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Hot Spot I
Thermocouple Welder

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Thermocouple Welder

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Capacitive Discharge Stud & Thermocouple Welder

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All Categories > Thermocouple Welders > Thermocouple Welders > HotSpot II Thermocouple Welders Heavy Duty Welders > Item # 20-A10240  
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Item # 20-A10240, International Voltage Market and Usage

List Price $965.00

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The HotSpot II is a portable heavy duty 250 joule capacative discharge wire welder for forming freestanding thermocouple beads. It can also weld thermocouples to metal surfaces or attach supporting harware and small gauge studs.

This unit will weld

Specifications  · Controls, Indicators, and Overload Protection  · Quick Action  · Economical  · Easy-to-Use  · Flexible  · HOTSPOT Users


Voltage Rating

240 V


3.5 inches


8.5 inches


11.5 inches


14 lbs

Stored Weld Energy

5 to 250 Watt

Weld Capability

Welds wire pairs of #14 gauge or finer, and #8 or lighter studs

Cycle Time

Charging time at maximum energy setting is less than 10 seconds


Provides energy adjustment control, dual 2 position energy range switch, and LED displays to indicate charging and energy storage status.


Uses 120 VAC 60 Hz line power (220 VAC 50 Hz optional) Circuit protected by 3 amp breaker

Product Type

Thermocouple Welders

Controls, Indicators, and Overload Protection
The HotSpot II is powered from the AC line through a step-down transformer and rectifier. Front panel indicators and controls allow the operator to easily monitor the status of the unit, determine the level of energy to be transferred to the storage capacitors, and initiate a weld cycle. The maximum power output of the HotSpot II is approximately 250 Joules. The power level is set by the position of the front panel control knob. The power ranges, normal (low) and turbo (high), are selected by a two position toggle switch. Initiation of the welding discharge is controlled by a snap action push button switch.

The range switch and power level control set the voltage to which the energy storage capacitors are charged. Peak voltage on the low range is approximately 35 VDC and on the high range 75 VDC. The stored energy is proportional to the square of the capacitor voltage. Increasing the setting of the control knob will cause the capacitor to be charged to a higher level. However, decreasing the setting will not immediately reduce the value already stored so a welding cycle will always release an energy pulse equal to the highest power setting since the last recent discharge. A resettable circuit breaker in the primary AC line is accessible on the unit's back panel and protects against damage from internal circuit shorts and similar fault conditions.

Quick Action
The HotSpot II is light and portable so you can move it right to where you need to make and attach thermocouples. The actual welding time in less than a second and the short recycle interval, even at full power, will allow you to make 6 or more welds a minute.

Making and installing thermocouple junctions using DCC's HotSpot II is extremely economical. Freestanding beads can be fabricated or junctions welded to fixturing hardware or directly to the surface being sensed, at the rate of 5 to 10 a minute. There is no need for elaborate set-ups or specially trained operators. Skip the pre-planning, expense, and delays involved with purchasing thermocouples outside or having them made through another department.

Anyone can quickly become proficient in the use of the HotSpot II. While sophisticated internally, the HotSpot II provides the operator with a firing button and a simple on/off and energy level adjustment. A weld is generated by holding the bared end of the thermocouple wire to the bead forming graphite electrode or the surface to be sensed, while pressing the firing button.

The HotSpot II welder is a dual range high-energy unit that has the versatility to provide fine control as well as the high power capability needed for heavier wires. Front panel indicators and controls allow the operator to easily monitor the status, set the energy level, and initiate a weld cycle

Abbott Labs
Advanced Cardiovascular Systems
Allegheny Ludlum Steel Corp.
Allied Bendix Corporation
Altech Specialty Steel Corp.
Aluminum Co. Of America
Amoco Chemicals Company
Analog Devices Inc.
Anheuser-Busch Inc.
A. P. Green Refractories
Appalachian Power Company
Apple Computer Company
Armour Pharmaceutical Co.
At&T Bell Labs
At&T Technologies Inc.
Avondale Shipyards, Inc.
Babcock & Wilcox
Beech Aircraft Corp.
Bethlehem Steel Corporation
Bio-Medicus Inc.
Briggs & Stratton Corp.
Brookhaven National Laboratory
Bucknell University
Burroughs Corporation
Cameron Iron Works
Carnegie Mellon University
Carolina Power & Light Co.
Caterpillar Inc.
Certainteed Corporation
China Lake Naval Weapons Center
City Of Colorado Springs
Colgate Palmolive Co.
Coca-Cola Co.
Compaq Computer Corp.
Combustion Engineering Inc.
Con Edison Co. Of New York
Connecticut Yankee Atomic Power
Continental Carbon Co.
Cooper Industries Inc. Bussmann Div.
Cornell University
Data General Corp.
David Taylor Naval Ship R&D
Detroit Diesel Allison
Detroit Edison
Digital Equipment Corp.
Eastman Kodak
Eaton Corporation
Eg&G Inc.
E.I. Dupont
Elmwood Sensors
Emerson Electric
Englehard Corp.
Erickson T.R.
E. R. Squibb & Sons Inc.
E Systems
Exxon Research & Engineering
Fiberglass Canada Inc.
Fisher Body
Fmc Corp.
Florida State University
Ford Motor Company
General Dynamics
General Instrument Corp.
General Motors Proving Ground
Genetech Inc.
Goodyear Aerospace Corp.
Goodyear Tire & Rubber Co.
Gould Electronics
Grumman Aerospace Corp.
Gte Communications Systems Corp.
Harris Semiconductor
Hatch Company Inc.
Hawaiian Electric Co. Inc.
Hercules Corp.
Hobart-Kitchen Aid
Honeywell, Inc.
Hughes Enterprises
Ibm Corporation
Ici Americas, Inc.
Inland Steel Co.
Intergraph Corporation
International Minerals & Chemicals
Iowa-Illinois Gas & Electric
Itt Neo-Dyn Aerospace Controls Div.
J I Case
John Deere Component Works
Keebler Company
Kentucky Fried Chicken Corp.
Kimberly-Clark Corporation
Kms Fusion, Inc.
Knolls Atomic Power Laboratory
Koehler Company
Lamb Weston, Inc.
Lee Data Corporation
Litton Systems Inc.
Lockheed Corporation
Lof Glass
Louisiana Pacific Corp.
Louisiana Tech University
Lower Colorado River Authority
Massachusetts Health Research Inst.
Martin Marietta Corp.
Mcdonnell Douglas
Medi-Physics Inc.
Merck & Co., Inc.
Michigan Department Of Health
Michigan State University
Miles Laboratory, Inc.
Mine Safety & Health Adm.
Minnesota Mining & Manufacturing
Morton Thikol Corporation
Motorola, Inc.
National Bureau Of Standards
National Gympsum Company
National Steel Corp.
Naval Air Development Center
Naval Research Laboratory
Naval Surface Weapon Center
Norden Systems
Nordson Corporation
Northeastern University
Northern Indiana Public Service Co.
Northern Telecom Electronics Inc.
Northrop Corporation
Oklahoma State University
Oregon State University
Owens-Corning Fiberglass Corp.
Pacific Gas And Electric Co.
Pennsylvania Power & Light Co.
Pfizer Corporation
Philadelphia Naval Shipyard
Pitney Bowes
Potters Industries, Inc.
Ppg Industries
Prestolite Electric Inc.
Proctor Silex
Public Service Company Of Oklahoma
Public Service Electric & Gas Co.
Purdue University Calumet
Ratheon Co.
Reynolds Metals Corporation
Rockwell International Corp.
Rubicon, Inc.
Sanders Associates
Sandia National Labs
Sears, Roebuck And Co.
Sharp Manufacturing Co.
Skega Ab - Sweden
Southern California Gas Co.
Sperry Computer Systems
Sprague Electric Company
Square D Company
Standard Oil Company
Stanford Linear Accelerator Center
Stanford University
Stevens Institute Of Technology
Sunbeam Appliance Co.
Tecumseh Products Company
Teledyne Total Power
Tennessee Valley Authority
Texas Instruments Inc.
Texas Tech University
Tektronix, Inc.
The Boeing Company
The B.F. Goodrich Co.
The Singer Company
The University Of Chicago
3-M Company
Titanium Metals Corporation
Union Carbide Corporation
Unisys Corp.
United Technologies
University Of Arizona
University Of Arkansas
University Of California
University Of Delaware
University Of Denver
University Of Illinois
University Of Maryland
University Of Missouri
University Of Notre Dame
University Of Pennsylvania
University Of Texas
University Of Utah
University Of Windsor
Upjohn Manufacturing Co.
U.S. Air Force - Mcclellan Afb
U.S. Army Aberdeen Proving Ground
U.S. Army - Cold Regions Research
U.S. Borax & Chemical Corp.
U.S. Dept. Of Agriculture
U.S. Dept. Of Energy
U.S. Environmental Protection Agency
U.S. Forest Service
Volkswagon Of America Inc.
Westinghouse Electric Corporation
Weyerhauser Company
Wheaton Industries
Whirlpool Corp.
W.L. Gore, Inc.
Vulcan-Hart Corporation
Zenith Electronics Corp.
Zilog Inc.


HotSpot I and II Expansion Kits

Hot Spot II & PLUS Expansion Kit

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