ESAB Renegade VOLT ES 200i Battery-Powered Stick and TIG Welder User Manual

1. Product Overview

The ESAB Renegade VOLT ES 200i is a cordless, battery-powered welding machine designed for Stick (SMAW) and Live TIG (GTAW) welding processes. It offers exceptional portability and performance, operating in three distinct modes: Battery, Mains, and AMP+ Hybrid. This welder is powered by DEWALT FLEXVOLT 20V/60V MAX 12Ah batteries, providing up to 150 amps of welding output on battery power and up to 200 amps when connected to AC mains.

Key features include:

• 200 A output on AC mains (230V)
• Up to 140 A output on battery power
• Includes (4) DeWALT FLEXVOLT 20V/60V 12Ah batteries
• AMP+ hybrid mode for enhanced power delivery
• Lightweight and portable design
• Durable, impact-resistant housing
• Sun-friendly, intuitive user interface with memory storage for welding parameters
• Efficiency at Maximum Current: 80%
• Power Factor at Maximum Current: 0.99

Figure 1: ESAB Renegade VOLT ES 200i with included accessories.

2. Safety Information

Always prioritize safety when operating welding equipment. Failure to follow safety precautions can result in serious injury or death.

• Electric Shock: Can kill. Do not touch live electrical parts. Wear dry welding gloves and protective clothing. Ensure proper grounding.
• Fumes and Gases: Can be hazardous to your health. Keep your head out of the fumes. Use ventilation or exhaust to remove fumes and gases from the breathing zone and general area.
• Arc Rays: Can injure eyes and burn skin. Wear an approved welding helmet with a proper shade filter. Wear appropriate eye protection with side shields. Wear protective clothing to cover exposed skin.
• Fire and Explosion: Welding sparks can cause fire or explosion. Keep flammable materials away from the welding area. Have a fire extinguisher readily available.
• Hot Parts: Can cause severe burns. Allow equipment to cool before touching. Wear insulated gloves.
• Battery Safety: Use only specified batteries and chargers. Do not expose batteries to fire or extreme temperatures. Do not short-circuit battery terminals.

3. Setup

Follow these steps to prepare your ESAB Renegade VOLT ES 200i for operation:

1. Unpacking: Carefully remove the welder and all accessories from the packaging. Inspect for any shipping damage.
2. Battery Installation: Open the battery compartment. Insert the four DEWALT FLEXVOLT 20V/60V MAX 12Ah batteries into their designated slots. Ensure they are securely latched. The welder can operate on battery power alone.

Figure 2: Installing batteries into the Renegade VOLT ES 200i.

3. Connecting Welding Cables: Connect the electrode holder cable and the work clamp cable to the appropriate terminals on the welder. Ensure connections are tight.
4. Power Source Selection:
   • Battery Mode: For completely cordless operation.
   • Mains Mode: Plug the welder into a 120V or 230V AC power outlet for continuous operation and higher output.
   • AMP+ Hybrid Mode: When connected to AC mains, the welder can draw additional power from the batteries to boost output beyond what the mains alone can provide.
5. TIG Welding Setup (Optional): For Live TIG (GTAW) welding, connect your TIG torch and gas supply as per standard TIG welding procedures.

Figure 3: Welder control panel displaying power specifications.

4. Operating Instructions

The Renegade VOLT ES 200i features an intuitive user interface for easy parameter adjustment.

1. Power On: Press the power button to turn on the welder. The sun-friendly display will illuminate.
2. Select Welding Process: Use the interface to select between Stick (SMAW) or Live TIG (GTAW) welding.
3. Adjust Parameters: Set the desired amperage and other welding parameters using the control knob and buttons. The welder can store welding parameters for future use.
4. Begin Welding: Once parameters are set and safety precautions are observed, you can begin welding. The battery mode allows for significant welding time, capable of striking up to 30 electrodes on a single charge.

For detailed guidance on specific welding techniques for Stick or TIG, refer to professional welding resources or training.

Video 1: An overview of the ESAB Renegade VOLT welder's capabilities and portability, demonstrating its use in various environments.

5. Maintenance

Regular maintenance ensures the longevity and optimal performance of your welding machine.

• Cleaning: Periodically clean the exterior of the welder with a dry, soft cloth. Ensure ventilation openings are free from dust and debris.
• Cable Inspection: Regularly inspect welding cables, electrode holder, and work clamp for damage, fraying, or loose connections. Replace damaged components immediately.
• Battery Care: Store batteries in a cool, dry place. Avoid fully discharging batteries for extended periods. Charge batteries regularly, especially if the unit is not used frequently.
• Internal Inspection: For internal cleaning or inspection, it is recommended to consult with qualified service personnel.

6. Troubleshooting

If you encounter issues with your ESAB Renegade VOLT ES 200i, refer to the following common troubleshooting tips:

• No Power: Check if the batteries are properly installed and charged. If using mains power, ensure the power cord is securely plugged into a functional outlet and the circuit breaker has not tripped.
• Poor Arc or No Arc: Verify that welding cables are securely connected to the welder and the workpiece. Ensure the work clamp has good contact with the base metal. Check electrode condition and proper selection for the material.
• Overheating: If the welder shuts down due to overheating, allow it to cool down. Ensure adequate ventilation around the machine. Reduce the duty cycle or amperage if continuously welding at high settings.
• Display Issues: If the display is not functioning correctly, try restarting the machine. If the problem persists, contact customer support.

For issues not covered here, or if troubleshooting steps do not resolve the problem, contact ESAB customer support.

7. Specifications

8. Warranty and Support

For warranty information, please refer to the official ESAB warranty documentation included with your product or visit the ESAB website. ESAB provides comprehensive support for its products.

For technical assistance, service, or to purchase replacement parts, please contact ESAB customer support through their official channels. You can also visit the ESAB Store on Amazon for additional product information and resources.