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

CategorySpecification
General DescriptionHigh-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 & ComplianceIEC 60068 (Environmental Testing), IEC 60664 (Insulation), IEC 61000 (EMC), UL/CE certification
System Voltage230 V / 400 V / 415 V / 480 V / 690 V (custom up to 1.2 kV)
Power Rating0.5 kW – 500 kW (customizable based on application)
Resistance Range0.1 Ω – 500 Ω (application dependent)
Duty CycleContinuous (100%) or Intermittent (5–10% braking duty)
Peak Load CapacityUp to 10 × rated power for short durations
Temperature RiseDesigned for ≤ 375 °C element temperature
Insulation ClassClass F (155°C) / Class H (180°C)
Enclosure ProtectionIP20 (indoor), IP23 (industrial), IP54 (dust/water resistant), IP65 (outdoor heavy-duty)
CoolingNatural air convection (AN) or Forced air cooling (AF)
ConstructionWire-wound, steel grid, or edge-wound resistive elements in robust steel casing
MountingFloor or panel-mounted, vibration-resistant design
Environmental LimitsAmbient 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
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