Miller Thunderbolt XL User Manual

Page 2 - From Miller to You

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributorto receive the latest full line catalog orindividual catalog sheets. To locate your nearestdistributor or service agency call 1-800-4...

Page 3 - TABLE OF CONTENTS; WARNING

TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS FOR ARC WELDING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazard...

Page 5 - SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING; Symbol Usage; Arc Welding Hazards; ELECTRIC SHOCK can kill.

OM-316 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This ...

Page 7 - Additional Symbols For Installation, Operation, And Maintenance; Principal Safety Standards

OM-316 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or nearcombustible surfaces. D Do not install unit near flammables. D Do not overload building wiring – be sure power supply system isproperly sized, ...

Page 8 - EMF Information

OM-316 Page 4 1-5. EMF Information Considerations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flows through welding cables, will cause electro-magnetic fields. There has been and still is some concern about suchfields. However, after examining mor...

Page 9 - Signification des symboles; Dangers relatifs au soudage à l’arc; UN CHOC ÉLECTRIQUE peut tuer.

OM-316 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédureprésente des risques de danger ! Ceux-ci sont identifiéspar des symboles adjacents aux directives. Y Identifie un message...

Page 10 - LE BRUIT peut affecter l’ouïe.

OM-316 Page 6 Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RAYONS DE L’ARC peuvent pro-voquer des ...

Page 13 - SECTION 2 – INSTALLATION; Specifications; AC Models

OM-316 Page 9 SECTION 2 – INSTALLATION 2-1. Specifications AC/DC Models Mode Rated Welding Amperage Maximum Open- Amperes Input at Rated Load Output 50 Or 60 Hz, Single-Phase Weight Mode Output Range Circuit Voltage 115 V 220 V 230 V 400 V 460 V Weight AC 225 A @ 25 Volts AC, 20% Duty Cycle @ 60 Hz;...

Page 14 - Duty Cycle Charts

OM-316 Page 10 2-2. Duty Cycle Charts A. For AC/DC Models 2 Minutes Welding 8 Minutes Resting SB-086 727 / SB-099 602-A Duty Cycle is percentage of 10 minutesthat unit can weld at rated load withoutoverheating. Y 20% Duty Cycle at 225 Amperes. Ex-ceeding duty cycle can damage unitand void warranty. ...

Page 16 - B. For 220 Volt Model

OM-316 Page 12 B. For AC Models 193 508 / 193 513 / 193 511 The volt-ampere curves show theminimum and maximum voltageand amperage output capabilities.Curves of other settings fall be-tween the curves shown. A. For 115/230 And 230 Volt Models (225 Amperes) B. For 220 Volt Model (300 Amperes) C. For ...

Page 17 - Selecting A Location

OM-316 Page 13 2-4. Selecting A Location Ref. ST-151 556 / ST-802 105-B 1 Rating Label Locate unit near correct inputpower. Y Special installation may berequired where gasoline orvolatile liquids are present –see NEC Article 511 or CECSection 20. 18 in (457 mm) for airflow 1

Page 18 - NOTE

OM-316 Page 14 2-5. Installing Electrode Holder And Work Clamp ST-802 251 / ST802 105-B Y Turn Off unit and disconnectinput power before installingelectrode holder or workclamp. Removing Barrel From Elec-trode Holder 1 Electrode Holder 2 Barrel 3 Access Hole 4 Set Screw Loosen set screw through acce...

Page 19 - Electrical Service Guide

OM-316 Page 15 2-7. Electrical Service Guide Input Voltage 115 220 230 400 460 Input Amperes At Rated Output 95 [70] 47.5 [67] [39] 23.7 [34] Max Recommended Standard Fuse Or Circuit Breaker RatingIn Amperes 150 [110] 70 [100] [60] 35 [50] Min Input Conductor Size In AWG/Kcmil 8 [8] 12 [10] [14] 14 ...

Page 23 - SECTION 3 – OPERATION; Controls

OM-316 Page 19 SECTION 3 – OPERATION 3-1. Controls A. Controls For AC/DC Models Ref. ST-190 600-B / ST-802 105-B 1 Amperage Adjustment Control 2 Power Switch 3 Mode Switch For DC Weld Output Use mode switch to select polarityof dc output, Electrode Posi-tive/DCEP (+),or Electrode Nega-tive/DCEN (–)....

Page 24 - B. Controls For AC Models

OM-316 Page 20 B. Controls For AC Models Ref. ST-190 599-A / ST-802 105-B 1 Amperage Adjustment Control 2 Power Switch 3 Mode Switch Use mode switch to select ac lowrange or high range output. 3 1 2

Page 25 - SECTION 4 – MAINTENANCE & TROUBLESHOOTING; Routine Maintenance; Months

OM-316 Page 21 SECTION 4 – MAINTENANCE & TROUBLESHOOTING 4-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace Unreadable Labels Repair Or Replace Cracked Cables 6 Months 12 Months Blow Out Or Vacuum Inside, During Heavy Service, Clean Monthly OR Lubricate Shunt Block ...

Page 26 - Reinstalling Amperage Adjustment Indicator

OM-316 Page 22 4-3. Reinstalling Amperage Adjustment Indicator ST-802 248-A Y Turn Off welding powersource and disconnect inputpower. 1 Wrapper Remove wrapper from unit. 2 Crank Handle 3 Shunt Shaft 4 Transformer And Shunt(Located Inside Unit) Insert crank handle onto shuntshaft protruding through f...

Page 27 - Troubleshooting; SECTION 5 – ELECTRICAL DIAGRAMS

OM-316 Page 23 4-4. Troubleshooting Trouble Remedy No weld output; fan does not run. Be sure line disconnect switch is in On position (see Section 2-10). Check and replace line fuses if open. Reset breakers if necessary (see Section 2-10). Fan does not run; weld output okay. Be sure nothing is block...

Page 33 - SECTION 6 – WELDING METHODS & TROUBLESHOOTING; Shielded Metal Arc Welding (SMAW) Procedure

OM-316 Page 29 SECTION 6 – WELDING METHODS & TROUBLESHOOTING mod5.1* 9/92 A. Welding Methods 6-1. Shielded Metal Arc Welding (SMAW) Procedure ST-151 593 1 Workpiece Make sure workpiece is clean before welding. 2 Work Clamp Place as close to the weld as possible. 3 Electrode A small diameter elec...

Page 34 - Electrode And Amperage Selection Chart

OM-316 Page 30 6-2. Electrode And Amperage Selection Chart Ref. ST-087 985-A 3/32 1/8 5/323/167/32 1/4 1/16 5/643/32 1/8 5/32 3/167/32 1/4 3/32 1/8 5/323/16 7/32 1/4 3/32 1/8 5/323/16 7/32 1/4 3/32 1/8 5/32 3/167/32 1/4 3/32 1/8 5/323/16 3/32 1/8 5/32 6010 & 6011 6013 7014 7018 7024 Ni-Cl 308L 5...

Page 37 - Electrode Movement During Welding; Butt Joints

OM-316 Page 33 6-7. Electrode Movement During Welding S-0054-A 1 Stringer Bead – Steady Move-ment Along Seam 2 Weave Bead – Side To SideMovement Along Seam 3 Weave Patterns Use weave patterns to cover a widearea in one pass of the electrode.Do not let weave width exceed2-1/2 times diameter of electr...

Page 41 - Notes

Page 42 - SECTION 7 – PARTS LIST

OM-316 Page 38 SECTION 7 – PARTS LIST Figure 7-1. Main Assembly (AC/DC model illustrated) SA-802 245-B 1 2 6 12 6 15 16 18 19 20 21 22 23 24 25 25 27 28 21 29 17 3 4 5 26 13 14 7 8 11 9 10 . Hardware is common andnot available unless listed.

Page 47 - (Equipment with a serial number preface of “LA” or newer)

Warranty Questions? Call1-800-4-A-MILLERfor your localMiller distributor. miller_warr 7/00 Your distributor also givesyou ... ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours. SupportNeed fast answers to thetough welding questions?Contac...

Page 48 - Please complete and retain with your personal records.; For Service

PRINTED IN USA  2001 Miller Electric Mfg. Co. 1/01 Miller Electric Mfg. Co. An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA International Headquarters–USAUSA Phone: 920-735-4505 Auto-AttendedUSA & Canada FAX: 920-735-4134International FAX: 920-735-4125 European Head...