DCMR-S: High-current DC Switch for On-load operation

The DCMR-S is G Corner's high-current DC switch for on-load make and break operation in demanding industrial environments. Built around vacuum encapsulated contact technology, it is designed to perform reliably under the electrical, thermal, and chemical stresses of continuous industrial operation - providing operators with the ability to switch circuits without interrupting the process.

Description

The DCMR-S is a compact, modular high-current DC switch rated from 6 kA to 48 kA at up to 1,500 Vdc. It is designed for on-load operation - meaning circuits can be made and broken at full rated current without shutting down the system, maintaining continuity of critical loads.

Vacuum encapsulated contacts seal the contact assembly from external contaminants including moisture, corrosive vapours, and conductive dust. The vacuum environment suppresses electrical arcing during operation, reducing contact wear and extending service life while maintaining consistent low-resistance current paths.

The DCMR-S is pneumatically actuated as standard and supports both horizontal and vertical mounting orientations. Its compact, self-supporting modular design makes it well suited to integration into existing busbar systems and new installations alike.

All G Corner products are engineered to the specific requirements of each application. The DCMR-S represents what we can achieve for high-current on-load DC switching - the exact configuration, current rating, and options will be developed with you to suit your installation.

Features

The following features are standard to the DCMR-S:

  • On-load make and break at rated current
  • Vacuum encapsulated contacts - hermetically sealed, isolated from contaminants
  • Compact, cost-effective modular design
  • Self-supporting construction
  • Pneumatic actuation as standard
  • Operation time under 1 second
  • Horizontal or vertical mounting orientation
  • Manual operation facility as standard
  • Low voltage drop at rated current
  • Low maintenance design
  • High deformability tolerance - accommodates busbar thermal movement
  • Connects to aluminium or copper busbars
  • Environmental protection to IEC 60947-3:2020 Level 4
1 S

Standard Operation Time (seconds)

48 kA

Maximum Current Rating

4 Level

Environmental protection (IEC 60947-3)

Capabilities

Typical  Applications

Shorting out individual cells or cell banks during maintenance or harvesting operations, allowing the rest of the circuit to remain in production. In electrowinning and electro-refining operations, the cell line carries a continuous high current that cannot be interrupted without affecting the entire production process. The DCMR-S allows operators to safely bypass individual cells by closing the switch across the cell terminals, short-circuiting that cell and allowing maintenance or cathode harvesting to take place while the line continues to run at full current.

Switching between circuits or cell groups while the system remains live, maintaining continuity of the process without requiring a shutdown. Transfer switching is used where the operating current needs to be redirected between different parts of the cell house circuit, for example when moving between rectifier feeds or reconfiguring cell groups. The DCMR-S is designed to make and break these connections under full load, eliminating the need to de-energise the system and reducing process downtime.

Configurations

Product options

The DCMR-S can be configured with a range of options to suit specific installation and operational requirements. These are discussed and agreed during the engineering process for each project.

RTD temperature monitoring
Inductive Limit switches
Operational / mechanical counter
Padlocking
Manual interlocking
Drip cover
Control panel
Torque limiter
Blocking magnets
Alternative current ratings (on request)

Specifications

Technical Data Overview

The values below represent the specification of a typical DCML-S configuration. All products are engineered to order and exact specifications are agreed with the customer.

01/ Product Classification

Product Classification Product Data

Product name DCMR-S
Category (L2) DC Switches
Product code / SKU root DCMR-S-X….
Product type Switch
Applicable standard(s) IEC 60947-3:2020
Device family description High Current DC Switches
Primary installation environment Tank house

Electrical Ratings Product Data

Rated voltage (Vdc) 1500
Rated current — min (kA) 6
Rated current — max (kA) 48
Rated current options (kA) 6,12, 18, 24, 36, 48, 60
Alternative current ratings available Yes
Short circuit withstand — 1s ≤10 × rated current
Voltage drop at rated current <50 mV
Temperature rise at rated current <65 °K
Utilisation category DC-21A
Switching current threshold (<50 Vdc) Rated current
Arcing contact requirement Required >10 Vdc

Dielectric Performance Product Data

Impulse voltage withstand — open position (kVp) 5 kVp
Withstand voltage — open contacts, dc 3,820 V
Withstand voltage — aux contacts to earth, 50 Hz 1 min 2.5 kV
Withstand voltage — actuator / motor to earth, 50 Hz 1 min 2 kV

Construction Product Data

Contact Insulation Medium Vacuum
Frame / drive material Stainless steel 316, FRP & GRP insulation components
Terminal / blade / finger material High conductivity copper
Busbar plate material Copper
Busbar connection method Bolted joint
Hermetically sealed contacts Yes
Isolation gap visibility Enclosed
Mounting orientation Horizontal or Vertical

Environmental Product Data

Standard degree of protection IP0
Standard environmental protection level (IEC 60947-3) Level 4
Ambient temperature range -5°C to +50°C
Relative humidity ≤95%
Installation altitude ≤1000 m

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