Miller Electric Thunderbolt XL AC/DC User manual

Processes
Stick (SMAW)
Input Power 1-Phase Power
Amperage Range
225 AC/150 DC: HIGH 40–235 A (AC),
LOW 30–150 A (AC)
30– 160 (DC)
300 AC/200 DC: HIGH 65–300 A (AC),
LOW 40–200 A (AC)
30– 200 (DC)
Max. Open-Circuit Voltage 80
Light Industrial Applications
Garage/Job Shops
Plant Fabrication/Maintenance
Vocational Training
Light Production-line Work
Thunderbolt®XL AC/DC Stick Welding
Power Source
Issued May2008• Index No. AD/8.0
The Power of Blue® .
Infinite current control allows the
operator to adjust output by as little as
1-amp increments. Users can always get
the exact heat they need, unlike the step
control design on competitive products.
High 100% duty cycle rating:
100 amps AC/65 amps DC for
the 225 AC/150 DC amp model.
130 amps AC/90 amps DC for
the 300 AC/200 DC amp model.
High DC weld output: up to 150 amps
for the 225 AC/150 DC model, and up to
200 amps for the 300 AC/200 DC model,
available at 20% duty cycle. Thunderbolt XL
225 AC/150 DC model has 20% more DC
output than competitive products.
Output selector switch allows you
to quickly select AC, DCEP or DCEN
without adjusting the output leads.
Fully varnished magnetic coils:
varnish protects and lengthens the
life of the coils inside.
Forced-draft cooling fan runs
continuously and helps to extend
the life of the power source.
Quick
Specs
Comes Complete With:
Power source with 15 ft (4.5 m)
electrode cable, electrode holder,
10 ft (3 m) work cable with clamp,
and power cord (without plug).
Note: Thunderbolt XL 225 AC/150 DC
(#903 642) includes 230 V plug.
Models do not include wall receptacle.
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Web Site
www.MillerWelds.com
International Headquarters
Phone: [phone]
USA FAX: [phone]
Canadian FAX: [phone]
International FAX: [phone]
Power source is warranted for 3 years, parts and labor.
Original main power rectifiers are warranted for 5 years.
The exclusive patented Accu-Set™
provides precise heat control with
infinite amperage control.
Model
Thunderbolt
XL 225 AC/
150 DC
Thunderbolt
XL 300 AC/
200 DC
AC
DC
AC
DC
Rated Output at 20% Duty Cycle
225 A at 25 VAC, 60 Hz (15% Duty Cycle at 50 Hz)
150 A at 25 VDC, 60 Hz (15% Duty Cycle at 50 Hz)
300 A at 30 VAC, 50/60 Hz
200 A at 25 VDC, 50/60 Hz
Welding
Amperage Range
High Low
40–235 30–150
30–160
65–300 40–200
30–200
Max. Open-
Circuit
Voltage
80
Net
Weight
104 lb
(47 kg)
134 lb
(61 kg)
Specifications (Subject to change without notice.)
Amps Input at Rated Output,
50 or 60 Hz
220 V 230 V
— 47.5
70 —
Dimensions
H: 18-3/4 in (476 mm)
W: 12-3/4 in (323 mm)
D: 17-1/2 in (445 mm)

Power Source Stock No. Description Qty. Price
Thunderbolt®XL 225 AC/150 DC #903 642* 230 V, 50/60 Hz. Includes 5 ft (1.5 m) power cord w/230 V plug
Thunderbolt®XL 300 AC/200 DC #903 686 220 V, 50/60 Hz. Includes 7 ft (2.1 m) power cord
Running Gear #043 927 Mounts easily to unit and provides convenient portability. Includes two wheels, two feet and handle.
Miscellaneous
Stick Electrodes See charts above
Helmet/Gloves/Scratch Brush
Chipping Slag Hammer
Wall Receptacle
Date: Total Quoted Price:
Ordering Information
Control Panel
ELECTRODE POLARITY CHART
ELECTRODE
DC*
AC
POSITION
USAGE
PENETRATION
7024 EP, EN FLAT
HORIZ.
FILLET LOW
MIN. PREP, ROUGH,
HIGH SPATTER
SMOOTH, EASY,
FASTER
CAST IRON
6011 EP ALL DEEP
✓
EP ALL LOW
✓
6013 EP, EN ALL LOW GENERAL
✓
7014 EP, EN ALL MED. SMOOTH, EASY, FAST
✓
7018 EP ALL LOW
LOW HYDROGEN,
STRONG
✓
308L
*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)
EP ALL LOW STAINLESS
✓
✓
6010 EP ALL DEEP
—
Ni-Cl
ELECTRODE/AMPERAGE CHART
ELECTRODE
DIAMETER
IN
7024
6010
&
6011
3/32
1/8
5/32
3/32
1/8
5/32
3/16
3/32
1/8
5/32
3/16
1/16
5/64
3/32
1/8
5/32
3/16
3/32
1/8
5/32
3/32
1/8
5/32
3/32
1/8
5/32
6013
7014
7018
Ni-Cl
308L
2.4
3.2
4.0
4.8
1.6
2.0
2.4
3.2
4.0
4.8
2.4
3.2
4.0
2.4
3.2
4.0
2.4
3.2
4.0
2.4
3.2
4.0
4.8
2.4
3.2
4.0
MM
MIN. MAX. 50A
100A 150A
200A
AMPERAGE RANGE
Performance Data
Electrode Charts
DUTY CYCLE – FOR 225 AC/150 DC MODELS
% DUTY CYCLE
RATED OUTPUT
WELD AMPERES
AC
DC
DUTY CYCLE – FOR 300 AC/200 DC MODELS
RATED OUTPUT
WELD AMPERES
% DUTY CYCLE
AC
DC
300
250
200
150
100
75
50
0
300
250
200
150
100
75
50
0
10 15 20 25 30 40 50 60 70 80 90 100
10 15 20 25 30 40 50 60 70 80 90100
Litho in USA
Distributed by:
3
1
2
3
3
3
Typical Installation
Power
Source
Work Clamp
Stick Electrode
Stick (SMAW) Basic Equipment
1.Power Switch
2.Selector Switch
3.Amperage
Adjustment
Control
Certified to both the Canadian and U.S. Standards for welding equipment.
*