Miller Electric Thunderbolt XL AC/DC User's Manual
Contents
1. Issued May 2008 Index No AD 8 0 l Power Source Light Industrial Applications Processes Amperage Range Garage Job Shops stick SMAW 225 AC 150 DC HIGH 40 235 A AC L Ir Plant Fabrication Maintenance Input P LOW 30 150 A AC Quic Vocational Training nput Power 1 Phase Power 30 160 DC g Light Production line Work 300 AC 200 DC HIGH 65 300 A AC pecs LOW 40 200 A AC 30 200 DC Max Open Circuit Voltage 30 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 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 High 100 duty cycle rating Models do not include wall receptacle 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 Output selector switch allows you to quickly select AC DCEP or DCEN without adjusting the output leads The exclusive patented Accu Set provides precise heat control with infinite amperage control Fully varnished magnetic coils varnish protects and lengthens the life of the coils inside High DC weld output up to 150 amps for the 225 AC 150 DC model and up to 200 amps for the 300 AC 202. 0 DC model available at 20 duty cycle Thunderbolt XL 225 AC 150 DC model has 20 more DC output than competitive products Specifications Subject to change without notice cc all Welding Max Open Amps Input at Rated Output Amperage Range Circuit 50 or 60 Hz Rated Output at 20 Duty Cycle High Low Voltage 220 V 230 V Thunderbolt AC 225 A at 25 VAC 60 Hz 15 Duty Cycle at 50 Hz 40 235 30 150 H 18 3 4 in 476 mm XL 225 AC W 12 3 4 in 323 mm 1 150 DC De 150 A at 25 VDC 60 Hz 15 Duty Cycle at 50 Hz 30 160 Aaa yea Thunderbolt AC 300 A at 30 VAC 50 60 Hz 65 300 40 200 XL 300 AC D 200 A at 25 VDC 50 60 Hz 30 200 Forced draft cooling fan runs continuously and helps to extend the life of the power source Power source is warranted for 3 years parts and labor MADE IN EIA A Original main power rectifiers are warranted for 5 years TEAS Miller Electric Mfg Co International Headquarters Web Site ISO 9001 2000 An Illinois Tool Works Company Phone 920 735 4505 www MillerWelds com 1635 West Spencer Street USA FAX 920 735 4134 QUAL IY SYSTEM Appleton WI 54914 USA Canadian FAX 920 735 4169 International FAX 920 735 4125 Control Panel Electrode Charts ELECTRODE POLARITY CHART ELECTRODE AMPERAGE CHART s 3 _ RATED WELD OUTPUT AC N AC DC VOLTS eo 25 A AMPS 225 150 ele Ty s MAX OCV 80 DIAMETER AMPERAGE RANGE 30 170 A N a a ag a
3. A WARNING ELECTRIC SHOCK CAN KILL DO NOT USE AC OUTPUT IN DAMP AREAS IF MOVEMENT IS CONFINED OR IF THERE SA POSITION ELECTRODE S ELECTRODE sam i DEEP MIN PREP ROUGH HIGH SPATTER GENERAL Q OFF DO NOT SWITCH POWER UNDER LOAD SMOOTH EASY FAST LOW HYDROGEN STRONG ER OF FALLING USE AC OUTPUT ONLY IF REQU R TI WELDING PROCESS 2 SMOOTH EASY FASTER CAST IRON STAINLESS EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY 225 150 AMP CC AC DC Welding Power Source ACCU SET AMPERAGE CONTROL N 1 Power Switch 2 Selector Switch 3 Amperage Adjustment Performance Data Control DUTY CYCLE FOR 225 AC 150 DC MODELS RATED OUTPUT 50 ELECTRODE 2 300 250 pe oO Sy _ oO 75 WELD AMPERES 10 15 20 25 30 40 50 60 70 8090100 DUTY CYCLE Stick SMAW Basic Equipment DUTY CYCLE FOR 300 AC 200 DC MODELS RATED OUTPUT 300 250 ua 200 H 450 Stick Electrode lt 100 am z 75 lt L RSS 5 Work Clamp 10 15 20 25 30 40 50 60 708090100 DUTY CYCLE Ordering Information Power Source Stock No Description Qty Price Thunderbolt XL 225 AC 150
4. 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 Certified to both the Canadian and U S Standards for welding equipment Distributed by E Miller Litho in USA
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