DH-630: 630A Hydraulic IGBT Rebar Butt Welding Machine — Heavy Construction Steel Bar Welder
DH-630
630A Hydraulic Rebar Butt Welder
Part of the Custom Power Supplies product line. Designed and manufactured in Qingdao, China with IGBT inverter technology for reliable industrial performance. CE certified for global export.
Typical Applications: Heavy construction, bridge reinforcement
DH-630 Rebar Butt Welder
The DH-630 is the largest model in the DH series, delivering 630 amps of DC welding current for flash-butt welding of heavy reinforcing bars from 20 mm to 40 mm diameter. Built on a 36 kVA IGBT inverter platform with 380V three-phase input, this machine provides the high current density and precise control required to produce full-strength butt joints in the largest rebar sizes used in bridge piers, dam construction, high-rise core walls, and heavy industrial foundations. Like the DH-280, it operates as the DC power source for an external hydraulic or mechanical clamping and upset forging fixture.
The DH-630 features an advanced digital control system with a 7-inch touchscreen HMI for programming and storing up to 50 weld recipes. Each recipe defines current ramp profiles, phase timing, and trigger points for the hydraulic clamping and upset cylinders. A built-in data logger records welding parameters (current, voltage, time, displacement) for each joint, enabling full traceability for quality assurance documentation — a requirement increasingly specified in major infrastructure contracts. The machine also serves as a versatile 630A DC power supply for electroplating lines, electrochemical processes, and industrial DC applications where high-current, low-ripple DC output is required.
Detailed Specs — DH-630
| Parameter | Specification |
|---|---|
| Model | DH-630 |
| Rated Input Voltage (V) | AC 380V +/- 10% |
| Phase | Three-Phase |
| Frequency (Hz) | 50 / 60 |
| Rated Input Power (kVA) | 36.0 |
| Rated Output Current (A) | 630 |
| Output Current Range (A) | 100 – 630 |
| No-Load Voltage (V) | 10 – 16 |
| Rated Duty Cycle | 60% @ 630A (40degC) |
| Rebar Diameter Range (mm) | 20 – 40 |
| Welding Time per Joint (s) | 15 – 65 (diameter-dependent) |
| Clamping Force (kN) | 50 – 100 (via external fixture) |
| Upset Force (kN) | 40 – 80 (via external fixture) |
| Control Interface | 7-inch touchscreen HMI + manual override |
| Weld Recipe Storage | Up to 50 user-defined programs |
| Data Logging | Built-in: current, voltage, time, displacement per joint |
| Power Factor (cos phi) | 0.85 or above |
| Efficiency (%) | 86 or above |
| Insulation Class | H (180degC) |
| Protection Class (IP) | IP22S |
| Dimensions L x W x H (mm) | 720 x 450 x 620 |
| Net Weight (kg) | 65 |
| Output Connection | Copper bus bars / 120 mm2 cable lugs |
| Cooling Method | Forced Air (Dual Fan Cooled) |
| Additional DC Applications | Electroplating, anodising, industrial DC bus, test loads |
| Certification | CE (CSA, EAC available) |
Where the DH-630 Excels
Bridge Pier & Pylon Construction
Butt welding of 32 to 40 mm main reinforcement bars in bridge piers and cable-stayed bridge pylons. Full-strength joints eliminate congestion from lapped splices in heavily reinforced sections.
Dam & Hydroelectric Projects
Welding of large-diameter rebar in mass concrete dam structures where joint reliability is critical. Data logging provides traceable QA records for each joint in compliance with dam safety regulations.
High-Rise Core & Shear Walls
Butt welding of 25 to 36 mm vertical reinforcement in high-rise building cores and shear walls. Welded joints reduce rebar congestion in link beam and coupling beam zones where seismic detailing is critical.
Heavy Industrial Foundations
Welding of rebar mats for turbine generator foundations, rolling mill foundations, and heavy press foundations. The 630A current capacity handles the largest rebar diameters specified in dynamic foundation designs.
Industrial Electroplating Lines
Serves as a high-current DC power supply for hard chrome plating, zinc electroplating, and copper electrorefining lines. Constant-current mode with less than 1 % ripple for uniform plating thickness across large workpieces.
Rail & Transit Infrastructure
Welding of heavy rebar cages for metro station boxes, tunnel portal structures, and elevated guideway piers. Stored weld recipes ensure consistent joint quality across multiple work fronts on large transit projects.
DH Series — Power Supply Comparison
| Parameter | DH-280 | DH-500 | DH-630 |
|---|---|---|---|
| Rated Current (A) | 280 | 500 | 630 |
| Input Power (kVA) | 16.5 | 28 | 36 |
| Rebar Dia. Range (mm) | 10 – 25 | 16 – 32 | 20 – 40 |
| Weld Time Range (s) | 8 – 35 | 12 – 50 | 15 – 65 |
| Duty Cycle | 60% @ 280A | 60% @ 500A | 60% @ 630A |
| Control Interface | Digital keypad | Digital keypad | 7-inch touchscreen HMI |
| Data Logging | Manual | Optional | Built-in |
| Weight (kg) | 35 | 52 | 65 |
| Best For | Mid-rise, precast, electroplating | High-rise, heavy columns | Bridges, dams, heavy construction |
Why Choose the DH-630
7-Inch Touchscreen HMI with Recipe Storage
A full-colour 7-inch touchscreen provides intuitive access to all welding parameters. Operators can store up to 50 weld recipes — each defining current profile, phase timing, and hydraulic trigger points for specific rebar diameters and grades. One-touch recipe recall eliminates setup error between different bar sizes.
Built-in QA Data Logging
Every weld joint is automatically recorded with a timestamp, current and voltage profile, total weld time, and upset displacement. Data can be exported via USB for inclusion in construction quality documentation, satisfying the traceability requirements of ISO 9001 quality management systems on major infrastructure projects.
630A Output for 40 mm Rebar
With more than double the current capacity of the DH-280, the DH-630 handles rebar up to 40 mm — the largest diameter commonly used in civil engineering. The high current density ensures complete fusion across the full bar cross-section, producing joints that match the parent metal tensile strength per ISO 17660-1 welding requirements.
Multi-Role DC Power Platform
When not deployed on rebar welding, the DH-630 functions as a high-capacity regulated DC power supply. Its low-ripple output and constant-current control mode make it suitable for electroplating lines, industrial anodising, cathodic protection systems, and DC bus supply for factory automation equipment.
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