HD-Series Torque & Automation Control System

Quick Answer

The HD-Series is a programmable torque and automation control system designed for high-precision fastening applications. By combining brushless electric screwdrivers with intelligent HDC controllers and a patented hybrid air/electric torque control system, the HD-Series provides digital torque selection, programmable fastening strategies, screw counting, angle control, PLC integration, and real-time process monitoring. The system can replace multiple conventional screwdrivers while improving fastening consistency and production flexibility.

Who This Is For

Manufacturing engineers
Automation engineers
Process engineers
Quality engineers
Production supervisors
Electronics manufacturers
Medical device manufacturers
Aerospace manufacturers
Automotive manufacturers
Industrial assembly facilities

When Should You Use This?

Use the HD-Series when:

Digital torque control is required
Multiple torque programs are needed
Automated or semi-automated fastening is performed
Screw counting and error detection are required
Torque verification is critical
PLC communication is required
Fastening data needs to be monitored in real time
One fastening system must replace multiple conventional screwdrivers

When Should You NOT Use This?

The HD-Series may not be the best choice when:

A simple mechanical clutch screwdriver is sufficient
Portable or cordless fastening is required
Torque-angle traceability is not necessary
Applications do not require programmable fastening parameters
Production volume does not justify an intelligent fastening system

How the HD-Series Works

The HD-Series combines compressed air, brushless electric screwdrivers, and an intelligent digital controller into a hybrid fastening system.

During operation, the system:

Uses a patented hybrid air/electric design to precisely control fastening torque.
Automatically recognizes the connected screwdriver.
Allows operators to select torque, speed, angle, and fastening strategy from the controller.
Continuously monitors the fastening cycle.
Detects fastening errors including cross-threading, screw omissions, incomplete rundowns, and torque failures.
Stores multiple fastening programs for different applications.
Communicates with PLCs and external equipment through built-in I/O.

Result:

Highly repeatable fastening
Programmable torque control
Real-time process monitoring
Improved assembly quality
Increased production flexibility

Core Features

HD-Series System

Patented hybrid air/electric torque control technology
Brushless electric screwdriver platform
Digital programmable torque selection
Real-time torque monitoring
Built-in screw counter
Fastening error detection
Programmable fastening strategies
Soft Start control
Speed control
Angle monitoring
Eight programmable torque presets
PLC communication
PC programming and monitoring software
Continuous-duty operation
ESD housing with 1-ohm bit-tip grounding (driver cable is not ESD)
Low reaction force
Low vibration
Low maintenance
Quiet operation

Configuration Options

Configuration	Best For
Inline Lever Start	Standard production fastening
Inline Push-to-Start	Vertical assembly applications
Pistol Grip	Ergonomic handheld fastening
Multiple controller options	Different torque capacities and production requirements

Available Screwdriver Models

The HD-Series includes multiple brushless electric screwdrivers covering torque ranges from 4.4 to 86.8 lbf.in (49.1–980.8 cN·m). Models are available in lever-start, push-to-start, and pistol-grip configurations.

HD-Series Screwdriver Model Chart

Model	Item Number	Configuration	Torque Range	High RPM	Low RPM	Drive Size
HD150-A	145741	Lever Start	4.4–13 lbf.in	1800	500	1/4" Female Hex
HD150P-A	145742	Push-to-Start	4.4–13 lbf.in	1800	500	1/4" Female Hex
HD220-A	145743	Lever Start	6.1–19.1 lbf.in	1250	400	1/4" Female Hex
HD220P-A	145744	Push-to-Start	6.1–19.1 lbf.in	1250	400	1/4" Female Hex
HD450-A	145745	Lever Start	8.7–39 lbf.in	600	300	1/4" Female Hex
HD450P-A	145746	Push-to-Start	8.7–39 lbf.in	600	300	1/4" Female Hex
PHD35N-A	145931	Pistol Grip	10.4–30.3 lbf.in	1500	500	1/4" Female Hex
PHD50N-A	145932	Pistol Grip	13–43.4 lbf.in	1200	300	1/4" Female Hex
PHD100N-A	145933	Pistol Grip	26–86.8 lbf.in	700	300	1/4" Female Hex
HD100N-A	145821	Lever Start	26–86.8 lbf.in	700	300	1/4" Female Hex

Specifications are based on the HD-Series Product Bulletin.

HDC Controller Models

The HD-Series uses intelligent HDC controllers that provide programmable torque control, speed adjustment, angle monitoring, screw counting, PLC communication, and PC-based programming.

HDC Controller Chart

Controller	Item Number	Output	Compatible Drivers
HDC40i	145740	DC40V, 3A	HD150, HD220, HD450
HDC35i	145820	DC35V, 4A	PHD35N, PHD50N, PHD100N, HD100N

Model Selection Guide

If you need:	Recommended Model
Low-torque precision fastening	HD150
General production assembly	HD220
Medium-torque applications	HD450
High-torque fastening	HD100N or PHD100N
Push-to-start operation	HD150P, HD220P, HD450P
Ergonomic handheld operation	PHD-Series
Programmable fastening strategies	Any HD-Series with HDC controller
PLC integration and production monitoring	Any HD-Series system

Compatible Accessories

Accessory	Purpose
HDC40i Controller	Required for HD150, HD220, and HD450 screwdrivers
HDC35i Controller	Required for HD100N and PHD-Series screwdrivers
1/4" Hex Power Bits	Fastening applications
Torque Cover	Prevents accidental torque adjustment
Tool Balancer	Reduces operator fatigue during repetitive fastening
PC Programming Software	Configure fastening parameters and monitor production
PLC Interface	Integration with automated manufacturing equipment

HDC Controller Overview

The HDC controller is the intelligence behind the HD-Series fastening system. It manages screwdriver operation, stores fastening programs, monitors every fastening cycle, and communicates with external production equipment.

Key controller capabilities include:

Digital torque selection
Speed adjustment
Soft Start programming
Angle monitoring
Screw counting
Fastening OK / NG judgment
Cross-thread detection
Fastener seating detection
Eight programmable fastening presets
Password-protected parameter settings
Digital I/O for PLC communication
PC software connectivity for programming and monitoring

Depending on the application, the HD-Series uses either the HDC40i or HDC35i intelligent controller.

Setup & Adjustment

Connect the HD-Series screwdriver to the appropriate HDC controller.
Connect the controller to the required compressed air supply.
Power on the controller and allow it to recognize the connected screwdriver.
Configure the desired fastening program, including torque, speed, Soft Start, angle limits, and screw count.
Connect PLCs, digital I/O, barcode scanners, or other automation equipment if required.
Verify torque output using a calibrated torque analyzer before production.
Run sample fastening cycles and confirm all fastening parameters before beginning production.

Common Applications

The HD-Series is commonly used in:

Automotive assembly
Aerospace manufacturing
Medical device manufacturing
Electronics assembly
Industrial equipment manufacturing
High-volume production lines
Smart manufacturing environments
Automated and semi-automated assembly workstations

Use Cases (Real-World Examples) Multi-Product Assembly Lines

Problem: Production lines assemble multiple products requiring different torque values and fastening strategies.

Solution: The HDC controller stores multiple fastening programs, allowing operators to quickly switch between torque settings without changing tools.

Error-Proofing Production

Problem: Missing fasteners, cross-threading, and incomplete rundowns result in costly rework and quality issues.

Solution: The HD-Series monitors every fastening cycle, detects fastening errors, performs screw counting, and provides immediate OK/NG feedback to improve assembly quality.

Smart Manufacturing Integration

Problem: Modern manufacturing environments require fastening systems that communicate with production equipment and support process monitoring.

Solution: The HDC controller integrates with PLCs through built-in digital I/O and supports PC programming software for monitoring and configuration.

High-Precision Assembly

Problem: Applications require highly repeatable torque with minimal operator influence.

Solution: The patented hybrid air/electric fastening system combines programmable digital control with brushless screwdriver technology to deliver consistent fastening performance throughout production.

Flexible Production

Problem: Manufacturers need one fastening system that can support multiple products and assembly processes.

Solution: The HD-Series allows multiple fastening presets, programmable strategies, and adjustable speed and torque settings, enabling a single system to support a wide range of assembly applications.

Maintenance

Verify torque output regularly using a calibrated torque analyzer.
Inspect the screwdriver drive spindle and bit holder for wear or damage.
Keep the screwdriver and controller clean and free of dust and debris.
Inspect all electrical cables, controller connections, and air lines before operation.
Verify that compressed air pressure meets system requirements.
Periodically inspect the HDC controller for proper operation and error messages.
Replace worn driver bits as needed to maintain fastening accuracy.
Periodically verify programmed fastening parameters as part of your preventive maintenance program.

Integration & Advanced Features

The HD-Series is designed to integrate into modern manufacturing environments and support advanced fastening strategies.

Key features include:

Patented hybrid air/electric torque control technology
Intelligent HDC controller
Brushless electric screwdriver platform
Programmable torque and speed settings
Soft Start control
Angle monitoring
Screw counting
Fastening OK / NG judgment
Cross-thread detection
Seating detection
Eight programmable fastening presets
Digital I/O for PLC communication
PC programming and monitoring software
Automatic tool recognition
Continuous-duty production operation
ESD housing with 1-ohm bit-tip grounding (driver cable is not ESD)
Low reaction force
Low vibration
Quiet operation
Supports Industry 4.0 and smart manufacturing initiatives through programmable process control and production monitoring.

Media & Supporting Content

Need Help?

Contact Applications Engineering for setup guidance
Speak with Sales for product selection
Call us:
- North America:(408) 850-9978
- International: +44 1428 741756

HD-Series Torque & Automation Control System – FAQ & User Guide

The Mountz HD-Series Torque & Automation Control System combines brushless electric screwdrivers, intelligent controllers, and hybrid air/electric technology to deliver programmable torque control, real-time process monitoring, and repeatable fastening for demanding production environments.