WeldKing Bench Measurement Reference

This page pulls the fastest bench-useful WeldKing measurements and state checks into one place so technicians can compare live readings without scanning every model guide first.

How to Use This Reference

Start with the machine simplified to one known-good process, one known-good current path, and the actual connected input voltage.
Treat the values below as branch-splitting checkpoints, not calibration specs, unless the local file or manual explicitly says otherwise.
If a WeldKing machine has an older board revision, use the local manifest and model guide before calling a connector reading wrong.
If the reading is correct but the symptom survives, move back into the full guide rather than forcing the diagnosis from the table alone.

Reading Rules Before You Compare Values

Prove branch power, plug condition, clamp bite, and accessory fit first. Several WeldKing complaints are external-path faults that mimic board failure.
Compare OCV only in the correct mode. VRD, sleep behavior, or first-weld wake-up behavior can make low OCV normal on some platforms.
Measure support rails at the named connector or LED point, not at a nearby harness that only looks equivalent.
Use behavioral checkpoints when the service note is better than a hard number. That is stronger than inventing a false spec.

Arc / Stick Checkpoints

Model	Checkpoint	Healthy expectation	If abnormal, keep diagnosis in...	Open next
`CoolArc160`	`CN101` high-voltage bus from capacitor PCB to inverter PCB	roughly `300 to 340 VDC` on a healthy high-line machine	capacitor PCB or primary-rectifier branch if bus is low with correct input power	CoolArc160 guide
`CoolArc160`	`CN108` or `CN104` fan connector depending on board revision	`24 VDC` auxiliary supply present with the correct polarity for the fitted revision	capacitor-board support path and early fan-polarity revision branch	CoolArc160 guide
`CoolArc160`	OCV with healthy bus already proven	healthy OCV and normal arc strike; low OCV around the `30 V` range with healthy bus is not normal	capacitor PCB first if low OCV remains with healthy bus; inverter PCB if no OCV with healthy bus	CoolArc160 bench test
`CoolArc200`	`J3` pins `2` and `7` on the input-sense branch	about `3.3 V` on `110 V` input and about `0.3 V` on `220 V` input	main-board input-detect or control-board indication branch	CoolArc200 guide
`CoolArc200`	OCV in non-`VRD` mode	low immediately after power-up can recover to normal high OCV after the first weld	sleep-state or mode-state interpretation before output-board repair	CoolArc200 guide
`CoolArc200`	OCV in `VRD` mode	stays at a low safe-voltage level by design	state interpretation and `VRD` behavior, not the welding section by itself	CoolArc200 guide

MIG / Flux-Cored Checkpoints

Model	Checkpoint	Healthy expectation	If abnormal, keep diagnosis in...	Open next
`MAG211`	gas-solenoid branch	about `36 VAC` at the solenoid branch when the weld command is active	solenoid or control branch before deeper transformer diagnosis	MAG211 measurement card
`MAG211`	voltage and wire-speed chart baseline	actual behavior tracks the official chart closely enough to produce a stable weld	setup or chart mismatch before internal repair	MAG211 measurement card
`MAG211`	base gun versus spool gun	base MIG proves first and the complaint stays isolated if it really belongs to the spool-gun branch	spool-gun and drive-roll branch before transformer or board blame	MAG211 measurement card
`MAG251`	gas-solenoid branch	about `36 VAC` when the machine is commanding gas flow	solenoid or control branch before calling the whole machine dead	MAG251 measurement card
`MAG251`	AC ripple at the output	about `1 VAC` healthy; roughly `6 to 7 VAC` points toward capacitor trouble	capacitor-bank condition first	MAG251 measurement card
`MAG251`	feed direction after PCB or motor work	motor feeds in the correct direction with no breaker drama	motor wiring or post-service branch before replacement-board blame	MAG251 measurement card
`MAG255`	spool-gun pins `1` and `9` when spool-gun mode is selected	welding voltage present on the selected spool-gun branch	spool-gun selector or accessory branch before transformer calls	MAG255 measurement card
`MAG255`	post-trigger discharge behavior	capacitor discharges cleanly and wire stops without abnormal creep	crater-fill or discharge-path branch if wire creeps after stop	MAG255 measurement card
`MAG255`	wire-tip behavior with no trigger command	no sparks or unexpected live-wire behavior at the tip	discharge-path resistor branch before control-board suspicion	MAG255 measurement card
`MigSonic145`	`24 V` support branch	stable auxiliary voltage without click-cycling	capacitor PCB and support-power branch	MigSonic145 measurement card
`MigSonic145`	trigger response after `24 V` is proven	machine responds normally to the gun trigger	trigger-wire or control branch, not the whole power source	MigSonic145 measurement card
`MigSonic145`	base-gun bare-wire feed with the contact tip removed	wire feeds normally on the base gun without a spool gun attached or a tip load masking the branch	gun-generation, drive, or trigger branch before deeper PCB blame	MigSonic145 measurement card
`MigSonic145`	startup click-cycling or post-capacitor feed behavior	stable startup with no repeated relay click and no runaway motor	support-power or control PCB branch before gun blame	MigSonic145 measurement card
`MigSonic252S+SS20`	feeder and readout response from the power source	commands from the power source are reflected at the remote feeder without frozen readouts or a solenoid stuck open at idle	power-source PCB branch rather than the remote feeder itself	MigSonic252S+SS20 measurement card
`MigSonic252S+SS20`	solenoid or readout state at power-up	gas stays closed until commanded and readouts behave normally	source-side PCB branch before feeder blame	MigSonic252S+SS20 measurement card
`MigSonic252S+SS20`	source-side jog or purge behavior before feeder teardown	source commands behave normally before the remote package is blamed	source-side PCB or control-state branch before feeder-package teardown	MigSonic252S+SS20 measurement card

Multiprocess Checkpoints

Model	Checkpoint	Healthy expectation	If abnormal, keep diagnosis in...	Open next
`MigSonic200 CVCC`	main bus voltage after input and rectifier proof	normal bus behavior rather than a persistent mid-`100 V` reading after board work	rectifier branch before process guessing	MigSonic200 CVCC guide
`MigSonic200 CVCC`	trigger response after `24 V` support is proven	gun trigger produces a real response in the active branch	broken trigger wire or control branch	MigSonic200 CVCC guide
`MultiSonic220`	startup state after reset	machine exits debug behavior and boots normally after the documented reset sequence	stored-state, ribbon, or support-power branch	MultiSonic220 guide
`MultiSonic220`	polarity connector when stick and TIG still work but MIG does not	tight and correctly installed for the active process	polarity and MIG-only current-path branch	MultiSonic220 guide
`MultiSonic220`	panel behavior on power-up	stable display and indicators, not all-lights flashing	ribbon, control, or power-supply branch	MultiSonic220 bench test
`MultiSonic220`	feeder motor at idle	stopped until a real feed command is given	power board or support-power branch if motor runs full speed at power-up	MultiSonic220 guide

TIG Checkpoints

Model	Checkpoint	Healthy expectation	If abnormal, keep diagnosis in...	Open next
`CoolTIG220`	basic DC TIG baseline	stable start, normal preflow and postflow, and a clean local-control branch	gas path, torch branch, or package-state branch before AC or HF repair	CoolTIG220 guide
`CoolTIG220`	HF-versus-no-HF version proof	behavior matches the documented version note before any HF complaint is trusted	wrong version assumption before board repair	CoolTIG220 guide
`CoolTIG220`	remote or torch-switch branch	control changes only when the correct switch or pedal branch is active	pedal, torch-switch, or package-state branch before control-board repair	CoolTIG220 guide
`PulseWave200`	torch polarity for HF start	torch on negative for TIG start	torch-path setup before any HF-board call	PulseWave200 guide
`PulseWave200`	display PCB switch `2` reset on later machines	factory defaults restore when the switch is used with power off and the machine restarts	stored-state or display-state branch	PulseWave200 bench test
`PulseWave200`	gas flow at very low current	moderate flow with preflow reduced as needed for low-current work	gas-path setup before blaming a dead HF branch	PulseWave200 guide
`PulseWave200`	AC versus DC TIG branch	both operate once the base machine is healthy	AC inverter section if DC works but AC does not	PulseWave200 guide
`TIG200PACDC`	simple DC TIG baseline before AC	repeatable DC TIG start on clean steel before AC is added back	gas, torch, or TIG-only branch before AC-board suspicion	TIG200PACDC measurement card
`TIG200PACDC`	local-control baseline with the remote isolated	panel control behaves normally before the pedal branch is trusted	remote, pedal, or local-control branch before AC-board repair	TIG200PACDC measurement card
`TIG200PACDC`	foot-control or current remote potentiometer	correct `4K7` resistance value for the fitted remote	pedal or remote branch before control-board repair	TIG200PACDC measurement card

Plasma Checkpoints

Model	Checkpoint	Healthy expectation	If abnormal, keep diagnosis in...	Open next
`CoolCut30`	upper-board green `24 V` indicator	stays on continuously when the support rail is healthy	capacitor-board versus upper-board supply split	CoolCut30 guide
`CoolCut30`	no-HF with OCV already measured	no-HF with OCV in the high `200 V` range stays in the lower-board relay or capacitor-board branch; lower OCV points toward the inverter or top board	the board family matched to the OCV level	WeldKing reference manifest
`CoolCut30`	HF strike gap	about `1 mm`	HF-striker cleanliness and gap before deeper plasma-board work	CoolCut30 guide
`CoolCut40air`	built-in compressor and dual-valve air path	steady airflow under trigger with no obvious pressure collapse	compressor, valve, or air-routing branch before output-board suspicion	CoolCut40air measurement card
`CoolCut40air`	internal versus external air mode split	complaint is bounded to one air mode or behaves correctly in both with the right path active	internal-air valve contamination or mode-routing branch before board calls	CoolCut40air measurement card
`CUT40`	external-air behavior under flow	clean, stable air delivery without wet-air contamination or unstable torch behavior	regulator, hose, filter, or CB50 front-end branch	CUT40 measurement card
`CUT40`	guide-hardware versus freehand behavior	freehand cutting stays healthy and guide hardware does not create the complaint	guide or CB50 hardware branch before board blame	CUT40 measurement card
`CUT65`	pilot behavior relative to pressure and `RV1`	pilot and transfer stay stable without extreme pressure tuning	air-pressure branch or pilot-maintain-current setting before PCB replacement	CUT65 measurement card
`CUT65`	torch-head rebound and postflow no-start split	torch head returns correctly and start is not lost after normal postflow	torch-head or A81 hardware branch before PCB blame	CUT65 measurement card
`CUT65`	freehand cut versus A81 hardware behavior	freehand cutting stays healthy before stand-off or circle-kit blame	A81 hardware branch before PCB blame	CUT65 measurement card
`ThunderCut65`	postflow, restrike, and pilot-maintain-current behavior	repeatable restrike without abnormal wait time or constant pressure chasing	air path, torch mechanics, or `RV1` pilot branch	ThunderCut65 guide
`ThunderCut65`	pressure-window or `RV1` response	start and pilot improve without extreme tuning once the correct pressure window is reached	air path or pilot-maintain-current branch before PCB replacement	ThunderCut65 guide
`ThunderCut65`	torch-head and guide-hardware behavior	torch head returns correctly and tracking hardware does not distort the complaint	torch-head rebound, guide carriage, or stand-off branch before electrical fault calls	ThunderCut65 guide

Best Companion Documents

Notes

The strongest numeric WeldKing checkpoints are concentrated in CoolArc160, CoolArc200, MAG251, MAG255, MultiSonic220, PulseWave200, and CoolCut30, while MAG211, CoolTIG220, CoolCut40air, and ThunderCut65 rely on strong behavior-plus-measurement splits.
Several WeldKing plasma and TIG platforms are better diagnosed by a combined behavior-plus-measurement branch than by a single numeric value. That is intentional and stronger than inventing a false spec.
When a local file gives a board revision split, use that split before calling a support-rail or connector reading wrong.
MAG211, MAG251, and MAG255 now route directly from this reference into their model-specific measurement cards, so the MAG family no longer has to be entered through one shared placeholder.
MigSonic145, MigSonic252S+SS20, TIG200PACDC, CoolCut40air, CUT40, and CUT65 now route directly from this reference into their model-specific measurement cards too.