Miller Thunderbolt XL Manuel Du Propriétaire
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Miller Thunderbolt XL Manuel Du Propriétaire

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Thunderbolt XL
225 AC, 225/150 AC/DC, And 300/200 AC/DC
OM-316
087 083U
2014−02
Processes
Stick (SMAW) Welding
Description
225/150 AC/DC Models:
300/200 AC/DC Models:
225 AC Models:
Arc Welding Power Source
R
File: Stick
(SMAW)

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  • Page 1 OM-316 087 083U 2014−02 Processes Stick (SMAW) Welding Description 225/150 AC/DC Models: 300/200 AC/DC Models: 225 AC Models: Arc Welding Power Source Thunderbolt XL 225 AC, 225/150 AC/DC, And 300/200 AC/DC File: Stick (SMAW) Visit our website at www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Des Matières

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2013−09 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 6 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear body protection made from durable, flame−resistant material Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high health.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 8: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer.

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2013−09 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 10 D Ne pas raccorder plus d’une électrode ou plus d’un câble de D Avoir recours à des écrans protecteurs ou à des rideaux pour masse à une même borne de sortie de soudage. Débrancher le protéger les autres contre les rayonnements les éblouissements câble pour le procédé...

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    LES BOUTEILLES peuvent exploser DES PIECES DE METAL ou DES si elles sont endommagées. SALETES peuvent provoquer des blessures dans les yeux. Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille est D Le soudage, l’écaillement, le passage de la endommagée, elle peut exploser.
  • Page 12 LES CHARGES ÉLECTROSTATI- RAYONNEMENT HAUTE QUES peuvent endommager les cir- FRÉQUENCE (H.F.) risque cuits imprimés. provoquer des interférences. D Établir la connexion avec la barrette de terre D Le rayonnement haute fréquence (H.F.) peut avant de manipuler des cartes ou des pièces. provoquer des interférences avec les équi- pements de radio−navigation et de com- D Utiliser des pochettes et des boîtes antista-...

  • Page 13: Proposition Californienne 65 Avertissements

    2-4. Proposition californienne 65 Avertissements Les équipements de soudage et de coupage produisent des Ce produit contient des produits chimiques, notamment du fumées et des gaz qui contiennent des produits chimiques plomb, dont l’État de Californie reconnaît qu’ils provoquent dont l’État de Californie reconnaît qu’ils provoquent des mal- des cancers, des malformations congénitales ou d’autres formations congénitales et, dans certains cas, des cancers.
  • Page 14 OM-316 Page 10...

  • Page 15: Section 3 − Definitions

    A complete Parts List is available at www.MillerWelds.com SECTION 3 − DEFINITIONS 3-1. Miscellaneous Symbols And Definitions Some symbols are found only on CE products. Do Not Switch Amperes Single Phase Input Under Load Output Hertz Alternating Electrode Positive Electrode Negative Direct Current Current Welding Arc...

  • Page 16: Section 4 − Specifications

    A complete Parts List is available at www.MillerWelds.com SECTION 4 − SPECIFICATIONS 4-1. Unit Specifications A. AC/DC Models Amperes Input at Rated Maximum Load Output Rated Welding Amperage Open- Mode Weight 50 Or 60 Hz, Output Range Circuit Single-Phase Voltage 220 V 230 V 225 A @ 25 Volts AC,...

  • Page 17: Duty Cycle Charts

    A complete Parts List is available at www.MillerWelds.com 4-2. Duty Cycle Charts A. For AC/DC Models Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. NOTICE − Exceeding duty cycle can damage unit and void warranty. 2 Minutes Welding 8 Minutes Resting A.

  • Page 18: Volt-Ampere Curves

    A complete Parts List is available at www.MillerWelds.com 4-3. Volt-Ampere Curves A. For AC/DC Models The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities. Curves of other settings fall be- tween the curves shown. A. For 225/150A Models A=LOW RANGE B=HIGH RANGE AC Amperes...
  • Page 19 A complete Parts List is available at www.MillerWelds.com B. For AC Models The volt-ampere curves show the For 225A Models minimum and maximum voltage and amperage output capabilities. Curves of other settings fall be- A=LOW RANGE tween the curves shown. B=HIGH RANGE AC Amperes 193 508...

  • Page 20: Section 5 − Installation

    A complete Parts List is available at www.MillerWelds.com SECTION 5 − INSTALLATION 5-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated output.

  • Page 21: Installing Electrode Holder And Work Clamp

    A complete Parts List is available at www.MillerWelds.com 5-3. Installing Electrode Holder And Work Clamp Turn Off unit and disconnect input power before installing electrode holder or work clamp. Removing Barrel From Elec- trode Holder Electrode Holder Barrel Access Hole Set Screw Loosen set screw through access hole and slide barrel away from...

  • Page 22: Weld Output Cables

    A complete Parts List is available at www.MillerWelds.com 5-4. Weld Output Cables For weld output cable replacements or extensions, contact your Factory Authorized Service Agent. 5-5. Electrical Service Guide Elec Serv 2014−01 Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda- tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.

  • Page 23: Connecting Input Power

    A complete Parts List is available at www.MillerWelds.com 5-6. Connecting Input Power For Models Supplied With Plug Disconnect and lockout/tag- out input power before instal- ling receptacle. =GND/PE Earth Ground Have only qualified persons make this installation. See rating label in Section 5-2, and be sure to supply correct in- put power.

  • Page 24: Section 6 − Operation

    A complete Parts List is available at www.MillerWelds.com SECTION 6 − OPERATION 6-1. Controls A. Controls For AC/DC Models Amperage Adjustment Control Power Switch Mode Switch For DC Weld Output Use mode switch to select polarity of dc output, Electrode Posi- tive/DCEP (+),or Electrode Nega- tive/DCEN (−).
  • Page 25 A complete Parts List is available at www.MillerWelds.com B. Controls For AC Models Amperage Adjustment Control Power Switch Mode Switch Use mode switch to select AC low range or high range output. Ref. 218 237-A / 802 105-D OM-316 Page 21...

  • Page 26: Section 7 − Maintenance & Troubleshooting

    A complete Parts List is available at www.MillerWelds.com SECTION 7 − MAINTENANCE & TROUBLESHOOTING 7-1. Routine Maintenance Disconnect power Maintain more often before maintaining. during severe conditions. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent Every Months...

  • Page 27: Reinstalling Amperage Adjustment Indicator

    A complete Parts List is available at www.MillerWelds.com 7-3. Reinstalling Amperage Adjustment Indicator Turn Off welding power source and disconnect input power. Wrapper Remove wrapper from unit. Crank Handle Shunt Shaft Transformer And Shunt (Located Inside Unit) Insert crank handle onto shunt shaft protruding through front panel and turn crank handle to adjust shunt to the proper vale of “X”, de-...

  • Page 28: Troubleshooting

    A complete Parts List is available at www.MillerWelds.com 7-4. Troubleshooting Trouble Remedy No weld output; fan does not run. Be sure line disconnect switch is in On position (see Section 5-6). Check and replace line fuses if open. Reset breakers if necessary (see Section 5-6). Fan does not run;...

  • Page 29: Section 8 − Electrical Diagrams

    SECTION 8 − ELECTRICAL DIAGRAMS 191 364 Figure 8-1. Circuit Diagram For 225/150 AC/DC (230 Volts) Models VOLT ONLY POWER CORD S.O.P. S.O.P. WORK ELECTRODE 191 368 Figure 8-2. Circuit Diagram For 300/200 AC/DC (220 Volts) Models OM-316 Page 25...
  • Page 30 VOLT ONLY PLG1 AC HIGH AC LOW WORK ELECTRODE 191 362 Figure 8-3. Circuit Diagram For 225 AC (230 Volts) Models OM-316 Page 26...

  • Page 31: Section 9 − Stick Welding (Smaw) Guidelines

    SECTION 9 − STICK WELDING (SMAW) GUIDELINES 9-1. Stick Welding Procedure Weld current starts when electrode touches work- piece. Weld current can damage electronic parts in vehicles. Disconnect both battery Equipment Needed: Tools Needed: cables before welding on a vehicle. Place work clamp as close to the weld as possible.

  • Page 32: Electrode And Amperage Selection Chart

    9-2. Electrode and Amperage Selection Chart 6010 DEEP 3/32 MIN. PREP, ROUGH HIGH SPATTER 6011 DEEP 6010 5/32 & 6013 EP,EN GENERAL 3/16 6011 7/32 SMOOTH, EASY, 7014 EP,EN FAST 1/16 LOW HYDROGEN, 7018 5/64 STRONG 3/32 FLAT SMOOTH, EASY, 7024 EP,EN HORIZ...
  • Page 33 9-4. Positioning Electrode Holder End View Of Work Angle Side View Of Electrode Angle After learning to start and hold an arc, practice running beads of weld metal on flat plates using a full electrode.   Hold the electrode nearly per- pendicular to the work, although tilting it ahead (in the direction of ...
  • Page 34 9-7. Conditions That Affect Weld Bead Shape Weld bead shape is affected electrode angle, length, travel speed, and thick- ness of base metal. Correct Angle Angle Too Large  -  Angle Too Small Electrode Angle Drag Spatter Arc Length Normal Too Long Too Short...
  • Page 35 9-10. Welding Groove (Butt) Joints Tack Welds Prevent butt joint distortion by tack welding the materials in position before final weld. Workpiece distortion occurs when heat is applied locally to a joint. One side of a metal plate will “curl” up toward the weld.
  • Page 36 9-12. Weld Test Vise Weld Joint Hammer Strike the weld joint in the direction shown. A good weld bends over but does not break. If the weld breaks, examine it to determine the cause. If the weld is porous (many holes), the arc length was probably too long.
  • Page 37 Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove. Improper weld technique. Keep arc on leading edge of weld puddle.
  • Page 38 Notes...
  • Page 39 Effective January 1, 2014 (Equipment with a serial number preface of ME or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...

  • Page 40: For Service

    Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department.  ORIGINAL INSTRUCTIONS − PRINTED IN USA 2014 Miller Electric Mfg. Co. 2014−01...

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