Process* DC stick (SMAW)
Input Power: 1-phase power
Max. Open-Circuit Voltage160: 91 V210: 85 V
Amperage Range160: 20–80 A (120 V)
20–160 A (240 V)210: 25–210 A (240 V)
Max Mild Steel Thickness160: 1/8 in. (120 V) 3/8 in. (240 V)210: 1/2 in. (240 V)
Best For Light Industrial ApplicationsGarage/job shopsFarm/ranchMaintenance repairLight production-line workShipyard install/repair
Power source is warranted for three years, parts and labor.Original main power recti�ers are warranted for �ve years.
Model
Thunderbolt 160
Input Power
120 V, 50/60 Hz
240 V, 50/60 Hz
Rated Output
65 A at 20% duty cycle
160 A at 30% duty cycle
WeldingAmperage Range
20–80 A
20–160 A
Max. Open-Circuit Voltage
91 V
Net Weight
15 lb. (6.8 kg)
Speci�cations Amps Input atRated Output
20.7
27.8
Dimensions
H: 10.5 in. W: 7.125 in. (181 mm)D: 13.375 in. (340 mm)
Conforms to ANSI/IEC Std. 60974-1. Conforms to CSA Std. E60974-1.
THUNDERBOLT 160 STICK WELDER
- Portable and Lightweight
- Weld Thicker Materials with Increased Power
- Quick Arc Starts with Hot Start Technology
- Dual Voltage with Multi-voltage Plug; allowsconnection with 120 or 240 volt receptacles
ITEM #: MI907721 PRICE: $425
10 ft. No. 4 electrode cable withheavy-duty electrode holder
10 ft. work cable with clamp
6.5 ft. power cord with MVP plugs
for 120V and 240V
Cable pouch
FEATURES:
INCLUDES:
Control PanelElectrode Polarity Chart
Elec
trod
e
DC* AC
Posi
tion
Usa
ge
Pene
trat
ion
7024 EP, ENFlat
horiz.fillet
Low
Min. prep, rough,high spatter
Smooth, easy,faster
Cast iron
6011 EP All Deep✓
All✓
All✓
All✓
All✓
All✓
EP Low
6013 EP, EN Low General
7014 EP, EN Med. Smooth, easy, fast
7018 EP Low Low hydrogen,strong
308L
*EP = Electrode positive (reverse polarity)EN = Electrode negative (straight polarity)
EP Low Stainless
✓
6010 EP All Deep—
Ni-Cl
Electrode/Amperage Chart
Elec
trod
e
Diameter
in.
7024
6010and
6011
3/321/85/32
3/321/85/323/16
3/321/85/323/161/165/643/321/85/323/163/321/85/323/321/85/323/321/85/32
6013
7014
7018
Ni-Cl
308L
2.43.24.04.81.62.02.43.24.04.82.43.24.02.43.24.02.43.24.02.43.24.04.82.43.24.0
mm Min
.
Max
.
50 A
100
A
150
A
200
A
Amperage Range
Performance Data
Electrode Charts
Duty Cycle Chart
% Duty Cycle
Wel
d Am
pere
s
225
200
150
100
50
25
75
125
175
0100 20 30 40 50 60 70 80 90 100
210 (240 V)
160 (240 V)
160 (120 V)
1
23
1
23
Typical Installation (DCEP)
PowerSource
Stick Electrode
Work Clamp
Note: Also DCEN polarity capable.
Stick (SMAW) Basic Equipment
1. Amperage Adjustment Control2. Power Indicator Light3. Overtemperature Light
© 2017 Miller Electric Mfg. Co.
Ideal performance for most 6010, 6011, 6013 and 7018 rods. Note: 6010 not recommended for open root welding.
Thunderbolt 160120 V: 1/16 –1/8 in. (some limitations with 3/32-inch rods and very limited with1/8-inch rods based on rod/amperage)240 V: 1/16 – 5/32 in. (some limitations with 5/32-inch rods based on amperage)
Thunderbolt 2101/16 – 3/16 in. (some limitations with 3/16-inch rods based on amperage)
* DC TIG capable.
