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OM-316 Page 4

1-4. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases

which contain chemicals known to the State of California to

cause birth defects and, in some cases, cancer. (California

Health & Safety Code Section 25249.5 et seq.)

This product contains chemicals, including lead, known to

the state of California to cause cancer, birth defects, or other

reproductive harm. 

Wash hands after use.

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes,

 ANSI Standard Z49.1,

is available as a free download from the American Welding Society at

http://www.aws.org or purchased from Global Engineering Documents

(phone: 1-877-413-5184, website: www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Welding

and Cutting,

 American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: 1-877-413-5184, website:

www.global.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Com-

bustibles,

 American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: 1-877-413-5184,

website: www.global.ihs.com).

National Electrical Code,

 NFPA Standard 70, from National Fire Protec-

tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:

www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders,

 CGA Pamphlet P-1,

from Compressed Gas Association, 14501 George Carter Way, Suite

103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cga-

net.com).

Safety in Welding, Cutting, and Allied Processes,

 CSA Standard

W117.2, from Canadian Standards Association, Standards Sales, 5060

Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:

800-463-6727, website: www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protec-

tion,

 ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-

site: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work,

 NFPA Standard 51B, from National Fire Protection Association,

Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,

and Part 1926, Subpart J, from U.S. Government Printing Office, Super-

intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954

(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—

phone for Region 5, Chicago, is 312-353-2220, website:

www.osha.gov).

Applications Manual for the Revised NIOSH Lifting Equation

, The Na-

tional Institute for Occupational Safety and Health (NIOSH), 1600

Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:

www.cdc.gov/NIOSH).

1-6. EMF Information

Electric current flowing through any conductor causes localized electric

and magnetic fields (EMF). The current from arc welding (and allied pro-

cesses including spot welding, gouging, plasma arc cutting, and

induction heating operations) creates an EMF field around the welding

circuit.  EMF fields may interfere with some medical implants, e.g. pace-

makers. Protective measures for persons wearing medical implants

have to be taken. For example, restrict access for passers

by or con-

duct individual risk assessment for welders. All welders should use the

following procedures in order to minimize exposure to EMF fields from

the welding circuit:

1. Keep cables close together by twisting or taping them, or using a

cable cover.

2. Do not place your body between welding cables. Arrange cables

to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep head and trunk as far away from the equipment in the

welding circuit as possible.

5. Connect work clamp to workpiece as close to the weld as

possible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wire

feeder.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the

device manufacturer before performing or going near arc welding,  spot

welding, gouging, plasma arc cutting, or induction heating operations.

If cleared by your doctor, then following the above procedures is recom-

mended.

Summary of Contents for Thunderbolt XL

Page 1: ...200 AC DC OM 316 087 083U 2014 02 Visit our website at www MillerWelds com File Stick SMAW Processes Stick SMAW Welding Description Arc Welding Power Source 225 AC Models 225 150 AC DC Models 300 200...

Page 2: ...ntinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get...

Page 3: ...ves aux CEM 9 SECTION 3 DEFINITIONS 11 3 1 Miscellaneous Symbols And Definitions 11 SECTION 4 SPECIFICATIONS 12 4 1 Unit Specifications 12 4 2 Duty Cycle Charts 13 4 3 Volt Ampere Curves 14 SECTION 5...

Page 4: ......

Page 5: ...eling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC c...

Page 6: ...ed according to AWS F4 1 and AWS A6 0 see Safety Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the work as close...

Page 7: ...PARTS can injure D Keep away from moving parts such as fans D Keep all doors panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards f...

Page 8: ...PA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of...

Page 9: ...IQUE MENT si le proc d de soudage le demande D Si l utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip D D autre...

Page 10: ...s et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc D Porter un quipement de protection pour le corps fait d un mat riau r sistant et ignifuge cuir coton robuste laine La...

Page 11: ...s en bon tat D Tourner le dos la sortie de vanne lors de l ouverture de la vanne de la bouteille Ne pas se tenir devant ou derri re le r gulateur lors de l ouverture de la vanne D Le couvercle du d t...

Page 12: ...de rechange recommand es par le constructeur D Effectuer l entretien en respectant les manuels d utilisation les normes industrielles et les codes nationaux d tat et locaux LE RAYONNEMENT HAUTE FR QU...

Page 13: ...Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part...

Page 14: ...OM 316 Page 10...

Page 15: ...rnating Current Electrode Positive Electrode Negative Direct Current Welding Arc V Volts Work Electrode Single Phase Transformer Single Phase Transformer AC Rectifier DC Power Source Line Connection I...

Page 16: ...ycle 50 Hz 30 160 80 VDC AC 300 A 30 Volts AC 20 Duty Cycle 50 60 Hz Low 40 200 High 65 300 80 VAC 70 5 4 134 lbs 61 kg DC 200 A 25 Volts DC 20 Duty Cycle 50 60 Hz 30 200 80 VDC Overall Dimensions Hei...

Page 17: ...E Exceeding duty cycle can damage unit and void warranty B For 300 200A Models A For 225 150A Models These models have a 15 duty cycle when used with 50 Hz input power 2 Minutes Welding 8 Minutes Rest...

Page 18: ...s fall be tween the curves shown A For 225 150A Models B For 300 200A Models 0 10 20 30 40 50 60 70 80 90 100 0 100 200 300 400 DC Amperes DC Volts MIN MAX 0 10 20 30 40 50 60 70 80 90 100 0 50 100 15...

Page 19: ...s 193 508 The volt ampere curves show the minimum and maximum voltage and amperage output capabilities Curves of other settings fall be tween the curves shown For 225A Models 0 10 20 30 40 50 60 70 80...

Page 20: ...er requirements and or rated output For future reference write serial number in space provided on back cover of this manual 5 2 Selecting A Location 804 292 A 802 105 D Special installation may be req...

Page 21: ...Electrode Cable and Barrel onto Electrode Holder 5 Electrode Cable From Unit Has Bare Conductors on End 6 Terminal Screw Back out terminal screw from elec trode holder Insert electrode cable through b...

Page 22: ...5 67 Max Recommended Standard Fuse Rating In Amperes1 Time Delay Fuses2 90 50 80 Normal Operating Fuses 3 110 70 100 Min Input Conductor Size In AWG 4 8 12 10 Max Recommended Input Conductor Length I...

Page 23: ...L2 For Models Not Supplied With Plug Installationmust meet all National and Local Codes have only qualified per sons make this installation Disconnect and lockout tagout input power before connecting...

Page 24: ...ntrols For AC DC Models Ref 217 857 B 802 105 D 1 Amperage Adjustment Control 2 Power Switch 3 Mode Switch For DC Weld Output Use mode switch to select polarity of dc output Electrode Posi tive DCEP o...

Page 25: ...s available at www MillerWelds com OM 316 Page 21 B Controls For AC Models Ref 218 237 A 802 105 D 1 Amperage Adjustment Control 2 Power Switch 3 Mode Switch Use mode switch to select AC low range or...

Page 26: ...nt 802 248 D Turn Off welding power source and disconnect input power 1 Wrapper Remove wrapper 2 Shunt Block Do not grease screw threads on shunt block Apply light coating of high tempera ture grease...

Page 27: ...Pinion Gear Install pinion gear onto front panel making sure anti rotation pins are in holes on front panel 6 Pointer Gear Install pointer gear overtop of pinion gear and rotate so pointer is indicat...

Page 28: ...ay Be sure nothing is blocking movement of fan If fan does not run freely replace fan motor Erratic weld current Clean and tighten all weld cable connections Erratic arc with excessive spatter Use dry...

Page 29: ...DIAGRAMS 191 364 Figure 8 1 Circuit Diagram For 225 150 AC DC 230 Volts Models 191 368 220 PRI SEC T1 GRN VOLT ONLY S2 WORK ELECTRODE R Z1 SR1 S O P POWER CORD FM S1 S O P Figure 8 2 Circuit Diagram...

Page 30: ...OM 316 Page 26 191 362 WORK 230 PRI SEC T1 GRN VOLT ONLY S2 AC HIGH AC LOW ELECTRODE PLG1 FM S1 Figure 8 3 Circuit Diagram For 225 AC 230 Volts Models...

Page 31: ...s current than a large one Fol low recommendations of the elec trode manufacturer when setting weld amperage see Section 9 2 4 Insulated Electrode Holder 5 Electrode Holder Position 6 Arc Length Arc l...

Page 32: ...ALL ALL EP EP EP EN EP EN EP EP EN EP EP 6010 6011 6013 7014 7018 7024 NI CL 308L EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY ELECTRODE AMPERAGE RANGE DIAMETER MED...

Page 33: ...produce the best results hold a short arc travel at a uniform speed and feed the electrode downward at a constant rate as it melts 1 1 2 2 Groove Welds Fillet Welds 9 5 Poor Weld Bead Characteristics...

Page 34: ...ide groove weld joints or bridging across gaps a weave bead or multiple stringer beads work better 1 Stringer Bead Steady Movement Along Seam 2 Weave Bead Side to Side Movement Along Seam 3 Weave Patt...

Page 35: ...good welds The single or double V groove weld is good for materials 3 16 3 4 in 5 19 mm thick Generally the single V groove is used on ma terials up to 3 4 in 19 mm thick and when regardless of thickn...

Page 36: ...Actions Arc length too long Reduce arc length Damp electrode Use dry electrode Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface before welding Excessi...

Page 37: ...and or maintain steady travel speed Burn Through weld metal melting completely through base metal resulting in holes where no metal remains Possible Causes Corrective Actions Excessive heat input Sel...

Page 38: ...Notes...

Page 39: ...Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes relays work station table tops and welding curtains or parts that fail due to normal wear Ex...

Page 40: ...your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equip...

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