Atlas Copco PF4002‑G‑HW Power Focus Nutrunner Controller

The Atlas Copco PF4002‑G‑HW is a compact yet powerful nutrunner controller from the Power Focus series, designed to operate on both 120 VAC and 240 VAC power supplies (auto‑sensing). This controller offers precise torque and angle control for electric tools, making it suitable for a wide range of assembly applications in automotive, electronics, and general manufacturing. Its modular hardware and comprehensive software features provide an optimal balance of performance and cost‑effectiveness.

Controller Overview

The PF4002‑G‑HW is built around a 32‑bit processor with real‑time capabilities, capable of managing up to two tools sequentially or in parallel. It features a rugged metal enclosure with a front‑facing keypad and a backlit LCD display for local status monitoring and parameter adjustment. The controller supports both handheld and fixtured nutrunners, and automatically adapts to tool‑specific characteristics.

Power and Input Specifications

The universal input accepts 120‑240 VAC, 50/60 Hz, simplifying global deployment. The internal power supply delivers 36 VDC to the tool, with continuous current up to 10 A. The controller also provides isolated 24 VDC outputs for peripheral sensors. Power consumption is typically 300 W, with peak power handled by internal reservoir capacitors.

Technical Specifications

• Supply Voltage: 120/240 VAC ±10% (auto‑select)

• Tool Output: 36 VDC, 10 A

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

• Angle Resolution: 0.1°

• Digital Inputs: 6 (24 VDC, isolated)

• Digital Outputs: 6 (relay, 2 A)

• Analog Input: 1 (0‑10 V or 4‑20 mA)

• Communication: Ethernet, Profibus (optional), Modbus RTU

• Memory: 2 GB flash, 512 MB RAM

• Display: 2.8″ LCD, 128x64 pixels

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

• Dimensions: 260 x 180 x 120 mm

Control Algorithms

The PF4002‑G‑HW supports torque control, angle control, and yield detection, with the ability to combine them in multi‑step tightening strategies. It includes a “smart” learning mode that analyses joint stiffness and sets optimal parameters automatically. The controller also features a pulse tightening mode for high‑speed applications where final torque is achieved through repeated impacts.

Programming and Operation

Programming is performed via the built‑in keypad or through the ToolsTalk PF software on a PC. Up to 100 tightening programs can be stored, each with up to 5 steps. The controller supports operator ID and workpiece serial number entry via barcode scanner (connected through USB or RS‑232). Real‑time data displays show torque, angle, and status for each cycle.

Connectivity and Data Logging

Standard Ethernet port enables integration with factory networks. The controller logs every tightening cycle with full details; internal memory holds 10,000 cycles, expandable via USB drive. Data export in CSV format is possible. The controller also supports a simple web interface for remote monitoring.

Safety and Reliability

Safety features include emergency stop input, motor overcurrent and overtemperature protection, and a hardware watchdog that resets the controller in case of software lockup. The unit is certified to CE and UL standards. It has a MTBF of over 50,000 hours.

Applications

This controller is ideal for light to medium‑duty assembly, including electronics housing, appliance manufacturing, bicycle and motorcycle assembly, and small engine production. Its compact size makes it suitable for mobile workstations.

Installation and Maintenance

Mounting is simple with the integrated DIN‑rail clips or optional panel brackets. Wiring connections are clearly labeled. Routine maintenance includes checking air filters (if used) and ensuring proper grounding. Firmware updates are done via USB.

Benefits

The PF4002‑G‑HW offers a cost‑effective entry into precision tightening, with the flexibility to handle different tools and applications. Its dual‑voltage input reduces inventory complexity, and the intuitive interface minimizes training time.

Conclusion

The Atlas Copco PF4002‑G‑HW Power Focus controller delivers reliable, accurate, and easy‑to‑use tightening control for a broad range of assembly tasks. Its robust design, flexible communication, and universal power supply make it a practical choice for manufacturers worldwide.