Miller Electric Welder XL AC DC User Manual

Issued May 2008 • Index No. AD/8.0  
Stick Welding  
®
Power Source  
Thunderbolt XL AC/DC  
Light Industrial Applications  
Processes  
Amperage Range  
225 AC/150 DC: HIGH 40235 A (AC),  
LOW 30150 A (AC)  
30 – 160 (DC)  
300 AC/200 DC: HIGH 65300 A (AC),  
LOW 40200 A (AC)  
Garage/Job Shops  
Stick (SMAW)  
Plant Fabrication/Maintenance  
Vocational Training  
Light Production-line Work  
Input Power 1-Phase Power  
Quick  
Specs  
30 – 200 (DC)  
Max. Open-Circuit Voltage 80  
®
The Power of Blue.  
Comes Complete With:  
Infinite current control allows the  
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.  
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:  
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/200 DC model,  
available at 20% duty cycle. Thunderbolt XL  
225 AC/150 DC model has 20% more DC  
output than competitive products.  
Forced-draft cooling fan runs  
continuously and helps to extend  
the life of the power source.  
Specifications  
(Subject to change without notice.)  
Welding  
Max. Open- Amps Input at Rated Output,  
Amperage Range  
Circuit  
50 or 60 Hz  
Net  
Model  
Rated Output at 20% Duty Cycle  
High  
Low  
Voltage  
220 V  
230 V  
Dimensions  
Weight  
Thunderbolt  
XL 225 AC/  
150 DC  
AC  
DC 150 A at 25 VDC, 60 Hz (15% Duty Cycle at 50 Hz)  
225 A at 25 VAC, 60 Hz (15% Duty Cycle at 50 Hz) 40235 30–150  
80  
47.5  
H: 18-3/4 in (476 mm) 104 lb  
W: 12-3/4 in (323 mm) (47 kg)  
D: 17-1/2 in (445 mm)  
134 lb  
30160  
65300 40200  
30200  
Thunderbolt AC  
XL 300 AC/  
200 DC  
300 A at 30 VAC, 50/60 Hz  
70  
(61 kg)  
DC 200 A at 25 VDC, 50/60 Hz  
Power source is warranted for 3 years, parts and labor.  
Original main power rectifiers are warranted for 5 years.  
Miller Electric Mfg. Co.  
An Illinois Tool Works Company  
1635 West Spencer Street  
Appleton, WI 54914 USA  
International Headquarters Web Site  
Phone: 920-735-4505  
USA FAX: 920-735-4134  
Canadian FAX: 920-735-4169  
International FAX: 920-735-4125  
 

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