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 - Technical data.

  • 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.

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

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 following processes can be selected:

The 3 product lines:

  • PulseARC
  • TIG DC*
  • MIG/MAG
  • Interpulse*
  • MMA/stick
  • electrode
  • DeepARC*
  • MIG brazing
  • ColdMIG*
  • High Performance welding (HighPULSE 550 DW)

* as an option

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

 (see also detailed product information)

 

 

 

 

 

 

 

 

 

 

 

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).

 

 

Merkle HighPULSE 284/354 K. The compact and portable Genius!

The multi process unit

This unit incorporates six different welding processes. According to the welding task, the material and the location, the following welding processes can be selected:

  • PulseARC (synergic pulse) welding
  • MIG/MAG welding (synergic)
  • TIG (DC) welding
  • Stick electrode welding (MMA)
  • Core wire welding (gasless)
  • MIG brazing
  • DeepARC process
  • ColdMIG process
  • Interpulse process

    Functions in TIG operation mode

    • Perfect LiftTIG ignition.
    • Variable down-slope time.
    • Gas pre/post flow time adjustable.
    • 2 welding currents separately adjustable at the welding torch.
    • TIG pulsation as a standard.

    Push-Pull torches

    • The torch length can be increased by using the Merkle push-pull torches.
    • These torches are recommended for welding thin aluminium wires.
    • Available with TEDAC® energy display and control.
    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 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 %

    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.

      Water cooling unit WK 300

      Technical details

      Electrical connection

      with plug connection at the welding unit

      Pump

      rotary pump

      Water pressure switch  

      integrated

      Water connection

      2 quick couplings

      Tank for cooling liquid

      3,0 l

      Weight

      23 kg

      Dimensions L x W x H

      600 x 300 x 260

       

       

      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 tobe connected.

      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.
        • 1. Large LED displays with pre-indication for Welding current, Welding voltage, Wire feed speed, Material thickness
        • 2. Automatic hold function (saves the last displayed welding parameters)
        • 3. Gas test (with automatic switch off)
        • 4. Welding process selector: MIG/MAG, PulseARC (synergic pulse), MMA/stick electrode welding Optional: TIG DC, Interpulse welding
        • 5. Selection of the energy control: Continuous control at the control panel, Continuous control on the wire feed unit, TEDAC® continuous control, Job programs, selectable through the TEDAC® torch or the main rotary switch, 256 different jobs
        • 6. Continuous control energy
        • 7. Arc trim
        • 8. Rotary switch for program selection and programming through the multi-functional display
        • 9. Operation modes: 2-stroke process, 4-stroke process with current down slope, 4-stroke process with start current and down slope (current program)
        • 10. Continuous energy control at the wire feed unit
        • 11. Arc trim at the wire feed unit
        • 12. Fully insulated wire feed unit
        • 13. Option: Socket with switch for remote controller and push-pull torch
        • 14. Euro connector

        The Merkle wire feeder unit

        MERKLE HighPULSE 354/454/554 DW. Perfect wire feeding and fast wire exchange!

        Detailed features

        • 1. Precise 4-roller gear with 4 motorized wire feeder 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 feeder rings allow a constant wire feed speed at a low pressure. 2 grooves respectively for 2 different wire diameters.
        • 3. Change of the wire feeder rings without any tools.
        • 4. Easy wire insertion due to superb accessibility and snap lock mechanism.
        • 5. Dust-tight drive motor with tacho guarantees a constant wire feed speed (DV-31).
        • 6. Euro torch connection as standard.
        • 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. Gas hoses, water hoses and all cables are 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.

        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.

        Easy to mount, universal in action.

        Standard horizontal mounting.
        Vertical mounting of the wire feeder can be achieved in seconds.