Merkle HighPULSE

The range consists of 10 models:

HighPULSE 284 K

HighPULSE 354 K
HighPULSE 354 DW
HighPULSE 454 KW & DW
HighPULSE 554 KW & DW
HighPULSE 352 RS
HighPULSE 452 RS
HighPULSE 552 RS

Modern technology in three ranges – portable, industrial and robotic!

The HighPULSE range uniquely combines power and high-speed welding for clear economic benefits. A further advantage is the TEDAC system, available on all models: the portable 284/354 K and the versatile industrial 354/454/554 DW.

The TEDAC® system is a prime example of Merkle's capacity for innovation, offering infinitely variable power control, feedback and even switching between JOBs. It offers continuous power control and display directly on the welding torch, making it convenient for difficult-to-access working areas.

The undeniable advantages of the HighPULSE series are its ease of operation, extensive functions and infinitely variable power control from the TEDAC® torch.

HighPULSE – The best technology in Merkle's 50-year history!

The portable HighPULSE 284/354 K (optionally with a water cooler on a trolley).

The industrial HighPULSE 354/454/554 DW range, with wheels or a separate wire feeder.

The perfect technology for automation too!

Product ranges and specifications

The following processes are available:

• PulseARC pulsed welding
• MIG/MAG welding
• TIG DC* TIG welding
• MMA welding
• Flux-cored wire welding
• Interpulse welding
• DeepARC 
• HighUP
• ColdMIG
• MIG brazing
• High-performance (rotating arc) welding

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The  3 product groups:

• 1. Portable:
  HighPULSE 284/354 K
• 2. Industrial:
  HighPULSE 454/554 KW and 
  HighPULSE 354/454/554 DW
• 3. Automation and robotics:
  HighPULSE 352/452/552 RS

New multifunction control panel for easier operation

1.   Large digital display: welding current voltage wire speed material thickness      2.    Automatic "HOLD" function      (retains the last measured values)      3.    Arc length control      4.    Current adjustment

5.   Operating mode selection:

•  2-step with automatic downslope
•  4-step with downslope and final current
• 4-step with starting current, I2 current, downslope and final current

6.    Control location selection:

•  Infinitely variable control from the front panel
•  Infinitely variable control from the wire feeder
•  Infinitely variable control from the TEDAC® torch
•  JOB mode available from the TEDAC® torch or via the menu button

7.    Welding process selection:

• MIG/MAG
• PulseARC
• Interpulse welding
• MMA welding
• Option: TIG DC welding

    
8.    Rotary menu knob for navigation and selection
    
9.    Wire inching
    
10.   Gas test
(with automatic shut-off)

Merkle HighPULSE 354/454/554 DW. The high-performance industrial series!

Easy operation

A simple, intuitive interface with large buttons for more comfortable operation.

• Easy to operate even while wearing gloves.
• Large, easy-to-read display for welding current, voltage, correction value or wire speed.
• Multifunction display for programme selection (with multilingual menu).
• Versatile use for workshop work, fabrication, industrial production or shipbuilding.
• With the practical suspension system (option), the wire feeder can be suspended above the work area for easier access to the workpiece (see our automation components catalogue). This increases the machine's working range.

Two configurations, one display – remote control

Configuration 1:

All controls are located on the front of the power source, allowing operation from there.

Configuration 2:

All controls are located on the wire feeder unit.

External control panels MFR 20 and MRC 50

Take the controller directly to the work area and adjust the parameters there.

PERFECT wire feeding - rapid wire changes!

1.   Precise 4-roll wire feeder with 4 driven rolls. Wire speed 0.5 – 25 m/min (model DV-26) or 0.5- 30 m/min for the higher-performance model DV-31.  2.    The large wire feed rolls provide even pressure even at low wire pressure. 2 grooves for 2 different wire diameters 3.    Tool-free roll changes.   4.    Quick and easy wire threading thanks to the quick-release mechanism.  5.    The dust-protected wire feed motor guarantees a constant speed.

6.    Euro connector for the torch, eliminating the need for an adaptor.
7.    Simultaneous wire pressure adjustment on both rolls.
8.    Wire straightening unit for more stable wire guidance (DV-31).
9.    Side-opening panel for easy access.
10.  Custom-designed enclosed hose and cable routing for better protection.
11.  2x4 rubber feet for stable horizontal or vertical positioning

Separate wire feeder unit – portable, suspendable, swivelling, mobile, twin = maximum flexibility

Asymmetrical swivel arrangement

The pivot point at the rear of the wire feeder provides a greater working radius.

Vertical positioning of the wire feeder

Can be converted in seconds.

Fitted with sturdy castors

Can also be fitted with swivel castors.

DV-32 TWIN twin wire feeder

Two different wires on one welding machine at the same time? With the DV-32TWIN wire feeder, there is no longer any need to keep changing wires and torches. Switch between two completely different welding tasks simply by pressing the appropriate torch trigger. The controller can optionally be mounted on the wire feeder. A version with swivel castors is also available.

The compact HighPULSE 284 and 354 K machines are also available with optional water cooling, mounted on a trolley

Compact and portable

HighPULSE power on the move.

Portable version with water cooler

Can optionally be fitted with a water cooler.

The most versatile configuration

Can be mounted on a trolley with a cylinder holder or drawers.

Merkle HighPULSE 284/354 K. - For versatile use!

This welding machine is a good choice for workshops, assembly, repairs and production tasks requiring lower power. Lightweight and easy to move at 33/36 kg. It can also be used in hard-to-reach places. It can even be suspended using our suspension system (option). All functions are available directly at the work area; only the power cable needs to be connected.

HighPULSE 454 and 554 KW for workshops, production and industrial use.

Mobile with integrated water cooling

Perfect for high power and long duty cycles.

Drive motor mounted directly at the torch connector

Compact and accessible wire feeder.

Robust transport handles

Easier handling and greater transport safety.

MERKLE HighPULSE 454/554 KW - with wire feeder integrated at the side!

Compact and clearly arranged construction.

When developing the Merkle HighPulse 454/554 KW welding units, particular importance was placed on a compact, clearly arranged design. This is evident in the arrangement of the wire feeder. The entire DV-26 4-roll wire feed system and wire spool are integrated at the side and are easily accessible through the top-opening housing flap.

HighPULSE technology for customised use

Slim design: HighPULSE 353 K

With suspension device – perfect for use on production lines with limited workspace.

Welding unit for shipbuilding

Modified to meet customer requirements.

Versatile accessories

From suspension devices to special trolleys.

Merkle power sources - perfect technology for automated welding processes!

With its HighPULSE RS series power sources, Merkle offers a perfectly matched product range for all welding automation requirements.

The HighPULSE series consists of synergic PulseARC power sources designed specifically for use in robotic systems or PLC-controlled applications. It is based on modern 100 kHz inverter power modules and a high-speed 32-bit processor.

HighPULSE RS - power sources:

Model	Welding current
HighPULSE 352 RS	20 - 350 A, 60 %
HighPULSE 452 RS	20 - 450 A, 50 %
HighPULSE 552 RS	20 - 550 A, 40 %

Productivity can be improved easily!

Merkle Weld Factory®

Merkle Weld Factory® is the latest development from the company's own software architects and demonstrates that Merkle is keeping pace with the times. In future, communication between people and machines will be just as important as communication between machines. Innovations in Industry 4.0 appear almost daily. That is why Merkle Weld Factory® will never be just an "out-of-the-box" product, but will always be adapted to the latest developments and your needs.

We are delighted to present our solution for a major increase in production at your company!

More precise results, faster production and verifiable quality = substantial cost savings.

The perfect combination - Merkle HighPULSE with Merkle welding torches

TEDAC^® and TEDAC^® DIGITAL

Perfect control via Merkle TEDAC^® welding torches.

Push-pull torches

Significantly extend the working range and are indispensable for aluminium wires, with optional TEDAC^® control.

Functions in TIG mode

Perfect ignition with LiftTIG and continuous adjustment of the slope and gas pre-flow and post-flow times

TEDAC DIGITAL® - digital innovation

The standard Merkle TEDAC® system has been used in numerous welding machines for many years. For the first time, power could be controlled directly from the welding torch and displayed via a multicolour LED - without an additional control cable.

With the new TEDAC® DIGITAL system, Merkle takes efficiency and ease of use to a new level.

Power is controlled directly on the welding torch, with a completely new display showing alphanumeric data on an easy-to-read digital screen on top of the torch.

The benefits for the user:

•     GREATER ACCURACY thanks to the numerical display of welding current
•     GREATER EFFICIENCY thanks to power control directly on the welding torch
•     EXCEPTIONAL CONVENIENCE thanks to the easy-to-read alphanumeric display
•     TIME SAVINGS IN MEASUREMENT thanks to optimal handling and control

Achieve EN 1090-certified results with Merkle WPS/WPQR packages

Job packages for HighPULSE and SpeedMIG machines!

As a leading manufacturer of welding equipment, Merkle offers customers complete WPS / WPQR packages, each containing the relevant WPQR certificates and welding procedure specifications for standard welding processes. As a welding expert, you can use these already certified welding procedure specifications to prepare your own specifications for the welding tasks required in your operations.

The pre-programmed jobs can be stored together with the certified parameters in the continuously controlled welding units of the HighPULSE and SpeedMIG series. The parameters from the WPS / WPQR manual therefore do not need to be entered separately and are immediately available to the user upon purchase of the WPS / WPQR package.

User benefits of Merkle PulseARC technology:

• Extremely low-spatter welding thanks to non-short-circuit characteristics and single-droplet transfer:
      - substantial time savings through reduced cleaning labour
      - high deposition rate
      - longer torch consumable life
      - less downtime thanks to cleaner consumables
   
• Reliable, low-spatter ignition thanks to the new ignition process controlled by 13 parameters:
      - 2 independent ignition pulses
      - precise soft starting of the wire
     - removal of the slag droplet from the wire end after every weld for reliable restarting
   
• Optimal processing of aluminium and aluminium alloys, as well as stainless steel.
   
• Optimised welding programmes:
       - for different materials
       - for different wire diameters
       - for different shielding gases
   
• Multiple variations of pulse parameters:
      - Adjustment of arc characteristics and penetration.
   
• Alloying elements are retained by adapting the pulse parameters when using highly alloyed wire.

Merkle HighPULSE 284/354 K. Water cooling unit and trolley!

WK 300 water cooling unit

The WK 300 water cooling unit is available as an option. It can be fitted and removed in seconds. A plug-in electrical connection is located at the rear of the unit.

Various applications are possible, such as welding with a water-cooled torch in the workshop or using a gas-cooled torch on site.

TW 110 trolley

The TW 110 trolley is designed for easy transport of the welding unit in the workshop or on site:

• Extra-large wheels.
• Gas cylinder holder for a 10 or 20 litre cylinder.
• Lowered galvanised gas cylinder holder.
• 2 supports for torch and cables.

Technical data