Manufacturer of Electronic Welding Machinery Controls

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Frequently Asked Questions (FAQ) on idler controls.

Do Weldtron idlers use any external reed switches or current transformers to sense the use of power?

• Yes and No.  No...our invented idler controls contain a special hall effect switch contained within the circuit board to sense AC or DC power, individually or concurrently.  Thus, no need for external triggering devices.  You will notice a little square black box on the circuit board.  This is the current sensor you simply route a wire through without the need to physically attach it to the circuit.
   
• Yes...our generic replacement idlers use the original OEM's internal factory switches and apparatus to trigger the idle board that the machine was manufactured with.

My Weldtron-57 idler quits working after about 20 seconds and then won't operate again.  If I turn the machine off for awhile and then start it again, the system works for about another 20 seconds and then quits again.  What causes that?

• First, it's the normal operation of the Weldtron-57's automatic protective circuitry.  What has happened is that there is some binding or mechanical problem with the throttle linkage that prevents the solenoid from fully retracting and tripping the internal switch that switches from intermittent duty (40 amps pull) to continuous duty (.8 amps) functions.  If the solenoid does not switch out of the intermittent mode it will destroy itself within minutes.
   
• The most common cause for this is that the throttle idle stop adjustment is contacting the carburetor body.  Let the Weldtron-57 solenoid control the idle speed by adjusting idle speed by the nuts on the threaded plunger of the solenoid...not the idle adjustment screw on the carburetor.  

My Weldtron-57 idler has been working great for about a year and now it won't pick-up on striking an arc.  It's OK when using the grinder but won't sense the striking of an arc.  What's the problem?

• It's the sensing wire that runs through the hole on the circuit board sensor.  If the unit works with the grinder but not the welding current, the circuit board is OK.  What has happened is that one end of the sensing wire that attaches to the welding lead has become corroded or loose and is no longer making very good contact with the welding cable.  Shine up the contact points on the cable and clean the sensing wire connections.  Reattach and the system should work correctly.  WARNING!  Do not use any type of spray cleaner or lubricant on the connections...it will only make them worse.  In some rare cases we have had people covering the connections with liquid electrical tape.  DON'T do it, use electrical tape only.  The liquid will insulate the sensing wire from the welding cable.

I have installed one of your idlers with the internal sensor and it worked great.  Now, when I plug in my old fashioned Cable brand remote amperage control the machine won't idle down.  Why?

• Nothing's wrong with your machine wiring.  You installed it correctly.  The problem is with the way the remote control is connected to the machine's wiring system.  The way that the Cable brand remote is installed causes it to route the machine's field current through the sensor, tricking the idler control into thinking that you are using power.  See the technical solution contained on the technical pages for a cure to the problem and the correct way to reconnect the Cable brand remote.

I have an old Lincoln with a R-57 vacuum idler that is in good operational shape and would like to buy the Linc-III upgrade module.  Now, I understand that the Linc-III is discontinued.  I don't want to install a whole new system until my R-57 needs replacement.  What can I do?

• The Linc-III was discontinued on April 26, 2006.  Many, many machines since 1990 had been upgraded with it.  We have replaced it with our Weldtron-UI idler module by including a single 5 ohm, 25 Watt resistor that is inserted inline with the solenoid's battery power.  The reason we discontinued the Linc-III and switched to the Weldtron-UI is because when the R-57 vacuum idler solenoid or vacuum diaphragm becomes inoperable and parts cannot be obtained, you will have already installed half of the Weldtron-57 idler system on your machine and only need to purchase a solenoid (either ours or someone else's) and you are back in business.  No need to buy a whole new system.