Welding of Welders All about Welding and Welders
ESAB® Renegade VOLT™ ES 200i Battery-Powered Stick and TIG Welder
Battery-powered welding used to be a dream. Not anymore. With the ESAB Renegade VOLT™ ES 200i, that dream has turned into a shockingly powerful, fully functional cordless welding solution. This machine isn’t just a novelty or a backup tool; it’s a serious piece of professional equipment engineered for real-world welding in the toughest, most remote locations.
Quick Tech Overview
| Feature | ESAB Renegade VOLT™ ES 200i |
|---|---|
| Processes | SMAW (Stick), GTAW-DC (TIG DC), Live TIG |
| Input Voltage | 120/230 VAC ±15%, 50/60 Hz |
| Output (Mains) | Up to 200A |
| Output (Battery) | Up to 150A |
| Hybrid Mode (AMP+) | Yes, combines AC + battery for higher output/lower draw |
| Max Electrode | 5/32″ |
| Battery Type | DEWALT FLEXVOLT (6Ah, 9Ah, 12Ah) |
| Display | Color display, battery status + arc time calculator |
| Weight (Full w/ Batteries) | 24.5 kg (54 lbs) |
| Enclosure Rating | IP23 (outdoor-rated) |
| Open Circuit Voltage | 80 VDC |
| Portability | Compact, rugged, multiple lift points |
Design & Build Quality
The Renegade VOLT ES 200i is about 5x smaller and lighter than a traditional welder-generator setup. It feels like a contractor’s tool instead of a bulky shop machine.
Build quality is premium. The outer casing is made from impact-resistant materials designed to handle jobsite abuse. Whether you’re crawling under a railcar or hoisting it into a lift basket, the integrated lift handles and rugged construction are confidence-inspiring.
Dimensions & Weight
| Configuration | Size (mm) | Size (inches) | Weight |
| With Battery Box | 480 x 220 x 485 | 19 x 9 x 19 | 19 kg (41 lbs) |
| With 4x 12Ah Batteries | Same as above | Same as above | 24.5 kg (54 lbs) |
Modes of Operation
The Renegade VOLT ES 200i supports three operation modes, giving users a flexible range of options:
- Battery Mode (Cordless DC) – Full portability.
- Mains Mode (AC) – Plug in for continuous use.
- AMP+ Hybrid Mode – Combine AC + Battery to prevent breaker trips and boost output.
This triple-threat capability makes it ideal for remote work, generator-limited environments, and high-duty-cycle tasks.
Performance & Welding Capability
Don’t let the compact size fool you—this unit performs like a full-sized professional welder. The arc quality is excellent across Stick and Live TIG.
SMAW (Stick) Output Performance Table
| Mode | Voltage | Max Amps | Duty Cycle @ Max | Notes |
| AC (230V) | 28.0V | 200A | 25% | Full capacity |
| AMP+ (120V) | 26.0V | 150A | 25% | Hybrid boost mode |
| Battery (DC) | 25.2V | 140A | 18% | Fully cordless operation |
Electrode capacity: Up to 5/32″, with cellulosic (6010) support and arc force/hot start features built-in.
On a single charge, you can expect:
- ~33 rods of E6013
- ~31 rods of E6010
- ~26 rods of E7018
GTAW (Live TIG) Output Table
| Mode | Voltage | Max Amps | Duty Cycle @ Max | Notes |
| AC (230V) | 18.0V | 200A | 25% | Smooth DC TIG |
| AMP+ (120V) | 17.2V | 180A | 25% | Hybrid performance boost |
| Battery (DC) | 16.0V | 150A | 18% | Best for short TIG jobs |
Note: The TIG torch must be Live TIG compatible and is sold separately.
Battery System: The DEWALT Advantage
What sets this welder apart is its swappable DEWALT FLEXVOLT power system.
Battery Compatibility
- Works with 6Ah, 9Ah, and 12Ah FLEXVOLT batteries.
- Includes 4x 12Ah FLEXVOLT batteries with the machine.
Each battery charges via the DEWALT 4-Port Fast Charger (included), and the whole setup feels like a system built for efficiency.
Battery Runtime Table (Approximate Rods per Charge)
| Electrode Type | Rods per Charge |
| E6013 | 33 |
| E6010 | 31 |
| E7018 | 26 |
Based on four 12Ah batteries in optimal conditions.
User Interface: Outdoor-Ready & Intuitive
The Renegade VOLT ES 200i has a bright color screen that remains visible even in direct sunlight—a huge plus when working outdoors. The screen includes:
- Battery status indicators
- Remaining arc time calculator
- Welding mode display
- Parameter memory recall
Smart Features
- Arc Force Control
- Hot Start
- Cellulosic Mode (optimized for E6010)
- Memory Storage (store/retrieve welding settings)
Included Accessories
Out of the box, this machine is well-equipped:
- Renegade VOLT ES 200i Power Source
- Battery Box (Detachable)
- 4x DEWALT FLEXVOLT 12Ah Batteries
- DEWALT 4-Port Fast Charger
- Electrode Holder
- Ground Clamp
- Shoulder Strap
Optional Accessories Available:
- TIG torches (SR-17V, SR-26V)
- TIG foot pedal
- Remote control leads
Portability: Shockingly Lightweight
At just 24.5 kg with batteries, the Renegade VOLT ES 200i is highly portable. It’s made for:
- Remote sites with no AC power
- Confined spaces
- Elevated positions (fits in lift baskets)
- Truck beds or mobile setups
No cables, no generator, no fuel—just grab and go.
Pros and Cons Table
| Pros | Cons |
| Fully cordless welding capability | No AC TIG (only DC) |
| Hybrid AMP+ mode for extra power | Battery TIG torch not included |
| High output (200A) in a portable form factor | 25% duty cycle at max output |
| Premium arc performance for Stick and TIG | Price may be high for hobbyist use |
| Color display, battery monitor, arc time calculator | Requires investment in FLEXVOLT ecosystem |
FAQs
Can I use this machine for TIG welding aluminum?
No, the Renegade VOLT ES 200i supports DC TIG only, not AC TIG, which is required for aluminum.
How long do the batteries last per charge?
On average, you can burn about 30 rods per full charge using 12Ah FLEXVOLT batteries.
Is it compatible with other battery brands?
No, it specifically supports DEWALT FLEXVOLT battery systems.
What’s the biggest electrode size it can handle?
It supports up to 5/32” electrodes.
Can it be used with a generator?
Yes, especially in AMP+ mode, it’s designed to minimize breaker trips when connected to smaller generators or 120V circuits.
Conclusion: A Game-Changer for the Field Welder
The ESAB® Renegade VOLT™ ES 200i isn’t just a fancy idea; it’s a practical, high-performance, battery-powered welding machine that delivers on all fronts. If your work takes you into the field, onto rooftops, or into power-restricted areas, this machine will likely outperform any generator-based setup you’ve relied on before.
It’s not the cheapest machine out there, but it’s arguably the most capable in its class when it comes to versatility, mobility, and raw welding power. For pros who need to get the job done anywhere—this machine is a beast.
