The Hot Spot II is a pulse high energy welding unit and can generate
voltages and hot particles that are dangerous to the operator. Care should
be taken to avoid coming into direct contact with the uninsulated portions
of the holding pliers or wire being welded while using this tool. Particular
steps should be taken to avoid damage caused by sparks and sprays of
molten metal produced by welding operations. The operator can be
protected by a plastic shield from the hot particles. In no case should the
unit be used without suitable eye protection such as the shaded goggles
provided with the welder. Avoid flammable clothing and do not operate in
areas containing inflammable or explosive materials. Very high currents
are produced by this device so care should be exercised using the unit in
any electrical environments sensitive to such pulses.
Internal power supply and energy storage capacitors will retain significant
charge for an extended time interval after the unit is turned off. Circuit
board inspection or repair should be performed by qualified personnel and
only after these capacitors have been discharged. The ground electrode of
the welder (heavy lug) is electrically common with power line safety
ground and the metal case of the welder. Take care to avoid accidental
discharge to the unit's case or other grounded conductors.
Use the Hot Spot II in well ventilated areas and minimize breathing the
toxic compounds generated by the high temperature arc from the various
elements of the components being welded.
All potential operators should be aware of the above cautions and the
welder's operating characteristics before using the Hot Spot II.
警告
(HotSpot II 的使用和维修)
HotSpot II 是脉冲高能焊接单元,它能产生电
压和热飞溅颗粒物,这些对操作者是有危险的。
在使用该设备时要格外小心,拿钳子时不要接触
非绝缘的部分或被焊接的线,并且要采取特别措
施来防止在焊接操作时熔融金属火花溅到身上。
操作人员可以使用塑料防护物来保护自己,使自
己免受热颗粒造成的伤害。操作人员绝对不能在
不戴合适的防护镜的情况下进行操作(焊接机已
配护目镜)。不要穿易燃的衣服,不要在有易燃或
易爆材料的地方操作。该设备能产生强电流,应
该小心不要在对脉冲比较敏感的地方使用该设
备。
内部电源和储能电容器能在设备断电后延长
操作时间。线路板检测或维修都应由专业人员操
作,而且在电容器完全放完电后进行。焊接机的
接地电极(插头上的粗接线柱)是电学通用的与
电源安全接地线和焊接机的金属盒连接的电极。
设备对外壳或其它接地导体的意外放电要格外小
心。
在通风良好的地方使用 Hot Spot II 来减少由
焊接各种零部件时产生的高温电弧附带的有毒气
体。
所有准备操作的人员在使用 Hot Spot II 之前
应该看一下以上警告和焊接机的特性。
第 2 页 / 共 12 页
Controls, Indicators, and Overload Protection
The Hot Spot 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 state 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 Hot Spot 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 last recent discharge.
When the internal capacitors are being charged to the level set by the
energy control potentiometer, the charging indicator glows brightly. The PI
and P2 indicators show that the two high energy storage capacitors have
been charged. Once the energy in the storage capacitors has been raised to
the value indicated by the control potentiometer, the charging indicator will
be only dimly lit or off. After a weld cycle has discharged these capacitors,
the charging cycle will be repeated automatically (following a short delay
to assure internal SCR turn -off) A reset table 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.
HOTSPOT II 产品使用说明书
调控、指示和超负荷保护
Hot Spot II 是通过降压变压器和整流器来给焊
接机提供交流电的。面板指示和控制便于操作人员
对设备状态进行监控,从而决定电容转换储存的能
量级别和启动的焊接周期。Hot Spot II 的最大输出功
率大约为 250 焦耳。能级是由面板控制按钮的调整
决定的。能级范围----正常(低位置)和涡轮(高位
The principal difference between the Hot Spot II and the Standard Hot
Spot is its heavier wire welding capacity. The Hot Spot II can handle
wire pairs as heavy as #14 gauge. It can also close larger tubes than the
standard unit and can do light duty stud welding as an aid in wire harness
attachment and in insulation blanket installation.
For the same weld power the Hot Spot II can operate at lower arc voltage
than Standard Hot Spots. This produces less weld splatter and somewhat
aesthetically superior thermocouple beads. There is no difference in the
reading accuracy of the junctions produced by either unit.
The Hot Spot II operates only from AC power. A battery powered
version of the unit is not offered. Its less than 14# weight and compact
design make it a very portable package. Simplified front panel controls
and status display facilitate operator training and understanding.
Identical procedures are used when making and attaching thermocouples
as were developed for the Standard Hot Spot. Expectedly, there are fewer
problems with T type junctions or heavier wire sizes, the same internal
power circuitry operates for both high and low energy ranges. Therefore,
control resolution desired and maximum energy required should dictate
which range is to be employed for a particular application.
HOTSPOT II 产品使用说明书
Hot Spot II 功能和特性
Hot Spot II 与标准的 Hot Spot 的主要区别是它
的粗丝焊接能力。Hot Spot II 可以焊接#14(1.6mm)
粗的线。它也可以将大尺寸的管子封口,可以连接轻
型螺柱和铠装线,以及协助安装隔热衬垫。
使用同样的焊接能量,HotSpot II 可以在比
HotSpot 的电弧电压低的情况下操作,这种焊接产生的
飞溅物少,而且产生的热电偶焊结球也要美观些。任
何一款设备在结球时,读取焊接能量的精确性上并没
有什么差别。
Hot Spot II 只能使用交流电源,我们不提供电
池供电的设备。其重量只有 14 磅(6.3 公斤),而且
设计紧凑、便携。简化的面板控制和状态显示便于操
作培训和学习。
制作和焊接热电偶的程序设计与 HotSpot 焊接时
的程序相同。该设计也达到了预期的效果,在焊接 T
型热电偶或粗丝时出现的问题较少,同样的内部能量
电路可以在高和低两个量程下操作。因此,所需的控
制能力和所需的最大能量要求应该指出特定设置的特
殊要求。
第 4 页 / 共 12 页
HOTSPOT II 产品使用说明书
Caution!
The Hot Spot II can be damaged if operated in a mode which allows
the charging circuit to operate continuously. The welder is designed to
recharge to maximum power in less than 10 seconds.
• Starting a CHARGING CYCLE while still in a DISCHARGE MODE will allow the charging circuit to Latch On in a continuous
discharge cycle. This extends the end of the normally short charging
cycle and will OVERHEAT and DESTROY the charging circuit FET switch and associate components.
• TO AVOID CHARGING CIRCUIT DAMAGE, OPEN the PLIERS CIRCUIT after each discharge. During welding operations,
the Red LED charging lamp should be on for NOT MORE than 10 SECONDS. Care should be taken that unusual welding modes,
modification to the circuitry, or discharge during a charging cycle do
not create the above damaging conditions.
警告!
如果在充电模式下进行持续操作的话,Hot Spot
II 有可能损坏。该焊接机在 10 秒钟内能达到充满状
态。
• 在放电模式下起动充电循环(就是放电后,电
极还在接通中),会使充电电路锁定在连续放电循环
中。这种情况下会延长正常的短时间充电模式,会导
致设备过热和损坏充电电路的 FET 开关和相关组件。
• 为了避免充电电路损坏,在每次放电完毕后拿
开钳子,断开电路。在焊接作业时,充电红色 LED 指
示灯显示的时间不能超过 10 秒。应该注意的是,不
要非正常焊接、不要修改电路和在充电周期内不要放
电,这样就不会产生上述的损坏。
第 5 页 / 共 12 页
Specifications
Size: 3.5" High, 8.5" Deep, 11.5" Wide (less handle)
Weight: 14 Pounds
Stored Weld Energy: 5 to 250 Watt seconds
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
Controls: Provides energy adjustment control, dual energy switch,
and LED displays to indicate charging and energy storage status.
Power: Uses 120 VAC 60 HZ line power
DCC warrants to the original purchaser each HOT SPOT to be
free from defects in material and workmanship for the period of
one year from date of delivery. This warranty does not include the
internal storage battery or wear and tear due to ordinary utilization
of the unit. Neither does it cover damage caused by misuse,
negligence or improper supply voltages. DCC will repair free of
charge any units returned to its factory and deemed by DCC to be
defective under this warranty. DCC shall not be liable for any
special or consequential damages caused directly or indirectly by
the use of the HOT SPOT or performance of this warranty.
Description about the function of front and back panel 面板功能描述
1、The power control knob:The Hot Spot 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 state 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
Hot Spot II is approximately 250 Joules. The power level is set by the
position of the front panel control knob.
2、Firing switch: Initiation of the welding discharge is controlled by a
snap action push button switch.
3、Power ranges control holder: The power ranges, normal (low) and
turbo (high), are selected by a two position toggle 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.
4、Incharge LED: Once the energy in the storage capacitors has been
raised to the value indicated by the control potentiometer, the charging
indicator will be only dimly lit or off. After a weld cycle has discharged
these capacitors, the charging cycle will be repeated automatically
(following a short delay to assure internal SCR turn -off)
5、Capacitors LED(P1):The P1 indicators show that the high energy
storage capacitors have been charged.
6、Capacitors LED(P1):The P2 indicators show that the another high
energy storage capacitors have been charged.
7、Welding cable (with washer): Connects to carbon block or magnetic
iron. The cable Length: 1.5m, Diameter: 4mm (#6), Voltage: 600V
Temperature range: -50-105℃. 8、Circuit breaker knob :A reset table 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.
9、 Three phase AC power cord: 220VAC 50HZ and ground
electrode. The ground electrode of the welder (heavy lug) is electrically
common with power line safety ground and the metal case of the welder.
Take care to avoid accidental discharge to the unit's case or other
grounded conductors.
10、Welding cable (with plier sleeve ): Connects to carbon block or
magnetic iron. The cable Length: 1.5m, Diameter: 4mm (#6), Voltage:
600V Temperature range: -50-105℃.
1、能量调控旋扭:此旋钮是调整能量大小的。能量
指示和控制便于操作人员对设备状态的监控,从而决
定电容转换储存的能量级别和启动的焊接周期。Hot Spot II 是通过降压变压器和整流器来给焊接机提供
交流电的,最大输出功率大约为 250 焦耳。
The combination of operator ingenuity and HotSpot flexibility allows a
wide variety of welded junctions to be produced. Illustrated here are
some HotSpot fabrication techniques and results. They provide a
suggestion of the range of possibilities and are not a definitive set of
weld examples.
●Free standing junctions are produced by holding the paired wires in the
electrode pliers and touching them to the carbon block electrode, after
the HotSpot firing switch has been pushed and continues to be held
in. The following energy settings may be used as an initial guide.
However, they should be modified to suit the individual operator, wire
type, and desired result. #30 wire pairs,20 Watt seconds; #26,30 Watt
seconds; #24,40 watt seconds; #20,50 Watt seconds; #16,100 Watt
seconds; and #14 pairs, 200 Watt seconds.
●Stripped wire pairs should be positioned in the plier electrode so that
each wire is contacted. Asymmetrical contact can produce a distorted
bead. Other factors, including wire material, contribute to bead
distortions. Multiple attempts with the same junction may help in
producing the desired shape.
●多根丝的热电偶线,应该保证所有的丝都和钳子接
触,达到充分的焊接。不对称的末端焊接,会使结球
不规则,材料的因素也会引起不规则。但在同一个接
合处的多次放电有助于产生预期的形状。
第 8 页 / 共 12 页
●Junctions which have a quick response and easily attach to plane
surfaces can be made by flattening the bead, after it is formed. The
Function of the bead is to create an identical thermal and electrical
environment at the wire ends. The thermocouple output is not meant to
be produced by the bead, a unique alloy peculiar to that particular
junction, but by the temperature gradient along the wire themselves.
Therefore, the flattening should extend to the wires. For critical
applications, the resulting quick response couple should be compared
against an unmodified bead, since cold working during the'flattening may
effect the calibration. Unacceptable differences can be mitigated by
annealing or heat cycling.
HOTSPOT II 产品使用说明书
●焊接点要迅速,并且给予压力,焊接点成扁平后,
就能焊接在表面上。热电偶结的功能是在焊接线末端
形成与基体同样的导热和导电环境,热电偶信号并不
是由结点产生的,结点仅仅是一个特殊的合金球,信
号是因为线的温度不同而产生的。因此,压扁的部分
应该与焊接线连接。对于特殊应用,快速形成的热电
偶应该和普通的
校对对比一下,
因为在压扁操作
过程中的冷处理
可能会影响校
准,通过退火或
热循环处理可以
减少差错的发生
●The HotSpot is very useful for welding thermocouples directly to
metal items which will be monitored or to brackets, nuts, bolts, clamps,
etc., which are assembled to such items. Best control and attachment is
obtained if free standing junctions are first made, and then touched down
to the metal surface (attached to the other welder wire) while the firing button is depressed. Where positioning is critical, the junction can be
held with some slight pressure against the metal base, and then the firing
button pushed. Neither approach is useful when the wires are finer than
#26 or #28 since they will not support the pressure needed to keep them
in contact with the base material during the welding period.
●Welding to materials like aluminum, copper, white metal, and brass
that have low melting temperatures and are easily oxidized, can be
facilitated by flushing the welding spot with nitrogen, argon, helium,
carbon dioxide or some similar protective gas. Also, attachment is
improved if the wire is gently "smacked" into the surface after the firing
button is depressed.
●Different physical results will be obtained if the wires are twisted, or
one wrapped around the other. For "T" type junctions, the copper can be
given a turn around the constantan to keep it from melting back too
rapidly from the arc area. Start with the constantan extended beyond the
copper ring a short distance. For welding type "T" to a copper base, first
weld the constantan wire to the base. Then cut off the wire flush with the
surface, and weld a pre-formed junction over the resulting constantan
pad. Wires can be welded to difficult bases by first passing them through
a short stub tube of similar material, and the n welding the assembly to
the base.
●Fine wire thermocouples can be protected by first passing them
through a thin stainless tube and welding the end closed in a grounded
junction configuration. The HotSpot is capable of making needle probes,
using .60" or .90" O.D. tubes. Expectedly, larger tubes whose ends have
been swaged to a smaller diameter for a short distance can be similarly
closed. To protect a simple surface junction, the HotSpot Expansion Kit
includes a utility cement useful to temperatures exceeding 4000 F. This
provides stress protection and some thermal insulation at the
thermocouple attachment point. If unsuccessful in any operation, call for help.
After each discharge, the HotSpot II automatically recharges. An internal
delay of a few seconds between the time the discharge button is pushed
and the start of the recharge cycle allows the storage capacitors to
discharge completely and the output SCR switches to open (unlatch). A
red LED indicator comes on during the charging cycle.
Some welding conditions (like a dirty contract) extend the discharge
cycle. If the discharge interval is too long, the charge/discharge cycle can
overlap and the internal charging circuitry may be damaged.
● THE RED CHARGING INDICATOR SHOULD NEVER BE ON
FOR MORE THAN 10 SECONDS OR DAMAGE MAY RESULT.
● THE PLIERS CIRCUIT SHOULD BE OPENED AFTER EACH
DISCHARGE TO ASSURE THE OUTPUT CIRCUIT IS OPEN.
● HIGH RESISTANCE DISCHARGE PATHS WHICH EXTEND
THE DISCHARGE INTERVAL SHOULD BE AVOIDED.
1 The length of warranty will last 1 year after the installation.
In the warranty period, when it is normally operated according to the
operational manual, attached note , in case of failure , our company will
be responsible for its maintenance or repair free of charge.
2. Our company is not responsible for any direct or indirect damage
caused by the failure of our machine or using our machine.
3. The following repair cases will be charged in the warranty period:
zFault or damage caused by the improper operation, poor repair or
change.
z Repair and replacement for the wearing parts.
z Fault or damage caused by unintentional drop during the
transportation or movement.
zFault or damage caused by the earthquake, fire, wind, flood,
thunder and other natural disasters; or caused by the external
factors such as abnormal voltage.
4. Repair cases beyond the length of warranty
If the machine can perform normally after the repair, we will charge for
the repair according to the user’s requirement.
5. After-sales service
Any repair requirement, components purchase and other unclear points,
please consult the suppliers. During the repair, please inform the
following information including name, model, manufacture number,
problem as well as the supplier’s name.
保修条款
1、保修期为收货验收合格之日起 1 年。保修期内用
户根据使用说明书、注意事项,正常使用的情况下,
万一发生故障时,本公司将免费负责修理。
2、本公司不负责由于本装置的故障或者使用本装置
时所造成的直接或间接的损失。
3、保修期内以下的修理为有偿修理:
z由于用户在操作上的错误以及不当的修理或改
造而造成的故障或者损坏。
z 易损件的修理和替换。
z 由于用户在运输、移动过程中跌落受冲击等用
户的使用不当而造成的故障或损坏。
z由于地震、火灾、风水灾害、雷击以及其它自
然灾害,或者由于异常电压等外部因素造成的
故障或损害。
4、超过保修期的修理:修理后可维持本装置性能的
前提下,跟据用户的要求,进行有偿的修理。
5、有关售后服务:如果有修理的要求、部件的购买
以及其它不清楚的地方,请向各供货商的销售人员询
问。另外,在商量修理时,请告知购买机器的名称、
型号、产品编号、状况以及供货商名称等信息。
第 12 页 / 共 12 页
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