ESAB Renegade VOLT ES 200i Instruction Manual
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ESAB Renegade VOLT ES 200i Instruction Manual

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Renegade VOLT ES 200i
Instruction manual
Valid for: HA329YY- & OP339YY-XXXXXX
0447 814 001   GB   20231120

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Summary of Contents for ESAB Renegade VOLT ES 200i

  • Page 1 Renegade VOLT ES 200i Instruction manual Valid for: HA329YY- & OP339YY-XXXXXX 0447 814 001   GB   20231120...

  • Page 3: Table Of Contents

    ........................6.2.8 Jobs ......................6.2.9 Hot start ......................6.2.10 Arc force ......................Welding screen .............. MMA / SMAW / Stick home screen settings ................TIG / GTAW home screen settings 0447 814 001 - 3 - © ESAB AB 2023...
  • Page 4 7.2.1 Cleaning the power source ..................7.2.2 Cleaning the battery box ........................ TROUBLESHOOTING .......................... ERROR CODES ....................Error code descriptions ....................... ORDERING SPARE PARTS ..........................WIRING DIAGRAM ......................... ORDERING NUMBERS ............................. ACCESSORIES 0447 814 001 - 4 - © ESAB AB 2023...

  • Page 5: Safety

    60 VDC and 1500 VDC. User responsibility Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of equipment. The following recommendations should be observed in addition to the standard regulations that apply to the workplace.
  • Page 6 Protect your eyes and body. Use the correct welding screen and filter lens and wear protective clothing. • Protect bystanders with suitable screens or curtains. NOISE - Excessive noise can damage hearing Protect your ears. Use earmuffs or other hearing protection. 0447 814 001 - 6 - © ESAB AB 2023...

  • Page 7: Precautions For Operations

    • To handle hot parts, use proper tools and/or insulated welding gloves to prevent burns. CAUTION! Battery box is recommended only for Renegade VOLT ES 200i power source. CAUTION! This product is solely intended for arc welding. CAUTION! Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system.

  • Page 8: Safety Instructions For Battery Packs

    • Charge the battery packs only in designated DeWALT chargers. • Do not splash or immerse in water or other liquids. 0447 814 001 - 8 - © ESAB AB 2023...
  • Page 9 ○ Use mode: The FLEXVOLT battery can operate as a 20V battery in a DeWALT 20V tool and a 60V battery in a DeWALT 60V tool. The Renegade Volt ES 200i can utilise only 20V of the DeWALT FLEXVOLT batteries.
  • Page 10 The charge status gauge is only an indication of the charge left on the battery pack. It does not indicate tool functionality and is subject to variation based on product components, temperature, and end-user application. For more information regarding charge status gauge battery packs, please visit DeWALT www.dewalt.com. 0447 814 001 - 10 - © ESAB AB 2023...

  • Page 11: Safety Instructions For Battery Chargers

    Take it to an authorized service center. • Do not disassemble the charger; take it to an authorized service center when service or repair is required. Incorrect reassembly may result in electric shock, electrocution, or fire. 0447 814 001 - 11 - © ESAB AB 2023...
  • Page 12 Always unplug the charger from the power supply when there is no battery pack in the cavity. Unplug the charger before attempting to clean. • Do not freeze or immerse the charger in water or any other liquid. 0447 814 001 - 12 - © ESAB AB 2023...
  • Page 13 ESAB has an assortment of welding accessories and personal protection equipment for purchase. For ordering information contact your local ESAB dealer or visit us on our website. 0447 814 001 - 13 -...

  • Page 14: Introduction

    2   INTRODUCTION INTRODUCTION The Renegade VOLT ES 200i is an inverter-based power source that can be run off either battery power (DC) or 120/230 VAC. This power source is intended to be used for MMA / SMAW / Stick and TIG / GTAW welding.
  • Page 15 Sweden 031 68 61 60 www.dewalt.se kundservice.se@sbdinc.com Turkey +90 216 665 2900 www.dewalt.com.tr support@dewalt.com.tr United Kingdom 01753-567055 www.dewalt.co.uk emeaservice@sbdinc.com Middle East Africa 971 4 812 7400 www.dewalt.ae support@dewalt.ae 0447 814 001 - 15 - © ESAB AB 2023...

  • Page 16: Technical Data

    3   TECHNICAL DATA TECHNICAL DATA Technical data for Mains Mode Renegade VOLT ES 200i Outlet voltage 120 V ±15%, 230 V ±15%, 1~ 50/60 Hz 1~ 50/60 Hz Primary current 27 A 28 A 1max 13.5 A 14 A...

  • Page 17: Technical Data For Battery Mode - 4 Dewalt Batteries

    3   TECHNICAL DATA Renegade VOLT ES 200i Power source 460 × 200 × 320 mm (18.1 × 7.9 × 12.6 in.) Power source with battery box 480 × 220 × 485 mm (18.9 × 8.7 × 19.1 in.) Weight Power source 12 kg (26.5 lbs)

  • Page 18: Technical Data For Amp + Hybrid Mode

    3   TECHNICAL DATA Renegade VOLT ES 200i MMA / SMAW / Stick TIG / GTAW Open-circuit voltage U VRD deactivated 68 V VRD activated <30 V Operating temperature -10 to +40°C (+14 to 104°F) Transportation temperature -20 to +55°C (-4 to +161°F) Constant sound pressure when idling <70 db (A)
  • Page 19 3   TECHNICAL DATA Renegade VOLT ES 200i 100% duty cycle 100 A / 14 V 100 A / 14 V Apparent power I at maximum 3.4 kVA 5.8 kVA current Active power I at maximum current 3.3 kW 5.7 kW...

  • Page 20: Eco Design Information

    Name Idle power Efficiency when max power consumption Renegade Volt ES 200i <50 W The value of efficiency and consumption in idle state have been measured by method and conditions defined in the product standard EN 60974-1:2012. Manufacturer’s name, product name, serial number, and date of production can be read from rating plate.

  • Page 21: Installation

    Position the power source and battery box in such a way that the cooling air inlets and outlets are not being obstructed. A. Minimum 200 mm (8 in). B. Minimum 200 mm (8 in). WARNING! Secure the equipment - particularly if the ground is uneven or sloping. 0447 814 001 - 21 - © ESAB AB 2023...

  • Page 22: Connecting Battery Box To Power Source

    5) Secure the latch on the rear of the battery box on the catches to the rear power interface mounting bracket. 6) Connect the battery box interface cable to the receptacle on the rear panel of the power source. 0447 814 001 - 22 - © ESAB AB 2023...

  • Page 23: Installing And Removing The Battery Pack

    5) To remove the battery pack from the holder, press the release button provided at the bottom side of the battery and firmly pull the battery pack out of the battery holder. 0447 814 001 - 23 - © ESAB AB 2023...

  • Page 24: Installing Shoulder Strap

    Falling equipment can cause serious personal injury and equipment damage. WARNING! Make sure that the hooks are firmly connected before lifting. Lift the unit with the handle on top of the case. 0447 814 001 - 24 - © ESAB AB 2023...

  • Page 25: Mains Supply

    S scmin 1. Rating plate with supply connection data. 0447 814 001 - 25 - © ESAB AB 2023...
  • Page 26 4   INSTALLATION Recommended fuse sizes and minimum cable area for the Renegade VOLT ES 200i Renegade VOLT ES 200i Supply voltage 120 VAC 1P - 50/60 Hz 230 VAC 1P - 50/60 Hz Maximum current rating (I 27 A...

  • Page 27: Operation

    2. ON/OFF Membrane switch 7. Mains switch (120/230 VAC) 3. Positive welding terminal 8. Battery box / DC interface cable 4. Remote socket 9. Mains supply cable 5. Negative welding terminal 0447 814 001 - 27 - © ESAB AB 2023...

  • Page 28: Connecting Welding And Return Cables

    This power source performs Live TIG / GTAW start. Live TIG / GTAW arc initiation The tungsten electrode is placed against the workpiece. When lifted away from workpiece the arc is struck at a limited current level. 0447 814 001 - 28 - © ESAB AB 2023...

  • Page 29: Turning The Power On/Off For Mains Mode

    The VRD function ensures that the open-circuit voltage does not exceed 35 V when welding is not being carried out. If the VRD is enabled, it will be indicated on the header bar of the menu screen. Contact an authorised ESAB service technician to activate / deactivate this function.

  • Page 30: Turning The Power On/Off For Battery Mode

    Do not turn off the power source during welding (with load). CAUTION! Do not remove the batteries during welding. 1) To turn the unit on: a) Install the four batteries. 0447 814 001 - 30 - © ESAB AB 2023...

  • Page 31: Fan Control

    All weld data will be saved when the power is interrupted or switched off under normal conditions. Fan control The Renegade VOLT ES 200i is fitted with a cooling fan. When cooling fan is not in use, the fan will automatically turn off. This functionality has two advantages: •...

  • Page 32: User Interface

    4. ON/OFF Membrane switch - used to turn the the power source on and off. • Single press – used to turn the power source on. • Long press (3 seconds) – used to turn the power source off. 0447 814 001 - 32 - © ESAB AB 2023...

  • Page 33: Menu Screen

    The option of selecting between MMA / SMAW / Stick or Live TIG / GTAW mode. From the home screeen, press the pushbutton encoder to enter the menu screeen. Select the desired welding process and press the pushbutton encoder. 0447 814 001 - 33 - © ESAB AB 2023...
  • Page 34 6   USER INTERFACE 0447 814 001 - 34 - © ESAB AB 2023...

  • Page 35: Settings

    This function enables the user to adjust the TFT display brightness from 20% to 100%. Press the pushbutton encoder, rotate the encoder to the desired brightness, and press the back button to confirm. 0447 814 001 - 35 - © ESAB AB 2023...
  • Page 36 For e.g., if the breaker size is selected as 10 A, the effective input current will be limited to 10 A through AMP Hybrid Mode. 0447 814 001 - 36 - © ESAB AB 2023...
  • Page 37 • Off: System will not enter “SLEEP MODE". • Manual: User determines when the sleep mode reminder will be displayed. • Adaptive: Will be activated based on the system temperature. 0447 814 001 - 37 - © ESAB AB 2023...
  • Page 38 Membrane switch” to turn the unit on. During AMP Hybrid Mode, if the unit has entered the sleep mode, the user will be prompted to press “ON/OFF Membrane switch” to exit sleep mode. 0447 814 001 - 38 - © ESAB AB 2023...
  • Page 39 20 A. If the current is set to 80 A and the remote min current function is set to 50, the remote min current will be 40 A. 0447 814 001 - 39 - © ESAB AB 2023...

  • Page 40: Information

    This information may be required if the unit ever needs to be serviced. 6.2.5 Information Provides information to the user that can be beneficial and recommended maintenance process. • Wears and spares • Accessories • Filler metals 0447 814 001 - 40 - © ESAB AB 2023...

  • Page 41: Electrode

    Allows the user to determine how to control the output of the unit, home screen or remotely. To enable the remote function, connect the remote control to the 8-pin remote control receptacle. The remote control is automatically detected. 0447 814 001 - 41 - © ESAB AB 2023...

  • Page 42: Jobs

    To create jobs: It is required to establish specific welding parameters that are desired in MMA / SMAW / Stick or Live TIG / GTAW mode. Ten (10) job operations are available distinctly for each mode (MMA / SMAW / Stick or Live TIG / GTAW). 0447 814 001 - 42 - © ESAB AB 2023...

  • Page 43: Hot Start

    Controls the amount of additional amperage when in short arc length condition. Increase the arc force percentage when in a tight or narrow weld joint or decrease the arc force percentage when welding a normal weld (range 0-10). 0447 814 001 - 43 - © ESAB AB 2023...

  • Page 44: Welding Screen

    Values of last weld will be displayed for 40 seconds after welding. When time expires, the display will return to the home view. MMA / SMAW / Stick home screen settings Mains Mode 0447 814 001 - 44 - © ESAB AB 2023...

  • Page 45: Tig / Gtaw Home Screen Settings

    To make any adjustment, press pushbutton encoder to enter menu screen, and navigate to the desire variable to be adjusted and select to make adjustment. TIG / GTAW home screen settings Mains Mode 0447 814 001 - 45 - © ESAB AB 2023...
  • Page 46 3. Footer bar of home screen display the status of the weld process, job selection and remote connection. To make any adjustment, press pushbutton encoder to enter menu screen and navigate to the desire variable to be adjusted and select to make adjustment. 0447 814 001 - 46 - © ESAB AB 2023...

  • Page 47: Maintenance

    WARNING! The mains supply must be disconnected during cleaning and maintenance. CAUTION! Repair, cleaning, and electrical work should be performed by an authorised ESAB service technician. Use only ESAB original spare and wear parts. CAUTION! The product is covered by manufacturer's warranty. Any attempt to carry out repair work by non-authorised service centers or personnel will invalidate the warranty.

  • Page 48: Cleaning

    During cleaning, always wear recommended personal safety equipment, such as ear plugs, safety glasses, masks, gloves and safety shoes. CAUTION! Repair, cleaning, and electrical work should be performed by an authorised ESAB service technician. Use only ESAB original spare and wear parts. 7.2.1 Cleaning the power source 1) Disconnect the power source from the mains supply.
  • Page 49 The IP shield should be angled approximately 90° into the power source, so that it is positioned between the welding outlet connector and the transformer outlets. 0447 814 001 - 49 - © ESAB AB 2023...

  • Page 50: Cleaning The Battery Box

    3) Clean the battery box, using dry compressed air with reduced pressure of 4 bar (58 psi). 4) Gently, close the left side panel. 5) To open the right-side panel, remove the two screws securing the door latch lock cover. 0447 814 001 - 50 - © ESAB AB 2023...
  • Page 51 7) Clean the battery box, using dry compressed air with reduced pressure of 4 bar (58 psi). 8) Close the right-side panel reassemble the door latch lock cover in the exact reverse order with the correct tightening torque mentioned in the previous illustrations. 0447 814 001 - 51 - © ESAB AB 2023...

  • Page 52: Troubleshooting

    See section "Duty cycle" in the TECHNICHAL DATA chapter. Make sure the air inlets and outlets are not clogged. Clean inside the power source according to routine maintenance. 0447 814 001 - 52 - © ESAB AB 2023...

  • Page 53: Error Codes

    If several errors have been detected only the code for the last occurring error is displayed. Error code descriptions Error codes that the user can handle are listed below. If any other error code appears, contact an authorised ESAB service technician. Error code Description 206.10...
  • Page 54 - voltage unbalance warning. Action: The error code indicates that the user needs to remove the batteries & charge them immediately. If the error persists, contact a service technician. 0447 814 001 - 54 - © ESAB AB 2023...

  • Page 55: Ordering Spare Parts

    Spare parts and wear parts can be ordered through your nearest ESAB dealer, see esab.com. When ordering, please state product type, serial number, designation and spare part number in accordance with the spare parts list.

  • Page 56: Wiring Diagram

    APPENDIX APPENDIX WIRING DIAGRAM Power source 0447 814 001 - 56 - © ESAB AB 2023...
  • Page 57 APPENDIX 0447 814 001 - 57 - © ESAB AB 2023...
  • Page 58 APPENDIX Battery box 0447 814 001 - 58 - © ESAB AB 2023...
  • Page 59 APPENDIX 0447 814 001 - 59 - © ESAB AB 2023...

  • Page 60: Ordering Numbers

    APPENDIX ORDERING NUMBERS Ordering number Denomination Notes 0447 800 881 Renegade VOLT ES 200i Power source with battery box - CE 0447 800 883 Renegade VOLT ES 200i Power source with battery box - UKCA 0447 813 001 Safety Instruction manual...

  • Page 61: Accessories

    10 m cable 0445 197 880 Shoulder strap W4014450 Foot pedal, with 4.5 m (15 ft) cable, 8-pin connector 0448 274 880 Mains plug kit (includes mains plug and assembly instruction) 0447 814 001 - 61 - © ESAB AB 2023...
  • Page 62 For contact information visit http://esab.com ESAB Corporation, 2800 Airport Road Denton, TX 76207, USA, Phone +1 800 378 8123 ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00 manuals.esab.com...

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