ESAB LAUNCHES RENEGADE VOLT EMP 200i MULTIPROCESS BATTERY WELDER AND NEW TWECO SPOOL GUN 250 FOR WIRE WELDING

When downtime is money, bank on the portability and fast setup of the ESAB Renegade VOLT battery welder for field repair and off-the-grid fabrication. MIG weld up to 22 feet on a single charge.

North Bethesda, Md. – ESAB will feature the Renegade VOLT™ EMP 200i battery-powered multiprocess welding system in booth #S29025 at FABTECH 2026 in Las Vegas. The VOLT adds MIG and flux-cored welding capability to its award-winning Renegade VOLT off-the-grid welding platform. Designed for field repair, maintenance and fabrication, the new system offers MIG, flux-cored, Stick and Live TIG welding in a unit that weighs 51 lbs. To weld with mild steel, flux cored, stainless steel or aluminum wires, the Renegade VOLT EMP 200i pairs with the new TWECO Spool Gun 250, which holds 4-inch spools of wire. 

Renegade VOLT operates from four DEWALT® FLEXVOLT® 12 Ah batteries, 120/230V AC primary power, or ESAB’s AMP+ hybrid mode. In battery mode when MIG welding, Renegade VOLT has a rated welding output of 150A/21.5V at 18% duty cycle. When connected to 230V primary power, MIG, Stick and TIG output extends to 200A. On 120V input, the AMP+ mode supplements available wall power with battery power, providing an output of up to 160A to help users work from weaker electrical circuits that would be otherwise prone to nuisance trips and power fluctuations. 

“When time is valuable, the Renegade VOLT is like money in the bank,” says Bartosz Kutarba, Global Director Light Industrial Equipment, ESAB. “Battery welders deliver a fast return on investment and cost savings because they set up quickly and give users the freedom to work in difficult-to-reach locations and areas without power. Operators loved the Renegade VOLT when it had a Stick/TIG output. Now that we added multiprocess flexibility and the Tweco Spool Gun 250, the new Renegade VOLT EMP 200i expands the number of situations where battery welders provide an unmatched return on investment.”

The Renegade VOLT EMP 200i replaces the previous VOLT model, retaining all of its functions, including adjustable Hot Start and Arc Force for Stick welding, Live TIG welding and a sun-friendly graphical interface. The VOLT EMP model speeds setup and operation because, by entering wire diameter, type and shielding gas mix, it will automatically set and maintain the correct wire feed speed and amperage, adjusting to the operator’s technique. To fine-tune the arc when working on a project, users can adjust wire feed speed on the spool gun and voltage on the machine.

Weld more with MIG

ESAB is the first major welding company to introduce a battery welder with a MIG output. MIG welding has faster travel speeds, completes work faster (especially projects with a lot of starts and stops), offers good heat control on thin materials to address warping and burn-through issues, is an easier process to learn, and enables welding on different metals. Self-shielded flux cored wires further enhance portability because they eliminate the need for a shielding gas cylinder. Ideal applications include aluminum (boats, docks and marine repair applications), sheet metal, body panels (cars, trucks, trailers, railcars), railings, fences, tubing, and tack or stitch welding.

“MIG welding can mitigate the higher risk of burn-through and thermal distortion associated with Stick welding,” says Kutarba. “For longer seams where heat build-up presents more risk, MIG welding provides clear benefits.” 

With fully charged 12 Ah batteries, the Renegade VOLT can MIG weld from 10 minutes to more than an hour, depending on the parameters. On a 3/32-inch fillet weld, it can MIG weld with an output of 82A/18V using a 0.030-inch ER70S-6 wire to produce a weld 22-feet long on a single battery charge. For Stick welding on the same joint with a 3/32-inch E6013 electrode at 80A, it can produce a fillet weld 11-feet long. 

“MIG welding enables you to complete a joint twice as long — 22 feet compared to 11 feet — because the MIG process uses energy more efficiently that Stick,” says Kutarba. “Regardless of process, many contractors find that with a second set of batteries or the ability to charge the batteries over lunch hour, they can work a full day without worrying about running out of battery power.”

A battery welder is a more portable and affordable alternative to engine drives for off-the-grid welding because it can be moved to the work location in the back seat of a car or utility cart or hand carried. It eliminates many of the costs and hassles of engine drives, including fumes, fuel costs, noise, and the need to drag hundreds of feet of heavy and expensive welding cables or extension cords. For large plants, shipyards, mines, construction sites, and marine applications, where the nearest outlet may be hundreds of feet away, a battery welder sets up faster than an inverter.    

“Even when wall power is available, the Renegade VOLT platform delivers more productivity,” says Kutarba. “Trying to weld at a machine’s maximum output when connected to a standard 120V/15A outlet is almost guaranteed to trip the breaker, and even more so on weak circuits. The Renegade VOLT’s patented AMP+ hybrid mode mitigates nuisance trips, enabling welders to work without interruption with an output of up to 160A.” 

Renegade VOLT uses the same batteries that work with other DEWALT FLEXVOLT-compatible hand tools. The VOLT comes with four DEWALT FLEXVOLT 12 Ah batteries and a DEWALT four-port fast charger that charges the batteries in about 100 minutes. The battery box is detachable, making the power source easier to transport when battery operation is not required. The system also features a detachable AC power cord for easier field replacement if a cord becomes worn or damaged. With the battery box and four 12 Ah battery packs installed, the system weighs approximately 51 lb.; the battery box with batteries weighs 22 lbs.

About ESAB  

For more than 120 years, ESAB has been a world leader in fabrication technology. Our distinctive portfolio of fabrication solutions encompasses more than 40 of the world’s most trusted brands across welding and cutting equipment, automation, robotics, fabrication software, filler metals, gas flow control, PPE, and inspection and monitoring. Industries and innovators that shape the world rely on ESAB’s products and solutions. To learn more, visit esab.com.

FOR MORE INFORMATION, CONTACT:

ESAB Trade Media Contact:
Chuck Schroeder
Tel (262) 618-4427
[email protected]

Corporate Media Contact: 
Tilea Coleman
Tel (301) 323-9092
[email protected]