Bench Test / KickingHorse / A220

Test intent

Separate utility-path and current-path loss from true internal output faults.
Confirm OCV and top-end stick performance are healthy after repair.
Catch clamp, holder, plug, or generator-related false faults before internal repair.
Prove the official 50 A source, 5 kW generator, and high-load rod baseline before the machine is treated as internally weak.

Check	Expected condition	Result
Input source	stable 208/230 V class branch, ideally 50 A for full-capacity proof	pass / fail
Generator path if used	meets or exceeds the official 5 kW baseline	pass / fail
Clamp and holder	clean bite, tight Dinse fit, no obvious heat damage	pass / fail
Extension cord or adapter path	not undersized or overheated	pass / fail
Rod condition	dry 7018 or 6010/6011 class rod matched to baseline and top-end proof	pass / fail
Lead polarity	holder and ground leads placed correctly for the actual rod test because A220 can run DCEN or DCEP	pass / fail

Checkpoint	Expected value or behavior	Record actual
Input supply at machine	stable 208/230 V class input under attempted load
OCV at output studs	about 74 V class OCV
Clamp or holder temperature under load	no rapid abnormal heating
Top-end arc feel	strong, stable field-inverter behavior when fed correctly
Yellow protection light at higher load	stays off in normal short heavy proof welding
Stock holder and clamp path	5 ft AWG #4 lead set stays electrically stable without fast abnormal heat

Test	Pass condition	Result
Cold power-up	normal idle state with no odd collapse	pass / fail
Short stick strike	repeatable strike on clean steel	pass / fail
Short weld	stable arc with no abnormal clamp or holder heating	pass / fail
Higher-load retest	top-end behavior remains stable on a true 230 V or healthy generator source using 7018 or 6010/6011 proof rod	pass / fail
Polarity sanity retest if arc is wrong	wrong-feel complaint disappears once lead placement matches the rod test	pass / fail

Better outlet or shorter cord changes the complaint: keep diagnosis in the utility path.
OCV normal but rod behavior poor: stay in clamp, holder, and current path first.
Rapid heating at clamp, holder, or plug: treat as current-path loss before board blame.
Weak only at the top end: verify real 230 V supply before deeper repair.
Protection light appears during a short heavy proof weld: stay in cooling, fan, and real source-strength branches first.
Complaint only exists on an improvised TIG setup: stop there because A220 is officially not recommended for TIG use.

Use these only after the complaint has been proven to follow the clamp, holder, or utility-side accessory branch.
A220 accessories path: official A220 accessories path
Stock holder KAA20410: official product page
Heavy-duty holder 07000460: official product page
Heavy-duty clamp 07000461: official product page

Signoff item	Result
OCV restored	pass / fail
High-load rod baseline restored	pass / fail
Short weld completed cleanly	pass / fail
No abnormal heating, protection light, or source-path collapse after retest	pass / fail

Technician: __________ Date: __________ Serial or shop tag: __________