Chassis Mount Resistors

Chassis mount resistors, also referred to as panel mount fixed resistors, are used to limit the flow of electricity in an electrical circuit (resistance). They are a type of fixed resistor which means the resistance is set at a specific value and can't be changed. Resistors are important because they help to prevent damage or destruction of other circuit components Many chassis mount resistors are wire wound resistors, known for their durability and ability to handle high power levels.

How Wire Wound Chassis Mount Resistors Work

Wire wound fixed resistors are constructed by winding a wire, usually made of a metal alloy, around a ceramic, plastic, or fibreglass core. When current flows through the wire, the resistance limits the current, converting excess electrical energy into heat, which is then dissipated through the resistor's chassis mount design.

Types of Chassis Mount Resistors

Chassis mount resistors come in various types featuring different characteristics to suit a variety of applications.

• Resistance: Available in a wide range of fixed resistance values to suit different circuit requirements.
• Power Rating: Designed for various power levels, from low-wattage resistors for small electronics to high-wattage options for industrial applications.
• Case Materials: Constructed from materials like ceramic, aluminium, and metal for varying levels of heat dissipation and cost.
• Termination Style: Features different termination styles such as solder lugs, screw terminals, and quick connect tabs to fit diverse installation needs.

Components & Construction of a Chassis Mount Resistor

Chassis mount resistors, or wire wound resistors, are built from several key components:

• Resistance Wire: Typically made from a high-resistance metal alloy, this wire is wound around a core to create the resistor. The precision winding determines the resistance value and ensures stability.
• Core: The core is usually made of ceramic or metal, providing a stable base for the wire winding and contributing to heat dissipation.
• Casing: The entire assembly is encapsulated in a heat-resistant casing, often made of aluminium or ceramic. This casing helps to dissipate the heat generated by the resistor during operation.
• Terminations: The ends of the resistance wire are connected to terminals, such as solder lugs, screw terminals, or quick connect tabs. These terminations allow for easy and secure connections in various applications.
• Mounting Hardware: Chassis mount resistors may include additional mounting hardware, such as brackets or flanges, to secure the resistor to a chassis or panel.

Benefits of Chassis Mount Resistors

Chassis mount resistors offer several advantages over other types of resistors, making them ideal for various industrial and high-power applications.

• High Power Handling: Chassis mount resistors can handle significantly higher power levels compared to other resistors, making them suitable for demanding applications like power supplies and amplifiers. Their construction allows for efficient heat dissipation, ensuring reliable performance under high loads.
• Durability and Stability: Built with robust materials like ceramic and metal, wire wound resistors offer excellent durability and stability. This makes them ideal for environments exposed to vibration, shock, and extreme temperatures.
• Precision: Wire wound fixed resistors provide precise resistance values, ensuring accurate performance in critical applications. Their construction minimizes variations and maintains stability over time.
• Versatile Mounting Options: These resistors come with various mounting hardware, such as brackets and flanges, allowing for secure and flexible installation in different configurations. This versatility makes them easy to integrate into existing systems.
• Heat Dissipation: The encapsulation and casing of chassis mount resistors are designed to dissipate heat efficiently. This prevents overheating and extends the lifespan of both the resistor and the surrounding components.

Industrial Applications of Chassis Mount Resistors

Chassis mount resistors are essential in numerous industrial applications due to their robust construction and reliable performance. They are particularly useful in scenarios requiring high power handling and efficient heat dissipation.

• Large Electrical and Production Machinery: Used to manage and control electrical currents, ensuring the safe and efficient operation of heavy machinery.
• Motor Start or Stop Cycles: Provide the necessary resistance to control the start and stop cycles of motors, preventing damage and enhancing performance.
• Equipment Discharge: Employed in equipment discharge applications to safely dissipate stored energy, protecting components from damage.
• Load Test Simulation: Used to simulate loads in testing environments, helping to verify the performance and stability of electrical systems under various conditions.
• Dynamic Braking: Essential in dynamic braking systems, chassis mount resistors help in safely slowing down and stopping motors by dissipating kinetic energy as heat.
• Heat Loss and Cooling Applications: With a low temperature coefficient of resistance (TCR), these resistors maintain stable resistance across a wide temperature range, making them ideal for applications focused on promoting heat loss and cooling.

How to Choose the Right Chassis Mount Resistor for Your Needs

There are many factors to consider when choosing the right chassis mount resistor for your needs. Consider factors such as resistance value, power rating, temperature coefficient, and the environmental conditions the resistor will face. It's also important to select the appropriate termination style for your setup.

RS Australia offers a wide range of high-quality chassis mount, wire wound power resistors in a variety of configurations, ensuring you can find the perfect one for any application.

Buying Chassis Mount Resistors: Ordering & Delivery

RS is a trusted supplier and distributor of chassis mount, wire wound resistors from leading brands in Australia. Our range includes brands such as TE connectivity, Vishay, Arcol and more. To place an order online, simply browse our extensive catalogue, filter your preferred products based on our extensive specifications, and add to your cart.

RS Group offers fast delivery of chassis mount resistors. For more details on delivery services and fees, please refer to our Delivery Page.