Atlas Copco PF4000‑C‑HW Controller (240VAC, 150W, 50‑60Hz)

The Atlas Copco PF4000‑C‑HW is a high‑performance tightening controller from the Power Focus family, designed for operation on a 240 VAC, 50‑60 Hz mains supply with a power rating of 150 W. This controller delivers precise torque and angle control for electric nutrunners, making it suitable for a wide range of assembly applications. Its modular construction, extensive I/O, and support for multiple communication protocols allow seamless integration into automated production lines. The PF4000‑C‑HW is built for continuous operation in demanding industrial environments, providing reliable and repeatable fastening results.

Controller Design

The unit features a rugged metal enclosure with a ventilated design for passive cooling. It is designed for panel or rack mounting, with all connectors located on the front panel for easy wiring. A backlit LCD display and a membrane keypad are integrated for local monitoring and parameter adjustment. The controller supports both brush and brushless DC motors, with automatic tool recognition and parameter loading.

Control Capabilities

This controller offers a full suite of tightening strategies: torque control, angle control, yield detection, and gradient monitoring. It supports multi‑step programs with up to 10 stages, enabling complex fastening sequences. An adaptive algorithm compensates for joint stiffness variations, ensuring consistent clamp load. Cycle times are exceptionally fast, with response times in the millisecond range.

Technical Specifications

• Supply Voltage: 240 VAC ±10%, 50‑60 Hz

• Power Consumption: 150 W nominal

• Tool Output: 36 VDC, up to 10 A

• Torque Range: 0.1 – 600 N·m (tool‑dependent)

• Angle Resolution: 0.1°

• Digital Inputs: 12 isolated (24 VDC)

• Digital Outputs: 12 relay (2 A)

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

• Analog Outputs: 2 (0‑10 V)

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

• Memory: 4 GB flash, 512 MB RAM

• Display: 2.8″ LCD, 128x64

• Operating Temperature: 0 °C to +45 °C

• Protection: IP20

• Dimensions: 280 x 200 x 130 mm

Programming and User Interface

Programming is performed using Atlas Copco ToolsTalk PF software, which provides a drag‑and‑drop interface for creating tightening programs, logic sequences, and condition monitoring. Up to 255 programs can be stored. The local display shows real‑time torque/angle values, tool status, and diagnostic messages. The keypad allows quick parameter changes without a PC.

Data Logging and Traceability

Every tightening cycle is recorded with detailed torque‑angle curves, time stamps, and tool/operator IDs. Internal memory stores up to 20,000 cycles, with USB export capability. The controller supports barcode integration for workpiece traceability and can generate pass/fail signals for quality control.

Communication and Networking

Standard Ethernet port enables OPC UA, MQTT, and web server access for remote monitoring. Optional fieldbus modules allow integration with Profibus, DeviceNet, or EtherNet/IP. The controller can be networked with other PF4000 units for coordinated multi‑spindle systems.

Safety Features

Includes emergency stop input, motor overcurrent and overtemperature protection, and a safety relay output. Compliant with ISO 13849‑1 (PL d). All I/O are galvanically isolated.

Applications

Suitable for automotive powertrain, chassis, and interior assembly; also used in aerospace, heavy machinery, and electronics manufacturing.

Maintenance

No routine maintenance required. Firmware updates via USB or Ethernet. Spare parts (connectors, fuses) are available through Atlas Copco service.

Benefits

Delivers consistent joint quality, reduces scrap, and improves productivity. Its versatile communication simplifies integration into existing networks.

Conclusion

The Atlas Copco PF4000‑C‑HW 240VAC controller is a robust, feature‑rich solution for precision tightening, offering high performance and flexibility for modern assembly environments.