry out these
alignments, enter the “Set Steps”
menu and select “All set- tings”.

The type of alignment to be performed will appear on top left of the display.
The two keys at the bottom, indicated with + and – allow moving the mechanical unit one step at a
time. Once the alignment has been completed and stored via the “Save” key, you can proceed
with the next alignment.
This menu allows you to perform two further alignments: the height of the sampling probe inside
the sample cup and the probe stop position following sample aspiration. Two keys indicated as
“Ck Up”
and “Ck Down” move the sampling probe in the required position to verify the alignments. The
numbers inside the boxes represent the number of steps the motors have to make to reach
the set positions. These numbers are to be increased or decreased according to the
specifications.

The distance between the base of the probe washing device and the tip of
the sampling probe must be ~ 1mm (Tolerance +0.5mm ; -0mm)

The distance A between the base of the sample cup and the tip of the
sampling probe must be ~ 2mm (Tolerance +0.5mm ; -0mm)

43
4 KENZA 240
Checks and adjustments

4.8. Sampling probe height

1. Disconnect the power cord and remove the external cover of the in-
strument; lift the worktop and fix it with its special support (see fig. a)
2. Connect the power cord and turn the instrument on.
3. Perform a mechanical reset of the instrument.
The following picture shows a detail of the sampling arm unit
for performing a vertical movement (red arrow). When in
idle state, the position of the probe in the probe washing
device is determi- ned by the position of the flag on the
transmission belt.

There are 24V in the board containing the optical detector and
the robotic cable; therefore, we recommend turning the
instrument off
during alignment operations to prevent short circuits.
4. Loosen the two locking screws and move the flag up or down to lift or
to lower the sampling probe.
5. Tighten the flag screws and carry out a mechanical reset.
6. Make sure that the position of the probe in the probe washing device
meets the specifications shown in the figure. If not, repeat the
align- ment procedure.
7. Lower the instrument worktop and mount the external cover back on.

4.9. Cuvette positioning

The top right part of the mechanical set-up menu allows aligning the
cu- vette in front of the light beam. Should the number of steps inside
the box
be modified, the cuvette position will also change. The alignment consists
in the centering of the cuvette in front of the light beam produced by
the photometer and brought into place through the optical fibre (red
arrow). The two screws used to fix the fibre and its support (yellow
arrows) can
be taken as a reference, or you can carry out a direct visual check of
the cuvette through the optical fibre duct.

The washing arm horizontal alignment must be repeated

every time the position of the cuvette tray changes.

44
 KENZA 240 4
Service
Manual

4.10. Washing arm horizontal and vertical alignment

Access the service menu; then, to set the correct washing arm position, proceed as follows:

1. Remove the washing arm cover and loosen fixing screws of the probe-
pad support (red arrows)and those of the pad vertical movement
(yel- low arrows).
2. Move the pad so that it is positioned slightly higher than the probes.
3. Carry out a mechanical reset to reposition the cuvette tray.
4. Lower the washing arm manually and move the probe support so that
the pad enters in the cuvette. Centre the four sides of the pad
inside the cuvette, considering that the pad perimeter is slightly
less than that of the cuvette.
5. Centre the two probes in the respective cuvettes and tighten the two
support fixing screws (yellow arrows).
6. Carry out a mechanical reset.
7. Lower the washing arm using the instrument diagnostic system and
make sure the two probes are slightly lifted.
8. Without moving the arm, lower the pad until it touches the bottom of
the cuvette and then tighten the two locking screws.
9. Carry out a mechanical reset and then lower and lift the washing arm
several times, verifying the following operative conditions:
a. No contact between pad and cuvette
b. The probes are centred in their respective cuvettes
c. The probes are lifted when the arm is lowered
10. Carry out a cuvette washing cycle with water; then remove and check
the cuvette tray to verify the succesful alignment. The cuvettes
must be dry, with no water drops on their walls.
11. Put the washing arm cover back on.

45
4 KENZA 240
Checks and adjustments

4.11. ADC board

The ADC board controls the correct photometer operation, as well as the signal conversion in
digital format via micro 5. Micro 0 of the interface board communicates in a bidirectional manner with
micro 5
of the ADC board.

1. Micro 5
2. Gain
3. Offset
4. -15 V
5. +15 V
6. Filt. Mot. Speed
7. TP+15 V
8. TP-15 V

4.12. +15v/-15v adjustment

This adjustment regards the two voltages that power the photodiode pre-amplification circuit.
These
two AC voltages supplied by the toroidal transformer and rectified in the lamp power supply
board,
are adjusted in the ADC board. Adjust P6 and P8 according to the specifications contained in the
table below.

Uni Test Specifications

t Point - 15 V ± 0.2V
PCB 920096 P6-P8 Adjusters U9-U10 + 15 V ± 0.2V

46
 KENZA 240 4
Service
Manual

4.13. Filter wheel speed

The pulse signal shown below is generated by one of the

two filter wheel photocouplers (see red arrow) and it
represents the home position. Each pulse
corresponds to a complete turn of the wheel;
therefore, by increasing or reducing the rotation speed,
the period of the signal will also be increased
or reduced. The waveform, visible with an
oscilloscope on pin 1 of the IC U3 or on the TP “RESET-
R-FilterS” of the ADC board, can be adjusted by means
of trimmer P10.
To carry out the adjustment, connect the oscilloscope
pro- be to the U3 pin 1 (microcontroller 5). Set the
oscilloscope time to 10 ms/square and the vertical
amplifier to 2V/square. Adjust P10 according to the
specifications contained in the table below.

Unit Test point Specifications

IC U3 Pin 1 / TP 40 ms ± 0.1 ms
Pcb 920096 P10
RESET-R-FilterS

47
4 KENZA 240
Checks and adjustments

4.14. Gain and Offset adjustment

Before performing the Gain

adjustment, we recommend carrying
out a readout cuvette washing cycle
with Ipocleaning and Extracleaning
solutions.
To set the Gain and Offset, access the
Service Menu and click on “ADC
Readout”.

A window will be displayed in which

you will be requested to select the
cuvette through which to perform the
optical readout. Select 1 and click
“OK”. The sampling arm will
automatically add water in cuvette 1
and then it will place it in front of the light
beam.

The following screen image will

appear within a few seconds:

Adjust P1 and P2 according to the specifications contained in the table below .

Uni Test Specifications

PCB t920096 FilterPoint
Readout 3.5V -
P1 Gain / P4 Offset Offset Readout 8.5V
+ 0.004V ± 0.002V

*Gain must be set taking the filter with the highest voltage as a reference

48
 KENZA 240 4
Service
Manual

4.15. Temperature adjustment

The whole KENZA 240 temperature adjustment

process requires a few hours. We recommend
proceeding by degrees and varying the
temperature gradually by rotating a quarter of a
turn each time, waiting for the temperature to
stabilise. If the measured value does not
correspond to the value in the specifications,
the operation must be repeated. All the
adjustment trimmers are on the Temperature
& Level detector board shown in the following
picture.

Pos. Potentiometer Description

1 P3 Cuvette tray heating
2 P4 Reagent cooling
3 P6 Reagent pre-heating

4.15.1. Cuvette tray heating

To set the cuvette tray temperature, add 500 µl of distilled water to some equidistant readout
cuvettes
and cover the tray with its lid. To guarantee an even heating of the cuvette tray, select the main
menu (this way the cuvette tray starts turning and the heat is better distributed over time). After 30
minutes, access the service menu to stop the cuvette tray and submerge the temperature
probe inside each cuvette. Adjust the temperature according to the specifications contained in
the following table.

Unit Test Point Specifications

Cuvette N.10
Cuvette N.20
920102 P3 Cuvette N.30 37°C + 0.5 – 0 °C
Cuvette N.40
Cuvette N.50

49
4 KENZA 240
Checks and adjustments

4.15.2. Reagent cooling

First of all, it is important to stress that the KENZA reagent cooling system cannot be
considered as a true refrigerator, but simply as a device to reduce the reagent temperature
approximately 10 degrees below the ambient temperature; therefore, for a better reagent
preservation, we recommend installing
the instrument in a conditioned environment. To carry out temperature checks and adjustments,
proceed
as follows:

1. Remove the sample and the reagent trays from their housing

2. Pour a few drops of water onto the metal tray in the area delimited by the 4 screws (the
Peltier
element is located underneath), leave to cool for a couple of minutes and then submerge the
tip of the temperature-measuring probe and read the temperature.

3. Adjust the temperature according to the specifications contained in the table below

Unit Test Point Specifications

PCB 920102 P4 Cooling surface 2°C + 0°C - 0.5°C

4.15.3. Reagent pre-heating

To allow the reagent-sample solution to quickly reach the incubation temperature of 37 ° C, during
the sampling phase the reagent is heated at a temperature of approximately 35 °C. This check can
be carried
out by simulating a routine analysis on some samples (distilled water can be used as a
reagent). To simulate the right operative conditions, it is important that the temperature of the
used reagent is the same as that of the reagents left to cool a whole night.
Simulate a routine analysis on a few samples and then, immediately after the sampling arm has
dispensed water in the readout cuvettes, dip the temperature probe in the cuvette and check
the temperature. Adjust P6 according to the specifications contained in the table below.

Unit Test Point Specifications

PCB 920102 P6 Readout cuvette 35 °C +1/-0 °C

50
 KENZA 240 4
Service
Manual

4.16. KENZA 240 troubleshooting table

In case of faults, use the instrument diagnostic system and the following table to identify the faulty
elec- tronic board or device.

Necessary instruments for carrying out the checks:

• Digital multimetre
• Oscilloscope
• Extension board p/n 920085 N.2

Unit Device Pcb Test Point Specification

Probe Washing device 920104 U11 pin 19
Solenoid valve 1
Probe Washing device 920096 U19 pin 8
Waste system Solenoid valve 2
Vacuum Pump 920104 U10 pin 19
Drain sump 920104 U11 pin 18
Waste container level detector 920104 U21 pin 13 LLL=waste full

Unit Device Pcb Test Point Specification

920098 U12 pin11
Diluter valve
920096 U28 pin 6 12V->0V
Sampling diluter Diluter home position 920098 U12 pin 9 LLL=0V
U8 pin 1-15
Diluter stepper motor 920098 Signa
U9 pin 1-15
l

Unit Device Pcb Test Point Specification

U11
DC motor filters 920096 Typical 3.5-4.0 V
pin2/screw
Photometer Filter wheel sync 920096 U3 pin 13 pulse signal 4
mspulse signal
Filter wheel home position 920096 U3 pin 1
40ms

Unit Device Pcb Test Point Specification

Home position detector 920098 U7 pin 9 HLL=5V
U4- pin 1-15
Cuvette tray Cuvette tray stepper motor 920098 Signa
U5 pin 1-15
l
Detected light signal 920096 R22 Analog signal

51
4 KENZA 240
Checks and adjustments

Unit Device Pcb Test Point Specification

Home position detector/ Horiz HLL=5V inner
920098 U14 pin 9
Mov. reagent
Home position detector / position
920098 U13 pin 9 LLL=0V
Vert. Mov.
Sampling arm
U10 pin 1-15
Stepper motor / Horiz. Mov. 920098 Signal
U11 pin 1-15
U16 pin 1-15
Stepper motor / Vert. Mov. 920098 Signal
U17 pin 1-15

Unit Device Pcb Test Point Specification

Home position detector 920099 U7 pin 9 HLL=5V

Sample &
reagent tray U4 pin 1-15
Stepper motor 920099 Signa
U5 pin 1-15
l

LLL= low logic level, HLL= high logic level

Unit Device Pcb Test Point Specification

Diluter home position 920099 U6 pin 9 LLL=0V
U2-pin 1-15
Diluter stepper motor 920099 Signa
U3 pin 1-15
l
920099 U6 pin11
Diluter upper electrovalve 920096 U18 pin 8 12V->0V
920104 U10 pin 15
Diluter lower electrovalve 920096 U17 pin 3 12V->0V
920099 U12 pin 11
Washing system
Washing pump 920096 U26 pin 8 12V->0V
Washing arm Home position
(upper detector) 920098 U6 pin 9 LLL=0V
Washing arm (lower detector) 920104 U21 pin 18 HLL= arm down
U2 pin 1-15
Washing arm stepper motor 920098 Signa
U3 pin 1-15
l
HLL=5V H2O
H2O container level detector 920104 U21 pin 12
empty

52
 KENZA 240 4
Service
Manual

Unit Device Pcb Test Point Specification

Level detector enable 920104 U9 pin 19
Level detector signal 920102 U13 pin 3 ~ 4V
Clock level detector 920102 R74 Clock ~ 2Vpp
Level detected 920102 DZ6 cathode Typical 7-8 V
Temperature &
NTC cuvette tray temperature Tie R15-
level detector 920102 ~ 3.5V at 22°C
compensation R13/ U8
NTC pre-heater temperature 920102 pin9
R76 ~ 5V at 35°C
NTC cooling detector 920102 Tie R63-R50 ~ 5V at 2°C
Cuvette temperature detector 920102 Tie R47-R28 ~ 3.5V at 37°C

Unit Device Pcb Test Point Specification

LLL=0V port
Port 920104 U21 pin 11
closed

53
4 KENZA 240
Checks and adjustments

4.17. KENZA Analyser Flags

At times, some letters (flags) may appear next to the results, to communicate important details
concer- ning the test being run to the operator. Here is a list of flags and their meaning.

Flag Meaning Notes

Valid for kinetic tests – It means that the readout points
FT Low Fit of a kinetic curve do not follow a linear trend
It means that the set reaction direction is incorrect or that the
VR Wrong reaction direction OD readouts do not follow the set direction.
It appears next to the result of a test that has been re- peated
R Repeated
It appears next to the result of a test that has been re- peated
RD Repeated with dilution with dilution
Valid for kinetic tests and Initial rate – It means that the
ES reagent substrate was exhausted before carrying out the
Substrate exhaustion first readout

It means that the result is below the set reference va- lue lower
LO Low value limit
It means that the result is above the set reference va- lue
HI High value higher limit
It means that the result is above the set linearity limit – We
FL Out of linearity limit recommend repeating with dilution
In case of tests with multistandard calibrations, it me- ans
FC that the result is above the maximum or below the minimum
Out of calibration curve calibration point

Next to the reagent blank extinction – It means that the

BHI High reagent blank extinction extinction is above the set reagent blank validity range
maximum limit

Next to the reagent blank – It means that the extinction

BLO Low reagent blank extinction is below the set reagent blank validity range minimum limit

For results that are close to 0 or negative, the shown result

will be 1 preceded by many decimal numbers as those
NV Not valid specified in the method parameters (1-0.1-0.01-0
.001-0.0001) sfollowed by the code NV

<B Below blank It means that the result is below the reagent blank

54
 KENZA 240 4
Service
Manual

4.18. Hardware error messages

Micro 0 constantly communicates in a unidirectional and bidirectional (micro 5) manner with the
other microcontrollers. Should a robotic movement fail following a mechanical, electronical or
detection pro- blem, a message with the indication of the microcontroller and the type of
movement will be displayed.

µController Movement Error Description

µ0 1 Computer cannot communicate with µController 0 (Interface)
µ1 1 µController 0 cannot communicate with µController 1 / Cuvettes
Ca- rousel motor does not rotate or cannot find its home position
µ2 1 µController 0 cannot communicate with µController 2 /
Horizontal
µ3 1 Sampling
µController Arm motor does
0 cannot not rotatewith
communicate or cannot find its
µController 3 /home
Vertical
position
Sam- pling Arm motor does not rotate or cannot find its home
µ4 1 position
µController 0 cannot communicate with µController 4 / Diluter
motor does not rotate or cannot find its home position
µ5 1 µController 0 (Interface) cannot communicate with µController 5 to
ac- tivate or deactivate the filter wheel
µ6 1 µController 0 cannot communicate with µController 6 / Samples
and
µ13 1 Reagents
µControllerTrays motorcommunicate
0 cannot does not rotate
withorµController
cannot find13its/ home
Washing
position
Arm motor does not rotate or cannot find its home position
µ3 2 µController 0 (Interface) cannot communicate with µController
3 or cannot receive the steps detected with the level detector
µ4 2 µController 0 (Interface) cannot communicate with µController 4
for activation or deactivation of diluter valve
µ5 2 µController 0 (Interface) cannot receive or transmit commands
related
µ9 2 to ADC from/to
µController µController
0 (Interface) 5 communicate with µController 9
cannot
for activation or deactivation of washing / aspiration pump
µ10 2 µController 0 (Interface) cannot communicate with µController 10
for activation or deactivation of waste washing valve
µ0 2 Computer cannot communicate with µController 0 or to read/write
data on EEPROM
µ0 3 Computer cannot communicate with µController 0 or transmit /
receive data to/from Barcode reader
µ13 2 µController 0 cannot communicate with µController 13 / Washing
Arm motor does not rotate or cannot find its lower position

55
Spare Parts 5
 KENZA 240 5
Service
Manual
5.1. Spare parts

Pos. Part. Description

1 18 Dilutor unit
2 34 Cuvette washing dilutor unit
3 35 Washing arm unit
4 19 Sampling arm unit
5 16 Photometer unit
6 49 Cooling unit
7 54 Complete power supply

59
5 KENZA 240
Spare Parts

Qty necessary for

Description Technical Service

Unit Code Part. Notes
<5 G. >10 G.
KENZA 240 KENZA 240
M000409 1 Filter locking ring (recessed) 2 2
000116 2 Interference filter 340nm (recessed) 1
Readout
000117 3 Interference filter 405nm (recessed)
system
000119 4 Interference filter 505nm (recessed)
000120 5 Interference filter 546nm (recessed)

60
 KENZA 240 5
Service
Manual

Qty necessary for

Technical Service
Unit Code Part. Description Notes
<5 G. >10 G.
KENZA 240 KENZA 240

000121 6 Interference filter 570nm (recessed)

000128 7 Interference filter 620nm (recessed)

000900 8 Interference filter 450nm (recessed)

OEM000124 9 Interference filter 700nm (recessed)

OEM000725 10 Interference filter 380nm (recessed)

000179 11 60°C Thermostat (recessed) 1 Cuvette tray

000966 12 Filter wheel bearing 4
Readout
system 000998 13 Optical fibre 1
9-0033 66 Pre-filter attenuators set (recessed) 1 1
13-0003 14 Lamp unit 2 5
13-0004 15 Filter wheel motor 1 2
13-0022 16 Photometer unit

13-0027 Cuvette tray optical sensor 1 2

13-0055 17 Tray with 50 cuvettes 2 5

61
5 KENZA 240
Spare Parts

Qty necessary for

Technical Service
Unit Code Part. Description Notes
<5 G. >10 G.
KENZA 240 KENZA 240
MA000014 18 Dilutor unit
MA000086 19 Sampling arm unit
Sampling system MA000140 20 Probe washing device 2 5
Teflon O’ring for syringe
M000135 67 (recessed) 1 2

M001237 21 plexiglas syringe support 1

62
 KENZA 240 5
Service
Manual

Qty necessary for

Technical Service
Unit Code Part. Description Notes
<5 G. >10 G.
KENZA KENZA
Sampling arm belt 240 240
000738 22 (recessed) 1 Horizontal movement

001128 23 Sampling arm belt 1 Vertical movement

001006 24 1000ul Syringe glass 2 5
001007 25 Syringe piston 2 5
11-0003 26 Sampling arm horiz. mov. and Dilutor stepper motor 1 2
Sampling system
11-0027 27 SMC esolenoid valve (recessed) 1 2 Dilutor unit
19-0009 28 Sampling probe 1 5
13-0023 29 Reagent preheating unit 1 2
13-0029 30 Sampling arm motor 2 Vertical movement
19-0014 31 Sampling arm robotic cable 1 2 Vertical movement
32 Sampling tube 1 5 *To be coded

63
5 KENZA 240
Spare Parts

Qty necessary for

Technical Service
Unit Code Part. Description Notes
<5 G. >10 G.
KENZA 240 KENZA 240
M001428 33 Solenoid valve support washing dilutor 1
Washing MA000072 34 Cuvette washing dilutor unit
System
MA000076 35 Washing arm unit

64
 KENZA 240 5
Service
Manual

Qty necessary for

Technical Service
Unit Code Part. Description Notes
<5 G. >10 G.
KENZA KENZA
Drain sump and solenoid valve support 240 240
M001506 36
Needles
M001362 37 Washing probe support not included
M001363 38 Washing probe cover
000951 39 10mm O’ring 1 2 Washing Diluter
001031 40 Washing probe spring
9-0041 41 Sirai solenoid valve 1 5
Washing
system 13-0015 42 Washing dispenser probe
13-0016 43 Washing cuvettes-drain probe
M000894 44 Washing dilutor piston
19-0008 Complete tube kit 1 5
13-0033 45 Vacum pump 1
13-0049 46 Discharge pump 1 2
13-0052 47 Cuvette drying pad unit 2 5

65
5 KENZA 240
Spare Parts

Qty necessary for

Technical Service
Unit Code Part. Description Notes
<5 G. >10 G.
KENZA KENZA
Sample 240 240
MA000146 48 Removable tray for secondary cups & tubes 12x100
Tray
MA000147 Removable tray for tubes 16x100

66
 KENZA 240 5
Service
Manual

Qty necessary for

Technical Service
Unit Code Part. Description Notes
<5 G. >10 G.
KENZA KENZA
Sistema 240 240
19-0004 49 Cooling unit 1
dei
Reagenti MA000145 50 Removable reagents tray

Qty necessary for

Technical Service
Unit Code Part. Description Notes
<5 G. >10 G.
KENZA KENZA
240 240
000718 51 Reagent cooling power supply 1
000149 52 AC plug with fuses+line filter+switch 1
001026 4 A delayed fuse 1 1 10 pieces
Power
supply 001207 53 +5v,+12v,-12v,+24v Switching power supply 1
unit
19-0013 54 Complete power supply
19-0006 55 Power transformer unit 1
920080 56 Lamp power supply 1
19-0015 57 24V power supply fan 2
19-0016 58 Cooling system fan 2

67
5 KENZA 240
Spare Parts

Qty necessary for

Technical Service
Description
Unit Code Part. Notes
<5 >10
KENZA KENZA
240 240
920078 59 S.level-reagent preheater support board 1

920081 Photodiode & Preamplifier board 1

2 boards
920085 Extension board 2 4
are
Electronic necessary
920098 60 Motor driver board 1 1
system
920096 61 ADC board 1
920099 62 Motor driver board 2 1
920102 63 Temperature control board 1
920104 64 Interface board 1
13-0035 65 9-pin flat cable 2 Interface PCB-RS 232

68
 KENZA 240 5
Service
Manual

Qty necessary for

Technical Service
Unit Code Description Notes
<5 G. >10 G.
KENZA KENZA
Optical sensor 240 240
000126 1 2
000178 Thermistor 4.7 KOhm 1 2 Cuvette unit
000615 cuvette tray and washing arm belt 2
000921 Single-hole optical sensor 1 2
000922 90° Optical sensor 1 2
Other 001024 Barcode reader
1-0091 Reagent tray movement belt 2
001093 RS 232 serial cable 1 2
M000340 metal nozzle 2
13-0002 Fan 1 2 Power supply
19-0007 Drained container level detector
19-0005 Distilled water level detector

69
5 KENZA 240
Spare Parts

19-0017 Thermistor cable 2

Other
11-0021 M4 ground cable 2

Qty necessary for

Technical Service
Unit Code Description Notes
<5 G. >10 G.
KENZA KENZA
240 240
Software 19-0022 CD with KENZA 240 Software 2 Latest release

70
 KENZA 240 5
5.2. Hydraulic system Service Manual

71
Communication 6
Protocol
 KENZA 240
6
Service Manual

6.1. On-Line communication protocol and data format

S ince KENZA 240 needs to be interconnected to the laboratory management system, the
computer requires a further COM 2 serial port as COM 1 is reservesd to the connection with the
analyser. The serial connection cable is made according to the diagram below:

Laboratory Serial port COM 2 KENZA Analyser

mana-
gement system 9 pin 25 pin 9 pin 25 pin
3 2 Transmiss. /Recept. 2 3

2 3 Recept. /Transmiss. 3 2

5 7 Bas 5 7
e

6.1.1. Serial port parameters

Datum Baud Rate Nr. of bits Stop bit Parity bit Handshakin Input Len
g
Val 19200 8 1 no 0 1
.

6.1.2. Data string description

Each string, both in reception and transmission is composed as

follows: STX .... data....

BCC ETX

Data strings are composed of printable ASCII digits only, whose codes range between ASCII 32
and
255.

BCC consits of 2 ASCII digits that represent the sum (module 256) of all the digits in the data string
(con- sidered in low case), except for STX, BCC and ETX digits. The sum must be expressed in
hexadecimal notation (HEX).

The BCC datum is represented by the last 2 ASCII low case digits on the right of the string
obtained by linking the digits “0” to the value Hex(i), where i is the sum (module 256) of all the
ASCII values of the data string digits (except for STX, BCC and ETX digits). E.g.:

Hex(i) =
AB
“0” & AB => “0AB”
BCC = LCase [ Right (“0AB”,2)] = “ab”

75
6 KENZA 240
Communication protocol

6.1.3. Protocol

Should the management computer want to send data to the Analyser, it must send an ENQ. If the
Analy-
ser is in Reception mode, it will respond with an ACK, then the Management computer can start
sending the data strings.

Here is the reception mode communication diagram (Man. comp. Analyser):

Should the Analyser want to send the result string to the Management computer, first of all it must
send
an ENQ to establish the serial connection. The management computer should respond with an
ACK. If no
ACK is received, the analyser sends an ENQ every 10 sec, until time-out.
Here is the transmission mode communication diagram (Man. comp. Analyser):

76
KENZA 240
6
Service Manual

77
6 KENZA 240
Communication protocol

6.1.4. String format

Here below are the details regarding the string from and towards the Analyser, indicating the name
and the length of the fields that compose them.
No separators are used in the data strings.
There are two cases according to the length of the Patient ID field:

(A) Patient string (Man. computer Analyser):

• case with 9-digit Patient ID:

• case with 8-digit Patient ID:

78
 KENZA 240
6
Service Manual

(B) Result string (Analyser Management computer):

• case with 9-digit Patient ID:

• case with 8-digit Patient ID:

NOTE: No separation digit is provided for between the fields composing the strings. The
result
is coded in the following format: xxxx.xxxx (9 digits including comma/period).

79
 6 KENZA 240
Communication protocol

Table of ASCII digits used in communication:

STX ASCII ( 2 decimal)

ET ASCII ( 3 decimal)
X
EO ASCII ( 4 decimal)
T
EN ASCII ( 5 decimal)
Q
AC ASCII ( 6 decimal)
K
NA ASCII ( 21 decimal)
C

80
 KENZA 240
6
Service Manual

Spare parts 7
List

81
MODULE Code ENGLISH / ANGLAIS FRENCH / Français

READING 000179 60°C Thermostat (for cuvette tray) Thermostat 60°C (pour portoir cuvettes)
MA000084 Cuvettes reading assembly Bloc de lecture des cuvettes (assemblage)
13-0027 Cuvettes tray optical sensor Senseur optique portoir cuvettes
LECTURE M000409 Filter locking ring anneau de blocage filtre
13-0004 Filter wheel motor assembly moteur de roue à filtre (assemblage)
000966 Filter wheel’s bearing Roulement roue à filtre
000116 Interference filter 340nm Filtre interférentiel 340nm
OEM000725 Interference filter 380nm Filtre interférentiel 380nm
000117 Interference filter 405nm Filtre interférentiel 405nm
000900 Interference filter 450nm Filtre interférentiel 450nm
000119 Interference filter 505nm Filtre interférentiel 505nm
000120 Interference filter 546nm Filtre interférentiel 546nm
000121 Interference filter 570nm Filtre interférentiel 570nm
000128 Interference filter 620nm Filtre interférentiel 620nm
OEM000124 Interference filter 700nm Filtre interférentiel 700nm
13-0003 Lamp assembly Lampe (assemblage)
000998 Optical fiber Fibre optique
13-0022 Photometer assembly Photometre (assemblage)
9-0033 Pre-filter attenuators set Set d'atténuateurs de filtres
13-0055 Tray with 50 cuvettes Portoir avec 50 cuvettes

SAMPLING 001007 1000 ul Syringe piston Piston de seringue 1000µL

001006 1000 ul Syringe glass Verre de seringue 1000µL
M001237 Plexiglas syringe header Bloc Plexiglas tête de seringue
DISTRIBUTION MA000140 Probe cleaner Dispositif de nettoyage de l'aiguille
13-0023 Reagents preheating assembly Préchauffage des réactifs (assemblage)
MA000086 Sampling arm assembly bras d'échantillonnage (assemblage)
000738 Sampling arm belt (horizontal) courroie bras d'échantillonnage (Horizontal)
001128 Sampling arm belt (vertical) courroie bras d'échantillonnage (Vertical)
13-0029 Sampling arm motor (vertical) moteur bras d'échantillonnage (Vertical)
19-0014 Sampling arm robotic cable (vertical) cable robotique bras d'échantillonnage (vertical)
MA000014 Sampling dilutor assembly diluteur échantillonnage (assemblage)
19-0009 Sampling probe Aiguille d'échantillonnage
19-0025 Sampling tubing Tube d'échantillonnage
11-0027 SMC electrovalve for dilutor Electrovalve SMC pour diluteur
13-0070 SMC electrovalve for washing system Electrovalve SMC pour système de lavage
M000135 Teflon O’ring for syringe Anneau teflon pour seringue

WASHING 13-0015 Aspiration needle Aiguille d'aspiration

19-0028 Complete tubing kit (washing station) Kit de tubes complet station de lavage
13-0016 Dispensing-draining needle aiguille dispense-aspiration station de lavage
LAVAGE 13-0052 Dryer pad assembly tampon séchage (assemblage)
M001362 Needles housing (needles not included) support d'aiguilles station de lavage (sans aiguilles)

M001363 Needles housing lid couvercle support d'aiguille station de lavage

000951 O’ring 10mm Anneau 10mm - station de lavage
M000894 Piston for washing dilutor Piston diluteur lavage
9-0041 Sirai electrovalve Electrovalve Sirai
001031 Spring for washing probe Ressort pour aiguille de lavage
13-0033 Vacuum pump pompe d'aspiration lavage
MA000076 Washing arm assembly bras de lavage (assemblage)
MA000072 Washing dilutor assembly Diluteur de lavage (assemblage)
M001594 Washing dilutor support for valve Support de valve diluteur de lavage
13-0049 Waste pump Pompe déchets
M001593 Waste well+electrovalve support Puits de lavage + support electrovalve

P.SUPPLY 001026 4 A delayed fuse Fusible 4 ampères

001207 +5v,+12v,-12v,+24v Switching power supply Commutateur Alimentation +5v,+12v,-12v,+24v
9-0020 AC plug + line filter + main switch prise AC + filtre ligne + interrupteur
ALIMENTATION 19-0031 Complete power supply Alimentation complète
001212 Cooling reagents power supply Alimentation réfrigération réactifs
920107 inverter Pcb for bright tag onduleur PCB etiquette lumineuse
920108 Lamp power supply Alimentation lampe
19-0006 Power transformer assembly Transformateur alimentation (assemblage)

ELECTRONIC 920096 ADC PCB ADC PCB

920085 Extension board (2 boards are needed) Carte extension (2 cartes sont nécessaires)
920081 Photodiode & Preamplifier Pcb Photodiode et PCB préamplification
ELECTRONIQUE 920110 Motor drivers PCB 1 PCB pilote moteurs 1
920133 Interface PCB Interface PCB
920124 Motor drivers PCB 2 / ISE PCB pilote moteurs / ISE 2
920078 Sensor level PCB+preheater PCB senseur de niveaux et préchauffage
920102 Temperature control PCB PCB contrôle temperature

MISC 13-0035 9 pins flat cable Câble plat 9 pins

000922 90° Optocoupler Optocoupleur 90°C
001024 Barcode reader Lecteur de codebar
DIVERS 000615 Belt for cuvettes tray+washing arm Courroie pour portoir cuvettes + bras de lavage
1-0091 Belt for reagents tray Courroie pour portoir réactifs
19-0030 Cable for bright tag Cable pour etiquette lumineuse
19-0004 Cooling assembly Réfrigération (assemblage)
9-0046 Distil water level detector Détecteur de niveau eau distillée
13-0002 Fan assembly (Power supply) Ventilateur (alimentation)
19-0016 Fan assembly for cooling system Ventilateur pour réfrigération (assemblage)
19-0015 fan for 24V power supply Ventilateur pour alimentation 24V
1275 Lamp for bright tag Lampe pour Etiquette lumineuse
11-0021 M4 ground cable Cable terre M4
000126 Optocoupler Optocoupleur
000921 Optocoupler type one hole fix Optocoupleur type un trou fixe
MA000145 Removable reagents tray Support réactifs amovible
MA000146 Removable tray for tube 12x100+cup Support amovible pour tubes 12x100 + cupules
MA000147 Removable tray for tube 16x100+cup Support amovible pour tubes 16x100 + cupules
001093 RS 232 serial cable Cable Serial RS 232
13-0024 Stepper motor for washing arm Moteur pas à pas pour bras de lavage
13-0071 Stepper motor for cuvettes tray,sampling arm Moteur pas à pas pour support cuvettes, bras
(horizontal mov.) or Dilutors échantillonnage (mouvement horizontal) ou diluteurs

19-0017 Termistor cable Cable Thermistor

000178 Thermistor 4,7 KOhm Thermistor 4,7 Kohm
M000340 Waste & Loading tube nozzle Embout tube déchet et Arrivée
19-0007 Waste level detector Detecteur de niveau déchets

I.S.E. 19-0018 ISE pump motor+rotor+bracket ISE moteur de pompe+rotor+crochet

19-0027 ISE reagent pack connection cable ISE cable de connexion pack réactifs
19-0020 ISE 4 ch complete kit ISE 4 canaux - kit complet
I.S.E. 001300 ISE 4 Ch pump tubing kit ISE 4 canaux - kit tube de pompe
001298 Straight connector for ISE tube Connecteur droit pour tube ISE

19-0029 CD with KENZA 240 Software CD logiciel KENZA 240

MAINTENANCE MKIT1-240 Maintenance Kit 1 (6 months) for Kenza Kit de Maintenance (6 mois) pour Kenza 240CUV50-
240CUV50-240PCLEAN-240SPROB-240 240PCLEAN-240SPROB-240
KITS

KITS DE MKIT2-240 Maintenance Kit 2 (12 months) for Kenza 240 Kit de Maintenance 2 (12 mois) pour Kenza 240
LAMP-240 LAMP-240
MAINTENANCE
SYGLAS-240 SYGLAS-240
SYPIS-240 SYPIS-240
WSDRY-240 WSDRY-240