GEM Premier 3000 Service Manual

GEM Premier 3000 Service Manual

Service Manual P/N 24002069 Rev 0 October, 2005

This publication and all materials (including software) concerning the products of the IL
GEM Premier 3000 are of proprietary nature and are communicated on a strictly
confidential basis; they may not be reproduced, recorded, stored in a retrieval system,
transmitted or disclosed in any way and by any means whatsoever, whether electronic,
mechanical through photocopying or otherwise, without IL’s prior written consent.
Information contained herein is believed by IL to be accurate: in any event, no
responsibility, whether express or implied is assumed hereby by IL for or in connection
with the use thereof, or for infringement of any third party right which might arise
therefrom, or from any representation or omission contained herein. Information is
subject to change and/or updating without notice.

i
GEM Premier 3000 Service Manual

CONTENTS
General Information

1.1 Overview 1-1

1.2 Measured Parameters 1-2
1.3 Derived Parameters 1-2
1.4 Front View 1-3
1.5 Back View 1-3
1.6 Symbology 1-4

Installation

2.1 Site Requirements 2-1

2.2 Electrical Requirements 2-1
2.3 Unpacking and inspection 2-2
2.3.1 Shipping Checklist 2-2
2.4 Applying Power 2-2
2.5 Start Up 2-3
2.6 Thermal Printer Paper Loading 2-3
2.7 Inserting Cartridge 2-3
2.8 Configuration 2-4
2.9 Instrument Shutdown 2-5

Operating Programs

3.1 Main Screen 3-1

3.2 Database 3-2
3.3 Configuration 3-3
3.4 Cartridge 3-4
3.5 Diagnostics 3-4
3.6 Shutdown 3-5

Fluidic/Cartridge Description

4.1 Cartridge Types 4-1

4.2 Storage and Shelf Life 4-2
4.3 Preparation for Use 4-2
4.4 Interpreting Cartridge Barcode 4-3
4.5 Calibration Frequency 4-10
4.6 Removal and Disposal 4-11

ii
GEM Premier 3000 Service Manual

Maintenance

5.1 Cartridge Replacement 5-1

5.2 Paper loading 5-1
5.3 Emptying ampoule Breaker 5-1
5.4 Cleaning 5-1
5.5 PM Procedure 5-1
5.6 PM Checklist 5-4

Check Out and Adjustment

6.1 Tools and Test Equipment Required 6-1

6.1.1 Torx Drivers 6-1
6.1.2 Pump Tension Fixture 6-1
6.1.3 ETC (Electronic Test Cartridge) 6-1
6.1.4 Loopback Connector 6-4
6.2 Gaining Access 6-4
6.3 Testing with ETC 6-3
6.4 Adjusting Pump Spring Tension 6-7
6.5 Loading Software 6-10
6.6 Calibrating Touchscreen 6-14
6.7 Replacing/Repairing LCD Backlight 6-15

Troubleshooting

7.1 Errors and Alarms 7-1

7.1.1 Alarms 7-4
7.1.2 Cartridge Errors 7-10
7.1.3 Hardware Errors 7-16
7.1.4 Software Errors 7-22
7.1.5 Event Logging 7-32
7.2 Symptom/Fix List 7-36

iii
GEM Premier 3000 Service Manual

Interfacing

8.1 Interface Specifications 8-1

8.2 Interfacing CO-Oximeter 8-1
8.2.1 Interfacing the IL682 8-1
8.2.2 Interfacing the IL OPL 8-2

Parts List

9.1 Items Sorted by Part Number 9-1

9.2 Service Tools 9-3
9.3 Customer Parts and Supplies 9-3

Drawings and Schematics

24005404 Interconnect Diagram 10-2

24005700 Final Assembly (sheet 1) 10-3
24005700 Final Assembly (sheet 2) 10-4
24005700 Final Assembly (sheet 3) 10-5
24005009 Chassis Subassembly (sheet 1) 10-6
24005009 Chassis Subassembly (sheet 2) 10-7
24005009 Chassis Subassembly (sheet 3) 10-8
24005009 Chassis Subassembly (sheet 4) 10-9
24005011 Assembly Front Panel (sheet 1) 10-10
24005011 Assembly Front Panel (sheet 2) 10-11
24005210 Display Assembly (sheet 1) 10-12
24005210 Display Assembly (sheet 2) 10-13
24005008 Assembly Rear Panel (sheet 1) 10-14
24005008 Assembly Rear Panel (sheet 2) 10-15
24005008 Assembly Rear Panel (sheet 3) 10-16
24005008 Assembly Rear Panel (sheet 4) 10-17
24005008 Assembly Rear Panel (sheet 5) 10-18
24005000 Heater block Assembly (sheet 1) 10-19
24005000 Heater block Assembly (sheet 1) 10-20
24005217 Assembly Guard Heater 10-21
24005097 Printer Mechanism 10-22
24005111 Assembly Cartridge Door 10-23
560031A Subassembly Pump Roller 10-24
24005229 Assembly Cartridge Motors 10-25
24005230 Motor Harness 10-26
24005013 Analog PCB Assembly 10-27
24005213 Analog PCB Schematic 10-28
500048A DCS PCB Assembly 10-29

iv
GEM Premier 3000 Service Manual

500048S DCS PCB Schematic (sheet 1) 10-30

500048S DCS PCB Schematic (sheet 2) 10-31
500057A Cl to DCS PCB Assembly 10-32
500057S Cl to DCS PCB Schematic 10-33
24001599 Assembly Sound Card 10-34
24005193 Backplane Assembly 10-35
24005213 Backplane Schematic 10-36
24005001 Electrode Input PCB Assembly 10-37
(sheet 1)
24005001 Electrode Input PCB Assembly 10-38
(sheet 2)
24005201 Electrode Input PCB Schematic 10-39
24005056 Display Transition PCB Assembly 10-40
24005256 Display Transition PCB Schematic 10-41
24005554 Floppy Drive Interface PCB 10-42
Assembly
500039A Line Filter Assembly 10-43
500039S Line Filter Schematic 10-44
55004401 Cartridge Motor Flex cable 10-45
Assembly
55004501 Cartridge Top Flex Cable 10-46
Assembly

Appendix A Service Information Bulletins

01-2002 Interfacing 11-2

02-2002 Printer Door 11-3
01-2003 5.3 Upgrade 11-4
02-2003 5.3 Time/Date Format 11-5
03-2003 New CPU Board 11-6
05-2003 Fan Interference 11-7
01-2004 New Power Supply 11-8
02-2004 New Disk Drive 11-9
03-2004 LCD Mounting 11-10
01-2005 CPU 11-11

v
GEM Premier 3000 Service Manual

1. General Information
This manual has been created to reflect the GEM® Premier 3000 at the current
time. All descriptions refer to the current configuration of hardware and software
version (5.4.2).

BIOLOGICAL HAZARDS EXIST. Avoid touching, with bare hands, any

parts of the system which may have come in contact with potentially
infectious fluids. ALWAYS wear gloves when performing any type of
Maintenance/Service action on these areas.

This section contains an Overview of the GEM Premier 3000, a list of the
measured and calculated parameters, a description of the front components of the
instrument, and a description of the rear components of the instrument.

1.1 Overview
The GEM Premier 3000 is a portable system for use by health care
professionals to analyze whole blood samples, in any clinical setting. The
instrument provides both measured and calculated results for blood gases,
hematocrit, electrolytes, glucose, and lactate. The instrument may be
interfaced to an external IL CO-Oximeter, the IL 682™ or the GEM
OPL®, with the CO-Ox results integrated into the GEM Premier 3000
results.

The GEM Premier 3000 system is comprised of the instrument and the
cartridge. The cartridge is a self contained, disposable package that
includes all of the Process Control Solutions, sensors, and the entire
sample pathway, including the pumps, valves, and waste bag. The
instrument controls the cartridge to perform all the necessary functions for
heating, calibration, probe movement, pumping, and sample aspiration.
The instrument accepts all of the sensor data from the cartridge and
processes this data to perform and verify the calibrations and to present the
data for the analyses. The instrument will display, store, print, and
transmit the data.

The GEM Premier 3000 can use a wide variety of cartridges, from a 35
test, 4-week cartridge to a 600-test 2-week cartridge. In addition, the
instrument and cartridges can be configured to use intelligent Quality
Management (iQM) or traditional, external QC.

1-1
GEM Premier 3000 Service Manual

1.2 Measured Parameters

The GEM Premier 3000 measures up to 9 parameters, depending on the
cartridge in use and the configuration of the instrument:

pH Hydrogen ion activity

pCO2 Partial pressure of Carbon Dioxide
pO2 Partial pressure of Oxygen
Na+ Sodium ion concentration
K+ Potassium ion concentration
Ca++ Calcium ion concentration
Glu Glucose
Lac Lactate
Hct Hematocrit

Refer to the Operators Manual for more information on these

parameters.

1.3 Derived Parameters

The GEM Premier 3000 will produce the following derived parameters,
depending on the cartridge in use and the configuration of the instrument:

HCO3- Actual bicarbonate

HCO3std Standard bicarbonate
TCO2 Total carbon dioxide
BEecf Base excess of extracellular fluid
BE(B) Base excess of blood
SO2c Oxygen saturation (calculated)
Ca++ (7.4) Ionized calcium standardized to pH 7.4
THbc Total hemoglobin (derived from Hct)
A-aDO2 Alveolar-arterial oxygen gradient
pAO2 Alveolar oxygen partial pressure
paO2/pAO2 Arterial-alveolar oxygen ratio
RI Respiratory Index
CaO2 Arterial Oxygen content
CvO2 Mixed venous oxygen content
CcO2 End pulmonary capillary oxygen content
a-vDO2 Arterial-mixed venous oxygen gradient
Qsp/Qt Physiologic shunt
P50 Partial pressure of oxygen at 50% saturation

Refer to the Operators Manual for more information on these

parameters, and for information on User-entered
analytes/parameters.

1-2
GEM Premier 3000 Service Manual

1.4 Front View

LCD Assembly

Printer Door

Ampoule Spinner

Sample Probe Port

Ampoule Breaker

1.5 Back view

Handle

Access Panel

Keyboard Port
Serial # Plate (covered)

Parallel Port Bar Code Port

Power Switch COM Ports A, B, C

Ground Lug Ethernet Port

Power Cord

1-3
GEM Premier 3000 Service Manual

1.6 Symbology

CE Mark Temperature Use By Manufacturer Batch Code

Limitation

Biological ATTENTION: CAUTION: NOTE: ATTENTION:

Risk See Risk of electric Important user Consult
Instructions Shock Information Documents
For use

Catalog In Vitro Authorized Contains

Number Serial Number Diagnostic Representative sufficient for
Device <n> tests

Protective Earth Off (supply) On (supply) End of Life

Conductor Disposal
terminal - (WEEE)
Earth

1-4
GEM Premier 3000 Service Manual

2. Installation

2.1 Site Requirements

The GEM Premier 3000 must be operated at an ambient temperature between

15 C (59 F) and 35 C (95 F), and a relative humidity between 5% and 90%. The
instrument is intended for indoor use only.

The instrument will operate independent of Barometric Pressure. The process

control Solution bags have zero head space and there is no affect on the dissolved
gas concentration over a wide range of atmospheric pressures.

The GEM must be placed in a location that allows adequate ventilation on the left
side and the rear of the instrument. The rear of the instrument will require
adequate clearance to allow for any connections (Ethernet, RS 232, Parallel port,
bar code reader) without putting stress on the cables. The right side of the
instrument requires 12 inches of clearance to allow insertion and removal of the
cartridge.

2.2 Power Requirements

The GEM Premier 3000 requires a grounded electrical supply. The switching
power supply accommodates 90 to 264 VAC, 50 or 60 HZ. The power
consumption of the GEM Premier 3000 is less than 120 watts. The instrument is
protected with a 1.5 amp circuit breaker integral to the power switch.

NOTE:
The GEM Premier 3000 has electrical filters to protect against line noise.
In locations where significant voltage or current fluctuations frequently
occur, the use of a line conditioner or an uninterruptible power supply
(UPS) is recommended

The GEM Premier 3000 is designed to recover from a power interruption

of less than one hour (or within 20 minutes if a low oxygen, or “A”
calibration is in progress, or blood is resting on the sensor). If routine
power failures are anticipated, a UPS can be used.

A 500VA/300W, 57 – 63 HZ UPS can power the instrument for

approximately one hour.

A 60-minute power interrupt feature allows instrument transport. The instrument

cannot be operated during power interruptions, unless connected to a UPS.

2-1
GEM Premier 3000 Service Manual

2.3 Unpacking and Inspection

An authorized IL representative should remove the GEM Premier 3000 from its
carton. Check that the instrument and its accessories have not been damaged
during transport. If damage is noted, initiate the proper procedures to file any
claims and obtain a replacement instrument, if required.

The GEM Premier 3000 will be packaged in a plastic bag, with two desiccant
packs. There will be a separate box with the instrument accessories in it. The
complete shipping list is:

2.3.1 Shipping List

Part Number Description

0024005700 GEM Premier 3000 Instrument
0014882100 Shielded Line Cord 110V
0019725500 Line Cord VDE Approved 220V
0024001379 Operators Manual with Disks GEM 3000
0024001450 GEM Premier 3000 Operator’s Guide
0024005140 Training and Installation GEM 3000
0024005141 Instrument Video GEM 3000 NTSC Format
0024005142 Instrument Video GEM 3000 PAL Format
0024005419 Quick Reference Guide GEM Premier 3000
005312 Bar Code Wand GEM Premier
005330 Formatted Diskettes HD (GP+/3K)
005508 Printer Paper GEM 5/Pack
Documents
00350224 MSDS GEM Premier Pak
0039005 Instrument Warranty
0024005144 Certificate of Compliance GEM 3000
0024005145 Declaration of Conformity GEM 3000

2.4 Applying Power

Verify that the line power is within the limits required (2.2). Verify that the
power switch on the GEM Premier 3000 is in the off position (bottom of switch
pushed in). Using the detachable line cord with the appropriate power
connections, plug the cord into the receptacle on the back of the GEM and to the
power source. Turn the power on by pushing the top half of the switch all the
way in.

2-2
GEM Premier 3000 Service Manual

2.5 Start Up

When power is first applied, the fan will turn on and the motors will home
themselves. The screen will then show a light colored bloom, followed by a very
brief logon display. It will then display “loading GEM 3000 software for several
seconds. After that the screen will display the normal startup screen with “The
instrument is performing self diagnostics. Please wait.” After several minutes,
the screen will blank out, the motors will find home again and the display will
come on in the “Insert Cartridge” screen.

2.6 Thermal Printer Paper Loading

For details, see chapter 2 of the Operators Manual:

1. Press bottom of printer door to open

2. Move tension lever up
3. Place paper in cup of door
4. Thread paper over top of roller, follow directions located inside
the printer door cover
5. Move tension lever down (paper should be coming out from the
front of the door)
6. Close door

2.7 Inserting Cartridge

Prior to inserting cartridge, verify the date and time are correct. No changes can
be made to the date or time after the cartridge is inserted. Using the proper date
and time is essential for the proper performance of the PO2 channel. The Date
format can be selected by pressing “Configuration” and “Instrument Setup”. The
possible selections are:

MM/DD/YYYY
DD/MM/YYYY
YYYY/MM/DD

To change the Date and/or Time, press “Configuration” and “Set Date and Time.
Any changes made in this screen will require restarting the instrument.

If the Daylight Saving Time feature is selected, the instrument will automatically
move the time forward one hour on the first Sunday in April, and it will move the
time back one hour on the last Sunday in October. If this is changed, it will
require restarting the instrument.

2-3
GEM Premier 3000 Service Manual

If the daylight Savings Time feature is not desired, it must be turned off by
pressing “Configuration”, Set Date and Time” and deselecting “Enable Daylight
Saving Time”.

Prior to inserting cartridge, verify that the desired setting for iQM is entered.
Press “configuration” and “iQM Setup”. If the cartridge is an iQM cartridge,
verify that the “iQM Mode” is selected.

1. Remove cartridge from foil pouch, ensure inside of foil pouch is

dry
2. Open door for cartridge
3. Remove dust cover – this activates the cartridge
4. Insert the cartridge into the GEM Premier 3000. Slide the
cartridge in with a smooth, continuous motion.
5. Follow prompt answering “Yes” or “No” to “Is instrument
date/time correct?”
6. If “Yes”, follow prompt – CLOSE DOOR, LOCK.
(CAUTION! Door will unlock if instrument is unplugged to be
moved)
7. If “No”, follow prompt – REMOVE CARTRIDGE, (correct for
date/time), restart process
8. Allow 30 minutes for cartridge to complete warm up cycle

For complete details on insertion of cartridge, and use of CVP/QC to

validate the cartridge, see section 2.7 (Insert Cartridge), section 6.3
(CVP Sampling), and section 5 (QC/ Calibrations) of the Operators
Manual.

2.8 Configuration
The GEM 3000 provides a significant amount of flexibility in the configuration
menu. Section 3 of the Operators Manual provides details on each of the
selections available. In the Configuration Menu, selections are available for :

Sample Setup
QC Setup
IQM Setup
Calibration Setup
Instrument Setup
Interface Setup
Security Setup

In addition, there are choices to save the configuration to a 1.44 M HD disk, and
to restore the configuration from this disk. The configuration can be saved with a
cartridge in use, but once a cartridge is inserted, the configuration disk cannot be
used to load a specific configuration onto an instrument.. This Save and Restore

2-4
GEM Premier 3000 Service Manual

feature can be very useful when installing multiple instruments in the same
facility. If one instrument is configured to suit the user’s requirements, the
configuration can be loaded onto the other instruments with the disk, saving a
significant amount of time.

The Configuration Menu also has a selection to “Restore KOPW” (Key Operator
Password). A Restore KOPW disk is provided with each instrument, in the back
of the Operators Manual. When this is selected, the Key Operator Password will
be restored to 1 2 3 4. The Date and Time can also be selected, as detailed in
Section 2.7 (above)

NOTE:
The key Operator Password is required to access all selections on the
Configuration Menu, except Restore KOPW.

2.9 Instrument Shutdown

The GEM can be shutdown for short periods of time to move the instrument, or to
load a software upgrade, or video disks, with a cartridge inserted. If the
instrument is shutdown with a cartridge, a popup screen will appear, indicating
that power must be restored within 60 minutes or the cartridge must be replaced.
In some instances, if the instrument is performing a 2 point cal, a C solution cal or
if there is blood on the sensors, power must be restored within 20 minutes.

If the instrument is to be shut down for an extended period of time, the cartridge
should be removed prior to shutdown.

Select “Shutdown” from the ready screen, press shutdown and confirm that the
instrument is to be turned off. There will be a prompt to wait while the
instrument is shutting down, followed by “It is now safe to turn off the
instrument.” Turning power off before this message is displayed can cause
corruption of the operating software, and will cause a delay in restarting the
instrument when power is restored.

2-5
GEM Premier 3000 Service Manual

3. Operating Programs
This section contains a brief overview of the available menu choices. Significant detail
about each of these choices is available in the Operators manual.

3.1 Main Screen

A B

D
E

H
I

A iQM status. IQM on if displayed

B Instrument date and Time
C Drop down menu selections
D Ready and iQM status
E Available sample types
F Analyte status
G Panel selection
H Current cartridge status
I Messages (if yellow), On board video, Next QC due (if yellow)

3-1
GEM Premier 3000 Service Manual

3.2 Database

B
C
D
E
F
G

A Allows viewing, printing and transmitting previous samples, starting with

most recent.
B Access to entering search criteria for patient samples in database
C Access to entering search criteria for QC samples in database
D Access to entering search criteria for CVP samples in database
E Access to entering search criteria for all samples in database
F Initiates printout of most recent 2-pt calibration results
G Opens drop down menu for iQM specific reports
Delta chart
Displays screen to enter criteria for selection of specific
charts. Charts can be viewed and printed. Printing is
limited to parallel or network printer.
Corrective Action Report (CAR)
Displays CAR for current month for viewing and printing.
Printing is limited to parallel or network printer. Selection
of previous months data available
CVP Report
Displays screen to enter month of CVP report to be printed.
Report is not displayed and printing is limited to parallel or
network printer.

All iQM Reports are available for 12 months, then are overwritten.

3-2
GEM Premier 3000 Service Manual

3.3 Configuration

A
B
C
D
E

F
G
H
I
J
K

A Accesses a screen with choices for; Analyte Enable/Disable, Panel Setup,

Demographics, Units of Measure Sample Print Options, Correlation
Factors Patient Ranges, Print Ranges, Auto Accept, Flag Interference and
Clots, and Report PCO2 when above 115 mmHg.
B Accesses a screen with choices for; Mandatory QC, QC Failure and
Patient Results, QC Material setup, CO-Ox QC Material Setup, Routine
QC Schedule Setup, New Cartridge QC Schedule Setup, and Range
requirements for QC Statistics.
C Allows turning iQM on or off and setting up CVP material ranges
D Allows for configuration of the Calibration Report printout and for setting
the Low Oxygen calibration time.
E Choices for Time and date format, Language, Instrument Name, Touch
screen volume and Screen color scheme. Any changes in this menu will
require rebooting the instrument.
F Choices for selecting output or input to Com Ports A, B, C, and Ethernet
Port. Accesses Network Setup, including GEMweb, and Printer Setup,
internal, parallel or network printer. Changes made in this menu may
require rebooting the instrument.
G Accesses a screen with choices for; Disable Patient Analysis, Enable E-
mail Sample Results, Operator Security, Default Operator, Authorized
Operator Setup, Save Authorized Operators, Restore Authorized Operators
and Change Key Operator Password.
H Displays a prompt to insert KOPW disk

3-3
GEM Premier 3000 Service Manual

I Displays a prompt to insert a blank disk to save the configuration for use
on another instrument, or on the same instrument at a later date.
J This menu choice is only accessible when no cartridge is inserted.
Prompts to insert the disk created in Save Config.
K This menu choice is only accessible when no cartridge is inserted. Allows
change of date and time and selection of Daylight saving Time.

With the exception of “Restore KOPW”, access to any of these menus

requires the use of the Key Operator Password.

3.4 Cartridge
This menu has only one selection; “Remove Cartridge”. When this choice is
selected, it must be verified, then the cartridge may be removed.

3.5 Diagnostics

A
B
C
D

E
F
G
H

A Provides screens for status and testing of Com Port A, B, C and the
Ethernet port.
B Provides screen for status and testing of the internal printer, parallel
printer and network printer.
C Provides specific information about software version, instrument serial
number and hardware, and cartridge information.
D Provides a screen to select specific cartridges for copying IL Data to a
disk. IL Data contains no patient information.
E Initiates a 2-pt calibration.

3-4
GEM Premier 3000 Service Manual

F Provides a screen to select specific cartridges for copying data to disk.

Data will contain patient information.
G provides a screen to select a month for which iQM data can be transmitted
via the selected COM Port.

3.6 Shutdown
This menu has only one selection “Shutdown”. When this is selected, it must be
verified, then the instrument will prepare for shutdown.

3-5
GEM Premier 3000 Service Manual

4. Fluidic/Cartridge
The GEM Premier 3000 uses a cartridge to perform all measurements. The cartridge
contains all of the fluidic components and sensors of the instrument. The sensors are
contained on a card that interfaces with the Heater Block for temperature control, and
with the analog PCB to provide the output voltages to the processor.

The Process Control solutions are contained in three airtight bags, with no headspace.
This eliminates any changes in values due to changes in Barometric pressure or
temperature, a key requirement for iQM.

4.1 Cartridge Types

Cartridges are available in multiple configurations, based on Menu (BG + Hct,
BG/Lytes + Hct, and BG/Lytes/Glucose Lactate + Hct) sample volume (75 to 600
tests), and use life (2, 3, or 4 weeks). In addition, each cartridge is available as
iQM or non-iQM. The chart below shows all of the available cartridges.

4-1
GEM Premier 3000 Service Manual

Cartridges

Test Menu non-iQM iQM Capacity Use-Life

Blood Gases, Hct N/A 24407584 75 4 weeks

24307504 24307584 75 3 weeks
24315004 24315084 150 3 weeks
24330004 24330084 300 3 weeks
24345004 24345084 450 3 weeks
Blood gases, Hct, 24307507 24307587 75 3 weeks
Electrolytes 24315007 24315087 150 3 weeks
24330007 24330087 300 3 weeks
24345007 24345087 450 3 weeks
24360007 24360087 600 2 weeks
Blood Gases, Hct, N/A 24307589 75 3 weeks
Electrolytes,
24315009 24315089 150 3 weeks
Glucose,
Lactate 24330009 24330089 300 3 weeks
24345009 24345089 450 3 weeks
24360009 24360089 600 2 weeks

4.2 Storage and Shelf Life

The are requirements for storage of the cartridges are ambient temperature 15 to
25° C (59 to 77° F). It cannot be frozen. The shelf life of the cartridge is 6
months from the date of manufacture. The cartridge is marked with an expiration
date (YYYY/MM/DD). The cartridge can be used as long as it is inserted before
midnight of the day following the expiration date.

4.3 Preparation for Use

There is a small notch in the edge of the foil pouch. The pouch can be opened by
hand by tearing at this notch. Remove the cartridge from the foil pouch. Inspect
the cartridge for leaks, and inspect the inside of the pouch to ensure that it is dry.
There is a clear plastic cover over the end of the cartridge, with a tab at the top of
the cartridge. Pull on this tab to remove this cover. Removing the cover will
open the four valves and allow the proper flow of the internal solutions.

The cartridge can now be inserted into the instrument, larger bar code label up.

4-2
GEM Premier 3000 Service Manual

4.4 Interpreting Cartridge Barcode

Each GEM 3000 cartridge, regardless of type, comes with a barcode label across
the top of the cartridge. The barcode format supported on the GEM 3000 is the
“code 128, subset C” format.
The cartridge barcode label contains information regarding the concentration of
calibration solutions present in the cartridge, the cartridge type, and expiration
information. This section explains how the software determines these values from
the barcode.
The cartridge barcode contains 40 digits. Each digit is an integer. The definitions
for the 40 digits, split into individual integer values and interpreted by the
operating software, are shown below:
example: 1234567890123456789012345678901234567890
field ID: abcdefghijklmnopqrstuvwxyABCDEFGHIJKLMNO

New ISE Cartridge Type:

The barcode for cartridges with new ISE sensors contains 41 digits. The fields and
their interpretations in the first 40 characters of barcode are identical to those
from barcode for cartridges with the current ISE sensors. An additional field “P”
at the end is provided (with a value of zero). Software shall use this field to
identify the ISE cartridge type, and apply different set of constants in sample
measurement functions, and perform different iQM pattern checks. See Volume
2 for details.
example:
12345678901234567890123456789012345678900
field ID:
abcdefghijklmnopqrstuvwxyABCDEFGHIJKLMNOP

4-3
GEM Premier 3000 Service Manual

Cartridge Barcode Definitions

Field ID Definition Notes
a First digit of the 2-digit Integer value 0 through 9
Cartridge Type
b First digit of the 2-digit Integer value 0 through 9
Cartridge Shelf Life
cdef Cartridge Expiration Date Expressed as number of days since
January 1, 1996
gh Range table index Selects a table of base values for
calculating calibration solution
concentration constants (see section 3.6).
ij 1000 * (pHA - pHAbase) pHA = pH of “A” calibration solution
kl 1000 * (pHB – pHBbase) pHB = pH of “B” calibration solution
mn pOI - pOIbase pOI = initial partial pressure of O2 in
“B” calibration solution expressed in
mmHg
op 100 * (pO2 drop rate) Rate of drop of O2 partial pressure in
“B” calibration solution expressed in
mmHg/week
q pCOA - pCOAbase pCOA = partial pressure of CO2 in “A”
calibration solution expressed in mmHg
r pCOB – pCOBbase pCOB = partial pressure of CO2 in “B”
calibration solution expressed in mmHg
st 100 * (KA – KAbase) KA = concentration of K in “A”
calibration solution expressed in mmol/L
uv 100 * (KB - KBbase) KB = concentration of K in “B”
calibration solution expressed in mmol/L
w NaA – NaAbase NaA = concentration of Na in “A”
calibration solution expressed in mmol/L
x NaB – NaBbase NaB = concentration of Na in “B”
calibration solution expressed in mmol/L
y 100 * (CaA - CaAbase) CaA = concentration of Ca in “A”
calibration solution expressed in mmol/L
AB 100 * (CaB - CaBbase) CaB = concentration of Ca in “B”
calibration solution expressed in mmol/L
CD GluA – GluAbase GluA = concentration of glucose in “A”
calibration solution expressed in mg/dL
E LacA – LacAbase LacA = concentration of lactate in “A”
calibration solution expressed in mg/dL
F pOA0 – pOA0base pOA0 = partial pressure of O2 in “C”
calibration solution expressed in mmHg

4-4
GEM Premier 3000 Service Manual

Field ID Definition Notes

G Second digit of the 2-digit Integer value 0 through 9
Cartridge Type
H Reserved for future use
I Second digit of the 2-digit Integer value 0 through 9
Cartridge Shelf Life
JKLMNO Cartridge Serial Number A sequential 6-digit integer value (each
digit 0 through 9)
P New ISE Cartridge Type Integer value of 0 (zero).
Identifier

The quantities represented by the concentration names subscripted with the word
“base” in the above table are determined from the operating software’s range table
(see section 3.3).
Interpreting Cartridge Type (fields a and G)
The operating software uses the Cartridge Type fields “a” and “G” to
determine the cartridge menu (allowed analytes), the cartridge use life
(comprising the maximum number of tests/weeks) and whether the
cartridge is a traditional or of the iQM type. The software accepts only the
following cartridge types (table entry represents a-G):
Cartridge Types
75-TEST 75-TEST 150-TEST 300-TEST 450-TEST 600-TEST
3-WKS 4-WKS 3-WKS 3-WKS 3-WKS 2-WKS
BG/Hct 3-0 3-2 4-0 5-5 6-0 N/A
P/N=24307504 P/N=24407504 P/N=24315004 P/N=24330004 P/N=24345004
BG/Hct (iQM) 3-3 3-5 4-3 5-7 6-3 N/A
P/N=24307584 P/N=24407584 P/N=24315084 P/N=24330084 P/N=24345084
BG/Hct/Lytes 3-1 3-6 4-1 5-1 6-1 7-1
P/N=24307507 P/N=24407507 P/N=24315007 P/N=24330007 P/N=24345007 P/N=24360007
BG/Hct/Lytes 3-4 3-7 4-4 5-4 6-4 7-4
(iQM) P/N=24307587 P/N=24407587 P/N=24315087 P/N=24330087 P/N=24345087 P/N=24360087

BG/Hct/Lytes/GL 3-8 N/A 4-2 5-2 6-2 7-2

P/N=24307509 P/N=24315009 P/N=24330009 P/N=24345009 P/N=24360009

BG/Hct/Lytes/GL 3-9 N/A 4-6 5-6 6-6 7-6

(iQM) P/N=24307589 P/N=24315089 P/N=24330089 P/N=24345089 P/N=24360089

Cart.Type Cart.Cap. Cart. Name

Life
ETC 0-0 600 3 wks Electronic Test
Cartridge
EXPERIMENTAL 5-0 550 3 wks Experimental Cartridge

4-5
GEM Premier 3000 Service Manual

In the tables above, “Cartridge Use Life” is the number of days the
cartridge may be used after it is inserted into the instrument. “BG” and
“Lytes” stand for “Blood Gases” and “Electrolytes”, respectively.
When an analyte is not on the cartridge menu, the software internally
disables the analyte and prevents the operator from re-enabling it.
The cartridge part numbers shown in the table above are used by GEMweb
software (see Volume 3).
iQM stands for “intelligent Quality Management”, which designates
cartridges with built-in quality management processes that substitute
traditional quality controls.
Software will also accept the ETC (Electronic Test Cartridge). The ETC
has a cartridge type of 0-0.
The cartridge type 5-0 (a=5 and G=0) is reserved for experimental
cartridges.

Interpreting Cartridge Expiration Date

The Expiration Date is expressed in terms of the number of days since
1/1/1996.
EXPIRATION DATE = field “cdef”
The cartridge is expired if:
INSERT DATE > EXPIRATION DATE
Where INSERT DATE is the date of cartridge insertion into the
instrument, expressed in terms of the number of days since
1/1/1996.
The software rejects the insertion of expired cartridges (see Insert
Cartridge state in volume 3).

Interpreting Cartridge Shelf Life

The operating software uses the cartridge shelf life fields “b” and “I” to
determine the cartridge shelf life in days. First, fields “b” and “I” are
concatenated to form the 2-digit number “bI”, then the shelf life is
computed as follows:
SHELF LIFE = bI*2 + 120 (days)

4-6
GEM Premier 3000 Service Manual

Interpreting Cartridge Age

The cartridge age is used in calculating the O2 concentrations in the bags.
The shelf life is used with the cartridge expiration date to determine the
manufacture date of the cartridge and the cartridge age. The manufacture
date is calculated as follows:
MANUFACTURE DATE = EXPIRATION DATE - SHELF
LIFE
Where MANUFACTURE DATE is expressed as the number of
days since 1/1/96
The cartridge age is calculated as follows:
AGE = INSERT DATE - MANUFACTURE DATE (days)
Calculating Cartridge Lot Number
The cartridge lot number is 8 6 digits long, in the following format:
Cartridge lot number = STUVWX,
Where:
S = last digit of the year the cartridge was manufactured (for example, 1
for 2001)
TUV = day of the year cartridge was manufactured (for ex. 032 for Feb 2)
WX = 2-digit cartridge type

Interpreting Range Table Index (field gh)

The operating software uses the cartridge barcode field “gh” as a range
table index to determine the base values for calculating the calibration
solution concentration constants (see section 0). For cartridge types
without glucose or lactate, “gh” = “00”. For cartridge types with glucose
or lactate, “gh” can be “01”, “02”, “03”, “04”, “05”, or “06” depending on
the concentration of Ca in the “A” calibration solution as follows:
• “gh” = “01” if: 2.26 ≤ CaA < 2.36 (mmol/L)
• “gh” = “02” if: 2.36 ≤ CaA < 2.46 (mmol/L)
• “gh” = “03” if: 2.46 ≤ CaA < 2.56 (mmol/L)
• “gh” = “04” if: 2.56 ≤ CaA < 2.66 (mmol/L)
• “gh” = “05” if: 2.66 ≤ CaA < 2.76 (mmol/L)
• “gh” = “06” if: 2.76 ≤ CaA ≤ 2.85 (mmol/L)

4-7
GEM Premier 3000 Service Manual

The following table gives the base values for the concentrations of
analytes in calibration solutions based on the value of the “gh” field in the
cartridge barcode:
Analyte Concentrations Base Values
Base Name gh = 00 gh = 01 gh = 02 gh = 03 gh = 04 gh = 05 gh = 06
pHAbase 6.85 6.85 6.85 6.85 6.85 6.85 6.85
pHBbase 7.35 7.35 7.35 7.35 7.35 7.35 7.35
pOIbase 180 130 130 130 130 130 130
pCOAbase 60 60 60 60 60 60 60
pCOBbase 30 30 30 30 30 30 30
KAbase 1.60 6.60 6.60 6.60 6.60 6.60 6.60
KBbase 5.60 3.10 3.10 3.10 3.10 3.10 3.10
NaAbase 150 96 96 96 96 96 96
NaBbase 130 140 140 140 140 140 140
CaAbase 0.16 2.26 2.36 2.46 2.56 2.66 2.76
CaBbase 1.75 0.80 0.80 0.80 0.80 0.80 0.80
GluAbase undefined 100 100 100 100 100 100
LacAbase undefined 26 26 26 26 26 26
pOA0base undefined 0 0 0 0 0 0

4-8
GEM Premier 3000 Service Manual

The following table describes each of the base names used in the table
above:
Base Names Description
Base Name Description
pHAbase “A” calibration solution pH base value
pHBbase “B” calibration solution pH base value
pOIbase “B” calibration solution initial O2 partial pressure base value
expressed in mmHg
pCOAbase “A” calibration solution CO2 concentration base value
expressed in mmHg
pCOBbase “B” calibration solution CO2 concentration base value
expressed in mmHg
KAbase “A” calibration solution K concentration base value expressed
in mmol/L
KBbase “B” calibration solution K concentration base value expressed
in mmol/L
NaAbase “A” calibration solution Na concentration base value
expressed in mmol/L
NaBbase “B” calibration solution Na concentration base value expressed
in mmol/L
CaAbase “A” calibration solution Ca concentration base value expressed
in mmol/L
CaBbase “B” calibration solution Ca concentration base value expressed
in mmol/L
GluAbase “A” calibration solution glucose concentration base value
expressed in mg/dL
LacAbase “A” calibration solution lactate concentration base value
expressed in mg/dL
pOA0base “C” calibration solution O2 partial pressure base value
expressed in mmHg
Calculating Calibration Solution Concentration Constants
The operating software uses the calibration solution concentrations of the
analytes to calculate both calibration and sample results. The following
table shows how the calibration solution concentration constants are
calculated and also shows the acceptable range for each constant. The
names shown for these constants are used throughout the documentation.
To calculate a calibration solution concentration constant, a calibration
solution base value and a cartridge barcode field value are used (see
sections 0 and Error! Reference source not found., respectively).

4-9
GEM Premier 3000 Service Manual

Calculation of Calibration Solution

Concentration Constants
Calculation of Acceptable Range Acceptable Range
Calibration Solution for Cartridge Types for Cartridge Types
Concentration Constant without Glu/Lac with Glu/Lac
pHA = pHAbase + (ij / 1000) 6.850 to 6.949 6.850 to 6.949
pHB = pHBbase + (kl / 1000) 7.350 to 7.449 7.350 to 7.449
pOI = pOIbase + mn 180 to 279 (mmHg) 130 to 229 (mmHg)
pOB =
pOI - ( (op / 100) * AGE / 7 )
pCOA = pCOAbase + q 60 to 69 (mmHg) 60 to 69 (mmHg)
pCOB = pCOBbase + r 30 to 39 (mmHg) 30 to 39 (mmHg)
KA = KAbase + st / 100 1.60 to 2.59 (mmol/L) 6.60 to 7.59 (mmol/L)
KB = KBbase + uv / 100 5.60 to 6.59 (mmol/L) 3.10 to 4.09 (mmol/L)
NaA = NaAbase + w 150 to 159 (mmol/L) 96 to 105 (mmol/L)
NaB = NaBbase + x 130 to 139 (mmol/L) 140 to 149 (mmol/L)
CaA = CaAbase + y / 100 0.16 to 0.25 (mmol/L) 2.26 to 2.85 (mmol/L)
CaB = CaBbase + AB / 100 1.75 to 2.74 (mmol/L) 0.80 to 1.79 (mmol/L)
GluA = GluAbase + CD undefined 100 to 199 (mg/dL)
LacA = LacAbase + E undefined 26 to 35 (mg/dL)
pOA0 = pOA0base + F undefined 0 to 9 (mmHg)

4.5 Calibration Frequency

Cartridge life (after warm-up) One-point Calibration

Frequency
0.5 to < 3 hours every 2 minutes
3 hours to < 6 hours every 4 minutes
6 hours to < 10 hours every 6 minutes
10 hours to < 20 hours every 10 minutes
20 hours to < 40 hours every 15 minutes
40 hours to < 80 hours every 20 minutes
80 hours to 504 hours every 30 minutes

Cartridge life (after warm-up) Two-point Calibration

Frequency
30 min to < 50 minutes every 20 minutes
50 minutes to < 80 minutes every 30 minutes
80 minutes to < 2 hours every 40 minutes
2 hours to < 8 hours every hour
8 hours to < 20 hours every 2 hours
20 hours to < 40 hours every 3 hours
40 hours to 504 hours every 4 hours

4-10
GEM Premier 3000 Service Manual

Cartridge life (after warm-up) Low Oxygen Calibration

Frequency
0 hours to 504 hours once every 24 hours

(The exact time of the day for performing Low Oxygen calibration is
user selectable, default is 0200)

Calibration evaluation
The calibration results will be reported (no errors or an error indicated)
according to the Calibration Report settings configured by the Key
Operator
If a calibration fails, results for the analyte(s) involved will not be
reported, however, results for analytes that passed calibration will
continue to be reported
Slope (two-point calibration) and drift (one and two point calibration)
errors must be corrected prior to reporting results for the failed
analyte(s)

Corrective action – calibration failure

Following a calibration failure, corrective two-point calibrations will be
performed automatically up to three times. Allow the instrument to
complete this self-diagnostics!
If desired, continue to use the cartridge and only report results from
working sensors
Additional two-point calibrations may be manually initiated

Calibration interruption
During the first 4 hours after cartridge insertion, a two-point calibration
cannot be interrupted for sample analysis
• Four hours after cartridge insertion, a two-point calibration
can be interrupted up to 3 consecutive times only for patient
sample analysis. Calibrations cannot be interrupted for QC
samples
• The first one-point calibration after sample analysis cannot
be interrupted
Low O2 calibration cannot be interrupted.

4.6 Removal and Disposal

BIOLOGICAL HAZARDS EXIST. Avoid touching, with bare hands, any

parts of the system which may have come in contact with potentially

4-11
GEM Premier 3000 Service Manual

infectious fluids. ALWAYS wear gloves when performing any type of

Maintenance/Service action on this area.

The cartridge must be removed for the following:

The cartridge has reached its time limit of 504 hours for a 3 week
cartridge, 336 hours for a 2 week cartridge or 672 hours for a 4 week
cartridge.

The cartridge has reached its sample capacity

Blood or process control solution C has rested on the sensors for more
than 20 minutes.

The power has been interrupted for greater than one hour

The cartridge encounters a fatal error.

In these cases, the instrument will prompt to “Remove and Discard cartridge”. In
addition, the cartridge can be removed at any time by pressing “Cartridge” on the
main screen and then pressing “Remove Cartridge” on the drop down menu. If
security is on, an authorized operator password must be entered to proceed. After
confirmation, the “Remove and Discard Cartridge” screen will be displayed.

Open the cartridge door by sliding the lock on the cartridge door forward and
opening the door. The cartridge can be removed and discarded at this time.

4-12
GEM Premier 3000 Service Manual

5. Maintenance
There is limited operator maintenance required on the GEM Premier 3000. The only
necessary maintenance is; changing printer paper, changing cartridge, emptying ampoule
breaker, and cleaning exposed surfaces. In addition, there is a Preventive Maintenance
(PM) procedure to be performed by an authorized IL service technician.

5.1 Cartridge Replacement

Removal of the cartridge is described in Section 4.6, insertion of a new cartridge
is described in section 4.3

5.2 Loading Paper

Loading paper is described in section 2.6

5.3 Emptying Ampoule Breaker

Remove the ampoule breaker by pulling straight out on the tab at the bottom of
the breaker. The top will open by lifting up from the back. The ampoule breaker
can then be emptied and cleaned before replacing.

NOTE: Use caution, contains broken glass. Dispose of properly.

5.4 Cleaning
The instrument surfaces can be wiped clean according to the laboratory protocols.
The painted surfaces can be sprayed with a mild (10%) bleach solution, or any
approved commercially available decontaminant. To clean the LCD, spray the
decontaminant onto the wiping material, then wipe the LCD surface. Do not use
excess liquid when cleaning the LCD.

5.5 PM Procedure
Instrumentation Laboratory currently recommends a PM after the first five years
and every other year thereafter.

Preliminary

If necessary, decontaminate instrument. Copy configuration to a floppy disk

using “Save Config” selection in Configuration Menu.

5-1
GEM Premier 3000 Service Manual

Tools

Key Operator ID Disk

Pump Spring Tension Force Gauge
Loopback Test Connector
Ethernet Test Cable

Preventive Maintenance Procedure

Remove cover. Visually inspect the following areas and repair if needed:

Perform Pump Spring Tension Test. Adjust pump tension to 6.2 +/- 0.1
lbs if necessary. Record pump tension as received and after setting.

Clean dust out of card rack.

Floppy Disk Ejection Test. Insert a floppy disk into the drive. Press the
ejection button to eject the floppy disk. Repeat the test three times.

Line cord: Inspect the line cord for nicks, breaks, or cuts.

General loose screw inspection: Verify that the hardware is secured on the
following assemblies and in the following areas.

Pump motor

Handle screws

Actuators

Cartridge compartment

Heater Block

Sensor flex cable: Visually inspect the sensor flex cable for fluid leak.

Display Assembly:

Check for faulty latch, loose hardware, and loose connections to the display.

Adjust the display to the upright position, and then push on the
display to tilt the unit; the latch should not slip.

Verify that display is uniformly bright, and that brightness is

adequate.

5-2
GEM Premier 3000 Service Manual

System Performance Tests

The instrument performance should be verified. One method of verifying the

performance is by using “live” cartridge. After the cartridge warm-up is
complete, all levels of CVP must be run, with acceptable results. Alternately, a
minimum of one ampoule of each level of Quality control material must be run
and all results must fall within acceptable ranges, as listed on the QC material
insert sheet.

Bar Code Reader Tests

When inserting the cartridge, verify that the cartridge bar code reader
correctly reads the cartridge barcode. Use the Bar code wand to enter
either the CVP or the QC ranges. Verify that the wand reads
correctly. Use the ampoule spinner to read the CVP or the QC
material. Verify that the ampoule spinner bar code reader reads the
ampoules correctly.

Loopback Test

Perform RS232 Loopback test

Ethernet Test:

Perform Ethernet “Ping” test.

Instrument Information

View the System Information screen and record the serial number and
software revision.

Restore Customer Configuration Back to System

Insert the “Copy Customer Configuration Disk” that was used in

Preliminary Check. Verify the copying status on the screen.

Final Verification:

Verify that the GEM Premier 3000 Test Record is complete

Incident Report - verify that the Incident Report form is complete

Printouts - verify that the calibration printouts are present

5-3
GEM Premier 3000 Service Manual

No missing screws - verify that there are no missing screws

Paper is removed - verify that the printer paper is removed

Time and date are set - verify that time and date are set correctly to the
customer’s geographic area

Software version - verify that the software version is the same as recorded on
the Preventive Maintenance Test Record “Preliminary Check-in.” The
software version is located in the upper left corner of the display screen.

Instrument cosmetics - the outside of the instrument should be cleaned.

5.6 PM Checklist
The following checklist can be used to record results and document the work
performed during the PM. Procedure.
ACCOUNT NAME_________________________________________________________________

S/N__________________ Call #________________

PM

Clean dust out of card rack _______

Pump Spring Tension Test

6.2 LB. +/- .1LB Initial Final

Adjusted Yes ____ No ____ _______ _______lb.

N/A

Check connections on line filter/power switch wires ________ ________

Check ejection of floppy disk drive ________ ________

Inspect line cord for nicks, breaks or cuts ________ ________

General loose screw inspections (pump motor, handle screws

actuators, cartridge compartment) ________ ________

Checks for fluid on sensor flex cable (LEAK) ________ ________

Display assembly ________ ________

Latch, hardware, connections, all screws tight

Latch slip test
Uniform and adequate brightness

Serial number correct ________

Record software revision ________

Comments _____________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

Tech______________________________ Date______________

5-4
GEM Premier 3000 Service Manual

System Performance Test

Test used : CVP _____ QC _____

All Parameters passed _____

Barcode readers operational

Cartridge _____ Wand _____ Spinner _____

RS 232 Loopback test

Port A _____ Port B _____ Port C _____

Ethernet Ping test Pass _____

Tech______________________________ Date______________

Restore System Configuration

. Customer Configuration Files (Copy Disk) _______

Tech______________________________ Date______________

Final Verification

Verify all items checked ______ Verify TIME and DATE _______

Printouts are present and correct ______ Verify software level is correct _______
S/W Rev Level
Verify all screws are installed ______ Inspect instrument cosmetics _______

Verify serial number installed ______

Tech______________________________ Date______________

5-5
GEM Premier 3000 Service Manual

6. Check Out and Adjustment

This section contains the instructions for testing and adjusting the GEM Premier 3000.
There is specialized test equipment required for several of the tests and adjustments

6.1 Tools and Test Equipment Required

6.1.1 Torx drivers and Allen wrenches

The majority of fasteners used on the GEM 3000 are Torx screws. There are 3
different size Torx drivers used

#15
#10
#8
#8 (6 inch long shaft –15cm) can be used to remove the three screws on
the bottom of the LCD without removing the assembly.

There are four different size Allen wrenches used

4 mm
2 mm
1/8 “
1/16”

6.1.2 Pump Spring Tension Fixture

Adjustment of the pump spring tension requires a 2-part fixture, consisting of a

“dummy” cartridge, containing a calibrated force gage and an indicator that
signals when the proper force is applied. These parts are IL specific and are
designated with IL Part Numbers

000995356 Test Cartridge

000995390 Indicator

6.1.3 Electronic Test cartridge (ETC)

The ETC is used to test the instrument prior to shipment and can be used to verify
repairs. Repairs can also be verified by use of a “live” cartridge and CVP or
liquid QC material.

There are several other parts required to utilize the ETC for testing. All of the
required parts are:

6-1
GEM Premier 3000 Service Manual

ETC 00024005050
ETC Test Harness 000995410
ETC Power Supply 000995100
ETC Adapter Board 00024005162
Premtest Disk 00024005534
Skipwarm Disk 000540177
PC or Laptop with 9-pin serial connection and Premtest disk loaded.

6.1.4 Loopback Tester

A Loopback test connector is available to test the three serial ports on the GEM.

Loopback Connector 24001581

The instructions to perform the Loopback test are displayed on the instrument
when “Diagnostics”, “Ports”, and “COM A, COM B, or COM C” are selected.
The test can be performed at any time. To avoid any potential problems with
future transmissions, any reports in the queue should be cleared after the
Loopback tests are completed.

6.2 Gaining Access

BIOLOGICAL HAZARDS EXIST. Avoid touching, with bare hands, any

parts of the system which may have come in contact with potentially
infectious fluids. ALWAYS wear gloves when performing any type of
Maintenance/Service action on this area.

To gain access to the GEM 3000, the cap (top cover) must be removed. To
remove the top cover:

Remove the two plastic, protective caps at each end of the handle

Remove the two Allen screws and remove the handle

6-2
GEM Premier 3000 Service Manual

Remove the three Torx screws from the cap on the back of the instrument
and lift the top cover off.

Remove the two screws from each side of the back cover that hold the side
plates on (older instruments may only have one screw on each side).

Remove the two screws on each side of the bottom plate that hold the side
plates on (older instruments may only have one screw on each side).

Remove the two side plates. Remove the two screws, one on each side,
that secure the back panel. When these screws are removed, the back
panel can be pivoted to the back to allow complete access.

Screw on left
side of unit

NOTE: When the back panel is pivoted back, there will be stress
put on the PCB connections. Do not open the back too quickly or
force it open, to avoid damage to the cables or PC Boards. To
allow the cover to be opened further, the PCB connectors must be
removed.

6.3 Testing with the ETC

There are two tests that can be performed with the ETC; the Cartridge Simulation
Test, using the PC, and the Manual Premtest, using the instrument under test. The
cartridge simulation test will allow the analysis of a simulated sample, to verify
the results fall within range. The Manual Premtest will not allow the analysis of
the simulated sample, but will exercise all of the mechanical components and the
heater. To completely test the instrument, without using an actual “live”
cartridge, both tests should be performed.

6-3
GEM Premier 3000 Service Manual

Cartridge Simulation Test

1. Connect ETC harness to ETC power Supply, Plug Power Supply into outlet.

2. Remove access cover from back panel of instrument to expose connector on

Analog PCB

Access Panel

Plug adapter Board, with ETC harness connected, into connector on Analog PCB.
Handle on adapter Board must be at top.

Handle

Adapter Board

3. Plug ETC harness into appropriate COM port on the PC.

4. Turn power OFF, inset skipwarm disk into instrument and turn power ON. Select
“Skipwarm” and “OK” on screen, then press “OK” again when prompted.

5. Instrument will restart and eject skipwarm disk.

6. Verify that the two actuators on the ETC are in the vertical position, with the
marked ends up. When the instrument displays the “Insert cartridge” screen,
insert the ETC.

7. Close, but DO NOT LATCH the cartridge door. Plug the ETC harness into the
connector inside the sample probe port.

6-4
GEM Premier 3000 Service Manual

Latch the cartridge door after the connection is made. The warm up will start
automatically. The warm up will take approximately 7 minutes.

8. When the warm up is completed, the instrument will display the READY screen,
and the PC will display the voltages and the temperature, along with other
information. The acceptable ranges for the voltages at are:

+11.25 to +12.75 VDC

-11.25 to –12.75 VDC
+4.75 to +5.25VDC
-4.75 to -5.25 VDC

The acceptable range for the temperature is:

36.4 to 37.6 °C

The other results displayed should read “PASS”. (The valve may display “Not
aligned”. This is acceptable, as it will be tested in the Manual Premtest.)

To simulate a sample, initiate a 2-pt Calibration from the Diagnostics drop down
menu on the instrument. When the calibration is completed, press “arterial” and
“OK”.

The instrument will simulate a sample and display the results. The acceptable
ranges for these results are:

PH 7.06 to 7.08
PCO2 60 to 63 mmHg
PO 24 to 27 mmHg
Na 138.7 to 141.0 mmol/L
K 2.79 to 2.83 mmol/L
Ca 0.56 to 0.58 mmol/L
Glu 93 to 105 mg/dL
Lac 1.4 to 1.6 mmol/L
Hct 39 to 42 %

If any values are out of range, initiate a second 2-pt calibration and repeat the test.

This completes the Cartridge Simulation Test. If the manual Premtest is to be

preformed immediately:

Manual Premtest

Turn power off.

6-5
GEM Premier 3000 Service Manual

Insert Premtest disk into instrument disk drive.

Disconnect G/IO cable from the CPU Board. The cable is part number 20402500.

G/IO Connector

Move the ETC harness from the PC COM port to the Serial Port B on the
instrument. (see section 1.5 – Back View)

Connect a parallel printer to the parallel connector on the instrument. (see section
1.5 – Back View)

Connect an external Keyboard to the Keyboard connector on the instrument. (see

section 1.5 – Back View) The Keyboard connector on the instrument is located
under the cover next to the Bar Code connector.

NOTE: All commands to press keys refer to the external keyboard,

and the SECO CPU Board. For instructions regarding the Radisys
CPU see “Loading Software” Section 6.5

Turn power on, press and hold the “delete” key while the instrument is starting.
The instrument will display the BIOS setup screen.

Highlight the “Basic CMOS Config” screen using the arrows on the keyboard and
press enter

Set the correct date and time, if necessary and press Esc.

Highlight the “Advanced CMOS Config” screen and press enter

Change the boot sequence to A:-> C: and press Esc.

Highlight “Write to CMOS and Exit” and press enter. This will initiate the
Premtest. The performance of the Manual Premtest is automatic and wiil take
approximately 21 minutes.

6-6
GEM Premier 3000 Service Manual

If the test is successful, a red status box will appear, indicating the test is complete
and there were no errors. Press enter to continue

Press enter again to access the “File” dropdown on the top left of the screen. Use
the down arrow to highlight “Quit” and press enter.

Press enter again to initiate a printout on the parallel printer. Verify that all of the
tests are labeled as “Pass”. The test is complete.

Remove the Premtest disk from the instrument, disconnect the cable to the ETC,
remove the ETC from the instrument, disconnect the adapter board and all the
ETC harness connections. DO NOT disconnect the keyboard. Reconnect the
G/IO Connection.

Insert skipwarm disk in the instrument and turn power on, press and hold the
“delete” key while the instrument is starting. The instrument will display the
BIOS setup screen.

Highlight the “Reset CMOS to Factory Default”” screen using the arrows on the
keyboard and press enter. Press “Y” to confirm.

Instrument will reboot, and display screen with selection for production or
skipwarm. Press skipwarm and OK. Press OK again when prompted. Instrument
will return to “Insert cartridge” screen. Reset time and date if necessary, and
disconnect keyboard.

6.4 Adjusting Pump Spring Tension

This section details the pump spring tension measurement and adjustment. The
pump spring tension is critical for the correct pumping, and pump rate, of the
pump windings in the cartridges. The pump spring tension must be at 6.2 +/- 0.1
lbs, and requires a specific fixture to measure and/or adjust.

The pump spring tension should be checked each time the left side cover is
removed, for any reason. The purpose of checking the tension at this time is to
verify that there is no interference with the pump slides when the cover is
replaced, caused by movement of cables and harnesses.

The fixtures required are:

000995356 Test Cartridge

000995390 Indicator

The test is to be performed with power off.

6-7
GEM Premier 3000 Service Manual

Test Cartridge with

calibrated Gage

Indicator

Tension measurement (covers on)

1. Mount the indicator inside the cartridge compartment on the lower slide of the
pump assembly. To mount the indicator, slide the pump all the way to the left by
pushing on the rollers with one hand. With the other hand, place the hook on the
indicator over the exposed lower slide, and release the pump assembly.

The pictures below show the process required to properly mount the
indicator. These pictures were taken to clarify the mounting, without
any covers, and without the printer or heater block mounted.

Indicator Mounting - Front

Gap created with

Pump all the pump to left
way to the left

Lower slide

Indicator Hook

Indicator Mounting - Back

Indicator Hook

Lower slide

6-8
GEM Premier 3000 Service Manual

2. After mounting the indicator, verify that the LED on the indicator is “ON”, by
looking through the sample probe port.

LED

3. On the test cartridge, reset the gage to 0, and insert the cartridge into the
instrument slowly. Do not insert the cartridge completely. Leave approximately
¼ inch exposed.

4. Slowly raise the cartridge door while observing the LED. Immediately when the
LED extinguishes, lower the cartridge door and remove the test cartridge.
Observe the reading of the gage.

This picture shows the cartridge door position at the point the LED
typically extinguishes.

5. Reset the Gage and repeat the test two more times. Taking 3 readings will
provide a more accurate result.

6. If the results are within the range of 6.1 to 6.3, the tension is acceptable, and does
not require adjustment.

6-9
GEM Premier 3000 Service Manual

Tension Adjustment

Adjustment of the pump spring tension requires removal of the left side cover of
the instrument (section 6.2 – Gaining Access).

Loosen the lock nut and turn the adjustment screw clockwise to increase the
tension, counterclockwise to decrease the tension (2 turns = approximately 1 lb.)
After adjusting the tension, tighten the lock nut and perform the measurement to
verify the proper result. After replacing the side cover, perform the measurement
to ensure that there is no interference with the slides.

Adjusting screw
and lock nut

6.5 Loading Software

This section provides instructions for loading the System software using a System
Disk. When software is loaded with a system disk, all information on the Hard
Drive will be lost.

Loading System Disk on a SECO CPU

The SECO board can be identified by checking the instrument serial number in
Diagnostics, System Info. If the letter “S” follows the Serial number, the CPU is
a SECO board. If the letter “R” follows the Serial number, the CPU is a Radisys
board and the appropriate instructions must be used.

Installation of a system disk in a GEM Premier 3000 requires the use of a

keyboard, and an appropriate revision System Disk.. The keyboard must have a
large 5-pin AT connector. If the keyboard has a small 6-pin PS2 connector, the
adapter must be used. The keyboard is connected to the port on the back of the

6-10
GEM Premier 3000 Service Manual

unit, next to the bar code reader port. The keyboard port is covered with a metal
plate that must be removed first.

Whenever software is loaded with the System Disk, ALL data will be lost on the
instrument. The hard drive is reformatted and started from scratch.

1. With Power off, connect the keyboard and insert the system disk in the
drive

NOTE: All commands to press keys refer to the keyboard.

2. While powering up, rapidly and continuously press DELETE, to enter

setup, wait until the BIOS setup Utility screen is displayed.

3. Using the Arrow keys move to the ADVANCED CMOS

CONFIGURATION selection and press ENTER.

4. Using the Arrow keys, highlight the BOOT SEQUENCE. Using the –
(minus) key toggle the sequence to A; -> C: and press ESCAPE to return
to the BIOS menu. Select WRITE TO CMOS AND EXIT, and press
ENTER.

5. The screen will prompt to continue. Press Y for yes.

6. The loading process will take about 6 minutes. The disk will be ejected
and the instrument will restart

7. After restarting, the GEM will continue loading the programs for
approximately three minutes, then it will display “System Halted”.

8. Turn the power off and then turn it back on. While powering up, rapidly
and continuously press DELETE, to enter setup and wait until the BIOS
setup screen is displayed.

9. Using the Arrow keys, move to the ADVANCED CMOS

CONFIGURATION selection AND PRESS enter.

10. Using the Arrow keys, highlight the BOOT SEQUENCE. Using the –
(minus) key toggle the sequence to C; -> A: and press ESCAPE to return
to the BIOS menu. Select WRITE TO CMOS AND EXIT, and press
ENTER.

6-11
GEM Premier 3000 Service Manual

11. When the prompt to enter the serial number appears, enter the unit serial
number and press enter for OK (make sure the Num Lock is enabled if
using the number pad on the keyboard).

12. Press enter to confirm the serial number.

13. The unit will display “follow the pointer and touch the spot!” There will
be a small “u” in the upper left corner.

14. Using a small, pointed object, press the spot inside the “u” on the GEM
LCD. The “u” will move to the upper right, lower left and lower right
after pressing the spot in each location.

15. The unit will display the maximum and minimum coordinates for X and
Y. These are used to calibrate the touch screen. Press Y to accept.

16. The display will change colors and the unit will restart to the insert
cartridge screen.

17. Disconnect the keyboard and replace the plate covering the connector.

Loading System Disk on a Radisys CPU

The Radisys board can be identified by checking the instrument serial number in
Diagnostics, System Info. If the letter “R” follows the Serial number, the CPU is
a Radisys board. If the letter “S” follows the Serial number, the CPU is a SECO
board and the appropriate instructions must be used.

Installation of a system disk in a GEM Premier 3000 requires the use of a

keyboard, and an appropriate revision System Disk.. The keyboard must have a
large 5-pin AT connector. If the keyboard has a small 6-pin PS2 connector, the
adapter must be used. The keyboard is connected to the port on the back of the
unit, next to the bar code reader port. The keyboard port is covered with a metal
plate that must be removed first.

Whenever software is loaded with the System Disk, ALL data will be lost on the
instrument. The hard drive is reformatted and started from scratch.

1. With Power off, connect the keyboard and insert the system disk in the drive

NOTE: All commands to press keys refer to the keyboard.

6-12
GEM Premier 3000 Service Manual

2. While powering up, rapidly and continuously press F2, to enter setup, wait until
the BIOS setup Utility screen is displayed.

3. Using the Arrow keys move to the BOOT selection

4. HARD DRIVE should be item 1 and highlighted. Using the down arrow,
highlight REMOVABLE DEVICES. Using the + key, move REMOVABLE
DEVICES to number 1. Press F10 to save and exit. Press enter to confirm.

5. The instrument will restart and ask for confirmation of the installation. Press
enter to begin. The loading process will take about 6 minutes. The disk will be
ejected and the instrument will restart

6. After restarting, the GEM will continue loading the programs for approximately
three minutes, then it will display “System Halted”.

7. Turn the power off and then turn it back on. While powering up, rapidly and
continuously press F2, to enter setup, wait until the BIOS setup Utility screen is
displayed.

8. Using the Arrow keys move to the BOOT selection

9. REMOVABLE DEVICES will be item 1 and highlighted. Using the down arrow,
highlight HARD DRIVE. Using the + key, move HARD DRIVE to number 1.

10. Press F10 to save and exit and press enter to confirm. The unit will restart.

11. When the prompt to enter the serial number appears, enter the unit serial number
and press enter for OK (make sure the Num Lock is enabled if using the number
pad on the keyboard).

12. Press enter to confirm the serial number.

13. The unit will display “follow the pointer and touch the spot!” There will be a
small “u” in the upper left corner.

14. Using a small, pointed object, press the spot inside the “u” on the GEM LCD.
The “u” will move to the upper right, lower left and lower right after pressing the
spot in each location.

15. The unit will display the maximum and minimum coordinates for X and Y. These
are used to calibrate the touch screen. Press Y to accept.

16. The display will change colors and the unit will restart to the insert cartridge
screen.

6-13
GEM Premier 3000 Service Manual

17. Disconnect the keyboard and replace the plate covering the connector.

6.6 Calibrating Touchscreen

When loading the System disk, the Touchscreen must be calibrated as part of the
procedure (see Section 6.5). If the Touchscreen requires calibration, without
loading the system disk, the following procedure may be used.

At the command line type the underlined texts then press <Enter>
Type lower case texts only and observe the spacing in the command lines 5,6 & 8.

*5 1 space between ‘t’ and ‘3’

*6 1 spaces between ‘m’ and ‘-‘ and 1 space between the ‘f’ and ‘/’
*8 1 space between ‘t’ and ‘5’
(1) The password does not display on the screen, just type it then press <Enter>
(2) Command line prompt may not be the same ..Eg. [root@TLH-OR /root]#

0) !! The ‘Ready’ or ‘Insert Cartridge’ screen must be displayed !!

1) Attach the keyboard to the rear of the unit.

2) On the keyboard Press: Ctrl Alt F1

The screen blanks out then displays:

[Command line Prompt] [Type]

3) ‘_ ‘ root <Enter>

4) Password: n0bridge <Enter>

↑=Zero
5) * [root@(none) /root]# init 3 <Enter>

6) * [root@(none) /root]# rm -f /etc/gem/elo.cal <Enter>

7) [root@(none) /root]# gemtouchcal <Enter>

The Gem unit should display the XYZ setup screen.

¾
Upper left

Follow the pointer and touch the spot !

6-14
GEM Premier 3000 Service Manual

To Exit
8) *[root@(none) /root]# init 5 <Enter>

6.7 Replacing/Repairing the LCD Backlight

The LCD backlights (00024001801) on instruments manufactured before
September, 2003 (approximately) can become dark over time. They may become
dark all at one time, or they may have dark areas that eventually spread over the
entire screen. The reflective foil in the backlight mount loosens and “wraps”
around the bulb, blocking the light. All newer instruments use a backlight
without the foil, and this dark screen will not occur.

The backlight can be replaced with a new one (part No. 24001801) or the foil can
be removed to restore the brightness. On the new backlights, as a replacement
part, the foil has been glued more completely and this should eliminate the
problem. If the foil is removed, the brightness will be restored, but will be very
slightly darker than a new light.

To replace the lamp:

Using a #10 Torx driver, remove the two screws in the back of the LCD display

# 10 Screws

Using a #8 Torx driver, remove the 3 screws from the bottom of the LCD display.
If a long Torx driver is used, the screws can be removed without removing the
display assembly

#8 Screws

6-15
GEM Premier 3000 Service Manual

Open the LCD assembly and remove the 4 screws holding the LCD in place.
Disconnect the cable to the backlight.

LCD mounting
screws
Backlight
cable
connector

Lift LCD carefully and push down on tab (located on left side) to disconnect the
LCD input.

Tab for connector

Turn the LCD over and press on release tab for backlight. With tab pressed, slide
backlight out of LCD.

6-16
GEM Premier 3000 Service Manual

Release tab

With tab pressed, slide backlight out of LCD.

Replace the bulb in the holder and reverse the steps above to reassemble the
instrument

To remove the foil:

With the backlight removed, carefully extract the wires from the plastic holder
and carefully lift the bulb out of the holder. The foil may come out of the holder
with the bulb, or it may have to be removed from the holder

6-17
GEM Premier 3000 Service Manual

Bulb

Holder

Foil

Discard the foil, replace the bulb in the holder and reverse the steps above to
reassemble the instrument.

6-18
GEM Premier 3000 Service Manual

7. Troubleshooting
This section contains a list of the GEM 3000 error codes and a description of the
associated error, along with the probable cause and fix. There is also a list of
reported symptoms and fixes that has been developed from the experience gained
to date. In addition, there are some part replacement procedures.

7.1 Errors and Alarms

Below is a list of the types of GEM 3000 errors that can occur. The range
of error numbers used is included with the description of each type of
error.
Type Description Number Range
Alarms Errors that must be resolved 0.01 - 0.99
by operator intervention.
Cartridge errors Errors that can occur due to a 1.01 - 1.99
faulty cartridge inserted in the
GEM 3000 instrument.
Hardware errors Errors that can occur due to a 2.01 - 2.99
problem with the GEM 3000
instrument hardware.
Software errors Errors that can occur due to a 3.01 - 3.99
problem with the GEM 3000
operating software.
Events Events, such as cartridge 9.01 - 9.99
insertion and removal, that 0.00 - -0.99
occur
Errors are handled by the GEM 3000 operating software in one of the
following ways:
• Alarm notification, with error message written to alarm log file and
system log file.
• User dialog box, with error message written to system log file.
• LLP (Low Level Processor) reset, with error message written to system
log file.
• System reset, with error message written to system log file.
• System log file.
Each of these types of error handling is described below. Note that all types of
error handling include writing a message to the operating software’s system log
file that uniquely identifies and describes the error that occurred.

7-1
GEM Premier 3000 Service Manual

Alarm Notification

For alarms that require operator intervention to resolve, such as the printer is out
of paper, the GEM 3000 operating software presents an alarm on the screen.

User Dialog Box

For error handling that requires immediate operator action, the operating software
displays a user dialog box, with an <OK> button, that describes the error that has
occurred and instructs the operator on what to do next. For example:
Error 1.06
No sample detected.
Test canceled.

Please repeat test

LLP Reset

The GEM 3000 HLP (High Level Processor) software commands the GEM 3000
LLP (Low Level Processor) to perform a hardware reset when certain error
conditions occur (for example, when the LLP reports a failure to calibrate the A/D
converter at the start of a sample or calibration). When the LLP resets, it restarts
at the beginning of its code, initializes all of the LLP hardware, calibrates the A/D
converter, and verifies that the valve and arm actuators can be moved to their
home positions.
When the LLP is reset due to an error that occurred while attempting to perform a
particular procedure (such as attempting to detect calibration solution), the desired
procedure is performed a second time. If an error occurs again, the LLP is reset a
second time, and the procedure is performed a third time. If an error occurs during
the third attempt, the operating software either displays a user dialog box that
explains what has happened, or the operating software performs a system reset.

System reset

When the GEM 3000 operating software is about to perform a system reset, a
display is presented with the following message:
<type of error> X.XX
This instrument will reset in 30 seconds.

If the problem persists, contact Technical Service.

7-2
GEM Premier 3000 Service Manual

where X.XX is the number of the error that occurred (for example, 3.01) and <type
of error> is one of the following lines of text:
Cartridge error
Hardware error
Software error
Then, the GEM 3000 system resets itself, which includes resetting both its HLP
(High Level Processor) and LLP (Low Level Processor).
After the instrument is reset, the following message is printed:
SYSTEM RESET
04/07/2000 15:25:00
<type of error> X.XX
If the problem persists,
contact Technical Service.
The GEM 3000 operating software maintains the number of times it resets itself,
due to an error, in a persistent data file on its internal disk. This persistent data file
is cleared during the daily log rotation. If a system reset occurs because of an
error (any error) four times between log rotations, the GEM 3000 performs a
system halt. While the system is halting, a display is presented with the following
message:
<type of error> X.XX
The instrument will be halted.

Please wait.
and the following message is printed:
SYSTEM BEING HALTED
04/07/2000 15:25:00
<type of error> X.XX
If the problem persists,
contact Technical Service.
When the system has halted, a display is presented with the following message:
<type of error> X.XX
The instrument has been halted.

Contact Technical Service.

7-3
GEM Premier 3000 Service Manual

System Log File

For all alarms and errors a message will be written to a system error log file called
syslog.dat. Each message logged will contain the date and time the error occurred,
the error type, the error code, and the error text. Examples:
MM/DD/YYYY hh:mm:ss Alarm 0.03 Transmission error
MM/DD/YYYY hh:mm:ss Cartridge Error 1.05 Insufficient
sample solution detected
The software will also log to syslog.dat system events that occur
[see Section Error! Reference source not found.]. For example,
in order to associate the errors with the installed cartridge,
cartridge installation and removal events, along with the cartridge
barcode, will be logged to syslog.dat as follows:
MM/DD/YYYY hh:mm:ss Event 9.01 Cartridge inserted:
nnnnnnnnnnn
MM/DD/YYYY hh:mm:ss Event 9.04 Cartridge removed:
nnnnnnnnnnn
In addition, the software will log to syslog.dat when alarms are
cleared. For example:
MM/DD/YYYY hh:mm:ss Alarm -0.03 Transmission error
corrected
syslog.dat is stored on the instrument’s internal disk in ASCII text
format to allow easy viewing after it is copied to diskette.
syslog.dat will be designed as a circular file to contain about the
last 256 messages and to limit the file size to about 10KB.
Syslog.dat is copied to diskette by selecting “Copy IL Data” on the Diagnostics
pull down menu.

7.1.1 Alarms (0.01 - 0.99)

This section describes the GEM 3000 operating software alarm conditions
that can occur.

0.01 Internal printer out of paper

Label ERR_NO_PAPER_INT
Alarm Message Internal printer out of paper
When Whenever the operating software is attempting to print,
such as when the results are ready to report during a
sample or calibration.
Cause The printer is out of paper.

7-4
GEM Premier 3000 Service Manual

Handling Alarm notification for each failed attempt to write to

the printer if an alarm is not already posted for this
error condition.
Remedy Install paper in the printer and clear the alarm. If the
alarm occurs again, turn the printer off, then on, in
configuration. If the alarm still occurs, cycle power on
the instrument. If the alarm continues to occur, contact
Technical Service.

0.02 Internal printer failure

Label ERR_PRINTER_FAILURE_INT
Alarm Message Internal printer error
When Whenever the operating software is attempting to print,
such as when the results are ready to report during a
sample or calibration.
Cause There is a hardware problem with the printer or printer
cable, or the paper lever is up.
Handling Alarm notification for each failed attempt to write to
the printer if an alarm is not already posted for this
error condition.
Remedy Install paper in the printer and clear the alarm. If the
alarm occurs again, turn the printer off, then on, in
configuration. If the alarm still occurs, cycle power on
the instrument.

0.03 External communication error

Label ERR_LIS_COMM
Alarm Message Transmission error
When Whenever the operating software is attempting to
transmit data, such as when the results are ready to
report during a sample or calibration and the system has
been configured to transmit sample or calibration data
to port A.
Cause Data could not be transmitted to the LIS (Laboratory
Information System) system successfully. The LIS
cable may be faulty or the LIS system configured
incorrectly.
Handling Alarm notification for each failed attempt to transmit
data to the LIS if an alarm is not already posted for this
error condition.

7-5
GEM Premier 3000 Service Manual

Remedy Check the connection with the LIS system and the
configuration of the LIS system then clear the alarm. If the
alarm occurs again, cycle power on the instrument.

0.04 Parallel printer failure

Label ERR_PRINTER_FAILURE_EXT
Alarm Message Parallel printer error
When Whenever the operating software is attempting to print
to the parallel printer.
Cause There is a hardware problem with the printer or printer
cable.
Handling Alarm notification for each failed attempt to write to
the printer if an alarm is not already posted for this
error condition.
Remedy Check parallel printer connections then reset printer
queue and try again. Cycle power to the printer if
necessary.

0.05 Parallel printer out of paper

Label ERR_NO_PAPER_EXT
Alarm Message Parallel printer out of paper
When Whenever the operating software is attempting to print
to the parallel printer.
Cause The printer is out of paper.
Handling Alarm notification for each failed attempt to write to
the printer if an alarm is not already posted for this
error condition.
Remedy Install paper in the printer and clear the alarm. Reset the
printer queue. Cycle power to the printer if necessary.

0.06 Network printer failure

Label ERR_PRINTER_FAILURE_NT
Alarm Message Network printer error

7-6
GEM Premier 3000 Service Manual

When Whenever the operating software is attempting to print

to the network printer.
Cause Communication error to the network printer, or network
printer returning an error.
Handling Alarm notification for each failed attempt to write to
the printer if an alarm is not already posted for this
error condition.
Remedy Check network printer connections then reset printer
queue and try again. Cycle power to the printer if
necessary.

0.07 Improper instrument shutdown

Label ERR_IMPROPER_SHUTDOWN
Alarm Message Improper instrument shutdown
When When the instrument restarts after it was improperly
shutdown.
Cause The “Shutdown” button was not used to shut down the
instrument before the instrument was powered off.
This can be due to an unexpected power outage or
operator error.
Handling The alarm message is logged in the system error log file
“syslog.dat”. The alarm is not displayed on the
“Alarms” screen.
Remedy Users/customers must be reminded to user proper
shutdown procedure from the Shutdown pull-down
menu.

0.11 iQM Disabled pH Sensor

Label ERR_IQM_PH
Alarm Message pH is permanently disabled due to iQM error
When After iQM corrective action failed to correct the iQM
error triggered following A, B, or C calibration.
Cause Sensor and/or calibration solution error.
Handling Alarm notification whenever a sensor is permanently
disabled due to unrecoverable iQM error.

7-7
GEM Premier 3000 Service Manual

Remedy Replace cartridge if failed sensor is essential to the

continued operation of the instrument

0.12 iQM Disabled pCO2 Sensor

Label ERR_IQM_PCO2
Alarm Message pCO2 is permanently disabled due to iQM error
When After iQM corrective action failed to correct the iQM
error triggered following A, B, or C calibration
Cause Sensor and/or calibration solution error.
Handling Alarm notification whenever a sensor is permanently
disabled due to unrecoverable iQM error.
Remedy Replace cartridge if failed sensor is essential to the
continued operation of the instrument

0.13 iQM Disabled pO2 Sensor

Label ERR_IQM_PO2
Alarm Message pO2 is permanently disabled due to iQM error
When After iQM corrective action failed to correct the iQM
error triggered following A, B, or C calibration.
Cause Sensor and/or calibration solution error.
Handling Alarm notification whenever a sensor is permanently
disabled due to unrecoverable iQM error.
Remedy Replace cartridge if failed sensor is essential to the
continued operation of the instrument.

0.14 iQM Disabled Na+ Sensor

Label ERR_IQM_NA
Alarm Message Na+ is permanently disabled due to iQM error
When After iQM corrective action failed to correct the iQM
error triggered following A or B calibration.
Cause Sensor and/or calibration solution error.
Handling Alarm notification whenever a sensor is permanently
disabled due to unrecoverable iQM error.

7-8
GEM Premier 3000 Service Manual

Remedy Replace cartridge if failed sensor is essential to the

continued operation of the instrument.

0.15 iQM Disabled K+ Sensor

Label ERR_IQM_K
Alarm Message K+ is permanently disabled due to iQM error
When After iQM corrective action failed to correct the iQM
error triggered following A or B calibration.
Cause Sensor and/or calibration solution error.
Handling Alarm notification whenever a sensor is permanently
disabled due to unrecoverable iQM error.
Remedy Replace cartridge if failed sensor is essential to the
continued operation of the instrument.

0.16 iQM Disabled Ca++ Sensor

Label ERR_IQM_CA
Alarm Message Ca++ is permanently disabled due to iQM error
When After iQM corrective action failed to correct the iQM
error triggered following A or B calibration.
Cause Sensor and/or calibration solution error.
Handling Alarm notification whenever a sensor is permanently
disabled due to unrecoverable iQM error.
Remedy Replace cartridge if failed sensor is essential to the
continued operation of the instrument

0.17 iQM Disabled Hct Sensor

Label ERR_IQM_HCT
Alarm Message Hct is permanently disabled due to iQM error
When After iQM corrective action failed to correct the iQM
error triggered following A or B calibration.
Cause Sensor and/or calibration solution error.
Handling Alarm notification whenever a sensor is permanently
disabled due to unrecoverable iQM error.

7-9
GEM Premier 3000 Service Manual

Remedy Replace cartridge if failed sensor is essential to the

continued operation of the instrument.

0.18 iQM Disabled Glu Sensor

Label ERR_IQM_GLU
Alarm Message Glu is permanently disabled due to iQM error
When After iQM corrective action failed to correct the iQM
error triggered following A or B calibration.
Cause Sensor and/or calibration solution error.
Handling Alarm notification whenever a sensor is permanently
disabled due to unrecoverable iQM error.
Remedy Replace cartridge if failed sensor is essential to the
continued operation of the instrument.

0.19 iQM Disabled Lac Sensor

Label ERR_IQM_LAC
Alarm Message Lac is permanently disabled due to iQM error
When After iQM corrective action failed to correct the iQM
error triggered following A or B calibration.
Cause Sensor and/or calibration solution error.
Handling Alarm notification whenever a sensor is permanently
disabled due to unrecoverable iQM error.
Remedy Replace cartridge if failed sensor is essential to the
continued operation of the instrument.

7.1.2 Cartridge Errors

This section describes the GEM 3000 cartridge errors that can occur (1.01
– 1.99). The remedy for a persistent cartridge error is to replace the
cartridge inserted in the instrument with a new cartridge.

1.01 Cartridge error

Message Calibration solution could not be detected.

Label ERR_NO_A_SOLN
Log Message No A calibration solution detected

7-10
GEM Premier 3000 Service Manual

When While A solution is being pumped from the cartridge

during an A calibration.
Cause Either the A solution has been depleted or there is a
hardware problem with the analog circuitry (A/D converter
out of calibration, faulty hematocrit sensor, etc.), the pump
or valve driver, or the cartridge (plugged tubing, arm not
fully homed, etc.).
Handling Up to three attempts to detect solution are made. With each
attempt, a set of sensor A/D readings is taken and saved to
the sensor data file with a no solution detected error status.
After each of the first two attempts, an LLP reset is
performed. If the third attempt is unsuccessful, the
operating software displays the Remove Cartridge screen
with the error type, number, and message shown above. No
calibration report is printed, saved to the database, or
transmitted.

1.02 Cartridge error

Message Calibration solution could not be detected.

Label ERR_NO_B_SOLN
Log Message No B calibration solution detected
When While B solution is being pumped from the cartridge
during a B calibration or cartridge warm up.
Cause Either the B solution has been depleted or there is a
hardware problem with the analog circuitry (A/D converter
out of calibration, faulty hematocrit sensor, etc.) the pump
or valve driver, or the cartridge (plugged tubing, arm not
fully homed, etc.).
Handling See Cartridge error 1.01

1.03 Cartridge error

Message Calibration solution could not be detected.

Label ERR_NO_AIR_BEFORE_A
Log Message No air before A calibration solution detected

7-11
GEM Premier 3000 Service Manual

When While A solution is being pumped from the cartridge

during an A calibration.
Cause Air is pumped between each solution (so the new solution
can be positively detected). No air being detected can be
caused by a bad pump, valve, tubing, or analog circuitry.
Failed solid-state relays can cause a valve to stick in the A
or B position.
Handling Up to three attempts to detect solution are made. With each
attempt, a set of sensor A/D readings is taken and saved to
the sensor data file with a no air detected before solution
error status. After each of the first two attempts, an LLP
reset is performed. If the third attempt is unsuccessful, the
operating software displays the Remove Cartridge screen
with the error type, number, and message shown above. No
calibration report is printed, saved to the database, or
transmitted.

1.04 Cartridge error

Message Calibration solution could not be detected.

Label ERR_NO_AIR_BEFORE_B
Log Message No air before B calibration solution detected
When While B solution is being pumped from the cartridge
during a B calibration or cartridge warm up.
Cause Air is pumped between each solution (so the new solution
can be positively detected). No air being detected can be
caused by a bad pump, valve, tubing, or analog circuitry.
Failed solid-state relays can cause a valve to stick in the A
or B position.
Handling See Cartridge error 1.03.

1.05 Cartridge error

Message Insufficient sample volume.

Test canceled.
Please repeat test.
Label ERR_INSUFF_SAMPLE
Log Message Insufficient sample solution detected
When During sample aspiration.

7-12
GEM Premier 3000 Service Manual

Cause Most likely, incorrect operator technique in introducing the

sample. Anything that could cause bubbles in the sample
slug (most likely bad tubing or a faulty arm septum) could
cause this to be a persistent problem.
Handling The sample is aborted and a user dialog box, that contains
an Ok button, is displayed with the error number, type, and
message shown above. When the Ok button is pressed, the
Ready screen appears. The operator may then attempt to
process the sample again.
The sensor A/D readings that were taken for the sample are
saved to the sensor data file with an air in sample detected
error status. An aborted sample report is saved to the
database, but no sample report is displayed, printed, or
transmitted.

1.06 Cartridge error

Message No sample detected.

Test canceled.
Please repeat test.
Label ERR_NO_SAMPLE
Log Message No sample solution detected
When During sample aspiration.
Cause Most likely, incorrect operator technique in introducing the
sample, obstructed tubing, or a bad valve or pump.
Handling The sample is aborted and a user dialog box, that contains
an Ok button, is displayed with the error number, type, and
message shown above. When the Ok button is pressed, the
Ready screen appears. The operator may then attempt to
process the sample again.
The sensor A/D readings that were taken for the sample are
saved to the sensor data file with a no solution detected
error status. An aborted sample report is saved to the
database, but no sample report is displayed, printed, or
transmitted.

7-13
GEM Premier 3000 Service Manual

1.07 Cartridge error

Message No sample detected.

Test canceled.
Please repeat test.
Label ERR_NO_AIR_BEFORE_SAMPLE
Log Message No air before sample solution detected
When During sample aspiration.
Cause Most likely, incorrect operator technique in introducing the
sample, obstructed tubing, or a bad valve or pump.
Handling The sample is aborted and a user dialog box, that contains
an Ok button, is displayed with the error number, type, and
message shown above. When the Ok button is pressed, the
Ready screen appears. The operator may then attempt to
process the sample again.
The sensor A/D readings that were taken for the sample are
saved to the sensor data file with a no air detected before
solution error status. An aborted sample report is saved to
the database, but no sample report is displayed, printed, or
transmitted.

1.08 Cartridge error

Label ERR_BAD_SENSOR_VALS
Log Message Na, K, Ca, pH at A/D rail for B cal
When During B calibration measurement.
Cause Any 3 of the Na, K, Ca, or pH sensor readings are at the
A/D rail and any 3 of those sensor readings were at the A/D
rail for the previous B calibration. This is probably due to
reference failure going to rail due to air bubble on reference
wire.
Handling The sensor A/D readings that were taken for the calibration
are saved to the sensor data file. Then, a system reset is
performed. No calibration report is printed, saved to the
database, or transmitted.

7-14
GEM Premier 3000 Service Manual

1.09 Cartridge error

Message No C solution detected

Label ERR_NO_C_SOLN
Log Message No C solution detected
When While C solution is being pumped from the cartridge
during low oxygen calibration.
Cause Either the C solution has been depleted or there is a
hardware problem with the analog circuitry (A/D converter
out of calibration, faulty hematocrit sensor, etc.), the pump
or valve driver, or the cartridge (plugged tubing, arm not
fully homed, etc.).
Handling Up to three attempts to detect solution are made. With each
attempt, a set of sensor A/D readings is taken and saved to
the sensor data file with a no solution detected error status.
After each of the first two attempts, an LLP reset is
performed. If the third attempt is unsuccessful, the
operating software displays the Remove Cartridge screen
with the error type, number, and message shown above. No
calibration report is printed, saved to the database, or
transmitted.

1.10 Cartridge error

Message No C solution detected

Label ERR_NO_AIR_BEFORE_C
Log Message No air before C solution detected
When While C solution is being pumped from the cartridge
during low oxygen calibration.
Cause Air is pumped between each solution (so the new solution
can be positively detected). No air being detected can be
caused by a bad pump, valve, tubing, or analog circuitry.
Failed solid-state relays can cause a valve to stick in the A
or B position.
Handling Up to three attempts to detect solution are made. With each
attempt, a set of sensor A/D readings is taken and saved to
the sensor data file with a no air detected before solution
error status. After each of the first two attempts, an LLP
reset is performed. If the third attempt is unsuccessful, the

7-15
GEM Premier 3000 Service Manual

operating software displays the Remove Cartridge screen

with the error type, number, and message shown above. No
calibration report is printed, saved to the database, or
transmitted.

1.11 Cartridge error

Message Low oxygen calibration failure

Label ERR_LOW_O2_CAL_FAILURE
Log Message Low oxygen calibration failure
When During low oxygen calibration.
Cause Low oxygen calibration failure that could not be corrected
by the 2 retries.
Handling After the third attempt to correct the calibration failure is
unsuccessful, the operating software displays the Remove
Cartridge screen with the error type, number, and message
shown above. All 3 calibration reports are printed to show
the cause of failure.

1.12 Cartridge error

Message Process control solutions stability failure.

Label ERR_PC_STABILITY_FAILURE
Log Message Process control solutions stability failure
When During A calibration.
Cause pO2 threshold check failure during A calibration.
Handling The operating software displays the Remove Cartridge
screen with the error type, number, and message shown
above.

7.1.3 Hardware Errors

This section describes the GEM 3000 hardware errors that can occur (2.01-2.99).
And be displayed. The first attempt at a remedy for a persistent hardware error is
to cycle the instrument power.

7-16
GEM Premier 3000 Service Manual

2.01 Hardware error

Message Cartridge error: 2.01

A cartridge error has occurred.
Label ERR_TEMP_NOT_AT_TARGET
Log Message Target temperature not reached during cartridge warm up
When During cartridge warm up.
Cause The GEM 3000 operating software timed out waiting for
the heater block to reach the cartridge warm up target
temperature.
Handling The operating software displays the Remove Cartridge
screen with the message shown above.

2.02 Hardware error

Label ERR_HBLK_WARM_UP_TOUT
Log Message Power Fail Recovery temperature error
When During power fail recovery.
Cause The GEM 3000 operating software timed out waiting for
the heater block to reach a temperature of 37.0 degrees C.
Handling System reset is performed.

2.03 Hardware error

Label ERR_BAD_CAL_GND
Log Message Calibration ground error
When During calibration measurement.
Cause The ground A/D reading is not within +/- five bits of the
expected value.
Handling The sensor A/D readings, including ground, that were taken
for the calibration are saved to the sensor data file with a
bad ground error status. Then, a system reset is performed.
No calibration report is printed, saved to the database, or
transmitted.

7-17
GEM Premier 3000 Service Manual

2.04 Hardware error

Message An unexpected system error has occurred

preventing normal software behavior.
Test canceled.
Please repeat test.
Label ERR_BAD_SAMPLE_GND
Log Message Sample ground error
When During sample measurement.
Cause The ground A/D reading is not within +/- five bits of the
expected value.
Handling The sample is aborted and a user dialog box, that contains
an Ok button, is displayed with the error number, type, and
message shown above. When the Ok button is pressed, the
Ready screen appears. The operator may then attempt to
process the sample again.
The sensor A/D readings, including ground, that were taken
for the sample are saved to the sensor data file with a bad
ground error status. An aborted sample report is saved to
the database, but no sample report is displayed, printed, or
transmitted.

2.05 Hardware error

Label ERR_BAD_CAL_TEMP
Log Message Calibration temperature error
When During calibration measurement.
Cause The temperature A/D reading is not 37.0 degrees C.
Handling The sensor A/D readings, including temperature, that were
taken for the calibration are saved to the sensor data file
with a bad temperature error status. Then, a system reset is
performed. No calibration report is printed, saved to the
database, or transmitted.

7-18
GEM Premier 3000 Service Manual

2.06 Hardware error

Message Sample Temperature Error.

Test canceled.
Please repeat test.
Label ERR_BAD_SAMPLE_TEMP
Log Message Sample temperature error
When During sample measurement.
Cause The temperature A/D reading is not 37.0 degrees C.
Handling The sample is aborted and a user dialog box, that contains
an Ok button, is displayed with the error number, type, and
message shown above. When the Ok button is pressed, the
Ready screen appears. The operator may then attempt to
process the sample again.
The sensor A/D readings, including temperature, that were
taken for the sample are saved to the sensor data file (see
Volume 6 - Files and Formats) with a bad temperature error
status. An aborted sample report is saved to the database,
but no sample report is displayed, printed, or transmitted.

2.07 Hardware error

Label ERR_A2D_CAL
Log Message A/D converter calibration error
When During sample or calibration preparation.
Cause The A/D converter was unable to obtain valid (+/- 5 bits)
readings from the ground and/or voltage reference channels
following calibration of the A/D converter.
Handling Up to three attempts are made to calibrate the A/D
converter. After each of the first two attempts, an LLP reset
is performed. If the third attempt is unsuccessful, a system
reset is performed. No sample or calibration report is
displayed, printed, saved to the database, or transmitted.

2.08 Hardware error

Label ERR_A2D_READ

7-19
GEM Premier 3000 Service Manual

Log Message A/D converter read error

When Whenever the HLP requests an A/D reading(s) from the
LLP, such as during sample or calibration measurement.
Cause An error was detected and signaled by the LLP (Low Level
Processor) when it attempted to read the A/D converter or
the multiplexer using the synchronous serial bus.
Handling System reset is performed.

2.09 Hardware error

Label ERR_D2A_WRITE
Log Message D/A converter write error
When During LLP initialization.
Cause An error was detected and signaled by the LLP (Low Level
Processor) when it attempted to write to a D/A converter
using the synchronous serial bus.
Handling System reset is performed.

2.10 Hardware error

Label ERR_ARM_HOMING
Log Message Sample arm homing error
When During sample preparation or LLP initialization.
Cause The sample arm could not be returned to the home position,
or the sample arm homing sensor could not detect the
homing pin.
Handling System reset is performed.

2.11 Hardware error

Label ERR_VALVE_HOMING
Log Message Valve homing error
When During sample or calibration preparation, or LLP
initialization.
Cause The valve could not be returned to the home position, or the
valve homing sensor could not detect the homing pin.

7-20
GEM Premier 3000 Service Manual

Handling System reset is performed.

2.12 Hardware error

Label ERR_NO_INST_SERIAL_NUM
Log Message Uninitialized instrument serial number
When During system start up.
Cause No instrument serial number was found in the instrument’s
non-volatile memory.
Handling System is halted.

2.13 Hardware error

Label ERR_FSCK_FAILED
Log Message File system check/repair failed
When During system start up.
Cause The file system check, performed when the GEM 3000
operating system software starts up, failed. This file system
check is performed by the Linux operating system utility
“fsck”.
Handling System is halted.

2.14 Hardware error

Message Cartridge error: 2.14

A cartridge error has occurred.
Label ERR_TEMP_OUT_OF_RANGE
Log Message Temperature out of range during cartridge warm up
When During cartridge warm up.
Cause The heater block temperature is outside the specified range
of 37±0.5°C.
Handling The operating software displays the Remove Cartridge
screen with the message shown above.

7-21
GEM Premier 3000 Service Manual

2.15 Hardware error

Message Cartridge error: 2.15

A cartridge error has occurred.
Label ERR_REF_OUT_OF_RANGE
Log Message Reference out of range during cartridge warm up
When During cartridge warm up.
Cause The reference voltage is outside the specified range of
±2.0V.
Handling The operating software displays the Remove Cartridge
screen with the message shown above.

7.1.4 Software Errors

This section describes the GEM 3000 software errors that can occur (3.01
– 3.99). The remedy for a persistent software error is to reinstall the GEM
3000 application software.
For any of the software errors, the message displayed by the instrument
will be:
<type of error> X.XX
This instrument will reset in 30 seconds.

If the problem persists, contact Technical Service.

3.01 Software error

Label ERR_BAD_TIME_DATE
Log Message Unknown cartridge age
When During cartridge warm up or power fail recovery.
Cause The amount of time that power was off or the age of the
cartridge could not be determined. That is, the last time
saved is negative or greater than the system time. This may
indicate corruption of the persistent data file that contains
the last time saved.
Handling System reset is performed.

7-22
GEM Premier 3000 Service Manual

Remedy Confirm that the system time is correct. If the error occurs
following the system reset, remove the cartridge, copy the
cartridge data to a diskette, then reinstall the GEM 3000
application software.

3.02 Software error

Label ERR_LLP_HDR_READ
Log Message No header in message from LLP
When Whenever the HLP is communicating with the LLP, such
as during a sample or calibration.
Cause The GEM 3000 HLP (High Level Processor) did not find a
header in the message it received from the LLP (Low Level
Processor). The HLP needs the header to determine the
type of data contained in the message.
Handling System reset is performed.

3.03 Software error

Label ERR_LLP_HDR_MISMATCH
Log Message Unexpected header in message from LLP
When Whenever the HLP is communicating with the LLP, such
as during a sample or calibration.
Cause The GEM 3000 HLP (High Level Processor) did not find
the header it expected in the message it received from the
LLP (Low Level Processor). The HLP needs the header to
determine the type of data contained in the message.
Handling System reset is performed.

3.04 Software error

Label ERR_LLP_DATA_READ
Log Message No data in message from LLP
When Whenever the HLP is communicating with the LLP, such
as during a sample or calibration.

7-23
GEM Premier 3000 Service Manual

Cause The GEM 3000 HLP (High Level Processor) found only a
header in the message it received from the LLP (Low Level
Processor) but did not find any data in the message.
Handling System reset is performed.

3.05 Software error

Label ERR_STS_MSG_HDR
Log Message No status message from LLP
When Whenever the HLP sends the status command to the LLP,
such as when the HLP polls the LLP to determine if a
cartridge has been inserted or removed, or when the HLP
sends the status command to the LLP a few seconds after
sending a reset command to the LLP.
Cause The GEM 3000 HLP (High Level Processor) was waiting
to receive a status message from the LLP (Low Level
Processor), but the message that the HLP received did not
contain a status message header.
Handling System reset is performed.

3.06 Software error

Label ERR_CMP_MSG_HDR
Log Message No batch complete message from LLP
When Whenever the HLP sends a batch of commands to the LLP,
such as during a sample, calibration, or LLP initialization.
Cause The GEM 3000 HLP (High Level Processor) was waiting
to receive a batch complete message (which indicates that a
set of commands has been processed by the LLP) from the
LLP (Low Level Processor), but the message that the HLP
received did not contain a batch complete message header.
Handling System reset is performed.

3.07 Software error

Label ERR_AD_MSG_HDR
Log Message No sensor reading message from LLP

7-24
GEM Premier 3000 Service Manual

When During sample or calibration measurement, or while

waiting for the heater block to reach a particular
temperature during cartridge warm up or power fail
recovery.
Cause The GEM 3000 HLP (High Level Processor) was waiting
to receive a single channel sensor reading message from the
LLP (Low Level Processor), but the message that the HLP
received did not contain a single channel sensor reading
message header.
Handling System reset is performed.

3.08 Software error

Label ERR_AS_MSG_HDR
Log Message No sensor readings message from LLP
When During sample or calibration measurement.
Cause The GEM 3000 HLP (High Level Processor) was waiting
to receive a signal channels (analyte channels, temperature,
ground, reference) sensor reading message from the LLP
(Low Level Processor), but the message that the HLP
received did not contain a signal channels sensor reading
message header.
Handling System reset is performed

3.09 Software error

Label ERR_SOLN_MSG_HDR
Log Message No solution type message from LLP
When During sample aspiration or when solution is pumped from
the cartridge during a calibration.
Cause The GEM 3000 HLP (High Level Processor) was waiting
to receive a solution type message from the LLP (Low
Level Processor), but the message that the HLP received
did not contain a solution type message header.
Handling System reset is performed.

7-25
GEM Premier 3000 Service Manual

3.10 Software error

Label ERR_REV_MSG_HDR
Log Message No revision message from LLP
When Whenever the HLP sends the revision command to the
LLP, such as during system initialization.
Cause The GEM 3000 HLP (High Level Processor) was waiting
to receive a revision message from the LLP (Low Level
Processor), but the message that the HLP received did not
contain a revision message header.
Handling System reset is performed.

3.11 Software error

Label ERR_INIT_LLP
Log Message LLP initialization failed
When During LLP initialization.
Cause The GEM 3000 HLP (High Level Processor) received an
unexpected error message from the LLP (Low Level
Processor) during LLP initialization.
Handling System reset is performed.

3.12 Software error

Label ERR_B_CAL_BAD_SOLN
Log Message No B solution message from LLP
When While B solution is being pumped from the cartridge
during a B calibration.
Cause The GEM 3000 HLP (High Level Processor) received an
incorrect solution message from the LLP (Low Level
Processor) during a B calibration. The HLP was expecting
a B solution message.
Handling System reset is performed.

7-26
GEM Premier 3000 Service Manual

3.13 Software error

Label ERR_A_CAL_BAD_SOLN
Log Message No A solution message from LLP
When While A solution is being pumped from the cartridge
during an A calibration.
Cause The GEM 3000 HLP (High Level Processor) received an
incorrect solution message from the LLP (Low Level
Processor) during an A calibration. The HLP was expecting
an A solution message.
Handling System reset is performed.

3.14 Software error

Label ERR_SAMP_BAD_SOLN
Log Message No sample solution message from LLP
When During sample aspiration.
Cause The GEM 3000 HLP (High Level Processor) received an
incorrect solution message from the LLP (Low Level
Processor) during sample processing. The HLP was
expecting a sample solution message.
Handling System reset is performed.

3.15 Software error

Label ERR_UNEXP_LLP_MSG
Log Message Unexpected message from LLP
When Whenever the HLP is communicating with the LLP, such
as during a sample or calibration.
Cause The GEM 3000 HLP (High Level Processor) received an
unexpected message from the LLP (Low Level Processor).
Handling System reset is performed.

7-27
GEM Premier 3000 Service Manual

3.16 Software error

Label ERR_LLPD_MAX_RESENDS
Log Message HLP to LLP maximum message resends
When Whenever the HLP is communicating with the LLP, such
as during a sample or calibration.
Cause The GEM 3000 LLP (Low Level Processor) is not
acknowledging (by responding with an ASCII ACK or
NAK character) a command sent from the HLP (High
Level Processor). Or, the GEM 3000 LLP has requested
the HLP to resend a command the maximum number of
times.
Handling System reset is performed.

3.17 Software error

Label ERR_CARTD_TIMEOUT
Log Message Cartridge daemon timeout
When When the GEM 3000 HLP (High Level Processor) is
waiting for the LLP (Low Level Processor) to complete a
cartridge function, such as positioning the valve or moving
the sample arm.
Cause The GEM 3000 HLP (High Level Processor) waited the
maximum amount of time for the LLP (Low Level
Processor) to complete a cartridge function.
Handling System reset is performed.

3.18 Software error

Label ERR_CARTD_UNEXP_EVENT
Log Message Unexpected cartridge daemon event
When When the GEM 3000 HLP (High Level Processor) is
waiting for the LLP (Low Level Processor) to complete a
cartridge function, such as positioning the valve or moving
the sample arm.
Cause Communication between the GEM 3000 HLP (High Level
Processor) and LLP (Low Level Processor) is not

7-28
GEM Premier 3000 Service Manual

synchronized because the HLP cannot successfully reset

the LLP. Failure to reset the LLP may be due to an
instrument failure, such as an unrecoverable valve error
when the LLP starts up. Failure to reset the LLP may also
be due to a problem with the signal line that the HLP uses
to reset the LLP.
Handling System reset is performed.

3.19 Software error

Label ERR_UNEXP_MSG_FROM_CARTD
Log Message Frontend and cartridge out of sync
When When a GEM 3000 front end process, such as Ready,
receives an unexpected message from the cartridge daemon
(for example, during sample aspiration).
Cause Communication between a GEM 3000 front end process
and the cartridge daemon is not synchronized. The
communication failure may be due to an error detected by
the cartridge daemon and for which the system is about to
reset (for example, an unrecoverable A/D calibration error).
Handling System reset is performed.

3.20 Software error

Label ERR_TIMEOUT_FROM_CARTD
Log Message Frontend timed out on cartridge response
When When a GEM 3000 front end process, such as Ready, times
out waiting to receive a message from the cartridge daemon
(for example, during sample aspiration).
Cause Communication between a GEM 3000 front end process
and the cartridge daemon is not synchronized. The
communication failure may be due to an error detected by
the cartridge daemon and for which the system is about to
reset (for example, an unrecoverable A/D calibration error).
Handling System reset is performed.

7-29
GEM Premier 3000 Service Manual

3.21 Software error

Label ERR_DB_ERROR
Log Message Database error: %s
(where %s is the database name)
When Whenever a database operation is performed.
Cause A database operation has failed.
Handling System reset is performed.

3.22 Software error

Label ERR_FILE_IO
Log Message File I/O error: %s
(where %s is the file name)
When Whenever a file I/O operation is performed.
Cause A file I/O operation has failed.
Handling System reset is performed.

3.23 Software error

Label ERR_IPC_ERROR
Log Message Inter Process Communication error: %s
(where %s is the process name)
When Whenever communication between two processes occurs.
Cause Communication between two processes has failed.
Handling System reset is performed.

3.24 Software error

Label ERR_FSCK_ERROR
Log Message File system check detected error
When During system start up.

7-30
GEM Premier 3000 Service Manual

Cause The file system check, performed when the GEM 3000
operating system software starts up, detected an error. This
may indicate that the instrument’s internal disk is starting
to fail. The file system check is performed by the Linux
operating system utility “fsck”. When an error is detected,
“fsck” attempts to fix the area of the file system that caused
the error.
Handling The log message is logged in the system error log file
“syslog.dat”.

3.25 Software error

Label ERR_ABORT_LLP
Log Message No abort message from LLP
When When the HLP sends an abort command to the LLP, which
causes the LLP to stop execution of any command it is
currently performing and clear its command queue.
Cause The GEM 3000 HLP (High Level Processor) was waiting
to receive an abort message from the LLP (Low Level
Processor) in response to the abort command, but the
message that the HLP received did not contain an abort
message header.
Handling System reset is performed.

3.26 Software error

Label ERR_A0_CAL_BAD_SOLN
Log Message No A0 solution message from LLP
When While A0 solution is being pumped from the cartridge
during an A0 calibration.
Cause The GEM 3000 HLP (High Level Processor) received an
incorrect solution message from the LLP (Low Level
Processor) during an A0 calibration. The HLP was
expecting an A0 solution message.
Handling System reset is performed.

7-31
GEM Premier 3000 Service Manual

7.1.5 Event Logging

This section describes the GEM 3000 events that are logged in the system
error log file “syslog.dat”. (9.01 - 9.99, 0.00 - -0.99)

9.01 Event
Label EVENT_INSERT_CART
Log Message Cartridge inserted: %s
(where %s is the cartridge barcode)
When When a cartridge is inserted into the instrument.

9.02 Event
Label EVENT_POWFAIL_STATE
Log Message Cartridge power fail recovery state
When When the instrument is restarted with a cartridge inserted.
Not implemented as of V5.4.

9.03 Event
Label EVENT_REMOVE_CART
Log Message Remove cartridge state: %s
(where %s is the reason the cartridge is to be removed)
When When the instrument goes to the remove cartridge state.

9.04 Event
Label EVENT_REMOVED_CART
Log Message Cartridge removed: %s
(where %s is the cartridge barcode)
When When a cartridge is removed from the instrument.

9.05 Event
Label EVENT_CHANGE_TIME_DATE
Log Message Time/date changed: %s
(where %s is the time and date)
When When time and date is changed on the instrument.

9.06 Event
Label EVENT_CHANGE_COLOR

7-32
GEM Premier 3000 Service Manual

Log Message Color palette changed: %s

(where %s is the color palette)
When When the color palette is changed on the instrument.

9.07 Event
Label EVENT_SYS_RESTART
Log Message Instrument restart
When When the instrument is restarted. Not implemented as of
V5.4.

9.08 Event
Label EVENT_SYS_SHUTDOWN
Log Message Instrument shutdown
When When the instrument is shut down. Not implemented as of
V5.4.

9.09 Event
Label EVENT_REF_SHIF
Log Message Reference channel shifted during cal A or B
When When the instrument detects a shift in Reference sensor
during A or B calibration.

9.10 Event
Label EVENT_BLOOD_CLOT_PATTERN1
Log Message Blood clot pattern 1 detected.
When When the instrument detects the iQM clot pattern 1 in B
calibration following patient sample.

9.11 Event
Label EVENT_BLOOD_CLOT_PATTERN2
Log Message Blood clot pattern 2 detected.
When When the instrument detects the iQM clot pattern 2 in A
calibration sometime after a patient sample.

9.12 Event
Label EVENT_BLOOD_PATTERN3
Log Message Pattern 3 pO2 malfunction detected.

7-33
GEM Premier 3000 Service Manual

When When the instrument detects the iQM pattern 3 when

measuring pO2 in B calibration.

9.13 Event
Label EVENT_NOAIR_DETECT
Log Message Clot Pattern No-Air in B after sample detected.
When When the instrument encounters Air detection failure
during the B calibration cycle immediately following a
patient sample.

9.14 Event
Label EVENT_NOSOLU_DETECT
Log Message Clot Pattern No-Solu in B after sample detected.
When When the instrument encounters calibration solution
detection failure during the B calibration cycle immediately
following a patient sample.

9.15 Event
Label EVENT_INTERFERENCE
Log Message Sample interference detected.
When When the instrument detects Thiopental or Benzalkonium
sample interference pattern in the B calibration
immediately following a patient sample.

0.00 Event
Label CLEAR_ERR_ALL
Log Message All alarms cleared
When When all the alarms [see Section 7.1.1] have been cleared.

0.07 Improper instrument shutdown

Label ERR_IMPROPER_SHUTDOWN
Log Message Improper instrument shutdown
When When the instrument restarts after it was improperly
shutdown.

7-34
GEM Premier 3000 Service Manual

0.11 iQM Disabled pH Sensor

Label ERR_IQM_PH
Log Message pH is permanently disabled due to iQM error
When Sensor fails calibration A, B, or C calibration.

0.12 iQM Disabled pCO2 Sensor

Label ERR_IQM_PCO2
Log Message pCO2 is permanently disabled due to iQM error
When Sensor fails calibration A, B, or C calibration.

0.13 iQM Disabled pO2 Sensor

Label ERR_IQM_PO2
Log Message pO2 is permanently disabled due to iQM error
When Sensor fails calibration A, B, or C calibration.

0.14 iQM Disabled Na+ Sensor

Label ERR_IQM_NA
Log Message Na+ is permanently disabled due to iQM error
When Sensor fails calibration A or B calibration.

0.15 iQM Disabled K+ Sensor

Label ERR_IQM_K
Log Message K+ is permanently disabled due to iQM error
When Sensor fails calibration A or B calibration.

0.16 iQM Disabled Ca++ Sensor

Label ERR_IQM_CA
Log Message Ca++ is permanently disabled due to iQM error
When Sensor fails calibration A or B calibration.

0.17 iQM Disabled Hct Sensor

Label ERR_IQM_HCT
Log Message Hct is permanently disabled due to iQM error
When Sensor fails calibration A or B calibration.

0.18 iQM Disabled Glu Sensor

Label ERR_IQM_GLU
Log Message Glu is permanently disabled due to iQM error

7-35
GEM Premier 3000 Service Manual

When Sensor fails calibration A or B calibration.

0.19 iQM Disabled Lac Sensor

Label ERR_IQM_LAC
Log Message Lac is permanently disabled due to iQM error
When Sensor fails calibration A or B calibration.

7.2 Symptom/Fix

This section contains a list of reported or observed symptoms and the most likely
method of repair. This has been developed from the experience of the Depot repair
department to date. Please note that these are not the only methods of repair, but
typically the most common. In some cases, there will be several fixes listed. These
are symptoms that have had multiple causes in the past, and are listed in order from
most likely to least likely. The cartridge errors listed (1.02 – 1.11) are fixes seen
when the errors are consistent on multiple cartridges. In all cases, errors 1.xx should
first have a cartridge replaced.

Error Fix
1.02 Pump Rollers, Pump Motor, DCS Bd., Analog Bd,
Heater block too tight.
1.04 Pump Roller, Pump motor, Poor contact at heater block
1.05 Pump Rollers, Pin in rollers Pump Bracket, DCS Bd.
1.06 Pump Rollers, Pin in rollers Pump Bracket.
1.08 Heater Block, pump rollers.
1.09 Pump rollers, Analog Bd., Heater Block, Pump motor.
1.11 Analog Bd., Power Supply.
2.01 Heater Block, Analog Bd.
2.03 Analog Bd., Power Supply, Grounds.
2.05 Fan, Heater Block.
2.07 Analog Bd., Power Supply, Grounds
2.08 CPU Bd.
2.10 Sample Arm loose.
2.11 Dust on Arm Sensor, CPU
2.14 Heater Block, Fan, Fan direction, Heat Sink on CPU.
2.15 Pump Roller, Pump Motor, Pump Bracket, Heater Block
tight.
3.05 Application Disk, Hard drive, DCS Bd. (need rev 4
minimum)
3.08 Application Disk, Hard drive, DCS Bd. (need rev 4
minimum)

7-36
GEM Premier 3000 Service Manual

3.15 CPU
3.16 Reload Software
3.17 Hard Drive, CPU
3.18 Application Disk
3.19 Reload software
PO2 High Heater Block, Analog Bd., DCS Bd.
Printer Failed Printer, Printer Controller Bd.
No Op. Sys Found Hard Drive
Display Dim Backlight or Remove Foil
Lac, Glu, PO2 slope Analog Bd.
Errors
K Failure Analog Bd.
Na Drift Analog Bd.
Disk Will not Eject Floppy Disk Drive.
Will not Recover from Hard Drive.
Improper Shutdown
Screen Blank LCD, Inverter Bd.
Will not Complete Start Hard Drive
Up
Resetting CPU, Backplane, Analog Bd., Heater Block.
PO2 or PCO2 PVP Heater Block.
Failure

7-37
GEM Premier 3000 Service Manual

8. Interfacing
8.1 Interface Specifications

The interface specifications for the GEM Premier 3000 are contained on a
1.44M disk, part number 24001695. These specifications are in a pdf
format and can be given to customers to address any questions that arise
regarding the instrument interface via the Ethernet or serial ports.

8.2 Interfacing a CO-Oximeter

8.2.1 Interfacing to the IL682

The Gem 3000 can be interfaced to either the IL682 or the ILOPL, to have
the CO-Oximeter data transferred to the GEM. The CO-Oximeter data
will be used to perform calculations for derived parameters, and it will be
printed, transmitted from and stored on the GEM. If a CO-Ox only
sample is analyzed and transmitted to the GEM, it will not affect the
number of tests available on the cartridge.

To interface either a 682 or an OPL, the same interface cable (18420238)

is used.

GEM 3000
Connect one end of the interface cable to Serial/COM port A, B, or C on
the back of the GEM.

In the “Configuration”, “Interface Setup” menu, place a checkmark

in the “IL682” box for the same COM Port.

Shutdown the GEM, then power it up again.

Enable the desired CO-Ox parameters in the “Configuration”,

“Sample Setup”, “Analyte Enable/Disable” menu, using both the
“Measured” and “Derived” tabs. If Fetal Hb corrections are to be
performed, use the “Entered” tab.

IL682
Connect the other end of the serial cable to the “Serial 2” port on
the back of the instrument.

8-1
GEM Premier 3000 Service Manual

Press “Menu”, “4 Utility”, “2 configuration”, “1 Interfaces”, “3

serial Port 2”, and “1 DMS”. Configure the port as:

Standard
Baud rate – 9600
Data Bits – 8
Parity – None
Stop Bits – 1
Ack/Nack – OFF
XON/XOFF – OFF
Send Cal Data – OFF
Send QC Data – ON or OFF (as required)
Start Char – STX
Header – ON
Instrument ID – 1

Disable the Fetal Mode on the 682 (Menu 4,2,3,3,2,2) as the GEM will
perform the calculations if the Fetal % is entered. If the 682 performs the
calculation also, the data can be affected.

Instructions for sampling are found in Section 4 of the Operators Manual.

8.2.2 Interfacing to the ILOPL

GEM 3000
Connect one end of the interface cable to Serial/COM port A, B, or C on
the back of the GEM.

In the “Configuration”, “Interface Setup” menu, place a checkmark

in the “IL682” box for the same COM Port.

Shutdown the GEM, then power it up again.

Enable the desired CO-Ox parameters in the “Configuration”,

“Sample Setup”, “Analyte Enable/Disable” menu, using both the
“Measured” and “Derived” tabs. If Fetal Hb corrections are to be
performed, use the “Entered” tab.

8-2
GEM Premier 3000 Service Manual

GEM OPL
Connect other end of the cable to the RS-232 Serial Port on the
back of the OPL

Activate “Data Transfer” on the OPL. Press “Computer”, “#1 Data

Management”, “#1 Data Transfer On/Off” and select “#2 ON”.
Press enter after each selection and press cancel to return to the
ready screen.

Activate “Auto Transfer” on the OPL. Press “Main Menu”, “#3

Stored Data”, “#3 Transfer”, “#3 Auto Transfer”, and select
“#2ON”. Press enter after each selection and press cancel to return
to the ready screen.

Confirm the OPL interface configuration. Press “Main Menu”,

“#2 Printer Mode”, “#3 Printer Parameters”. Confirm that the
Baud Rate is 9600 and Parity is NONE. These are the only
configurable settings. If a setting needs to be changed, use the
YES+ or NO- keys until the appropriate setting is displayed. Press
enter after each selection and press cancel to return to the ready
screen

Instructions for sampling are found in Section 4 of the Operators Manual.

8-3
GEM Premier 3000 Service Manual

9. Parts List
9.1 Items Sorted by Part Number

5312 bar code wand,

5330 formatted diskettes
500048 dcs board
540171 gem demo disk v5.2 sw
540174 gem system disk v5.3 sw
540175 gem application disk v5.3 sw
540180 demo disk gem 3000 v5.4.0
540184 gem application disk v5.4.2 sw
550044 assy,cart motors
560031 subassy pump roller
560058 assembly,power su
630066 standoff,shaft .
630086 c.i. door hinge
630102 pump motor bracke
640022 rear wall
660026 fastener magnet
690385 puller
693083 puller post
695207 cap,cycoloy c2800
730012 belt,sq cut rubbe
740040 printer,thermal,5
750010 motor 5000 rpm dc
790035 power supply swit
810011 welsh-allen read
850010 printer controlle
860027 speaker pc mount
995101 fixture,etc harness
995356 fixture pump spring cartridge
6945408 lcd display
14882100 cord line shielded
18420238 cable, rs232 , acl 9000/futura/advance
20404900 power supply 130 w
20405000 power output cable
20405100 power input cable
20405200 power supply kit 130 w
20491400 solenoid door lock
20491800 lcd cover front/back
24000131 cable, barcode gun, g3k
24001436 gemweb certificate patch
24001597 cpu board, seco

9-1
GEM Premier 3000 Service Manual

24001599 pcb sound card assy

24001632 seco cpu kit
24001670 kit software upgrade v5.1-v5.3 gem 3000
24001690 kit, upgrade gem 3000 v5.4
24001801 lcd backlight sharp
24002057 cable assembly,works in a drawer
24005000 heater block assy
24005012 right ext. panel
24005013 pcb assy analog g
24005028 cap
24005030 bracket upper
24005033 front panel
24005035 display support
24005042 inverter ls380 cf
24005044 touchscreen resis
24005082 door ampule rotat
24005096 base plate gp3k
24005101 cartridge door gp
24005109 ampoule drawer as
24005162 pcb assy test adapter
24005193 backplane 2 assy
24005208 cable disp flex 2
24005214 display transitio
24005223 assy lcd flex
24005241 floppy disk drive
24005242 cpu single board
24005243 io card pc-104 fo
24005244 hard disk drive 9
24005245 cable ext. printer
24005269 fan, 12v, 16.6 cf
24005412 panel right exterior painted
24005413 slimline floppy drive
24005414 disk drive bracket slimline
24005541 switch pow/ckt br
24005548 ethernet bulkhead cable assembly
24005554 pcb drive interface
63006801 arm driver
66005101 arm motor
75000501 pump motor

9-2
GEM Premier 3000 Service Manual

9.2 Service Tools

995356 Pump Tension Test Cartridge
995390 Pump Tension Indicator
24005050 Electronic Test cartridge (ETC)
995410 ETC Harness
995100 ETC Power Supply
24005162 ETC Adapter Board
24005534 Premtest Disk V4.12
540177 Skipwarm Disk
24001581 Loopback Connector

9.3 Customer Parts and Supplies

Cartridges
Cartridges

Test Menu non-iQM iQM Capacity Use-Life

Blood Gases, Hct N/A 24407584 75 4 weeks

24307504 24307584 75 3 weeks
24315004 24315084 150 3 weeks
24330004 24330084 300 3 weeks
24345004 24345084 450 3 weeks
Blood gases, Hct, 24307507 24307587 75 3 weeks
Electrolytes 24315007 24315087 150 3 weeks
24330007 24330087 300 3 weeks
24345007 24345087 450 3 weeks
24360007 24360087 600 2 weeks
Blood Gases, Hct, N/A 24307589 75 3 weeks
Electrolytes,
24315009 24315089 150 3 weeks
Glucose,
Lactate 24330009 24330089 300 3 weeks
24345009 24345089 450 3 weeks
24360009 24360089 600 2 weeks

Supplies
005508 Print paper, 5 rolls
000825900 Capillary Sample kit, 200 tubes
24001170 Kit safety draw plastic capillary 1000pk
005330 Formatted Blank Diskette, 10/pack

9-3
GEM Premier 3000 Service Manual

CVP
Multipak, 20 ampoules x 2.5 mL x 4
24001587
levels
24001811 CVP 1, 20 ampoules x 2.5 mL
24001812 CVP 2, 20 ampoules x 2.5 mL
24001813 CVP 3, 20 ampoules x 2.5 mL
24001814 CVP 4, 20 ampoules x 2.5 mL

ContrIL 7
24001380 Multipak, 30 ampoules x 2mL x 3 levels
24001381 Level 1, 30 ampoules x 2mL
24001382 Level 2, 30 ampoules x 2 mL
24001383 Level 3, 30 ampoules x 2 mL

ContrIL 9
24001418 Multipak, 30 ampoules x 2mL x 3 levels
24001419 Level 1, 30 ampoules x 2mL
24001420 Level 2, 30 ampoules x 2mL
24001421 Level 3, 30 ampoules x 2mL

Accessories
18420238 Interface cable GEM to CO-Ox
005315 Mounting Bracket
24000130 Bar code gun (optional)

9-4
GEM Premier 3000 Service Manual

10. Drawings and Schematics

10-1
10-2
10-3
10-4
10-5
10-6
10-7
10-8
10-9
10-10
10-11
10-12
10-13
10-14
10-15
10-16
10-17
10-18
10-19
10-20
10-21
10-22
10-23
10-24
10-25
10-26
10-27
10-28
10-29
10-30
10-31
10-32
10-33
10-34
10-35
10-36
10-37
10-38
10-39
10-40
10-41
10-42
10-43
10-44
10-45
10-46
GEM Premier 3000 Service Manual

11. Appendix A – Service Information Bulletins

11-1
 Service Product Information
Gem Premier 3000
1

GEM Premier 3000 interfacing

When setting up an interface on the GEM 3000, with Revision 5.1.1, the instrument must be restarted any time
a setting on a COM Port is changed. If the instrument is not shut down and restarted, the COM Port may not
work properly.

Point of Care

March, 02 Page 1
11-2
 Service Product Information

GEM Premier 3000 - 02/2002

Service Product Information 02– May, 2002

GEM Premier 3000 printer door

Purpose: The purpose of this Service Product Information Bulletin is to inform you
of a problem currently being seen with the GEM Premier 3000 printer doors and
what is being done to resolve this issue.

We have had several reports of broken printer doors during installation in the last
couple of months (3 of the last 50 installations). One or both of the tabs holding the
printer door breaks off during shipping. These tabs are part of the entire front panel
and the panel must be replaced to repair the door.

We are currently in the process of changing the mold and revising the printer door
tabs. Starting with serial number 13643, during July’s production, the molded tabs
will be tapered to relieve the stress and eliminate the breakage.

Critical Care
Jim Carpenter
Product Line Support Manager – Critical Care

Page 1
11-3
 Service Product Information

Service Product Information No. 01US – Feb 2003

01-2003

GEM Premier 3000 5.3 upgrade

For all GEM Premier 3000 instruments that are currently at revision 5.2, the upgrade to 5.3 is
mandatory and has a higher priority than upgrading instruments at revisions below 5.2. The upgrade
to 5.3 must be performed on site, by an IL representative, and the Faxback form must be completed
and returned. This upgrade is mandatory for ALL instruments, customer and Demo. The Faxback
form is required for Demo instruments also.

There will be two upgrade kits made available, one for 5.2 to 5.3, one for 5.0/5.1 to 5.3. The 5.2 to
5.3 kit will be distributed immediately when it is available. A sufficient quantity will be distributed to
each TSR to accomodate the accounts identified as being at revision 5.2. The second kit will be
available at a later date and can be utilized after the 5.2 upgrades are completed.

When installing 5.3 software on a 5.2 instrument, the video disks will not need to be reinstalled, as
the video will not be lost with the upgrade. If an account has instruments at 5.2 and at earlier
revisions, all of the units may be upgraded to 5.3 using the same upgrade disk. It is important to
remember that the upgrade disk(s) and the video disks used at a specific account must be left at the
account and not used at other accounts.

Point of Care
The Faxback form, for 5.2 to 5.3 upgrades, has been sent to all field personnel. Please complete and
fax this form for all Demo instruments. This will enable the use of an application disk rather than an
upgrade kit for IL instrumentation.

The 5.2 Demo disk (00540171) will not be updated. The 5.2 Demo disk will work with 5.3 software.
The Video disks (24001612 – set of 2) are labelled for 5.2 and will also work with 5.3. These disks
will not be changed at his time, but will be used with revision 5.3

IMPORTANT: For 5.2 to 5.3 upgrades, Service Representatives MUST inform customers that an
instruction label was added to p. 3.1 of the Operator’s Manual, requiring the
verification of manual configuration changes.

Jim Carpenter
Product Line Support Manager
Critical Care

Page 1
11-4
 Service Product Information

Service Product Information No. 02US – February 2003

02-2003

GEM Premier 3000 5.3 time/date format

PURPOSE The purpose of this Service Information Bulletin is to inform you of a

limitation of the GEM Premier 3000 with version 5.3 and the use of the date/time
format of YYYY/MM/DD.

If the format of YYYY/MM/DD is selected, the instrument will not be able to access
the Delta Charts, either at the instrument, or via GEMweb. When the chart is
selected, the instrument screen, or the GEMweb screen, will turn gray and remain in
that state until the instrument is powered off and on. All other time/date formats
work properly.

Accessing the Delta Charts is the only function affected. The cause has been
identified and will be corrected in version 5.4

Jim Carpenter
Product Line Support Manager
Critical Care

Page 1
11-5
 Service Product Information

GEM Premier 3000 - 03/2003

Service Product Information 03– June, 2003

GEM Premier 3000 – new CPU board

Purpose: The purpose of this Service Product Information Bulletin is to inform you
that a new CPU board has been put into production for the GEM Premier 3000, and
to provide instructions for replacement of the old style board with the new style. This
information is only intended for use by authorized GEM depot repair facilities.

The GEM Premier 3000 has utilized a Radysis CPU board (P/N 0024005242) since
release. There is a new Seco CPU board (P/N 0024001597) currently being used.
The new CPU was installed in GEM instruments starting with SN 14015 until SN
14101. Instruments with SN 14102 through 14689 then had Radisys boards
installed. From SN 14690 on SECO boards have been used. The Seco board will
only work with software revision 5.1.2 and higher, the Radysis board will work with
all revisions. With Revision 5.3 and higher, select the Diagnostics Menu and
System Info. The Serial number of the instrument will be displayed, with an R or an

Critical Care
S several spaces over. This will help to determine the type of CPU in use (R =
Radysis, S = SECO).

The new Seco board is complete as received, with all components installed. There
is no need to add any parts from the old Radysis board when installing it.

In order to install a Seco board in place of a Radysis board, there are several parts
that must be changed. To facilitate this change, a kit will be been made available
with all of the required parts. The kit part number is 0024001632 and contains:

1. CPU Board 0024001597

2. GIO Cable 0020402500
3. Com 7 & 8 Cable 0020403900
4. Ethernet Cable 0024005548

If the super floppy drive is an older version used on all GEMs below SN 13411, it
must also be changed, along with the power cable. If the super floppy has only 2
wires to the power connection, it is the old version. The proper floppy drive has a 3-
wire power connection. The part number of the floppy drive is 0024005241 and the
part number for the power cable is 0056005800.

After installing the new CPU board, connect the new GIO cable from the backplane
(J-21) to the CPU board (J-4) and the sound card (J-3). The sound card is mounted
onto the CPU board.

Page 1
11-6
 Service Product Information

GEM® Premier 3000 - 05/2003

Service Product Information 05– November, 2003

GEM® Premier 3000 – fan interference

Purpose: The purpose of this Service Product Information Bulletin is to inform you
that we have recently become aware of a potential problem with the GEM Premier
3000. There are two cables in the GEM that could interfere with the cooling fan,
causing the fan to run slowly or not at all. The two cables are the large, black cable
that runs from the Heater Block to the Analog board and a gray cable that runs to
the DCS Board.

These cables were secured to the instrument chassis with a tie wrap to keep them
from interfering with the fan. The use of the tie wrap was discontinued when the
SECO CPU board was introduced (Serial Number 14690). After discovering that the
cables could still interfere with the fan, the use of the tie wrap was implemented
again with October 2003 production (Serial Number 15137).

Critical Care
If a GEM in this serial number range displays any temperature errors, particularly
Error 2.14, the fan should be checked for proper operation. If the fan is not blowing
air OUT, the cover should be removed and the fan checked for interference. There
is a bracket a few inches from the fan, toward the middle of the instrument. This
bracket has a single hole in it and a tie wrap, or anything suitable, can be passed
through this hole, wrapped around the two cables and secured. This will prevent the
cables from causing any problems if they shift during operation or when the
instrument is moved.

Jim Carpenter

Product Line Support Manager

Critical Care

Page 1
11-7
 Service Product Information
Service Product Information 01– February, 2004

GEM® Premier 3000 - 01/2004

GEM® Premier 3000 – New Power Supply

Purpose: The purpose of this Service Product Information Bulletin is to inform you
that the GEM Premier 3000 has a new 130W Power Supply. This new Power
Supply was implemented in instruments with serial number 14849 and higher.

The new supply can be utilized in older instruments by using a Power Supply Kit,
part number 0020405200. This kit contains:

New Power Supply 0020404900

Output Cable 0020405000
Input Cable 0020405100

These parts are used to replace the older Power Supply (00790035), the old Power
Cable (00560058), and the black, green, and white wires that run from the power

Critical Care
switch to the power supply.

At this time there is a limited quantity of the old Power Supply (00790035) available
to support the depot repair facilities. When these old supplies are no longer
available, the kit (0020405200) must be used.

Jim Carpenter

Product Line Support Manager

Critical Care

Page 1
11-8
 Service Product Information
Service Product Information– February, 2004

GEM® Premier 3000 - 02/2004

GEM® Premier 3000 – New Disk Drive

Purpose: The purpose of this Service Product Information Bulletin is to inform you
that the GEM Premier 3000 has a new “slim line” disk drive. This new disk drive
was implemented in instruments with serial number 15456 and higher.

The new drive can be utilized in older instruments by ordering the four required parts
individually. There is not a kit available at this time. The four parts required are:

New Disk Drive 0024005413

Bracket 0024005414
PCB Interface 0024005554
Right Side Panel 0024005412

If a new, slim line drive fails, it can be replaced with just the new drive

Critical Care
(0024005413).

The existing drive, on the older GEM 3000 instruments is part number 0024005241.
A significant quantity of the old drives is available, to eliminate the need to replace
all of the parts required. It is recommended that the old drives be used in the old
instruments whenever possible

Jim Carpenter

Product Line Support Manager

Critical Care

Page 1
11-9
 Service Product Information

GEM® Premier 3000 - 03/2004

Service Product Information 03– June, 2004

GEM® Premier 3000 – LCD mounting

Purpose: The purpose of this Service Product Information Bulletin is to inform you
that we have made two changes in the manufacturing process of the GEM Premier
3000 to eliminate problems recently seen with shipping of the instrument.

The first change is in the length of the double-sided tape used to mount the glass
touch screen. The tape on both sides was previously 7.375 inches long, and is now
5 inches long. This will remove the pressure point in the corners that resulted in
several touch screens being broken during shipping.

The second change is in the mounting of the Ethernet connector to the back panel.
There have been several instances where the Ethernet connector has fallen inside
the instrument during shipping. There is now a shim under the fitting that snaps the
connector in place on the back panel. This will increase the amount of pressure on

Critical Care
the fitting, securing it tightly to the panel. The connector can still be removed, if
necessary, by squeezing the tabs together, but more force will be required to
release the connector.

Both of these changes are being implemented on instrument serial number 15950.

Jim Carpenter

Product Line Support Manager

Critical Care

Page 1
11-10
 Service Information Notes

GEM® Premier 3000 – 01/2005

Service Information No. 01 – May 2005

GEM® Premier 3000 – CPU

Purpose: The purpose of this Service Product Information Bulletin is to inform
you that we have recently become aware of a potential problem with the GEM
Premier 3000 CPU Board. We have addressed the issue with the vendor, and
have developed a means of providing you with tested CPU boards that will not
exhibit the problem.

Symptom: The CPU board may have a timing conflict with the memory cache.
If this occurs, the instrument will “freeze”, and it must be powered off and on to
recover the operation. This may result in loss of the cartridge. This will only
occur with the SECO CPU Board (00024001597). The SECO CPU can be
identified on the instrument by accessing “Diagnostics” and “System Info”. If the
letter following the Instrument serial number is “S”, that indicates a SECO CPU.

This symptom is most likely to occur on instruments above serial number 15750,
although it is possible that earlier serial numbers may freeze. The reported

Critical Care
incidence of the freezing has been very low at this time.

The vendor has identified the cause of the problem and developed a screening
test that has been very effective in eliminating the occurrence. All CPUs are now
screened and the good boards are marked with a green “dot”, placed on U-2.
There have been no instances of the freezing seen with a CPU that has been
screened and has the green dot on it. All instruments with serial number 17034
and above have CPUs that have been screened and have the green dot on
them. All CPU boards in stock, and all GEM SECO CPU and Cable kits
(00024001632) in Orangeburg stock have been verified to have the screened
CPU Boards.

Action Required: Check any stock of CPU Boards and Kits to determine if they
have the green dot. If there are any boards in your stock that are not screened,
contact Jim Carpenter ([email protected]) with a quantity of the unscreened
boards that you have. A quantity of screened boards will be sent to you to
replace the boards you have in stock, with an RGA to return the unscreened
boards. The unscreened boards are to be returned to Jim Carpenter in
Lexington. To facilitate the process, please remove the CPU boards from the kits
and replace them with the screened boards when they are received.

For Internal Use Only

Page 1

11-11
Service Information No. 01 – May 2005

The first priority is to replace all unscreened CPU Boards in your stock. After that
is complete, CPU Boards that are replaced for this specific problem will be
replenished following the same procedure. It is important that only CPU Boards,
without the green dot, and that experience this specific problem will be
replenished in this manner. Other CPU failures will continue to be addressed as
they are now.

There is a limited quantity of screened CPU Boards to maintain this

replenishment process. Every effort will be made to replace the unscreened
CPU Boards as quickly as possible.

Jim Carpenter

Product Line Support Manager

Critical Care

For Internal Use Only

Page 2

11-12