Product Overview
The TC-4000-S-ES is an advanced smart torque controller engineered by Atlas Copco—an industry leader in industrial fastening and torque management solutions—designed to deliver precision torque control, real-time data analytics, and seamless smart factory integration for mid-to-large-scale manufacturing operations. As a premium upgrade to entry-level models like the PF3110-S-S4/S7, this controller expands on core torque control capabilities with enhanced performance: it supports a wider torque range, offers cloud-based data logging, and features ruggedized construction for 24/7 industrial use. Unlike the compact-focused PF3110-S-S4/S7, the TC-4000-S-ES is built to handle high-volume, mission-critical applications—such as automotive powertrain assembly, heavy machinery fastening, and aerospace component manufacturing—where torque accuracy (to prevent component failure) and data traceability (for compliance) are non-negotiable. It integrates with Atlas Copco’s Power Focus ecosystem and third-party MES (Manufacturing Execution Systems), enabling centralized control of multiple fastening tools and real-time monitoring of torque processes. Hainan Jinlin Mechanical & Electrical, a trusted distributor of industrial control products, offers the TC-4000-S-ES with specialized expertise in smart torque management, providing pre-sales support (e.g., system integration planning, torque range matching) and post-purchase technical assistance (e.g., software setup, data analytics training). Guided by the “Customer First, Forge Ahead” philosophy, the company ensures the TC-4000-S-ES is accessible with dependable service, helping businesses elevate production quality, reduce defects, and meet strict industry compliance standards.
Technical Specifications
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Parameter
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Value
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Product Model
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TC-4000-S-ES
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Manufacturer
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Atlas Copco
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Product Type
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Advanced Smart Torque Controller (for Industrial Fastening Systems)
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Torque Control Range
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0.5 N·m to 400 N·m (0.37 lbf·ft to 295 lbf·ft)
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Torque Accuracy
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±0.5% of set torque (at 20%-100% of full range)
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Data Connectivity
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Ethernet/IP, OPC UA, MQTT (for cloud/MES integration); USB 3.0 (local data export)
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Operating Temperature
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-10°C to +50°C (14°F to +122°F)
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Dimensions (W×H×D)
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210 mm × 320 mm × 150 mm (8.27”×12.60”×5.91”)
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Weight
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8.5 kg (18.7 lbs)
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Mounting Type
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Panel Mount (NEMA 12 enclosure) / Floor Stand (optional)
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Protection Features
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IP54 Rating (dust and water splash resistant), overvoltage protection (100-240 V AC), short-circuit protection
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Compliance Standards
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ISO 9001 (Quality), IEC 61010-1 (Electrical Safety), RoHS (Environmental)
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Key Features and Benefits
The TC-4000-S-ES stands out as a smart, high-performance torque controller, addressing the unique challenges of large-scale industrial fastening while building on the PF3110-S-S4/S7’s foundational strengths:
Wide Torque Range & Superior Accuracy
With a torque control range of 0.5 N·m to 400 N·m and accuracy of ±0.5% of set torque, the TC-4000-S-ES outperforms the PF3110-S-S4/S7 (typically limited to lower torque ranges) and handles diverse applications—from delicate electronics component fastening (0.5 N·m) to heavy-duty truck axle bolts (400 N·m). This versatility eliminates the need for multiple controllers in mixed-production facilities. For example, in an automotive plant, it can control both dashboard screw fastening (5 N·m) and engine crankshaft bolt tightening (350 N·m) with consistent precision, reducing the risk of under-tightening (which causes component loosening) or over-tightening (which damages threads).
Smart Factory Integration & Data Traceability
A defining feature of the TC-4000-S-ES is its support for industrial IoT (IIoT) protocols: Ethernet/IP, OPC UA, and MQTT. Unlike the PF3110-S-S4/S7 (limited to basic local data logging), this controller streams real-time torque data to cloud platforms (e.g., Atlas Copco’s Insight Analytics) or on-premises MES systems. This enables:
- Centralized monitoring of up to 32 connected fastening tools (e.g., tracking torque values, cycle times, and pass/fail rates for each tool).
- Automated data logging for compliance (e.g., aerospace AS9100 or automotive IATF 16949), with time-stamped records of every fastening operation—eliminating manual paperwork and reducing audit preparation time by up to 70%.
- Predictive maintenance alerts (e.g., tool calibration reminders based on usage cycles), minimizing unplanned downtime.
Ruggedized Design for Continuous Industrial Use
Built with a NEMA 12 enclosure and IP54 rating, the TC-4000-S-ES resists dust, oil mist, and water splashes—critical for 24/7 operations in automotive assembly plants, heavy machinery factories, or aerospace facilities. Its robust internal components (e.g., industrial-grade capacitors, shock-resistant circuit boards) withstand the vibration of nearby production equipment, ensuring consistent performance even in high-stress environments. This durability extends the controller’s service life to 7+ years (vs. 3-5 years for entry-level models like the PF3110-S-S4/S7), lowering total cost of ownership.
Intuitive Software & Tool Compatibility
The TC-4000-S-ES runs on Atlas Copco’s Power Focus software, which offers a user-friendly interface for configuring torque parameters (e.g., torque setpoints, dwell time, angle monitoring) and generating compliance reports. It is fully compatible with Atlas Copco’s QX and ST series smart fastening tools, as well as legacy tools via adapter cables—allowing businesses to upgrade their controller without replacing existing tools (a key cost-saving advantage over proprietary systems). For example, a factory using older Atlas Copco ST tools can integrate them with the TC-4000-S-ES to add smart data features, extending the tools’ utility.
Advanced Error Detection & Process Optimization
Beyond basic torque control, the TC-4000-S-ES includes built-in error-detection algorithms: it monitors not just torque, but also angle of rotation (to identify cross-threaded bolts) and fastening speed (to detect tool wear). If an anomaly is detected (e.g., a bolt that reaches torque too quickly, indicating a cross-thread), the controller immediately stops the operation, alerts operators via HMI, and logs the error for root-cause analysis. This proactive approach reduces defect rates by up to 40% compared to entry-level controllers like the PF3110-S-S4/S7, which lack angle-based error detection.
Related Models
- PF3110-S-S4/S7 – Entry-level compact torque controller (detailed earlier), ideal for small-scale operations (e.g., bench-top electronics assembly) where smart features are not required.
- TC-4000-S-ES-H – High-temperature variant of the TC-4000-S-ES, with an extended operating range (-20°C to +60°C) for harsh environments (e.g., foundry component fastening).
- TC-6000-S-ES – Higher-torque upgrade, supporting 1 N·m to 600 N·m (0.74 lbf·ft to 442 lbf·ft) for heavy-industry applications (e.g., mining equipment axle fastening).
- Atlas Copco QX40 – Smart fastening tool, optimized to pair with the TC-4000-S-ES for precision torque delivery (0.5 N·m to 40 N·m) in electronics and light automotive assembly.
- Atlas Copco Insight Analytics – Cloud-based data platform, designed to integrate with the TC-4000-S-ES for real-time torque process monitoring, trend analysis, and compliance reporting.
- TC-4000-S-ES-R – Redundant controller variant, featuring dual power supplies and fail-over logic, for safety-critical applications (e.g., aerospace engine component fastening).
- Atlas Copco CAB-TC-01 – Shielded Ethernet cable, used to connect the TC-4000-S-ES to MES systems or cloud gateways, reducing EMI interference in factory environments.
- TC-CAL-KIT-04 – Calibration kit for the TC-4000-S-ES, including torque transducers and software, ensuring compliance with ISO 6789 (torque tool calibration standards).
Typical Application Areas
As a certified partner of Atlas Copco, Hainan Jinlin Mechanical & Electrical supplies the TC-4000-S-ES for critical torque control needs in large-scale industrial sectors, often as an upgrade from entry-level models like the PF3110-S-S4/S7:
Automotive Manufacturing
- Powertrain Assembly: The TC-4000-S-ES controls torque for engine block, transmission, and axle bolts—using its ±0.5% accuracy to prevent oil leaks or component failure, and MQTT connectivity to log every fastening operation for IATF 16949 compliance.
- Electric Vehicle (EV) Battery Assembly: The controller ensures precise torque for battery cell mounting (delicate, low-torque) and battery pack frame fastening (high-torque), with angle monitoring to detect damaged threads in EV-specific aluminum components.
Aerospace & Defense
- Aircraft Component Manufacturing: The TC-4000-S-ES tightens bolts in wing structures and landing gear—leveraging its wide torque range (0.5 N·m to 400 N·m) and OPC UA connectivity to stream data to aerospace MES systems, ensuring compliance with AS9100 traceability requirements.
- Defense Equipment Production: The controller fastens components in military vehicles (e.g., tank hulls), with its IP54 rating resisting dust and debris in heavy-manufacturing environments.
Heavy Machinery & Industrial Equipment
- Construction Machinery: The TC-4000-S-ES controls torque for excavator arm pins and bulldozer transmission bolts—using its rugged design to operate 24/7 in factory settings, and Ethernet/IP to integrate with MES systems for production scheduling.
- Agricultural Equipment: The controller tightens tractor engine and implement attachment bolts, with cloud data logging to track maintenance cycles for fleet owners.
All products, including the TC-4000-S-ES, come with a one-year warranty. Our team provides specialized pre-sales support—such as comparing it to the PF3110-S-S4/S7 for your production scale, verifying compatibility with existing fastening tools, or designing MES integration workflows—and comprehensive after-sales service, including on-site software training, calibration assistance, and troubleshooting for smart factory connectivity. If you cannot find the exact model you need, please contact us immediately for personalized assistance tailored to your advanced torque management requirements.