Product Short Description

Product Overview

TC-4000-P-PB-ES is a high-precision industrial torque tightening controller manufactured by Atlas Copco, integrated with Profibus-DP industrial fieldbus communication and enhanced safety circuit design (ES variant). It controls servo electric tightening tools for assembly line bolt fastening, delivering closed-loop torque/angle monitoring, real-time tightening curve recording and fault detection for automotive, aerospace and heavy machinery production lines. The P suffix indicates Profibus interface, PB = Profibus-DP protocol, ES = enhanced machine safety circuit with safe torque off (STO) function.
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ATLAS COPCO TC-4000-P-PB-ES
ATLAS COPCO TC-4000-P-PB-ES - Image 2

Description

Core Technical Specifications

  • Rated Control Output Power: 4000W maximum for driving Atlas Copco electric servo tightening nutrunners
  • Communication Interface: Profibus-DP slave station, 9.6kbps to 12Mbps adjustable baud rate
  • Control Modes: Torque control, angle control, torque + angle window monitoring, yield point fastening
  • Torque Measurement Range: 0.1Nm – 4000Nm (matched with compatible Atlas Copco tool transducers)
  • Torque Accuracy: ±2% full scale calibrated tightening precision
  • Angle Resolution: 0.01° incremental encoder position sampling
  • Safety Function: STO Safe Torque Off SIL 2 certified per IEC 61508
  • Digital I/O Channels: 16 configurable discrete input / 16 discrete output logic terminals
  • Analog Monitor Output: 0–10VDC real-time torque curve analog signal
  • Operating Power Supply: 3-phase 380–480VAC ±10%, 50/60Hz industrial mains
  • Operating Temperature: 0°C to +45°C cabinet mounted; storage -20°C to +70°C
  • Humidity: 10%–85% RH non-condensing
  • Protection Class: IP20 cabinet indoor installation only
  • Physical Dimensions: 320(H) × 240(W) × 180(D) mm
  • Net Weight: 12.8kg

Key Functional Features

  1. Closed-loop torque-angle dual monitoring with real-time tightening curve storage for quality traceability (stores 100,000 tightening cycles)
  2. Profibus-DP fieldbus communication for seamless integration with PLC assembly line control systems
  3. ES enhanced safety circuit with dual-channel STO safe torque off; compliant with machine safety EN 60204-1
  4. Multi-program batch tightening support: up to 999 independent tightening parameter sets selectable via fieldbus or digital input
  5. Built-in tool transducer automatic calibration routine; one-click torque offset compensation
  6. Comprehensive tightening fault detection: cross thread, stripped thread, loose fastener, torque overshoot, angle deviation, tool stall
  7. Real-time production data upload to MES manufacturing execution systems via Profibus
  8. Overvoltage, undervoltage, overcurrent, motor overheat and short circuit multi-level power protection

Working Principle

3-phase mains power enters the internal active power rectifier module to generate regulated DC bus voltage for the servo drive stage. The controller receives tightening program selection and start/stop commands from upper PLC via Profibus-DP bus or hardwired digital inputs. Drive signals are sent to the connected electric tightening tool servo motor; integrated torque and angle transducers inside the tool feed real-time feedback signals back to the TC-4000 internal high-speed sampling circuit. The main processing unit compares measured torque/angle values against pre-programmed tightening windows, adjusts motor output torque dynamically via closed-loop PID control. If measured parameters exceed tolerance thresholds, the controller immediately triggers fault alarm and stops tool rotation via STO safety circuit. All tightening cycle data (torque peak, rotation angle, cycle timestamp, fault code) is stored in non-volatile flash memory and transmitted to PLC/MES via Profibus-DP for production quality tracking.

Material Composition & Structural Characteristics

  • Outer Cabinet Housing: Cold-rolled steel sheet with epoxy anti-corrosion powder coating, IP20 dust protection
  • Internal Power Module: Aluminum alloy heat sink for power IGBT thermal dissipation, high-temperature electrolytic capacitors
  • Main Control PCB: Multi-layer FR-4 fiberglass board with industrial-grade DSP processing chip, gold-plated communication bus connectors
  • Profibus Interface Module: Isolated RS485 transceiver circuit with surge protection for fieldbus wiring
  • Safety Circuit Board: Dual redundant STO safety relay channels with forced-guided contact design for SIL 2 compliance
  • Terminal Interface: Heavy-duty screw-clamp copper terminals for 3-phase power, tool wiring and digital I/O signals
  • Human Machine Interface: Front panel monochrome LCD display with physical navigation buttons, status LED array (power, run, fault, bus communication)

Installation Requirements

  1. Install inside standard industrial electrical control cabinet with vertical mounting orientation only; horizontal mounting prohibited
  2. Maintain minimum 100mm top & bottom ventilation clearance for power heat sink cooling
  3. 3-phase mains input wiring must use shielded power cables with cable shield grounded at cabinet earth bar
  4. Profibus-DP fieldbus wiring requires standardized Profibus shielded twisted pair cable with 120Ω termination resistor at bus end station
  5. STO safety circuit wiring must use dual-channel separate cable routing per machine safety standard EN 60204
  6. Cabinet cooling fan required if ambient operating temperature exceeds 35°C; maximum continuous ambient temperature limit 45°C
  7. Controller grounding terminal connected to cabinet protective earth with minimum 4mm² copper grounding wire

Typical Application Scenarios

  • Automotive assembly line engine bolt torque tightening stations
  • Commercial vehicle chassis frame fastener assembly workstations
  • Aerospace aircraft component precision bolt fastening production lines
  • Heavy-duty construction machinery hydraulic component assembly
  • Wind turbine generator hub bolt tightening automated stations
  • Household appliance motor and frame automated fastening lines

Operation & Maintenance Precautions

  1. Cut off 3-phase mains power before opening controller cabinet cover for inspection or wiring modification
  2. Execute full tool transducer torque calibration every 3 months during regular production maintenance
  3. Clean internal aluminum heat sink dust accumulation every 6 months to prevent power module overheating shutdown
  4. Avoid mounting controller near welding equipment or high-frequency inverters to reduce fieldbus communication interference
  5. Do not connect tightening tools with rated torque exceeding the controller’s 4000W power output limit
  6. Verify STO safety circuit dual-channel integrity monthly via controller built-in safety test function
  7. Store spare controller units in dry constant-temperature warehouse environment; avoid humidity and temperature fluctuation damage to power capacitors

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