The brand new HighPULSE

Experience High Tech, Quality and design, paired with overwhelming economic advantages. Never was Pulse-Arc welding with Merkle so outstandingly quick. Reduce your man-hour costs in the DeepArc process by 30% or reduce the heat input with the new ColdMIG process for thin metal sheet welding.


Witness a new level of functionality thanks to a brand new operator control panel with extra large function switches and the new chassis design with Protec-edge protection.


The yet again optimized, perfectly controlled welding arc ensures an absolutely spatter free weld bead. Plus the ability to download any updates or new programs also secures your investment decision for the future.

Merkle HighPULSE - Versatile in use!

HighPULSE Series

  • Power supply:
  • Frequency:
  • Prim. continuous power:
  • Prim. continuous current:
  • Max. current:
  • cos phi:
  • Open circuit Voltage:
  • Welding voltage:
  • Welding current:
  • Duty cycle 35 % (10 min):
  • Duty cycle 40 % (10 min):
  • Duty cycle 50 % (10 min):
  • Duty cycle 60 % (10 min):
  • Duty cycle 100 %:
  • Protection class
  • Cooling:
  • Arc length:
  • Program capacity:
  • Programs:
  • Program selection:
  • Wire feed:
  • Operation modes:
  • Gas check:
  • Job mode:
  • Adjustable parameters:
  • Power source:
  • Digital display:
  • Wire feeder unit:
  • Torch cooling:
  • Norm:
  • Gas bottle holder:
  • Weight:
  • Dimensions L x W x H:
  • HighPULSE 284 K

    HighPULSE 284 K
    • 3 x 400 V
    • 50 - 60 Hz
    • 11.1 kVA
    • 16 A
    • 19 A
    • 0.98
    • 57 V
    • 15 - 28 V
    • 25 - 280 A
    • 280 A (40 °C)
    • -
    • -
    • 240 A (40 °C), 280 A (20 °C)
    • 200 A (40 °C), 230 A (20 °C)
    • IP 23
    • AF
    • automatic energy control
    • 256 programs
    • MIG/MAG, PulseARC, MMA/stick electrode, MIG brazing, TIG (DC). optional: Interpulse, ColdMIG, DeepARC
    • material, wire diameter and gas 0at the display
    • synergic wire feed control
    • 2-stroke, 4-stroke, 4-stroke with start current and down slope
    • button with hold function and automatic switch off
    • 512 jobs programmable
    • choke inductance, pulse shape
    • inverter
    • current, voltage, wire feed speed and material thickess with pre-display and hold function
    • 4-roller-drive DV-26
    • option: separate water cooler WK 300
    • EN 60974-1“S“/CE
    • optional with trolley TW 110: 10 - 20 l cylinders
    • 33 kg
    • 600 x 300 x 565 mm
  • HighPULSE 354 K

    HighPULSE 354 K
    • 3 x 400 V
    • 50 - 60 Hz
    • 12.5 kVA
    • 18 A
    • 25 A
    • 0.98
    • 57 V
    • 15 - 31.5 V
    • 25 - 280 A
    • -
    • 350 A (40 °C)
    • -
    • 280 A (40 °C), 330 A (20 °C)
    • 250 A (40 °C), 280 A (20 °C)
    • IP 23
    • AF
    • automatic energy control
    • 256 programs
    • MIG/MAG, PulseARC, MMA/stick electrode, MIG brazing, TIG (DC). optional: Interpulse, ColdMIG, DeepARC
    • material, wire diameter and gas at the display
    • synergic wire feed control
    • 2-stroke, 4-stroke, 4-stroke with start current and down slope
    • button with hold function and automatic switch off
    • 512 jobs programmable
    • choke inductance, pulse shape
    • inverter
    • current, voltage, wire feed speed and material thickess with pre-display and hold function
    • 4-roller-drive DV-26
    • option: separate water cooler WK 300
    • EN 60974-1“S“/CE
    • optional with trolley TW 110: 10 - 20 l cylinders
    • 36,5 kg
    • 600 x 300 x 565 mm
  • HighPULSE 354 DW

    HighPULSE 354 DW
    • 3 x 400 V
    • 50 - 60 Hz
    • 14.5 kVA
    • 21 A
    • 25 A
    • 0.98
    • 57 V
    • 15 - 31.5 V
    • 25 - 350 A
    • -
    • 350 A (40 °C)
    • -
    • 330 A (40 °C), 350 A (20 °C)
    • 280 A (40 °C), 300 A (20 °C)
    • IP 23
    • AF
    • automatic energy control
    • 256 programs
    • MIG/MAG, PulseARC, MMA/stick electrode, MIG brazing, TIG (DC). optional: Interpulse, ColdMIG, DeepARC
    • material, wire diameter and gas at the display
    • synergic wire feed control
    • 2-stroke, 4-stroke, interval, stitch
    • control at the machine, wire feed unit, TEDAC torch, jobe mode
    • 256 jobs programmable
    • choke inductance, pulse shape
    • inverter
    • current, voltage, wire feed speed and material thickess with pre-display and hold function
    • 4-roller-drive DV-26
    • integrated water cooler
    • EN 60974-1“S“/CE
    • 10 - 20 - 50 l cylinders
    • 130 kg
    • 1100 x 490 x 1200 mm
  • HighPULSE 454 DW

    HighPULSE 454 DW
    • 3 x 400 V
    • 50 - 60 Hz
    • 15.9 kVA
    • 23 A
    • 34 A
    • 0.98
    • 72 V
    • 15 - 36.5 V
    • 25 - 450 A
    • -
    • 450 A (40 °C)
    • -
    • 400 A (40 °C), 450 A (25 °C)
    • 330 A (40 °C), 400 A (25 °C)
    • IP 23
    • AF
    • automatic energy control
    • 256 programs
    • MIG/MAG, PulseARC, MMA/stick electrode, MIG brazing, TIG (DC). optional: Interpulse, ColdMIG, DeepARC
    • material, wire diameter and gas at the display
    • synergic wire feed control
    • 2-stroke, 4-stroke, interval, stitch
    • control at the machine, wire feed unit, TEDAC torch, jobe mode
    • 256 jobs programmable
    • choke inductance, pulse shape
    • inverter
    • current, voltage, wire feed speed and material thickess with pre-display and hold function
    • 4-roller-drive DV-26 optional DV-31, separate
    • integrated water cooler
    • EN 60974-1“S“/CE
    • 10 - 20 - 50 l cylinders
    • 140 kg
    • 1100 x 490 x 1200 mm
  • HighPULSE 554 DW

    HighPULSE 554 DW
    • 3 x 400 V
    • 50 - 60 Hz
    • 19.4 kVA
    • 28 A
    • 45 A
    • 0.98
    • 72 V
    • 15 - 41.5 V
    • 25 - 550 A
    • -
    • 550 A (40 °C)
    • -
    • 470 A (40 °C), 550 A (20 °C)
    • 420 A (40 °C), 500 A (20 °C)
    • IP 23
    • AF
    • automatic energy control
    • 256 programs
    • MIG/MAG, PulseARC, MMA/stick electrode, MIG brazing, TIG (DC). optional: Interpulse, ColdMIG, DeepARC
    • material, wire diameter and gas at the display
    • synergic wire feed control
    • 2-stroke, 4-stroke, interval, stitch
    • control at the machine, wire feed unit, TEDAC torch, jobe mode
    • 256 jobs programmable
    • choke inductance, pulse shape
    • inverter
    • current, voltage, wire feed speed and material thickess with pre-display and hold function
    • 4-roller-drive DV-26 optional DV-31, separate
    • integrated water cooler
    • EN 60974-1“S“/CE
    • 10 - 20 - 50 l cylinders
    • 145 kg
    • 1100 x 490 x 1200 mm
  • HighPULSE 454 KW

    HighPULSE 454 KW
    • 3 x 400 V
    • 50 - 60 Hz
    • 15.9 kVA
    • 23 A
    • 34 A
    • 0.98
    • 72 V
    • 15 - 36.5 V
    • 20 - 450 A
    • -
    • -
    • 450 A (40 °C)
    • 450 A (25 °C), 400 A (40 °C)
    • 400 A (25 °C), 330 A (40 °C)
    • IP 23
    • AF
    • automatic energy control
    • 256 programs
    • MIG/MAG, PulseARC, MMA/stick electrode, MIG brazing. optional: Interpulse, ColdMIG, DeepARC, TIG (DC)
    • material, wire diameter and gas at the display
    • synergic wire feed control
    • 2-stroke, 4-stroke, interval, stitch
    • button with hold function and automatic switch off
    • 512 jobs programmable
    • choke inductance, pulse shape
    • inverter
    • current, voltage, wire feed speed and material thickess with pre-display and hold function
    • 4-roller-drive DV-26 integrated
    • integrated water cooler
    • EN 60974-1“S“/CE
    • 10 - 20 - 50 l cylinders
    • 115 kg
    • 1100 x 490 x 895 mm
  • HighPULSE 554 KW

    HighPULSE 554 KW
    • 3 x 400 V
    • 50 - 60 Hz
    • 19.4 kVA
    • 28 A
    • 45 A
    • 0.98
    • 72 V
    • 15 - 41.5 V
    • 20 - 550 A
    • -
    • -
    • 550 A (40 °C)
    • 550 A (20 °C), 470 A (40 °C)
    • 500 A (20 °C), 420 A (40 °C)
    • IP 23
    • AF
    • automatic energy control
    • 256 programs
    • MIG/MAG, PulseARC, MMA/stick electrode, MIG brazing. optional: Interpulse, ColdMIG, DeepARC, TIG (DC)
    • material, wire diameter and gas at the display
    • synergic wire feed control
    • 2-stroke, 4-stroke, interval, stitch
    • button with hold function and automatic switch off
    • 512 jobs programmable
    • choke inductance, pulse shape
    • inverter
    • current, voltage, wire feed speed and material thickess with pre-display and hold function
    • 4-roller-drive DV-26 integrated
    • integrated water cooler
    • EN 60974-1“S“/CE
    • 10 - 20 - 50 l cylinders
    • 120 kg
    • 1100 x 490 x 895 mm
  • HighPULSE 352 RS

    HighPULSE 352 RS
    • 3 x 400 V
    • 50 - 60 Hz
    • 12 kVA
    • 17 A
    • 25 A
    • 0.98
    • 57 V
    • 15 - 31.5 V
    • 20 - 350 A
    • -
    • -
    • -
    • 350 A (40 °C)
    • 300 A (40 °C)
    • IP 23
    • AF
    • automatic energy control
    • 512 programs
    • MIG/MAG, PulseARC, MMA/stick electrode, MIG brazing. optional: Interpulse, ColdMIG, DeepARC, TIG (DC)
    • material, wire diameter and gas at the display
    • synergic wire feed control
    • 2-stroke, 4-stroke, interval, stitch
    • button with hold function and automatic switch off
    • 2048 jobs programmable
    • choke inductance, pulse shape
    • inverter
    • current, voltage, wire feed speed and material thickess with pre-display and hold function
    • 4-roller-drive DV-26 integrated
    • integrated water cooler
    • EN 60974-1“S“/CE
    • -
    • 51 kg
    • 740 x 350 x 690 mm
  • HighPULSE 452 RS

    HighPULSE 452 RS
    • 3 x 400 V
    • 50 - 60 Hz
    • 14.4 kVA
    • 25 A
    • 34 A
    • 0.98
    • 72 V
    • 15 - 36.5 V
    • 20 - 450 A
    • -
    • -
    • 450 A (40 °C)
    • 400 A (40 °C)
    • 300 A (40 °C)
    • IP 23
    • AF
    • automatic energy control
    • 512 programs
    • MIG/MAG, PulseARC, MMA/stick electrode, MIG brazing. optional: Interpulse, ColdMIG, DeepARC, TIG (DC)
    • material, wire diameter and gas at the display
    • synergic wire feed control
    • 2-stroke, 4-stroke, interval, stitch
    • button with hold function and automatic switch off
    • 2048 jobs programmable
    • choke inductance, pulse shape
    • inverter
    • current, voltage, wire feed speed and material thickess with pre-display and hold function
    • 4-roller-drive DV-26 integrated
    • integrated water cooler
    • EN 60974-1“S“/CE
    • -
    • 62 kg
    • 740 x 350 x 690 mm
  • HighPULSE 552 RS

    HighPULSE 552 RS
    • 3 x 400 V
    • 50 - 60 Hz
    • 19.4 kVA
    • 28 A
    • 45 A
    • 0.98
    • 72 V
    • 15 - 41.5 V
    • 20 - 550 A
    • -
    • -
    • 550 A (40 °C)
    • 550 A (20 °C), 470 A (40 °C)
    • 500 A (20 °C), 420 A (40 °C)
    • IP 23
    • AF
    • automatic energy control
    • 512 programs
    • MIG/MAG, PulseARC, MMA/stick electrode, MIG brazing. optional: Interpulse, ColdMIG, DeepARC, TIG (DC)
    • material, wire diameter and gas at the display
    • synergic wire feed control
    • 2-stroke, 4-stroke, interval, stitch
    • button with hold function and automatic switch off
    • 2048 jobs programmable
    • choke inductance, pulse shape
    • inverter
    • current, voltage, wire feed speed and material thickess with pre-display and hold function
    • 4-roller-drive DV-26 integrated
    • integrated water cooler
    • EN 60974-1“S“/CE
    • -
    • 64 kg
    • 740 x 350 x 895 mm
Further technical details

Technical changes reserved.

Modern technology in 3 perfect product lines – Portable, industrial and robotics!

HighPULSE – The best out of 50 years Merkle welding technology! The HighPULSE product line combines unique performance, high speed welding with overwhelming economical advantages and high precision through the Merkle TEDAC® system: the portable allrounders 284/354 K as well as the universal industrial units 354/454/554 DW


Best example for the innovational strength of Merkle is the TEDAC® system which offers continuous energy control and display directly on the welding torch. This makes it convenient for difficult accessible working areas.

Clear advantages of the HighPULSE series are the ease of use, the extensive functions and program variety as well as the continuous energy control at the TEDAC® torch.

 

Merkle HighPULSE.The revolution in PulseARC welding!

The portable HighPULSE 284/354 K (optional with water cooling unit and trolley).
The industrial line HighPULSE 354/454/554 DW with wheels and separate wire feeder.
Perfect welding technology universal use for automation!

Product lines and specifics

The following processes can be selected:

The three product lines:

 

  • PulseARC welding
  • MIG/MAG welding
  • TIG DC* welding
  • MMA/stick electrode welding
  • Flux cored arc welding
  • Interpulse welding
  • DeepARC
  • HighUP
  • ColdMIG
  • MIG-Löten
  • High performance welding
  • * as an option

 

 

 

 

New multifunctional control panel for maximum comfort

1.    Large LED displays with preview for :

  • welding current
  • welding voltage
  • wire feed speed
  • material thickness

   
2.    Automatic hold function
     (saves the last displayed welding parameters)
   
3.    Setting of the arc length
   
4.    Setting of the energy
   

   

5.    Selection of operating modes:

  •  2-stroke operation
  •  4-stroke operation with down slope
  • 4-stroke operation with start current

     


6.    Selection of energy setting:

  •  Continuously at the front panel
  •  Continuously at the wire feeder
  •  Continuously at the TEDAC® torch
  •  Job mode available on TEDAC® torch or rotary switch

7.    Selection of welding processes:

  • MIG/MAG
  • PulseARC
  • Interpuls welding
  • MMA/stick electrode welding
  • Option: TIG DC

   
8.    Rotary switch for program selection and programming of the multi-functional display
   
9.    Wire inching
   
10.   Gas test
(with automatic switch-off)

Merkle HighPULSE 354/454/554 DW. The powerful industrial series!

Ease of operation

Simple self-explaining controls with extra big sized functional knobs enable an easy operation.

  • Easy to use, even with gloves.
  • Big bright LED displays for welding current, voltage and wire feed speed.
  • Universal multifunctional display for program selection (different languages selectable).
  • Various application fields in all areas like metal working industry, workshops, automotive industry, shipyards, etc.
  • With the practical suspension device (optional) the mounting of the wire feeder unit at a swivel arm (see our automation components catalogue) can easily take place. The action scope can considerably be enhanced.

 

 

Two versions, one display – and remote control

Version 1:

All control buttons of the welding unit are integrated in the power source and can be operated directly at the front.

Version 2:

The complete operation panel is integrated in the separate wire feeder.

External remote control MFR 20 and MRC 50

Control your welding unit where you work.

PERFECT wire feeding - fast wire Exchange!

1.    Precise 4-roller gear with 4 motorized wire feed rollers. Wire feed speed 0.5 – 25 m/min (model DV-26) or high performance drive 0.5- 30 m/min (model DV-31).
2.    Big wire feed rings allow a constant wire feed speed at a low pressure. 2 grooves for 2 different wire diameters.
3.    Change of the wire feed rings without any tools. 
4.    Easy wire insertion due to superb accessibility and snap lock mechanism.
5.    Dust-tight drive motor guarantees a constant wire feed speed.

6.    Euro torch connector as a standard, directly mounted without need for alignment.
7.    Pressure adjustment of both rollers.
8.    Wire straightening device for perfect and constant wire feeding (DV-31).
9.    Cut away side panels facilitate easy insertion of the wire spool.
10.    Insulated interior, gas and water hoses and all cables are well protected from environmental damage due to a unique closed case design.
11.    2 x 4 rubber feet ensure operation in both, vertical and horizontal position.

External wire feeder – portable, rotatable, rollable, dual = maximum flexibility

Asymmetrical swiveling axis

at the rear allows a wide working area.

Vertical mounting of the wire feeder

can be achieved within seconds.

Mobile with stable wheels

attachable on swiveling axis with wheels.

Double wire feeder DV-31 TWIN

Two different wires should be welded with the same machine? The annoying changing of the wire and the torch is no longer required with the double wire feeder DV-31 TWIN. Two different programs can beselected, the machine switches automatically to the selected torch by pressing the torch trigger. As an option the operation panel can be integrated in the wire feeder. A wheeled version is also available.

The compact HighPULSE units 284 and 354 K with water cooling unit and trolley as an option

Compact and portable

HighPULSE power to go.

Portable with water cooling unit

As an option a water cooling unit can be installed.

For the most flexible use

Mountable to a trolley with gas bottle holder and optional drawer for accessories.

Merkle HighPULSE 284/354 K. - Universal in use!

The unit is manufactured to operate in metal fabrication companies, workshops, installation companies, on site and in automobile production and repair. It is lightweight and portable at a weight of only 33/36 kg. It can be used even in difficult working areas. With a suspension device the complete machine can be mounted to a swivel arm (option). All control functions are easy accessible direct at the working place, only the main supply cable has to be connected.

Functionality and ease of use

Easy to adjust and a maximum of functions in MIG/MAG and PulseARC (synergic pulse) welding are the major advantages of the Merkle HighPULSE 284 K and HighPULSE 354 K.

  • Continuous one button adjustment.
  • Setting and indication of the energy on the
    TEDAC® welding torch.
  • 2-stroke/4-stroke/stitch/spot welding.
  • 4-roller wire feeding system.
  • Reproducible welding results due to digital
    microprocessor welding control.
  • Proven welding programs for steel, stainless steel, aluminium, aluminium alloys and MIG brazing.


  • DeepARC process, ColdMIG and Interpulse welding optional
  • Multifunctional display for easy program selection.
  • Digital display for welding current, welding voltage, wire feed speed and material thickness with pre-indication and HOLD-function.
  • Approved for operation in confined areas, S-symbol.
  • Optional: socket for remote control and push-pull torch.
  • TIG-DC welding with lift-arc ignition.
  • Stick electrode welding (MMA).

 

 

HighPULSE 454 and 554 KW for the use in the work shop or industrial use.

Mobile with integrated water cooling

Perfect for high power and long lasting duty cicles.

Drive motor directly mounted at the torch connector

Compact and accessible wire feeder.

Robust transport handles

Easier handling and better transport safety.

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

Compact and clear structure.

By developing the welding units Merkle HighPulse 454/554 KW special importance was placed on a compact and clear design.

This becomes apparent due to the arrangement of the wire feeder. The entire 4-roller wire feed system DV-26 and the wire coil are integrated on the side and very easily accessible through the top-opening housing flap.

HighPULSE technology for customized use

Slim design: HighPULSE 353 K

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

Welding unit for ship building

Modified for customer needs.

Versatile accessories

From suspension devices to special trolleys.

Merkle power sources - perfect technology for automated welding processes!

With the power sources of the HighPULSE RS series Merkle offers a perfectly tuned product range for all requirements needed for the automation of welding processes.

 

The HighPULSE series is consisting of synergic PulseARC power sources espacially engineered for the use at robotic systems or SPS-control. It is based on a modern 100 kHz inverter power modules and a high speed 32-bit processor.

HighPULSE RS - power sources:

The Merkle power sources of the HighPULSE RS series

Type

Welding current

HighPULSE 352 RS

20 - 350 A, 60 %

HighPULSE 452 RS

20 - 450 A, 50 %

HighPULSE 552 RS

20 - 550 A, 40 %

Productivity easily improved!

Development and programming

Merkle Weld Factory® is the newest development from the company own software architects and shows that Merkle is keeping up with the pace of times. Communication between man and machine will be just as important in the future as the communication between the machines among themselves. Almost on a daily bases there are innovations in the field of Industry 4.0. That is why the Merkle Weld Factory® will never be just a product "out of the box", but will always be adapted to the latest developments and your requirements.

We're looking forward to introduce our solution for a huge production increase to your company!

 

More precise results, faster production and verifiable quality = extensive cost reduction.

 

Merkle Weld Factory®

TEDAC DIGITAL® - the digital innovation

The standard Merkle TEDAC® system is working for many years in a huge number of welding machines. For the first time the energy could be controlled and displayed directly at the welding torch via a multi-colored LED - without the need for an additional control cable.

Merkle is now entering a new level of innovation with the new system TEDAC® DIGITAL in terms of efficiency and ease-of-use.

The energy control is carried out directly at the welding torch, the display is brand new with alphanumeric data shown in a well readable digital display on top of the torch.

These are the benefits for the user:

  •     HIGHER PRECISION due to numeric display of the welding current
  •     CLEARLY MORE EFFICIENCY due to energy control directly at the welding torch
  •     EXTREMELY MORE COMFORT thanks to an easily readable alphanumeric display
  •     MEASURABLE TIME SAVING due to ideal handling and control

The development of the HighPULSE series signalizes welding technology of the latest generation:

  • Continuous energy control with the TEDAC® torch
  • Easy to use operation panel
  • DeepARC, ColdMIG and interpulse optional
  • Multifunctional display with language selection
  • Various welding processes selectable
  • Expenses of labour costs reduced by up to 30 %
Precise 4-roller drive as a standard. Suitable for 5 kg or 15 kg wire spools.
Sockets for earth cable, electrode welding cable and water cooling unit are mounted on the rear. Quick polarity change for welding gasless core wires by using different plugs mounted on the rear.

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

Compact portable unit or with water cooler and trolley.

Water cooling unit WK 300

The water cooling unit WK 300 can be used as an option. The mounting and dismounting is done in a few seconds. One pluggable electrical connection is placed on the rearof the unit.

Different applications are possible, for example: welding with a water cooled torch in the workshop or using a gascooled torch on site.

 

Trolley TW 110

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

  • Extra large wheels.
  • Gas bottle holder for a 10 or 20 l cylinder.
  • Lowered galvanized gas bottle holder.
  • 2 supports for torch and cables.