Miller Electric XL AC-DC User Manual

Thunderbolt®XL AC/DC

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]

Issued May 2008 • Index No. AD/8.0

Stick Welding

Power Source

Light Industrial Applications

Garage/Job Shops

Quick

Plant Fabrication/Maintenance
Vocational Training
Light Production-line Work

Specs

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.

The exclusive patented Accu-Set
provides precise heat control with
infinite amperage control.

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.

™

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

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.

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.

80

Specifications (Subject to change without notice.)

Model

Thunderbolt
XL 225 AC/
150 DC

Thunderbolt
XL 300 AC/
200 DC

Rated Output at 20% Duty Cycle

225 A at 25 VAC, 60 Hz (15% Duty Cycle at 50 Hz)

AC

150 A at 25 VDC, 60 Hz (15% Duty Cycle at 50 Hz)

DC

300 A at 30 VAC, 50/60 Hz

AC

200 A at 25 VDC, 50/60 Hz

DC

Power source is warranted for 3 years, parts and labor.

Original main power rectifiers are warranted for 5 years.

Welding
Amperage Range
High Low

40–235 30–150

30–160

65–300 40–200

30–200

Max. Open­Circuit
Voltage

80

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)

Net
Weight

104 lb
(47 kg)

134 lb
(61 kg)

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 90 100

Litho in USA

Distributed by:

Typical Installation

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.

*

3

3

3

3

1

2

Power

Source

Stick Electrode

Work Clamp