Lincoln Electric CWT WFD-3 User manual

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

THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELECTRIC.
PLEASE EXAMINE CARTON AND EQUIPMENT FOR
DAMAGE IMMEDIATELY
When this equipment is shipped, title passes to the purchaser
upon receipt by the carrier. Consequently, claims for material
damaged in shipment must be made by the purchaser against the
transportation company at the time the shipment is received.
SAFETY DEPENDS ON YOU
Lincoln arc welding and cutting equipment is designed and built
with safety in mind. However, your overall safety can be increased
by proper installation ... and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,
think before you act and be careful.
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed
to avoid minor personal injury or damage to this equipment.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc.
Use corrective lenses if necessary
to stay a reasonable distance
away from the arc.
READ and obey the Safety Data
Sheet (SDS) and the warning label
that appears on all containers of
welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to
keep the fumes and gases from
your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away
from your face.
If you develop unusual symptoms, see your supervisor.
Perhaps the welding atmosphere and ventilation system
should be checked.
WEAR CORRECT EYE, EAR &
BODY PROTECTION
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.
PROTECT others from splatter, flash, and glare
with protective screens or barriers.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
WARNING
CAUTION
Safety 01 of 04 - 5/16/2018

SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
WARNING: Breathing diesel engine exhaust
exposes you to chemicals known to the State
of California to cause cancer and birth defects,
or other reproductive harm.
• Always start and operate the engine in a
well-ventilated area.
• If in an exposed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to
www.P65 warnings.ca.gov/diesel
WARNING: This product, when used for welding or
cutting, produces fumes or gases which contain
chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California
Health & Safety Code § 25249.5 et seq.)
WARNING: Cancer and Reproductive Harm
www.P65warnings.ca.gov
ARC WELDING CAN BE HAZARDOUS. PROTECT
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS
INJURY OR DEATH. KEEP CHILDREN AWAY.
PACEMAKER WEARERS SHOULD CONSULT WITH
THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For
additional safety information, it is strongly recommended
that you purchase a copy of “Safety in Welding & Cutting -
ANSI Standard Z49.1” from the American Welding Society,
P.O. Box 351040, Miami, Florida 33135 or CSA Standard
W117.2-1974. A Free copy of “Arc Welding Safety” booklet
E205 is available from the Lincoln Electric Company,
22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE POWERED
EQUIPMENT.
1.a. Turn the engine off before troubleshooting
and maintenance work unless the
maintenance work requires it to be running.
1.b. Operate engines in open, well-ventilated areas or vent the engine
exhaust fumes outdoors.
1.c. Do not add the fuel near an open flame welding
arc or when the engine is running. Stop the
engine and allow it to cool before refueling to
prevent spilled fuel from vaporizing on contact
with hot engine parts and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not start engine until
fumes have been eliminated.
1.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
1.e. In some cases it may be necessary to remove safety guards to
perform required maintenance. Remove guards only when
necessary and replace them when the maintenance requiring
their removal is complete. Always use the greatest care when
working near moving parts.
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control
rods while the engine is running.
1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto wire
as appropriate.
1.h. To avoid scalding, do not remove the radiator
pressure cap when the engine is hot.
ELECTRIC AND
MAGNETIC FIELDS MAY
BE DANGEROUS
2.a. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF).
Welding current creates EMF fields around welding cables
and welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work
cables. If the electrode cable is on your right side, the
work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as pos-
sible to the area being welded.
2.d.5. Do not work next to welding power source.
SAFETY
Safety 02 of 04 - 5/16/2018

ELECTRIC SHOCK
CAN KILL.
3.a. The electrode and work (or ground) circuits are
electrically “hot” when the welder is on. Do
not touch these “hot” parts with your bare skin or wet clothing.
Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full area
of physical contact with work and ground.
In addition to the normal safety precautions, if
welding must be performed under electrically
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following
equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic welding
gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection should
be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth)
ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode
holders connected to two welders because voltage
between the
two can be the total of the open circuit voltage of both
welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS CAN BURN.
4.a. Use a shield with the proper filter and cover plates to protect your
eyes from sparks and the rays of the arc when welding or
observing open arc welding. Headshield and filter lens should
conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material
to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
CAN BE DANGEROUS.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep your head out of the fume.
Use enough ventilation and/or exhaust at the arc to keep fumes
and gases away from the breathing zone. When welding
hardfacing (see instructions on container or SDS)
or on lead or cadmium plated steel and other
metals or coatings which produce highly toxic
fumes, keep exposure as low as possible and
within applicable OSHA PEL and ACGIH TLV limits
using local exhaust or mechanical ventilation
unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
outdoors, a respirator may also be required.
Additional precautions are also required when
welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PEL and
ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause
injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
SAFETY
Safety 03 of 04 - 5/16/2018

WELDING AND CUTTING
SPARKS CAN CAUSE
FIRE OR EXPLOSION.
6.a. Remove fire hazards from the welding area. If
this is not possible, cover them to prevent the welding sparks
from starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks and
openings to adjacent areas. Avoid welding near hydraulic lines.
Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special
precautions should be used to prevent hazardous situations.
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is
touching the work or ground. Accidental contact can cause
overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances inside.
They can cause an explosion even though they have been
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the
possibility of the welding current passing through lifting chains,
crane cables or other alternate circuits. This can create fire
hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “Standard for Fire Prevention During
Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
CYLINDER MAY EXPLODE IF
DAMAGED.
7.a. Use only compressed gas cylinders containing
the correct shielding gas for the process used
and properly operating regulators designed for
the gas and pressure used. All hoses, fittings,
etc. should be suitable for the application and
maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to
an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected
to physical damage.
• A safe distance from arc welding or cutting operations
and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders,
associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in Cylinders,” available from
the Compressed Gas Association, 14501 George Carter Way
Chantilly, VA 20151.
FOR ELECTRICALLY
POWERED EQUIPMENT.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical
Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
SAFETY
Safety 04 of 04 - 5/16/2018

ELECTROMAGNETIC
COMPATIBILITY (EMC)
CONFORMANCE
Products displ ying the CE m rk re in conformity with Europe n
Community Council Directive. It w s m nuf ctured in conformity
with n tion l st nd rd th t implements h rmonized st nd rd: EN
60974-10 Electrom gnetic Comp tibility (EMC) Product St nd rd for
Arc Welding Equipment. It is for use with other Lincoln Electric
equipment. It is designed for industri l nd profession l use.
INTRODUCTION
All electric l equipment gener tes sm ll mounts of electrom gnetic
emission. Electric l emission m y be tr nsmitted through power
lines or r di ted through sp ce, simil r to r dio tr nsmitter. When
emissions re received by other equipment, electric l interference
m y result. Electric l emissions m y ffect m ny kinds of electric l
equipment; other ne rby welding equipment, r dio nd TV reception,
numeric l controlled m chines, telephone systems, computers, etc.
WARNING: This Cl ss A equipment is not intended for use in
residenti l loc tions where the electric l power is provided by the
public low-volt ge supply system. There m y be potenti l difficulties
in ensuring electro-m gnetic comp tibility in those loc tions, due to
conducted s well s r di ted disturb nces.
INSTALLATION AND USE
The user is responsible for inst lling nd using the welding
equipment ccording to the m nuf cturer’s instructions.
If electrom gnetic disturb nces re detected then it sh ll be the
responsibility of the user of the welding equipment to resolve the
situ tion with the technic l ssist nce of the m nuf cturer. In some
c ses this remedi l ction m y be s simple s e rthing (grounding)
the welding circuit, see Note. In other c ses it could involve
constructing n electrom gnetic screen enclosing the power source
nd the work complete with ssoci ted input filters. In ll c ses
electrom gnetic disturb nces must be reduced to the point where
they re no longer troublesome.
NOTE: The welding circuit m y or m y not be e rthed for s fety
re sons. Follow your loc l nd n tion l st nd rds for inst ll tion nd
use. Ch nging the e rthing rr ngements should only be uthorized
by person who is competent to ssess whether the ch nges will
incre se the risk of injury, e.g., by llowing p r llel welding current
return p ths which m y d m ge the e rth circuits of other
equipment.
ASSESSMENT OF AREA
Before inst lling welding equipment the user sh ll m ke n
ssessment of potenti l electrom gnetic problems in the
surrounding re . The following sh ll be t ken into ccount:
) other supply c bles, control c bles, sign ling nd telephone
c bles; bove, below nd dj cent to the welding equipment;
b) r dio nd television tr nsmitters nd receivers;
c) computer nd other control equipment;
d) s fety critic l equipment, e.g., gu rding of industri l equipment;
e) the he lth of the people round, e.g., the use of p cem kers
nd he ring ids;
f) equipment used for c libr tion or me surement;
g) the immunity of other equipment in the environment. The user
sh ll ensure th t other equipment being used in the
environment is comp tible. This m y require ddition l
protection me sures;
h) the time of d y th t welding or other ctivities re to be
c rried out.
The size of the surrounding re to be considered will depend on
the structure of the building nd other ctivities th t re t king
pl ce. The surrounding re m y extend beyond the bound ries
of the premises.
METHODS OF REDUCING EMISSIONS
Public Supply System
Welding equipment should be connected to the public supply system
ccording to the m nuf cturer’s recommend tions. If interference
occurs, it m y be necess ry to t ke ddition l prec utions such s
filtering of the system. Consider tion should be given to shielding
the supply c ble of perm nently inst lled welding equipment, in
met llic conduit or equiv lent. Shielding should be electric lly
continuous throughout its length. The shielding should be
connected to the welding power source so th t good electric l
cont ct is m int ined between the conduit nd the welding power
source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely m int ined ccording to
the m nuf cturer’s recommend tions. All ccess nd service doors
nd covers should be closed nd properly f stened when the
welding equipment is in oper tion. The welding equipment should
not be modified in ny w y except for those ch nges nd
djustments covered in the m nuf cturer’s instructions. In
p rticul r, the sp rk g ps of rc striking nd st bilizing devices
should be djusted nd m int ined ccording to the m nuf cturer’s
recommend tions.
Welding Cables
The welding c bles should be kept s short s possible nd should
be positioned close together, running t or close to the floor level.
Equipotential Bonding
Bonding of ll met llic components in the welding inst ll tion nd
dj cent to it should be considered. However, met llic components
bonded to the work piece will incre se the risk th t the oper tor
could receive shock by touching these met llic components nd
the electrode t the s me time. The oper tor should be insul ted
from ll such bonded met llic components.
Earthing of the Workpiece
Where the workpiece is not bonded to e rth for electric l s fety, nor
connected to e rth bec use of its size nd position, e.g., ship’s hull
or building steelwork, connection bonding the workpiece to e rth
m y reduce emissions in some, but not ll inst nces. C re should be
t ken to prevent the e rthing of the workpiece incre sing the risk of
injury to users, or d m ge to other electric l equipment. Where
necess ry, the connection of the workpiece to e rth should be m de
by direct connection to the workpiece, but in some countries
where direct connection is not permitted, the bonding should be
chieved by suit ble c p cit nce, selected ccording to n tion l
regul tions.
Screening and Shielding
Selective screening nd shielding of other c bles nd equipment in
the surrounding re m y llevi te problems of interference.
Screening of the entire welding inst ll tion m y be considered for
speci l pplic tions. 1
1 Portions of the receding text are contained in EN 60974-10
“Electromagnetic Com atibility (EMC) roduct standard for arc welding
equi ment.”
L10093 D

Table of Contents
1.0 GENERAL DESCRIPTION ............................................................................................ 1
1.1 FUNCTIONAL DESCRIPTION....................................................................................................................1
1.2 REMOTE I/O CONTROL.............................................................................................................................1
1.3 MOTOR OUTPUT ........................................................................................................................................1
1.4 OPERATIONAL STATUS............................................................................................................................2
1.5 OPERATOR PENDANT ..............................................................................................................................2
1.6 CONTROL SPECIFICATION ......................................................................................................................3
2.0 INSTALLATION.............................................................................................................. 4
2.1 LOCATION....................................................................................................................................................4
2.2 CONTROLLER AND PENDANT DIMENSIONS .......................................................................................5
2.3 DC MOTOR CONNECTOR PIN-OUT ........................................................................................................7
2.4 OPTIONAL ENCODER CONNECTIONS ..................................................................................................7
2.5 MOTOR CONNECTION ..............................................................................................................................8
2.6 REMOTE I/O CONNECTOR CONNECTION ............................................................................................8
3.0 OPERATION................................................................................................................. 10
3.1 THEORY OF OPERATION ...................................................................................................................... 10
3.2 CONTROL CALIBRATION ....................................................................................................................... 10
4.0 MODBUS MEMORY MAP ........................................................................................... 12
4.1 GENERAL DESCRIPTION....................................................................................................................... 12
4.2 SUPPORTED MODBUS COMMANDS................................................................................................... 12
4.3 MEMORY MAP FOR COILS (MODBUS COMMAND 01,05,15) ........................................................... 12
4.4 COIL DEFINITIONS AND OPERATION.................................................................................................. 13
4.5 MEMORY MAP FOR HOLDING REGISTER (MODBUS COMMAND 03, 06, 16) .............................. 13
4.6 HOLDING REGISTER AND OPERATION.............................................................................................. 13
4.7 MEMORY MAP FOR SLAVE ID (MODBUS COMMAND 17)................................................................ 14
APPENDIX A SYSTEM DRAWINGS ................................................................................. 15
A.1 WFD-3 ENCLOSURE ASSEMBLY 110VAC - P/N: S3A5233 ............................................................... 15
A.2 CAPSTAN WIRE FEEDER MOTOR CABLE – P/N: S3W5166............................................................. 17
A.3 OPEN ENDED REMOTE I/O CABLE – P/N: S3W5219......................................................................... 18
A.4 COMMUNICATION DIAGRAMS.............................................................................................................. 19

1
1.0 GENERAL DESCRIPTION
1.1 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. The Capstan wire drive is designed
specifically for automation. The Capstan's small size and light weight (less than 6 lbs without torch - less
than 8 lbs with 350 amp water cooled torch) allows the wire feeder to be placed directly on the automated
fixture or robot wrist, eliminating the wire guide liners normally associated with conventional wire drive
systems. The Capstan also provides an increase in wire drive contact area by wrapping the wire around
a wire drive wheel. This wire drive method has four major benefits:
Plastic deforms the filler wire, virtually eliminating existing wire cast.
Increased drive force eliminates wire slip and flattening or damage to wire surface.
Integral wire straightener on the discharge side of the wire allows the wire drive to
precisely locate the filler wire independent of wire cast.
Locate the filler wire independent of wire cast.
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.
The WFD-3 is used to control linear DC drive motors for wire feed and or travel speed functions. The
WFD-3 provides speed and torque regulation using an optical encoder or phase sampled Back EMF.
The embedded controller provides precise motor braking and anti-plugging features to extend motor life.
1.2 Remote I/O Control
The WFD-3 provides remote speed control using a 0-10 VDC input signal. Two 24 VDC inputs provide
remote direction control. The control provides an optional isolated encoder output signal. A remote I/O
connector located on the rear of the enclosure provides all user control connections.
1.3 Motor Output
The standard WFD-3 can be used with 24 VDC permanent magnet motors up to 150 watts. A motor
connector located on the rear of the enclosure provides all user motor connections. The control can be
used with or without an optical tachometer. The control uses a 100 line optical tachometer input and can
provide a 5 VDC or 15 VDC output for the tachometer. The tachometer input mode is automatically
enabled when an encoder signal is active. If the encoder is not used the control will switch to the back
EMF sample mode for speed regulation.

2
1.4 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 – 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 isolated I/O.
•FWD/CW – Illuminates when the control has a FWD/CW input applied to the remote I/O.
•REV/CW – Illuminates when the control has a REV/CCW input applied to the remote I/O.
•NET PWR – Illuminates when power is applied to the isolate RS-485 serial Com port.
•+3.6V– Illuminates when the 3.6 volt power supply is active.
•+12V – Illuminates when the 12 volt power supply is active.
•+36V – Illuminates when the main motor power supply is active.
1.5 Operator Pendant
The WFD-3 wire drive control provides all of the required wire feed drive control functions and a tach-
less Tachometer feedback Pulse Width Modulated (PWM) motor drive control. The PWM control
provides auto tachometer sensing and will use the tachometer for feedback regulation if available. The
following operator pendant controls are provided:
•RUN - This switch is used to start and stop the wire feed drive. Setting the switch to the
“ON” position will start the wire feed drive motor. Setting the switch to the “OFF” position
will terminate the wire feed drive motor.

3
•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 – The speed pot is used to control the speed of the wire drive.
•JOG – The switch used to manually control the wire feed.
1.6 Control Specification
The following are the mechanical 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)
The following are the electrical specifications for the WFD-3 Control:
Power Input
120 vac ± 10% @ 2.5amps
Armature Current
0.5 – 6.5 amps
Armature Voltage
0 – 24 vdc
Encoder Input
5 or 15 vdc 100 lines/rev max frequency 25.0khz
Forward Input
24 vdc @ 20ma (Active High)
Reverse Input
24 vdc @ 20ma (Active High)
Speed Reference Input
0-10 vdc @ 0.1 ma
The following are the mechanical specifications for the WFD-3 Pendant:
Control Dimension
2.0”H x 3.5”W x 5.75”L (50mm x 89mm x 147 mm)
Mounting Dimension
Hand Held
Weight
1 lbs (1.18 kgms)
Power Input
24 VDC @ 0.2 amps
Operating Temperature
-10°F (-23°C) to +140°F (+60°c)

4
2.0 INSTALLATION
2.1 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.
FIG 2-1: WOC-2 System Diagram
WFD-3 Operator
Pendant
WFD-3 Control
Enclosure
Remote I/O Cable

5
2.2 Controller and Pendant Dimensions
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. Connect the remote I/O cable or operator pendant to I/O connector on
rear of enclosure.
POWER
I/O PWR TORQUE READY DRIVE ON FWD / CW REV / CCW NET PWR +3.6V +12V +36V
COMMI/O
10.250
0.375
11.000
9.250
0.875
1.250
0.477
2.250
4X Ø0.281
4.750
MOTOR
MAX 6" FOR
CABLE CLEARANCE TOP VIEWSIDE VIEW
FRONT VIEW
REAR VIEW

6
FIG 2-3: Rear Panel of WFD-3 Control Enclosure
FIG 2-4: WFD-3 Operator Pendant Dimensions
COMMI/O
MOTOR
WFD-3 Control
Enclosure
I/O Connector
used for
Operator Pendant and
Remote I/O Cable
Motor Control
Connector
Power Cable
WOC-2
PENDANT
2.000
3.000
3.500
5.750
0.250
RUBBER FEET
HANDLES
19 FT

7
2.3 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:
PIN
DESCRIPTION
A
+15 VDC for optional encoder
B
+5 VDC for optional encoder
C
Not used
D
Not used
E
Not used
F
Chassis Ground
G
Encoder Pulse input ( TTL or 15 Volt Pulse)
H
Encoder Common
J
Motor Field -
K
Motor Armature -
L
Motor Field +
M
Motor Armature +
Figure 2-5: Motor Connector Pin-out
2.4 Optional Encoder Connections
The WFD-3 can use a 5-volt or 15-volt encoder. Both power outputs are provided on the connector.
Connect the optional motor encoder to the correct voltage output. Use Pin A for a 15-volt encoder or
Pin B for a 5-volt encoder. The WFD-3 is designed for a 100-line encoder and can be used for motor
speeds up to 3000 rpm. For faster speeds, contact the factory. The following is a typical connection for
a 5-volt TTL encoder:
ENC +5VDC
ENC PULSE 5 volt TTL Encoder
ENC COM
Fig 2-6 5-volt TTL encoder connection
A
B
C
D
E
F
G
H
J
K
L
M

8
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
2.5 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+
Fig 2-8 Permanent magnetic motor wiring
2.6 Remote I/O Connector Connection
The WFD-3 is controlled via the REMOTE I/O connector. The control has two (2) 24 VDC inputs for
motor direction control, a 0-10 vdc input for speed control and a 24 VDC output. The following is the pin-
out for the REMOTE I/O connector:
A
B
C
D
E
F
G
H
J
K
L
M
A
B
C
D
E
F
G
H
J
K
L
M

9
PIN
FUNCTIONAL DEPWMIPTION
1
+24 vdc output @ 100ma output
2
24 vdc common
3
Speed Input signal common
4
Speed input signal ( 0 – 10 vdc)
5
Drive Forward command input (24 vdc @ 10 ma)
6
Drive Reverse command input (24 vdc @ 10 ma)
7
Motor Tachometer output (24 vdc)
8
Frame ground (Cable Shield connection)
Fig 2-9 Remote I/O connector pin-out
A remote I/O cable S3W5058 is available for interfacing the WFD-3 to the CWT controller or for direct
interface to user supplied PLC controller. The following is an example of using the WFD-3 controller with
a user supplied PLC controller:
FWD REV
SPEED SIGNAL COM
SPEED SIGNAL (0 – 10 vdc)
Fig 2-10 PLC interface to WFD-3
1
2
3
4
5
6
7
8

10
3.0 OPERATION
3.1 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. The Anti-plug feature prevents reversing the drive before the motor armature
has stopped. This prevents excessive motor current and brush arcing in the motor.
The Micro-Controller synchronizes all input commands to the incoming line frequency and assures
proper phase angle firing of the power PWM devices. The Analog speed signal is coupled to a
Voltage-to-Frequency convert and is electrically isolated from the off-line control. The remote
direction control inputs are optically coupled to the controller. An isolated 12-vdc-power supply is
provided for all remote input control functions. The user can use this supply to operate remote
input relays or switches for direction control. The supply has a solid-state circuit breaker, which
protects the 12-volt I/O control from external shorts. The circuit breaker will reset when the 115-
vac power is cycled off.
Optional optical tach input is provided which can be used with a 5 or 12 VDC 60-line encoder. The
encoder input is also provided as an output on the remote I/O connector. This output is an isolated
24-vdc pulse representing the encoder input. When an encoder is installed on the motor shaft, the
WFD-3 can be set for encoder feedback by installing a jumper on JP3. When the jumper is
installed, the controller uses the tachometer to regulate motor speed. When the jumper is removed,
the controller will use the motor back EMF for speed regulation.
3.2 Control Calibration
The WFD-3 controller is factory calibrated to produce 2300 rpm with an input of 10 volts. This is
performed using a 100 line Tach and a permanent magnet 1/8 motor. No adjustment is required
to operate different drive motors. However, there may be a need to check or recalibrate the WFD-
3 for use with a different motor or motor speed range. To calibrate the WFD-3 perform the following
steps:
Warning - The WFD-3 is a direct off-line controller. Do not use grounded instruments during
calibration. 115 VAC is exposed on the PC Board. Only qualified personal should perform test
or calibrations on the control.
1) Remove the cover from the WFD-3 controller. Connect a calibrated digital voltmeter to the
speed reference signal on JP1-3 (-) and JP1-4 (+).
2) If encoder is installed on the drive motor connect a frequency counter to the encoder output
JP1-7(+) and JP1-2(-). A 60-line tachometer will produce a direct readout of motor RPM.
If a tach is not installed, use a hand tach to measure actual motor RPM.
3) Connect the WFD-3 to a suitable 115vac source. Make sure that the motor is free to rotate
then power up the WFD-3 control.

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4) 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.
5) Disable the forward direction input. Turn the power off and reinstall the DMC cover.