Lincoln Electric S0A5150 Operator's Manual
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Lincoln Electric S0A5150 Operator's Manual

Lincoln Electric S0A5150 Operator's Manual

Tig wire feed system
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Operator's Manual
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CWT
WFD-3
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
S8M5026-A
I Issue Date Jun-24
© Lincoln Glob al, Inc. All Rights Reserved.
For use with machines having Numbers:
SOA515O
THE LINCOLN ELECTRIC COMPANY
22801 St. Clair Avenue• Cleveland, OH • 44117-1199 • U.S.A.
Phone: + 1.216.481.8100 • www.lincolnelectric.com
I irnt!l•l!�I·
ELECTRIC]

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Summary of Contents for Lincoln Electric S0A5150

  • Page 1 .lincolnelectric.com/locator Save for future reference Date Purchased Code: (ex: 10859) Serial: (ex: U1060512345) THE LINCOLN ELECTRIC COMPANY S8M5026-A 22801 St. Clair Avenue• Cleveland, OH • 44117-1199 • U.S.A. I Issue Date Jun-24 Phone: + 1.216.481.8100 • www.lincolnelectric.com © Lincoln Glob al, Inc. All Rights Reserved.
  • 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 INTRODUCTION ............................1 CONTROLS ..............................1 WIRE FEED DRIVE .............................2 WIRE ARTICULATOR ..........................3 WIRE SIZE AND TYPE KITS ........................4 REMOTE I/O CONTROL ..........................4 MOTOR OUTPUT ............................4 OPERATIONAL STATUS ..........................4 OPERATOR PENDANT ..........................5 1.10 CONTROL SPECIFICATION ........................6 INSTALLATION ..........

  • Page 10: General Description

    40 LBS (18kg). Other wire size kits are available upon request. WF-200 Low Speed TIG System WFD-3 Drive Control FIGURE 1-1: WFD-3 TIG Wire Feed System (P/N: S0A5150) WFD-3 System Components Unit Part No WFD-3 Wire Feed Dive Control – 110vac...

  • Page 11: Wire Feed Drive

    sampled Back EMF. The embedded controller provides precise motor braking and anti-plugging features to extend motor life. The WFD-3 also provides a RS-485 serial port configured to support Modbus RTU protocol. This port can be used to Operate and configure various features of the WFD-3. Motor Cable WFD-3 Operator Pendant WFD-3 Controller...

  • Page 12: Wire Articulator

    Wire Articulator The wire articulator consists of a guide mechanism to allow full position adjustment for vertical, cross seam, feed angle and distance from the electrode. Tips and liners can be changed to suit the wire size being used. Standard length of the conduit supplied with the system is 30" (762mm) and may cut to the desired length.

  • Page 13: Wire Size And Type Kits

    Wire Size and Type Kits Wire Kits are available for different wire size and type (steel alloys, stainless or aluminum). Kits will accommodate wire sizes from 0.035" (0.89mm) to 0.062" (1.57mm) diameter. Other wire size kits are available upon request. The kits consist of parts needed to setup the WF-200 Wire Feeder, liner and contact.

  • Page 14: Operator Pendant

    • READY – Indicates when the controller is ready to respond to input commands. DRIVE ON – Illuminates when the Motor drive output is • active. TORQUE – Illuminates when the motor controller detects • max current output. I/O PWR – Illuminates when power is applied to the •...

  • Page 15: 1.10 Control Specification

    1.10 Control Specification The following are the specifications for the WFD-3 Control: Dimension 4.75"h x 2.0"w x 11.0"l (120.6mm x 50.8mm x 279.4mm) Mounting Dimension 1.25" wide x 10.25" long, four 0.25” diameter hole Weight 5 lbs (2.27 kgms) Operating Temperature -10°F (-23°C) to +140°F (+60°c) Power Input 120 vac ±...

  • Page 16: Installation

    INSTALLATION WFD-3 Controls Location The WFD-3 controller should be located near the drive motor it is controlling. The standard length of the motor drive cable is 25 feet with a maximum length of 75 feet. Mount the WFD-3 controller in a location that allows easy access to the front and rear panel.
  • Page 17 FIGURE 2-1: Enclosure Mounting Dimensions Connect power cable to suitable 115 VAC power outlet. Connect motor control cable to MOTOR connector on rear of enclosure. Connect the remote I/O cable or operator pendant to I/O connector on rear of enclosure. I/O Connector COMM may be used for the...

  • Page 18: 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 +12 VDC for optional encoder...

  • Page 19: Motor Connection

    ENC +12VDC ENC PULSE 12 vdc TTL Encoder ENC COM FIGURE 2-6: 12 vdc 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+ FIGURE 2-7: Permanent magnetic motor wiring...

  • Page 20: Wf-200 Wire Feed Drive Mounting

    FUNCTIONAL DESCRIPTION Drive Forward command input (24 vdc @ 10 ma) +24 vdc output @ 100ma output Drive Reverse command input (24 vdc @ 10 ma) Drive-on signal Ready signal Reference signal 24 vdc common Speed Input signal (0-10 vdc input) SHLD Frame ground (Cable Shield connection) FIGURE 2-8: Remote I/O connector pin-out...
  • Page 21 5.641 60° MOTOR DRIVE CONNECTOR 12.000 PIVOT BRACKET 90° ROTATION IN EACH DIRECTION WIRE INLET QUICK DISCONNECT 1.250 FITTING 0.625 8.436 3.691 5X Ø0.170 MOUNTING HOLES FOR #8-32 SCREWS 3.00 1.38 0.625 3.475 1.016 1.250 LINER AND CASING RETAINER 0.773 2.375 FIGURE 2-10: WF-200 Capstan Mounting Dimensions (P/N: E2A5225)

  • Page 22: Welding Wire Liner And Casing Installation On Wf-200

    Welding Wire Liner and Casing Installation on WF-200 Wire Outlet Guide Liner Note: Make sure Liner is inserted all the way into Wire Oulet Guide as shown Casing/Liner Retainer Liner Casing FIGURE 2-11: Liner and Casing Installation on WF-200 with Steel Alloy Kit Aluminum Pick-up Block Liner...
  • Page 23 Wire Outlet Guide Liner Note: Make sure Liner is inserted all the way into Wire Oulet Guide as shown Casing/Liner Retainer Liner Casing FIGURE 2-11: Liner and Casing Installation on WF-200 with Aluminum Wire Straightener Kit...

  • Page 24: Welding Wire Liner And Casing Installation On Tig Wire Articulator

    Welding Wire Liner and Casing Installation on TIG Wire Articulator Hex Adaptor Liner Retainer Fitting Liner Casing Contact Tip Retainer Note: Make sure Liner is inserted into Contact Tip Retainer as shown...

  • Page 25: Wf-200 Steel Alloy Wire Straightener Kit Installation

    WF-200 Steel Alloy Wire Straightener Kit Installation When using a steel alloy filler wire with the capstan, a Non-aluminum Wire Kit specifically made for each size wire must be installed on the capstan. Figure 2012 show all the parts that are included in these kits.

  • Page 26: 2.10 Wf-200 Aluminum Wire Pick-Up Block Kit Installation

    2.10 WF-200 Aluminum Wire Pick-up Block Kit Installation When using an aluminum filler wire with the capstan, an Aluminum Wire Pick-up Block Kit specifically made for each size wire must be installed on the capstan. Figure 8 and 9 show all the parts that are included in these kits.
  • Page 27 Wire Feed Cover 6-32 x 1/4 Lg. Socket Head Cap Screw - 4 Places 6-32 x 3/4 Lg. Button Head Screw - 2 Places Capstan Wheel (see chart below) 8-32 x 3/16 Long Socket Set Screw Alum. Wire Guide (see chart below) Torch Liner (see chart below) O-Ring P/N: X4S5005 Hex Fitting P/N: X6F5061...

  • Page 28: 2.11 Wf-200 Aluminum Wire Straightener Kit Installation

    2.11 WF-200 Aluminum Wire Straightener Kit Installation When using an aluminum filler wire with the capstan, an Aluminum Wire Straightener Kit specifically made for each size wire must be installed on the capstan. Figure 2-14 show all the parts that are included in these kits.
  • Page 29 Wire Feed Cover 10-32 x 3/4 Long Button Head Screw 6-32 x 3/4 Long Button Hedd Screw - 2 Places 6-32 x 1/4 Lg. Socket Head Cap Screw - 4 Places Bearing P/N: X2B0373 Stripper Bearing Spacer P/N: E2M5590 Capstan Wheel (see chart below) Stripper P/N: E2M5767 Cam Follower P/N: X2B5028 #10 Internal Lock Washer...

  • Page 30: Wf-200 Wire Drive Wheel And Inlet Guide Installation

    2.12 WF-200 Wire Drive Wheel and Inlet Guide Installation The WF-200 requires a different drive wheel and inlet wire guide for each diameter of filler wire used. To change the inlet wire guide and drive wheel, remove any existing filler wire from the capstan. Pull the existing inlet wire guide out of the capstan wire drive block.

  • Page 31: 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 32 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 33: 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 34: 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 35: 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 36: Appendix Asystem Drawings

    APPENDIX A SYSTEM DRAWINGS WFD-3 Enclosure Assembly 110VAC - P/N: S3A5233...
  • Page 37 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 38: 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 39: 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 40: Standard Hand Low Speed Capstan P/N: E2A5218

    Standard Hand Low Speed Capstan P/N: E2A5218...
  • Page 41 ITEM QTY. PART NO. DESCRIPTION E2A5214 CAPSTAN BEARING CARTRIDGE ASSEMBLY E2A5129 PRESSURE ROLLER SHOE ASSEMBLY E2M5867 WIRE FEEDER BLOCK E2M5151 SLIDE BLOCK E2M5611 KNOB SHAFT E2M5751 CAPSTAN SPRING HOLDER E2M5750 CAPSTAN SCREW E2M5752 CAPSTAN SPRING GUIDE E2M5753 CAPSTAN SPRING INSERT E2M5162 BEARING SLEEVE E2M5608...

  • Page 42: 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 43 Multiple WFD-3 Enclosures to a NetHub with RS-232/RS-485 Communications Diagram...
  • Page 44 Multiple WFD-3 Enclosure to a NetHub with Ethernet Communications Diagram...
  • Page 46 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 47 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 48 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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