Lincoln Electric CWT WFD-3 Operator's Manual
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Lincoln Electric CWT WFD-3 Operator's Manual

Lincoln Electric CWT WFD-3 Operator's Manual

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Operator's Manual
CWT WFD-3
TM
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
S8M5026
| Issue D ate Sep-21 ©
Lincoln Global, Inc. All Rights Reserved.
For use with machines having Numbers:
S0A5147

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Summary of Contents for Lincoln Electric CWT WFD-3

  • Page 1 Operator’s Manual CWT WFD-3 For use with machines having Numbers: S0A5147 Register your machine: www.lincolnelectric.com/register Authorized Service and Distributor Locator: www.lincolnelectric.com/locator Save for future reference Date Purchased Code: (ex: 10859) Serial: (ex: U1060512345) S8M5026 | Issue D ate Sep-21 ©...
  • Page 3 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 4 W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 2.d. All welders should use the following procedures in order to 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
  • Page 5 SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 6 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.
  • Page 7 EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for METHODS OF REDUCING EMISSIONS Arc Welding Equipment. It is for use with other Lincoln Electric Public Supply System equipment. It is designed for industrial and professional use.

  • Page 8: Table Of Contents

    Table of Contents GENERAL DESCRIPTION .................... 1 FUNCTIONAL DESCRIPTION ........................1 REMOTE I/O CONTROL ..........................1 MOTOR OUTPUT ............................1 OPERATIONAL STATUS ..........................2 OPERATOR PENDANT ..........................2 CONTROL SPECIFICATION ........................3 INSTALLATION ......................4 LOCATION ..............................4 CONTROLLER AND PENDANT DIMENSIONS ..................5 DC MOTOR CONNECTOR PIN-OUT ......................7 OPTIONAL ENCODER CONNECTIONS ....................7 MOTOR CONNECTION ..........................8 REMOTE I/O CONNECTOR CONNECTION ....................8...

  • Page 10: General Description

    GENERAL DESCRIPTION Functional Description The WFD-3 Wire Feed Drive Control is a PWM motor speed controller using an embedded micro controller to provide motor speed regulation and torque compensation. The WFD-3 is a general purpose GMAW/GTAW wire feed system using the CWT Capstan Wire Feeder. The system is designed to be used with automated welding fixtures and robotic welding systems.

  • Page 11: Operational Status

    Operational Status The operational status of the WFD-3 is displayed using 9 LED’s located on the front panel. The following is a description of the LED functions: • READY – Indicates when the controller is ready to respond to input commands. DRIVE ON –...

  • Page 12: Control Specification

    DIRECTION – This switch is used select the direction to feed the wire. When the switch • is set to the “CCW” position slide will be move in the CCW direction. When the switch is set to the “CW” position the slide will be moved in the CW direction. SPEED –...

  • Page 13: Installation

    INSTALLATION Location The WFD-3 controller should be located near the drive motor it is controlling. The maximum motor drive cable length is 75 ft. Mount the WFD-3 controller in a location that allows easy access to the front and rear panel. Figure 2-1 shows the WOC-2 System Diagram. Figure 2-2 and 2-3 shows the dimensions for the control enclosure and operator pendant.

  • Page 14: Controller And Pendant Dimensions

    Controller and Pendant Dimensions 2.250 FRONT VIEW 1.250 0.477 4X Ø0.281 4.750 0.875 0.375 11.000 10.250 9.250 MAX 6" FOR CABLE CLEARANCE SIDE VIEW TOP VIEW REAR VIEW FIG 2-2: Enclosure Mounting Dimensions Connect power cable to suitable 115 VAC power outlet. Connect motor control cable to MOTOR connector on rear of enclosure.
  • Page 15 I/O Connector COMM used for Operator Pendant and Remote I/O Cable MOTOR WFD-3 Control Motor Control Enclosure Connector Power Cable FIG 2-3: Rear Panel of WFD-3 Control Enclosure 3.000 2.000 0.250 RUBBER FEET HANDLES 19 FT 5.750 WOC-2 PENDANT 3.500 FIG 2-4: WFD-3 Operator Pendant Dimensions...

  • Page 16: Dc Motor Connector Pin-Out

    DC Motor Connector Pin-Out Several cables are available from the factory, which and can be used for connecting a DC drive motor to the WFD-3. Consult the factory for available cable assemblies. The following is the pin-out for the WFD- 3 motor connector: DESCRIPTION +15 VDC for optional encoder...

  • Page 17: Motor Connection

    The following is the connection diagram for a 15 VDC encoder: ENC +15VDC ENC PULSE 15 volt Encoder ENC COM Fig 2-7 15-volt TTL encoder connection Motor Connection The WFD-3 can be used with a permanent magnet motors with an armature rating of 10 – 24 volt dc. The following is the connection diagram for a permanent magnet motor: ARM- ARM+...
  • Page 18 FUNCTIONAL DEPWMIPTION +24 vdc output @ 100ma output 24 vdc common Speed Input signal common Speed input signal ( 0 – 10 vdc) Drive Forward command input (24 vdc @ 10 ma) Drive Reverse command input (24 vdc @ 10 ma) Motor Tachometer output (24 vdc) Frame ground (Cable Shield connection) Fig 2-9...

  • Page 19: Operation

    OPERATION Theory of Operation The WFD-3 is PWM motor speed controller. The control uses an embedded micro-controller to provide line synchronization, phased back EMF sampling and direction control logic with anti-plug motor reversing. The phased EMF sample provides precise back EMF sample for improve motor speed regulation.
  • Page 20 Set the speed reference to 10.0 volts and adjust R4 (MAX) for 2300 (HZ or RPM) or desired motor speed. When using a Tachometer the maximum motor speed is 3000 RPM. Disable the forward direction input. Turn the power off and reinstall the DMC cover.

  • Page 21: Modbus Memory Map

    MODBUS MEMORY MAP General Description This document provides the basic Modbus memory map and command structure for the WFD-3 RS-485 communications port. The WFD-3 supports the Modbus Protocol as specified in the Modicon Technical publications “Modbus Protocol” (intr7.html). The WFD-3 control does not support the Broadcast mode.

  • Page 22: Coil Definitions And Operation

    Coil Definitions and Operation The WFD-3 has 16 simulated coils. These coils are used as internal bit flags to perform specific functions. The WFD-3 supports both single and group force coil commands. Refer to Section 4.3 for summary of the Coil functions. Memory Map for Holding Register (Modbus Command 03, 06, 16) The following is the Register definitions address 0-19: REGISTER...

  • Page 23: Memory Map For Slave Id (Modbus Command 17)

    Modifying the Holding Register[14 – 20] values may result in a catastrophic failure of the controller Memory Map for Slave ID (Modbus Command 17) The following is a summary of the Report Slave ID and Status (Code 17) Response Data fields: Byte Contents Sensor ID Number =10 Hex (Version 1, Rev0)

  • Page 24: Appendix Asystem Drawings

    APPENDIX A SYSTEM DRAWINGS WFD-3 Enclosure Assembly 110VAC - P/N: S3A5233...
  • Page 25 ITEM PART NO DESCRIPTION S3W5216 Harness, Power Supply S3E5165 Enclosure S3E5166 Cover S3E5198 Overlay, Front S3E5111 Overlay, Rear S3W5159 Cable, 110VAC Power S3W5160 Harness, Power Switch S3W5162 Harness, Motor/Encoder S3W5163 Harness, I/O S3W5164 Harness, Comm S5A5076 PCB Assembly, DMC-2 36V Drive X3P5841 Connector, Housing 8 Circuit X3P5875...

  • Page 26: Capstan Wire Feeder Motor Cable - P/N: S3W5166

    Capstan Wire Feeder Motor Cable – P/N: S3W5166 25' ±3" PN S3W5166 WF-100 MTR TYPE TEXT ONTO LABEL AS FOLLOWS: PN S3W5166 WF-100 MTR 6 REQD 2 REQD 4 REQD ITEM PART NO DESCRIPTION X3P5586 CONN., PLUG 9 CIRCUIT - BENDIX #PT06A-14-12P X3P5589 CLAMP, CABLE - AMPHENOL #97-3057-1008 X3P5505...

  • Page 27: Open Ended Remote I/O Cable - P/N: S3W5219

    Open Ended Remote I/O Cable – P/N: S3W5219 DESCRIPTION WIRE TYPE CONNECTOR WHITE PIN 1 +24 I/O BROWN PIN 2 GREEN PIN 3 DRVON YELLOW PIN 4 GRAY PIN 5 REF+ PINK PIN 6 I/O COM BLUE PIN 7 WIPER PIN 8...

  • Page 28: Communication Diagrams

    Communication Diagrams RS-232/RS-485 Converter P/N: C3A5023 – To be Personal connected to the COM Port Computer on your Personal Computer Power Supply P/N: X3T5036 RS-485 Comm Cable P/N: S3W5220 MOTOR WFD-3 Enclosure Single WFD-3 Enclosure to a RS-232/RS-485 Converter Diagram RS-232/RS-485 Ethernet Converter Ethernet Cable...
  • Page 29 Multiple WFD-3 Enclosures to a NetHub with RS-232/RS-485 Communications Diagram...
  • Page 30 Multiple WFD-3 Enclosure to a NetHub with Ethernet Communications Diagram...
  • Page 34 WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. Insulate yourself from work and AVISO DE ground. Spanish PRECAuCION No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
  • Page 35 WARNING Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. remove fumes from breathing zone. AVISO DE Spanish PRECAuCION Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
  • Page 36 Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.

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