HighPULSE. The revolution in PulseARC welding! PLASMA MERKL ROBOTI CUTTI CUTTING TIG ELECTRO AUTOMATION

Transcription

1 HighPULSE The revolution in PulseARC welding! MIG/ M MIGTIG / MAG PLASMA TIG AUTOMATION CUTTING PLAS CUTTI ELECTRO MERKL PLAS ROBOTI WELD

2 MIG/ MAG Merkle PulseARC Merkle HighPULSE 1. Portable 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 280/350 K (optional with water cooling unit and trolley). 2

3 Merkle HighPULSE welding units. Modern technology in 3 perfect product lines Portable, industrial and robotics! HighPULSE The best out of 45 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 280/350 K as well as the universal industrial units 450/550 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: PulseARC TIG DC* MIG/MAG Interpulse* MMA/stick electrode DeepARC* MIG brazing ColdMIG* High Performance welding (HighPULSE 550 DW) * as an option The 3 product lines: 1. Portable: HighPULSE 280/350 K 2. Industrial: HighPULSE 450/550 DW 3. Robotics: HighPULSE 350/450/550 RS (see also detailed product information) 2. Industrial 3. Robotics The industrial line HighPULSE 450/550 DW with wheels and separate wire feeder. Perfect welding technology universal use for every robot! 3

4 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 280 K and HighPULSE 350 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). 4

5 Merkle HighPULSE 280/350 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. 5

6 Merkle HighPULSE 280/350 K. Water cooling unit 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 rear of the unit. Different applications are possible, for example: welding with a water cooled torch in the workshop or using a gas cooled 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. Compact portable unit or with water cooler and trolley. Technical details Water cooling unit WK 300 Electrical connection Pump Water pressure switch Water connection Tank for cooling liquid Weight Dimensions L x W x H with plug connection at the welding unit rotary pump integrated 2 quick couplings 3,0 l 23 kg 600 x 300 x 260 mm 6

7 Merkle HighPULSE 280/350 K. Universal in use! Various operational areas 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. 7

8 8

9 Merkle HighPULSE 450/550 DW. The powerful industrial series! Functionality and 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 9

10 Merkle HighPULSE 450/550 DW. HighTech, quality and efficiency! Compact and well designed case with integrated water cooler The separate wire feeder can be mounted on a rotatable device on top of the welding unit. The swivelling axis is placed asymmetrically at the rear of the wire feeder allowing a wide working area for the welding torch. The wire feeder rotates easily to the desired position without kinking the torch lead. Due to this construction the movements of the connection cable at the rear are reduced to a minimum. Perfection in detail 1. Asymmetrical mounting of the wire feeder unit (optional), provides a wider working area for the welding torch. 2. Safe transportation through the wire feed unit locking mechanism. 3. Connection cables available in different lengths: quick and easy change due to clampable and pluggable couplings on both sides Gas bottle holder for 10, 20, and 50 litre cylinders. Lowered for easy handling of the cylinders and galvanized: no corrosion Large swivel and carriage wheels for easy handling within the workshop or plant/factory. 6. Optimal cooling of the electronic components in a separate air tunnel. The electronic components are protected from dirt and dust by being housed in a separate compartment Minimum electricity cost through the stand-by mode, automatic activation of the water pump and cooling fans through temperature control. Higher efficiency through high quality modern electronic components which reduces the power consumption. 4 HighPULSE with gas bottle holder and cylinder. 5 10

11 Merkle HighPULSE. Technical data. HighPULSE 280 K HighPULSE 350 K HighPULSE 450 DW HighPULSE 550 DW Primary: Power supply 3 x 400 V 3 x 400 V 3 x 400 V 3 x 400 V Frequency 50/60 Hz 50/60 Hz 50/60 Hz 50/60 Hz Continuous power 11,1 kva 12,5 kva 15,9 kva 19,4 kva Continuous current 16 A 18 A 23 A 28 A Max. current 19 A 25 A 34 A 45 A cos phi 0,98 0,98 0,98 0,98 Secondary Open circuit voltage 57 V 57 V 72 V 72 V Welding voltage V 15-31,5 V 15-36,5 V 15-41,5 V Welding current A A A A Duty cycle 35 % (10 min.) 280 A (40 C) Duty cycle 40 % (10 min.) 350 A (40 C) 550 A (40 C) Duty cycle 50 % (10 min.) A (40 C) 500 A (40 C) Duty cycle 60 % (10 min.) 240 A (40 C), 280 A (20 C) 280 A (40 C), 330 A (20 C) 450 A (20 C), 400 A (40 C) 550 A (20 C), 470 A (40 C) Duty cycle 100% 200 A (40 C), 230 A (20 C) 250 A (40 C), 280 A (20 C) 400 A (20 C), 330 A (40 C) 500 A (20 C), 420 A (40 C) Protection class IP 23 IP 23 IP 23 IP 23 Cooling AF AF AF AF Arc length automatic energy control automatic energy control Program capacity 256 programs 256 programs Programs MIG/MAG, PulseARC, MMA/stick electrode, MIG brazing, TIG (DC). optional: Interpulse, ColdMIG, DeepARC MIG/MAG, PulseARC, MMA/stick electrode, MIG brazing. optional: Interpulse, ColdMIG, DeepARC, TIG (DC) Program selection material, wire diameter and gas at the display material, wire diameter and gas at the display Wire feed synergic wire feed control synergic wire feed control Operation modes 2-stroke, 4-stroke, 4-stroke with start current and down slope 2-stroke, 4-stroke, 4-stroke with start current and down slope Gas check button with hold function and automatic switch off button with hold function and automatic switch off Job mode 512 jobs programmable 512 jobs programmable Adjustable parameters choke inductance, pulse shape choke inductance, pulse shape Power source inverter inverter Digital display current, voltage, wire feed speed and material thickess with pre-display and hold function current, voltage, wire feed speed and material thickess with pre-display and hold function Wire feeder unit 4-roller-drive DV-26 4-roller-drive DV-26 optional: DV-31 High performance 4-roller-drive DV-31 Torch cooling option: separate water cooler WK 300 integrated water cooler Norm EN S /CE EN S /CE Gas bottle holder optional with trolley TW 110: l cylinders l cylinders Weight 33 kg 36,5 kg 155 kg (incl. wire feeder) 165 kg (incl. wire feeder) Dimensions L x W x H: 600 x 300 x 565 mm 1030 x 480 x 1170 mm Technical changes reserved. 11

12 Merkle HighPULSE 450/550 DW. Perfect wire feeding! Detailed features 1. Precise 4-roller gear with 4 motorized wire feeder rollers. Wire feed speed m/min (model DV-26) or high performance drive m/min (model DV-31) Big wire feeder rings allow a constant wire feed speed at a low pressure. 2 grooves respectively for 2 different wire diameters 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 Pressure adjustment of both rollers. 8. Wire straightening device for perfect and constant wire feeding (DV-31) 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. Consumables and spare part identification chart attached as standard x 4 rubber feet ensure operation in both, vertical and horizontal position. 1 6 Double wire feeder DV-26 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-26 TWIN. Two different programs can be selected, 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. 12

13 Easy to mount, universal in action. Wire feeder positions: 1 2 Standard horizontal mounting. Vertical mounting of the wire feeder can be achieved in seconds roller-drive DV-31. Universal applications: A: Placed on the work piece. B: Mounted to a swivel arm with suspension device. C: With 4 wheels mounted. D: Mounted on our balancer with a wide work area. E: Easy to carry due to the integrated handle. A B C D E 13

14 Merkle TEDAC system. Direct control on the torch! The Merkle TEDAC system offers continuous energy Continuous setting of the energy control where it counts directly on the torch itself. Using the slide switch mounted on the top of the TEDAC torch handle the energy can be manually adjusted during the welding process. Using a visually good, multicolour LED indicator any energy modifications will be shown directly on the TEDAC torch. The colours will change in a stepless sequence from green (the lowest setting) through yellow (low setting) through orange (medium setting) up to red (maximum setting). The TEDAC torches are perfect for any work in hard to reach positions due to the fact that the operator can control the welding process from the TEDAC system and does not need to return to the power source to change settings. Thanks to the standard EURO connector no additional control wires are required. Ergonomically formed handle, torch trigger with a micro switch for guaranteed more than 10 mio. operations. 14 min. energy max. Precise energy control is realized through the slide switch mounted on the top of the torch handle before, during and after the welding process. The present conditions are shown through the stepless multi-coloured LED display mounted on the top of the torch handle. Recall of programmed jobs With the slide switch free selectable operating points can be recalled. All settings can be adjusted on the existing welding characteristics. Perfectly reproducible welding results in every adjustment. Standard Euro connector, no further control cables are necessary. The multi-coloured LED shows the selected energy.

15 Merkle welding torches. The user optimized answer for every job! The crucial component in PulseARC technology is the high quality welding torch. Merkle welding torches are manufactured on the basis of 45 years of experience. Out-standing cooling characteristics guarantee long useful life of consumables and low spare part costs. MIG/MAG hand welding torches: gas cooled MIG/MAG hand welding torches: water cooled model welding current cooling model welding current cooling SB/SBT 157 G 180 A, 60% gas SB/SBT 307 G 300 A, 60% gas SB/SBT 351 G 280 A, 60% gas SB/SBT 350 W 350 A, 60% ED water SB/SBT 502 W 450 A, 60% ED water SB/SBT 603 W 600 A, 60% ED water HSB/HSBT 600 W 600 A, 100% ED water Push-pull welding torches: MIG/MAG machine and robot welding torches: water cooled model welding current cooling model welding current cooling PP/PPT 307 G 300 A, 60% ED gas PP/PPT 502 W 450 A, 60% ED water MSB 400 W 380 A, 60% ED water ROB 505 W 500 A, 60% ED water MSB 603 W 600 A, 60% ED water 15

16 Merkle PulseARC. Economical, safe, versatile! User advantages with Merkle PulseARC: Extremely spatter free welding due to the non short-circuit characteristics, one drop transfer: - tremendous time saving due to reduction of working hours for cleaning - high output of wire melting - longer life of torch consumables - less down time due to cleaner consumables Optimal processing of aluminium and aluminium alloys and stainless steel. 144 stored welding programs for - different materials - different wire diameters - different shield gases Safe, spatter reduced ignition due to a new ignition process controlled by 13 parameters: - 2 independent ignition pulses - precise soft start of the wire - slag droplet is removed from the wire end at the end of each weld to ensure a safe re-ignition. Multiple variations of pulse parameters: - Manipulation of the arc characteristics and the penetration. Alloy elements are maintained due to adaption of the pulse parameters when using high alloyed wire. PulseARC welding programs: Structure of the pulse welding programs: Welding process control with 35 free programmable parameters. Perfect ignition due to 13 variable parameters within the ignition process. 144 different pulse forms programmable. Generation of different forms of welding characteristic curves and parameters are possible. Comparison between MAG and PulseARC: Spatter emission in relation to the welding current in percent. The drawing shows the outstanding results in favour of PulseARC welding compared to traditional MIG/MAG welding using CO 2 or mixed gas as shield gas. ignition process welding process end process current Iab tab Is ts Iab tab f lp Rb Se Ss Sa San Sab Ige tsa SPA lgs lgs tas tp lg time 10,0 % short arc mixed arc spread arc wire speed feed DRS DR RB time 7,5 % MAG CO2 I ge T sa spatters 5,0 % 2,5 % MAG mixed gas gas nozzle after 3 min. of welding 0 PulseARC welding A 200 A 300 A 400 A welding current 16

17 Interpulse process, current program. Perfect welding quality! Interpulse process: With this process we enter a new dimension in welding aluminium and stainless steel. A second pulse process is added to the base pulse. All our synergic pulse welding units can be equipped with Interpulse technology as an option. Current program (special 4-stroke): The current program function allows the activation of a higher start current (adjustable). Especially designed for aluminum welding giving a higher performance and more heat during the initial arc ignition period. The down slope time and the final current (crater filler) are also adjustable. In the high performance welding mode the start current is set to a lower value to achieve a softer start. The advantages of the Interpulse process: Scaled weld and welding quality similar to TIG welding process. Welding speed as high as in MIG welding. Exact manipulation of the scaled weld. Reduced heating up of the material. Reduced distortion of the work piece. Easy adjustment by only one potentiometer (different pulse parameters are adapted automatically). welding current energy 1. stroke: activation of start current 2. stroke: welding with main current 3. stroke: activation of down slope 4. stroke: switching off the process time time 17

18 DeepARC process. The HighSpeed formula! DeepARC DeepARC process Witness yourself the new high speed formula of MIG/MAG welding! An extremely narrow welding arc (similar to a plasma arc) is achieved through a highly dynamic voltage control system in the HighPULSE series welding unit. This new welding arc defines itself through several characteristics. The DeepARC process is perfect for use with mild and stainless steels as well as for aluminum and aluminum alloys. The DeepARC process is available as an option in all units of the series HighPULSE. Welcome to the future! DeepARC process Applications: - Steel construction - Ship yards - Machine building - Apparatus engineering - Container construction 18

19 DeepARC process benefits. Deep penetration, faster welding! Special temperature input profile Lower temperature at the outer edges of the welded zone Reduced heat damage at the heat input zone Reduced material distortion welding wire Reduced quantity of welding layers Due to the deeper penetration the preparation angle can be less Reduced costs for material preparation Less filler wire and less gas is needed Reduced time for welding due to less welding layers welding layer temperature profile spray arc DeepARC process spray arc DeepARC process Deeper penetration Deeper penetration due to higher arc pressure Garanteed root penetration Welding of geometries with limited access spray arc DeepARC process Sharp end of wire High arc pressure Extremely stable arc Short arc Long stick-out of up to 40 mm Stable arc Fast length control of the wire spray arc DeepARC process Spatter-free welding result The short and concentrated arc is directing the wire precisely into the weld pool. No spatter adherence at the surface. Nearly no undercut Concentrated narrow arc Reduced heat input Low re-inforcement No undercut, not depending on torch angle 19

20 ColdMIG process. Up to 30% heat reduction! ColdMIG ColdMIG process The Merkle ColdMIG process sets new standards in welding with up to 30% less heat input. Thin metal sheet hand welding ( mm) is achieved to perfection. Its high gap bridging capacity and optimum welding facility of mixed materials and coated sheet metals are other world class features. The ColdMIG process is available for all HighPULSE machines as an option. DeepARC Arc sections Welding current: A Arc voltage: V Wire feed speed: m/min Process benefits: - Welding of thin sheet metals mm - High gap bridging capacity - MIG brazing at low heat input - Welding of coated sheet metals - Welding of different materials 20

21 ColdMIG process benefits. Less heat input, high gap bridging capability! The ColdMIG process principle The characteristic curve is controlled in the up and down slope cycle by an ultrafast digital signal processor. Steep controlled upslope in the short-circuit cycle Steep (almost vertical) downslope of the current after drop transfer Constant frequency of the drop transfer Short Arc Comparison of heat inputs 20-30% less heat input in comparison to conventional short arc welding. current voltage time time heat reduction from ColdMIG ColdMIG Gap bridging capability MIG brazing of galvanised sheet metals The high gap bridging capability sets new standards even with complex requirements and applications. MIG brazing of galvanised sheet metals to perfection thanks up to 30% less heat input. 21

22 MIG brazing, High Performance welding. Perfect welds in shortest time! MIG brazing: Joining of coated metal sheets! Galvanized or aluminum coated sheets can be brazed together by the MIG brazing process. When using a wire with a low melting point a brazed joint can be achieved without melting the sheets utilising a specially designed program. Due to the low temperatures, the coating will not burn in large areas. The weld is resistant to corrosion. The machines series HighPULSE have standard brazing programs. In the ColdMIG process the heat input is again drastically reduced. High Performance welding process: 30 % higher deposition rate! The important increasing of the deposition rate leads to a tremendous reduction of welding time. The synergic pulse welding unit HighPULSE 550 DW is prepared for the high performance welding: Wire feeding system gives up to 30 m/min. wire speed. Various welding programs for 3- and 4-component gases. 5-phase-process with start and final current, up and down slopes. Specially designed high performance welding torch HSB/HSBT 600 W with a water cooled gas nozzle to resist the extreme heat of the welding arc. MIG brazing of coated sheet metals. High Performance welding. 22

23 Programming, MQC measuring and monitoring system. Control, documentation and analysis! Programming: Set up all parameters individually! The welding programs for most of the common wires are included in the machine as a standard. New programs can be loaded to the machine at any time. Program modifications can be realized when new wires enter the market in future times. In connection with the programming software ProDok32 and a standard PC all welding programs can be documented, changed or reprogrammed. MQC Merkle Quality Control: The measuring and control system! A standard PC is connected via a converter to the welding machine at the standard serial interface. The new software MQC (Merkle Quality Control) monitors and controls automatically up to 8 different parameters. The software is designed for use with stand-alone machines and network applications. Three important MQC functions: Recording of welding parameters: The measured parameters are displayed as coloured curves on the screen. A welding report can be printed and stored. Controlling of welding parameters: Limits for all parameters can be preset. A warning is activated or the machine is switched off if a limit is exceeded. Evaluation of welding parameters: The welding time, machine s working time, wire and gas consumption are calculated automatically. 23

24 Create your future successfully. With Merkle. Your specialist for welding units, welding machines, torches and intelligent automation systems. With own subsidiaries and Merkle dealers in Germany, Europe and many other countries throughout the world. WD2000/02-11 Welcome to Merkle. MIG/MAG Welding Units Synergic Pulse Welding Units TIG Welding Units MMA / Stick Electrode Welding Units Plasma Welding and Cutting Units Turntables and Roller Drive Units Welding and Cutting Torches Automation Components and Solutions Merkle Robotics Merkle Schweissanlagen-Technik GmbH I Industriestr. 3 I D Koetz I Germany I Tel.: +49 (0) Fax: +49 (0) I info@merkle.de