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
80
Light Industrial Applications
Garage/Job Shops
Plant Fabrication/Maintenance
Vocational Training
Light Production-line Work
Thunderbolt
®
XL AC/DC
Stick Welding
Power Source
Issued May 2008 • Index No. AD/8.0
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.
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.
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.
Quick
Specs
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.
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: 920-735-4505
USA FAX: 920-735-4134
Canadian FAX: 920-735-4169
International FAX: 920-735-4125
Power source is warranted for 3 years, parts and labor.
Original main power rectifiers are warranted for 5 years.
The exclusive patented Accu-Set
™
provides precise heat control with
infinite amperage control.
Model
Thunderbolt
XL 225 AC/
150 DC
Thunderbolt
XL 300 AC/
200 DC
AC
DC
AC
DC
Rated Output at 20% Duty Cycle
225 A at 25 VAC, 60 Hz (15% Duty Cycle at 50 Hz)
150 A at 25 VDC, 60 Hz (15% Duty Cycle at 50 Hz)
300 A at 30 VAC, 50/60 Hz
200 A at 25 VDC, 50/60 Hz
Welding
Amperage Range
High Low
40–235 30–150
30–160
65–300 40–200
30–200
Max. Open-
Circuit
Voltage
80
Net
Weight
104 lb
(47 kg)
134 lb
(61 kg)
Specifications (Subject to change without notice.)
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)
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