ESAB HC-4B Remote Hand Control Troubleshooting instruction

INSTRUCTIONS for

1.

2.

3.

4.

F-15-124

HC-4B REMOTE HAND CONTROL, P/N 33840

A. DESCRIPTION

The HC-4B remote control is designed to operate with CV/
CC (constant voltage/constant current) inverter power sources
equipped with a matching (14) pin receptacle connector.

This compact multi-process remote control accessory incor­porates the following features:

A three position PROCESS switch allows you to select the
process you intend to use. The process selection sets the
correct power supply characteristic as follows:

The CC position sets a constant current characteristic

a.

required for stick, tig or air carbon gouging applications.
The CV position sets a constant voltage characteristic

b.

required for all conventional "non-digital" mig welding.

c.

The DIGITAL MIG (Center) position of this switch totally
disables remote voltage control from the pendant. In
this position the power supply is set with a constant volt­age characteristic required for use with "digital-type" mi­croprocessor wire feeder/control.

A two position CONTACTOR switch allows you to turn the
power supply contactor On or Off in the constant current
(CC) mode for the Stick/Tig/Arc Gouging process. This

switch is disabled for all mig operations when a con­stant voltage (CV) characteristic is set up.

The CURRENT/VOLTAGE control provides variable full
range control of power supply output. In the "CC" mode,
this potentiometer controls output current. In the "CV" mode
(non-digital), this potentiometer controls output voltage.
This function is disabled when the Process switch is in its
DIGITAL MIG (center) position.

This control also incorporates two additional control fea­tures; a TIG/STICK selector, and an ARC FORCE potenti­ometer, as follows.

The two-position TIG/STICK switch allows you to select

a.

the "process mode" to be used. Both modes provide the
cc-type characteristic; however, the slope of the STICK
output can be further adjusted with the ARC FORCE con­trol pot.

The ARC FORCE control, is only functional in the Stick

b.

mode, and it allows you to control the Stick welding arc
characteristics. The lower settings provide less short
circuit (see Fig. 1) and a Globular Metal Transfer. The
higher settings provide more short circuit and a forcefull,
more penetrating arc; Globular Transfer is reduced and
Arc stability is improved. For most stick applications set
the control at 4 or 5 and readjust as needed. With the
control set at MIN. position, a longer arc length can be
maintained; and at MAX. setting, the arc will extinguish
much easier whrn drawing the rod away from the work.

F-15-124

March, 1995

80
70
60
50
40
30

Volts D.C.

20
10

0

0 100

Minimum Current

200

Amperes D.C.

Max. AF

Min. AF

300

400 500 600 700

Fig. 1 - Volt Ampere Curves

B. STICK/TIG/ARC GOUGING (CC) OPERA TION

Make sure the HC-4B's Contactor On/Off switch is
placed in it's OFF position prior to and after each
welding operation. In this position, the power source
welding contactor is deenergized and the torch elec­trode is electrically "cold".

1.

Place the poower source's Panel/Remote switch in its RE­MOTE position. Insert the HC-4B's control cable plug into
the power source's remote control receptacle.

2.

Pick up and hold the torch or electrode holder away from
the work or other grounded oblects.

3.

Place the Process switch in the CC position to provide a
constant current (CC) type characteristic.

4.

Place the TIG/STICK switch to the process mode you plan
to use, Tig or Stick.
If the Stick mode is selected, set the ARC FORCE control
at 4 or 5 setting, and adjust as necessary for a softer or
harder welding arc (see section A, #4, part b).

J1
J2

Arc Force Range

@ a Medium

Current Setting

AF=Arc Force Setting

Maximum Current

Control
Cable

HC-4B

Be sure this information reaches the operator.
You can get extra copies through your supplier .

Fig. 2 - HC-4B Connection Diagram

5.

Energize the main contactor by placing the Contactor switch
in its ON position.

6.

Set the Current control potentiometer to provide the de­sired current required (up to full range), and commence
welding.

7.

Remember the "Warning", and place the Contactor switch
OFF after each operation.

C. MIG (CV) OPERA TION

1.

Place the power source's Panel/Remote switch in its RE­MOTE position. Insert the HC-4B's control cable pluf into
the power source's remote control receptacle.

2.

Place the Process switch as follows:

Set CV position for non-digital (conventional) feeder/con-

a.

trol operations - to provide constant voltage type charac­teristic and allow remote voltage control.

Set to DIGITAL MIG (center) position for digital micropro-

b.

96W85 - STRAIN RELIEF

cessor feeder/control operations - this establishes re­quired CV-type characteristic, but disables remote volt­age pot.

3.

Although the CONTACTOR switch is disabled when the
Process switch is in either its DIGIT AL MIG or CV position,
it is suggested that you place it in the OFF position. Re­member that in all Mig-CV operations, the main contactor
is controlled from the feeder/control.

4.

Set the VOLTAGE control potentiometer as follows:

For non-digital (Conventional) feeder/control operations,

a.

this pot provides variable full-range welding voltage con­trol when the Process switch is in the CV position.

For digital-microprocessor mig feeder/control operations,

b.

this pot is totally disabled when the Process switch is in
its DIGITAL MIG position.

5.

Commence welding operation by energising the feeder/
control.

SW1

636702 ­SWITCH TOGGLE
DPDT 10A 250V
951474 ­SWITCH SEAL BLACK

SW2

634518 ­SWITCH TOGGLE
DPDT 10A 125V
951474 ­SWITCH SEAL BLACK

SW3

634518 ­SWITCH TOGGLE
DPDT 15A 125V
951474 ­SWITCH SEAL BLACK

951495 - CABLE ASSEMBL Y

96W85 - STRAIN RELIEF

2062018 POTENTIOMETER

VCP

1k/2W

934518 - SWITCH

TOGGLE

DPDT 15A 125V

951502 - KNOB

PROCESS

CC

DIGITAL MIG

CONTACTOR

ON

OFF

TIG

STICK/MMA

34019 - COVER

CV

4

3

2

1

0

VOLTAGE
CURRENT

3

2

1

ARC FORCE

TR-1

5

5

4

MIN MAX

P2

6

7

8

9

10

6

7

8

9

31436­BOARD ASS'Y . P .C.

ARC FORCE

P2-5 RED

P2-6 BLU

P2-2 ORN

P2-3 BLU

5

SW 3

P2-4 BLK

1 P2 10

951016 Receptacle 10 Pole

AFP

1

3

2

GRN P2-9

J1-A BLK

J1-B BLU

13

SW 2

246

P2-4 BLK

951009 Receptacle 6 Pole

1 P1 6

PCB

P2-7 ORN

P2-8 BRN

135

246

P1

1-RED J1-E
2-ORN J1-G
3-VIO J1-K
4-VIO SW1-3
5-WHT J1-F
6- NOT USED

CV/CC REF

3

P1-4 VIO

J1-C BRN

VCP

1

2

1 2
3 4

5 6

GRN P2-9

J1

A-BLK SW2-3
B-BLU SW2-5
C-BRN SW1-5
D-YEL SW1-4
E-RED P1-1
F-WHT P1-5
G-ORN P1-2
H-GRN GROUND
J- NOT USED
K-VIO P1-3

GRN P2-9
YEL J1-D

SW 1

P2

1- NOT USED
2-ORN SW3-3
3-BLU SW3-5
4-BLK SW3-2
5-RED AFP-2
6-BLU AFP-2
7-ORN VCP-3
8-BRN VCP-2
9-GRN VCP-1,AFP-1,SW1-2
10- NOT USED

951154 - POTENTIOMETER

AFP

1k/2W

951086 ­HANDLE

F-15-124 3/95 1C

182W12 - RUBBER BUMPER