This is the short printable KickingHorse triage poster for fast bench intake and first-proof routing.
| Complaint family | First proof step | Open first | Open next if still unresolved |
|---|---|---|---|
A100 unstable stick output, blinking power light, or collapse on a 120 V portable stick machine |
prove real 120 V / 20 A or healthy 3 kW, correct DCEN / DCEP, clean-steel 3/32 in 7018 or 6010/6011 baseline, and basic OCV first |
A100 measurement card | A100 fault workflow router |
A220 weak top-end stick output, bad arc blow, or poor rod behavior on a 208/230 V field machine |
prove real 208/230 V, ideally 50 A or healthy 5 kW, correct DCEN / DCEP, clean-steel 7018 or 6010/6011 baseline, and basic OCV first |
A220 measurement card | A220 fault workflow router |
| wire feeds at power-up, one-second shutdown, maxed display, or stick works but MIG does not | prove one healthy process first, set drive pressure correctly, verify feed does not move at power-up, and confirm the display tracks the active process | MA200TS measurement card | MA200TS fault workflow router |
| compact MIG no feed, higher-wire-speed start trouble, breaker trip, or torch-front-end suspicion | return to factory 0.035 in baseline or proper 0.030 in conversion, then prove bare-wire feed and 12 VDC to 44 VDC trigger-state rise on a real 120 V / 20 A or 3 kW source |
F130 measurement card | F130 fault workflow router |
| wrong MIG display, feed and display wrong together, or shared digital weirdness | prove real 208/230 V source, reset inductance to sane baseline, and confirm preset-versus-actual display behavior before blaming power hardware |
M185 measurement card | M185 fault workflow router |
| no HF, HF but no OCV, air but no cut, or warm drift on plasma | prove fresh SG55 stack, clean clamp, dry air under flow near 65 psi / 4.5 bar, about 1.5 mm HF gap, 24 VDC to the HF board, and the correct OCV test point first |
P40 measurement card | P40 fault workflow router |
A100 clears on real 120 V / 20 A, healthy 3 kW, corrected DCEN / DCEP, or abandoning an improvised TIG complaintA220 clears on real 208/230 V, ideally 50 A or healthy 5 kW, corrected DCEN / DCEP, heavier current path, or abandoning an improvised TIG complaintF130 clears on correct wire-size setup or stronger 120 V sourceM185 clears on sane inductance or stronger 208/230 V sourceMA200TS clears when one healthy process remains or the complaint follows one accessory kit or polarity path onlyP40 clears on dry air, correct pressure, fresh SG55 stack, clean clamp, or corrected HF-gap setupA100 clamp or holder path only after correct polarity and supported stick baseline are proven: A100 accessoriesA220 clamp or holder path only after correct polarity and supported stick baseline are proven: A220 accessoriesF130 front-end or wire-size path: F130 accessoriesM185 torch or consumable path: M185 product and accessoriesMA200TS aluminum or accessory branch: MA200TS accessoriesP40 SG55 stack or consumables: P40 accessories