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Manufacturer
Model
Manual Reference
Zimmer Surgical A.T.S. 4000TS Operator / Service Manual, REF 60-4000-101-00 (2013). The site's A.T.S. 4000 model taxonomy corresponds to the A.T.S. 4000TS designation used by this manual; confirm the nameplate before work.
Manufacturer Recommendation / AEM Status
Perform the functional and calibration check at least every 3 months. Perform full calibration at least every 6 months and after scheduled or unscheduled maintenance. Perform the internal leak test during the six-month PM and after service. Service-menu tests, calibration, and repairs are for qualified biomedical/service personnel familiar with electronic medical equipment.
Apply stricter regulatory or facility requirements where applicable. A different interval belongs under the facility's approved AEM program. Do not dismantle or modify the system without authorization.
What This PM Procedure Covers
- Identity, service history, exterior, controls, labels, pole clamp, ports, cords, cuffs, hoses, and LOP sensor
- Startup self-test, touchscreen, pressure/time controls, channel operation, and alarms
- Cuff-pressure verification, full calibration when due, and internal leak testing
- Battery-health review and service information
- Protective-earth, leakage-current, and insulation-resistance testing
- Final restoration, disposition, and CMMS documentation
Required Tools and Equipment
- Current A.T.S. 4000TS Operator / Service Manual and qualified access to the service menu
- Calibrated pressure meter with at least a 0-700 mmHg range
- Regulated pressure source with a 0-700 mmHg range
- Zimmer calibration hose kit and compatible cuffs/hoses
- Electrical safety analyzer capable of protective-earth testing at 200 mA or greater, leakage-current testing, and 500 VDC insulation-resistance testing
- Manufacturer-compatible cleaning supplies, mild detergent, soft cloth, and isopropyl alcohol when disinfecting the LOP sensor
Step-by-Step PM Procedure
1. Verify Identity and Applicability
Action: Record the asset tag, serial number, department, line rating, software version if available, and installed accessories. Confirm the unit belongs to the site's Zimmer Biomet / A.T.S. 4000 / Pneumatic Tourniquet System taxonomy and that the nameplate/manual applicability identifies the A.T.S. 4000TS.
Expected outcome: The equipment matches CMMS and the correct manual, electrical configuration, and accessories are identified.
2. Review History and Prepare the Unit
Action: Review reported pressure, leak, alarm, touchscreen, battery, power, and LOP-sensor issues; prior error codes; repairs; and previous PM/calibration readings. Remove the unit from clinical use, disconnect cuffs from patients, and place it in a controlled service area. Only qualified personnel may enter the service menu or perform calibration.
Expected outcome: The unit is safely available for testing and known faults or post-service requirements are identified before work begins.
3. Clean and Inspect the Exterior
Action: Disconnect mains. Clean in accordance with the manual. Inspect the housing, touchscreen, buttons, pole clamp, accessible hardware, cuff ports, labels, fuse ratings, ventilation openings, and mounting surfaces. Verify labels are complete and legible and no parts are loose, cracked, contaminated, or missing.
Expected outcome: The exterior is clean and intact; the pole clamp, hardware, ports, fuses, and labels are secure and serviceable.
4. Inspect Power, Cuffs, Hoses, and LOP Sensor
Action: Inspect the power cord, plug, grounding pin, inlet, strain reliefs, cuffs, tubing, connectors, and Low Occlusion Pressure sensor for damage, wear, contamination, obstruction, or loose fit. Clean the unplugged LOP sensor with a damp soft cloth and mild detergent; use isopropyl alcohol when disinfection is required. Replace damaged accessories only with compatible parts.
Expected outcome: The power path, pneumatic accessories, and LOP sensor are clean, correctly connected, and free of visible defects.
5. Verify AC Power and Startup Diagnostics
Action: Connect the unit to AC mains and verify the green AC indicator illuminates the Power button in standby. Power on and observe the complete startup sequence. Confirm the display reports DIAGNOSTIC OKAY and CALIBRATION OKAY, both actual-pressure and time fields initialize at zero, and the normal default settings appear as 250 mmHg and 60 minutes.
Expected outcome: Startup completes without an error, both channels initialize at zero, and the specified default pressure/time values appear. Any nonzero startup pressure or CALIBRATION ERROR requires qualified calibration/service.
6. Perform the Touchscreen Test
Action: Enter the qualified service menu and run Touch Test. Drag the red ball over the complete X/Y test line without leaving untested sections. Repeat once if technique caused a gap.
Expected outcome: The entire test line is erased and all tested touchscreen areas respond. A repeatable dead area fails the test and requires removal from service.
7. Verify Pressure Setpoint Controls
Action: On both Main and Second channels, verify pressure can be set throughout 50-400 mmHg in 1 mmHg steps and that holding an arrow changes the value in 5 mmHg steps. If the facility uses Extended Pressure Mode, verify the yellow confirmation/warning and operation to 600 mmHg only with cuffs and hoses rated for that pressure.
Expected outcome: Both channels adjust correctly through the standard range, accelerated adjustment works, and any extended-pressure operation is clearly warned and safely configured.
8. Verify Time Setpoint Controls
Action: On both channels, verify time can be set from 5-240 minutes in 1-minute steps and that holding an arrow changes the value in 5-minute steps. Return both channels to a safe test setting.
Expected outcome: Both time controls respond correctly throughout their ranges with no sticking, skipped input, or display error.
9. Verify Channel Inflation and Deflation
Action: Connect compatible test cuffs or closed test volumes. Operate Main and Second independently and, where supported, together. Verify inflate/deflate commands, channel identification, actual-pressure display, time display, audible indications, and control response. Confirm each channel deflates fully when commanded.
Expected outcome: Each channel inflates, regulates, times, and deflates only as commanded without crossover, abnormal noise, or unintended operation.
10. Verify Low-Pressure and Cuff-Leak Alarms
Action: Inflate each test cuff to 250 mmHg. Create a controlled leak that lowers pressure more than 15 mmHg below the setpoint. Verify the audible alarm, flashing red alarm indicator, and LOW PRESSURE warning. Sustain a substantial leak long enough to verify CUFF LEAK, then correct the leak and confirm pressure recovery and alarm clearing. Repeat for both channels.
Expected outcome: Both channels detect the pressure loss, produce the specified visual/audible indications and messages, restore pressure after correction, and clear the alarm normally.
11. Review Unit Information and Battery Health
Action: In Unit Info, record software version, total cuff runtime, successful calibration count, backup-battery usage, battery health, and the last three error codes. Verify battery health is greater than 50%. If replacement is required, use only the specified Zimmer battery and charge on AC for at least 10 hours before clinical return.
Expected outcome: Service information is readable and documented, no unresolved error indicates an unsafe condition, and battery health is above 50% or the battery is replaced and charged.
12. Perform the Three-Month Cuff Calibration Check
Action: Using a calibrated pressure meter and the specified calibration connections, verify both cuff-channel displays at 50, 250, 475, and 600 mmHg without changing saved calibration values. Compare displayed pressure with the reference meter at each point.
Expected outcome: Each reading on both channels is within ±5 mmHg of the reference. Any reading outside ±5 mmHg requires full recalibration before return to service.
13. Perform Full Six-Month Calibration When Due
Action: When the six-month interval is due, after scheduled/unscheduled maintenance, or after a failed check, perform the manual's qualified full-calibration sequence in the exact prescribed order. Calibrate both cuff channels at 0, 50, 250, 475, and 600 mmHg and the reservoir at 0, 50, 250, 475, and 700 mmHg. Save only after all connections, reference pressures, and entries are confirmed.
Expected outcome: The complete ordered calibration succeeds, is stored without an error, and a repeat check confirms both cuff channels within ±5 mmHg.
14. Perform the Six-Month Internal Leak Test
Action: Connect both supplied calibration hoses, clamp their ends, and verify all external test connections are leak-free. Run the service-menu Leak Test, which pressurizes the system near 475 mmHg. Record initial/final pressure or displayed change for both circuits.
Expected outcome: Pressure loss is no greater than 30 mmHg and pressure gain is no greater than 10 mmHg. If failure persists after external connections are verified, remove the unit from service for qualified repair.
15. Test Protective-Earth Resistance
Action: Before leakage testing, use an analyzer that supplies at least 200 mA into 500 mΩ with open-circuit voltage no greater than 24 V. Measure from the mains-plug ground pin to exposed aluminum chassis at the rear. Flex the full power cord while observing the reading.
Expected outcome: Protective-earth resistance is 300 mΩ or less and remains stable while the cord is flexed. Any intermittent change or excessive reading requires cord replacement/service.
16. Test Leakage Current and Insulation Resistance
Action: Perform applicable earth/equipment leakage tests, including required normal and single-fault conditions, using the adopted facility standard and the manual's 500 microamp maximum. With mains disconnected, apply 500 VDC from the mains part to protective earth and measure insulation resistance. Record analyzer, standard, modes, and readings.
Expected outcome: Leakage current is 500 microamps or less in the applicable single-fault test and insulation resistance is greater than 50 MΩ with no significant deterioration from prior results.
17. Restore, Recheck, and Document
Action: Exit service mode, remove test equipment, reconnect correct accessories, restore normal settings, clean/dry the unit, and perform a final startup, channel, deflation, and alarm-clear check. Do not run Burn Mode as routine PM; it is reserved for significant service involving control, pneumatic, or power parts. Document all results, corrective action, and disposition.
Expected outcome: The unit is fully assembled, clean, correctly configured, operational, and either returned to service with complete records or clearly removed from service.
Electrical Safety Testing
The A.T.S. 4000TS is a Type BF device. Test protective-earth resistance first using at least 200 mA; acceptance is 300 mΩ or less from the plug ground pin to exposed rear aluminum chassis. Flex the cord throughout the test. Applicable earth/equipment leakage must not exceed 500 microamps in single-fault condition. With mains disconnected, test insulation at 500 VDC from mains parts to protective earth; the manual's reference acceptance is greater than 50 MΩ. Record the analyzer, adopted standard, test configurations, readings, and result.
Pass / Fail Criteria
Pass
- Exterior, pole clamp, controls, ports, labels, cord, cuffs, hoses, and LOP sensor pass inspection
- Startup reports DIAGNOSTIC OKAY and CALIBRATION OKAY with zero actual-pressure/time values
- Touchscreen, pressure/time controls, both channels, inflation/deflation, and alarms pass
- Both cuff channels read within ±5 mmHg at 50, 250, 475, and 600 mmHg
- Required full calibration completes and the leak test shows no loss greater than 30 mmHg and no gain greater than 10 mmHg
- Battery health is greater than 50% and no unresolved error indicates an unsafe condition
- Protective earth is 300 mΩ or less, leakage is 500 microamps or less, and insulation is greater than 50 MΩ
Remove From Service
- Physical damage, missing/illegible safety labeling, unsafe mounting, damaged power/pneumatic component, contamination, or unauthorized modification exists
- Startup diagnostic/calibration, touchscreen, channel control, pressure regulation, deflation, alarm, or accessory test fails
- Any cuff calibration point is outside ±5 mmHg and cannot be corrected by qualified calibration
- Leak test exceeds 30 mmHg loss or 10 mmHg gain after external connections are verified
- Battery health is 50% or less and the specified battery cannot be replaced/charged, or an unresolved error remains
- Any protective-earth, leakage-current, or insulation-resistance result fails
Copy/Paste CMMS Work Order Procedure
Follow the current Zimmer Biomet/Zimmer Surgical manual and authorized service information for the exact configuration. This field guide does not replace OEM training, service documentation, or facility safety policy.