Atlas Copco PF3107‑C‑HW Tensor 3‑7 Controller (8433‑2700‑05)

The Atlas Copco PF3107‑C‑HW, identified by part number 8433‑2700‑05, is a compact and powerful tightening controller from the Tensor 3‑7 series. Designed for controlling electric nutrunners, this controller delivers high‑precision torque and angle control for a wide range of assembly applications. Its modular hardware, flexible I/O, and support for multiple fieldbus protocols make it an ideal choice for both standalone workstations and integrated production lines. The PF3107‑C‑HW is engineered to provide reliable, repeatable fastening results while offering ease of programming and diagnostics.

Controller Architecture

The PF3107‑C‑HW is built on a 32‑bit microcontroller with real‑time capabilities, ensuring deterministic control loops for fast‑responding tightening cycles. The unit features a rugged metal housing designed for DIN‑rail mounting, with all connections located on the front and bottom for easy access. A passive cooling system eliminates the need for fans, improving reliability in dusty environments. The controller supports up to two tools in a master‑slave configuration, with automatic tool recognition.

Control and Tightening Functions

This controller supports a comprehensive range of tightening strategies: torque control, angle control, yield detection, and gradient monitoring. It also includes a multi‑step tightening mode with up to 8 stages per program, allowing sophisticated sequences such as snug, final torque, and re‑tightening. The PF3107‑C‑HW features an adaptive control algorithm that compensates for joint stiffness variations, ensuring consistent clamp load. Cycle times as low as 0.15 seconds per fastener are achievable.

Technical Specifications

• Supply Voltage: 24 VDC (18‑30 VDC), 120 W max

• Tool Channels: 1 (expandable to 2 with optional splitter)

• Torque Range: 0.1 – 300 N·m (tool‑dependent)

• Angle Resolution: 0.1°

• Digital Inputs: 8 isolated (24 VDC)

• Digital Outputs: 8 solid‑state (0.5 A, 24 VDC)

• Analog Inputs: 2 (0‑10 V or 4‑20 mA)

• Analog Output: 1 (0‑10 V)

• Communication: Ethernet, Profinet, EtherNet/IP, DeviceNet, Profibus (optional)

• Memory: 2 GB flash, 256 MB RAM

• Operating Temperature: 0 °C to +50 °C

• Protection: IP20

• Dimensions: 160 x 130 x 80 mm

Programming and Operation

Programming is accomplished using Atlas Copco ToolsTalk Tensor software, which provides a graphical environment for creating tightening programs, logic sequences, and parameter sets. The controller stores up to 100 programs, each with independent settings. Real‑time data display is available via the optional local HMI or through a connected PC. The controller supports operator ID and workpiece traceability via barcode or RFID input.

Data Logging and Quality Assurance

The PF3107‑C‑HW logs detailed data for every tightening cycle, including torque‑angle curve, final torque, angle, and status. Internal memory holds 5,000 cycles, expandable via USB. Results can be exported in CSV format or transmitted to a higher‑level system via fieldbus. The controller includes built‑in statistical process control (SPC) functions, displaying real‑time Cp and Cpk values to monitor process stability.

Communication and Integration

Standard Ethernet port enables integration with factory networks, while optional fieldbus modules allow connection to major PLC systems. The controller supports OPC UA for IIoT applications, enabling remote monitoring and predictive maintenance. A built‑in web server provides browser‑based diagnostics and configuration.

Safety and Protection

Safety features include emergency stop input, motor overcurrent and overtemperature protection, and a hardware watchdog. The controller complies with ISO 13849‑1 (PL d) and includes a safety relay output for tool power cutoff. All I/O are galvanically isolated to prevent ground loops.

Applications

Typical applications include automotive sub‑assembly, electronics manufacturing, appliance assembly, and general industrial fastening. The compact size makes it suitable for mobile workstations and retrofitting existing equipment.

Maintenance and Reliability

With no internal batteries and passive cooling, the PF3107‑C‑HW requires minimal maintenance. Firmware updates are performed via Ethernet or USB. The unit has a MTBF exceeding 100,000 hours at 40 °C.

Benefits for Production

By delivering accurate, repeatable fastening, this controller reduces rework and scrap. Its flexible communication and programming simplify integration and changeovers, supporting lean manufacturing and just‑in‑time production.

Conclusion

The Atlas Copco PF3107‑C‑HW Tensor 3‑7 controller (8433‑2700‑05) offers a powerful, compact, and versatile solution for precision tightening. Its advanced features and robust design make it a reliable choice for modern assembly operations.