Power & Braking Resistors
Power & Braking Resistors
Power Resistors are high-capacity resistive components designed to safely dissipate electrical energy as heat under heavy load conditions. They are commonly used for current limiting, load testing, voltage division, dynamic braking, and energy absorption in power systems. Built to handle high energy surges, these resistors are engineered with robust materials such as stainless steel grids, wire-wound elements, or metal film construction to ensure durability, thermal stability, and long service life.
Braking Resistors, a specific type of power resistor, are used with Variable Frequency Drives (VFDs), inverters, and electric motors to absorb excess regenerative energy during braking. When a motor decelerates, it acts as a generator, sending energy back to the drive’s DC bus. If this energy is not controlled, it can cause overvoltage faults or damage equipment. Braking resistors safely dissipate this energy as heat, ensuring controlled deceleration, protecting the drive, and extending the life of the motor and associated components.
Power & Braking Resistors – Technical Specification
| Category | Specification |
|---|---|
| General Description | High-capacity resistors designed for current limiting, load testing, dynamic braking, and safe energy dissipation. Braking resistors absorb regenerative energy from motors during deceleration to prevent overvoltage in drives. |
| Standards & Compliance | IEC 60068 (Environmental Testing), IEC 60664 (Insulation), IEC 61000 (EMC), UL/CE certification |
| System Voltage | 230 V / 400 V / 415 V / 480 V / 690 V (custom up to 1.2 kV) |
| Power Rating | 0.5 kW – 500 kW (customizable based on application) |
| Resistance Range | 0.1 Ω – 500 Ω (application dependent) |
| Duty Cycle | Continuous (100%) or Intermittent (5–10% braking duty) |
| Peak Load Capacity | Up to 10 × rated power for short durations |
| Temperature Rise | Designed for ≤ 375 °C element temperature |
| Insulation Class | Class F (155°C) / Class H (180°C) |
| Enclosure Protection | IP20 (indoor), IP23 (industrial), IP54 (dust/water resistant), IP65 (outdoor heavy-duty) |
| Cooling | Natural air convection (AN) or Forced air cooling (AF) |
| Construction | Wire-wound, steel grid, or edge-wound resistive elements in robust steel casing |
| Mounting | Floor or panel-mounted, vibration-resistant design |
| Environmental Limits | Ambient Temperature: –25 °C to +50 °C Humidity: ≤ 95% RH (non-condensing) Altitude: ≤ 1000 m (derating required above) |
| Applications | – VFD braking in cranes, hoists, conveyors, elevators – Wind turbine energy dumping – Railway & traction braking – Motor dynamic stopping – Power system load testing |
| Typical Example (Braking Resistor) | Voltage: 415 V AC Resistance: 15 Ω Power: 10 kW Duty Cycle: 10% Cooling: Forced Air Protection: IP23 |