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The DUFEW CRR Series Inverter Corrugated Resistor is a high-power braking component designed for inverter energy dissipation systems. During rapid motor deceleration, regenerative energy is returned to the inverter DC bus, causing voltage rise. Without proper energy management, excessive voltage can trigger overvoltage protection or damage power semiconductor components.
The CRR Series uses high-quality Nickel-Chromium (Ni-Cr) or Constantan alloy ribbon, precision-formed into a corrugated structure and vertically wound around a high-alumina hollow ceramic core. This design increases the heat dissipation area, improves thermal efficiency, and reduces parasitic inductance to minimize voltage spikes during high-frequency switching.
Designed for frequent braking conditions, the product provides strong short-time overload capability, stable thermal performance, and reliable operation in industrial environments. It is commonly used in elevators, cranes, rolling mills, injection molding machines, centrifuges, conveyors, and other variable frequency drive systems.
During motor deceleration, regenerative energy is transferred from the inverter DC bus to the braking unit and converted into heat through the resistance element. This process helps prevent DC bus overvoltage, protect inverter components, and maintain stable braking performance under repeated operating conditions.
| Model Code | Meaning | Description |
|---|---|---|
| CRR | Product Series | Inverter Corrugated Resistor |
| 2500W | Rated Power | 2500 Watts |
| 54.4R | Rated Resistance | 54.4 Ω |
| J | Resistance Tolerance | J = ±5% (Optional: K = ±10%, H = ±3%) |
| Parameter | Specification |
|---|---|
| Power Range | 50W--10kW |
| Operating Voltage | ≤1200V |
| Resistance Range | 0.01Ω--1kΩ |
| Resistance Tolerance | ±3%, ±5%, ±10% |
| Protection Rating | IP00 |
| Temperature Coefficient (TCR) | ≤300 ppm/°C |
| Flame Retardant Rating | UL 94V-2 |
| Compliance Standard | GB/T 5792 |
The resistor is built on a one-piece high-alumina ceramic core with a hollow air channel that promotes continuous airflow for efficient cooling. The ceramic structure withstands repeated high-temperature braking cycles without cracking, maintains excellent insulation performance, and effectively absorbs thermal shock during rapid energy dissipation.
The heating element is manufactured from high-resistivity Nickel-Chromium alloy ribbon, precision-stamped into a continuous corrugated profile. Compared with conventional round wire winding, the corrugated ribbon provides a larger heat dissipation area, higher current-carrying capacity, and more stable resistance under repeated start-stop braking conditions. The temperature coefficient remains below 300 ppm/°C.
The terminals, locking clamps, and mounting brackets are manufactured from thickened stainless steel with anti-corrosion passivation treatment. The assembly maintains secure mechanical fastening under continuous vibration, withstands repeated soldering heat, and minimizes contact resistance caused by oxidation, ensuring reliable operation in demanding inverter applications.
An environmentally friendly inorganic insulating coating provides excellent resistance to high temperatures, corrosion, moisture, and dust. During short-term overload conditions, the resistor may glow red without producing open flames, helping improve operational safety while extending the service life of the alloy ribbon in industrial environments.
Specifically designed for VFD braking applications, the resistor rapidly dissipates regenerative energy generated during motor deceleration, effectively preventing DC bus voltage rise and eliminating inverter overvoltage (OV) alarms.
The vertically wound corrugated alloy ribbon provides a significantly larger cooling surface than conventional wirewound resistors. Combined with the hollow ceramic core, it delivers efficient heat transfer, lower operating temperatures, and stable performance during frequent start-stop braking cycles.
Designed to withstand 10 times the rated power for up to 5 seconds, the resistor easily handles the high-energy pulses generated during emergency stops, heavy-load lowering, and rapid motor deceleration without visible damage.
Constructed with high-alumina ceramic, heavy-duty stainless steel hardware, and a UL94V-2 flame-retardant coating, the resistor offers excellent resistance to vibration, corrosion, dust, moisture, and repeated thermal cycling, ensuring long-term reliability in demanding industrial applications.
The reinforced stainless steel mounting assembly maintains secure electrical connections even under continuous vibration, making the resistor ideal for cranes, rolling mills, elevators, and other heavy-duty inverter-driven equipment.
Available with resistance tolerances of ±3%, ±5%, and ±10%, the CRR Series covers power ratings from 50W to 10kW and supports custom resistance values, dimensions, terminal styles, and mounting configurations to meet specific inverter requirements.
The inorganic insulating coating is flame retardant, smoke-free, and compliant with UL94V-2 requirements. During overload conditions, the resistor glows red without producing open flames, helping improve operational safety.
Ideal for cranes, elevators, hoists, winches, and lifting platforms that require frequent acceleration and braking while maintaining stable inverter performance.
Suitable for rolling mills, injection molding machines, CNC equipment, wire drawing machines, textile machinery, and other processing equipment with repetitive braking cycles.
Widely used in conveyor systems, automated production lines, logistics equipment, and warehouse automation to absorb regenerative braking energy and improve system stability.
Recommended for motor testing systems, load simulation equipment, laboratory test benches, centrifuges, and other specialized industrial applications requiring reliable braking energy dissipation.
DUFEW specializes in the development and manufacturing of high-quality power electronic components, providing reliable products and integrated solutions for industrial users, distributors, and OEM customers.
Modern production facilities, standardized manufacturing processes, and strict quality control ensure stable electrical performance, consistent product quality, and dependable long-term operation.
In addition to inverter braking resistors, DUFEW offers a comprehensive range of power electronic products, including reactors, braking units, filters, transformers, load banks, and various industrial resistor solutions.
Customized resistance values, power ratings, dimensions, terminal configurations, and mounting options are available based on customer drawings or technical specifications.
With efficient production management and experienced engineering support, DUFEW provides stable lead times, rapid technical assistance, and professional product selection services for global customers.
| Characteristic | Test Conditions | Performance |
|---|---|---|
| Dielectric Withstand Voltage | 2500VAC / 50Hz / 60s | Leakage Current ≤10mA |
| Insulation Resistance | 1000VDC | ≥100MΩ |
| Short-Time Overload | 10× Rated Power for 5 Seconds | No Visible Damage |
| Load Life | Cyclic Operation (10s ON / 90s OFF) | ＞9,000 Hours |
| Damp Heat Resistance | 40°C ±2°C, 90--95% RH, 100 Hours | ΔR ≤ ±(1%R + 0.05Ω) |
| Rapid Temperature Cycling | -55°C / 55°C / 155°C, 15 Minutes Each, 5 Cycles | ΔR ≤ ±(2%R + 0.05Ω) |
| Heat Resistance | 350°C for 2 Hours | No Visible Discoloration or Damage |
| Temperature Coefficient | Rated Load vs. Initial Resistance | ＜300 ppm/°C |
| Flame Resistance | 10× Rated Power for 5 Minutes | Glows Red Without Open Flame |
| Characteristic | Test Conditions | Performance |
|---|---|---|
| Terminal Strength | 45N / 30 Seconds | No Loosening or Visible Damage |
| Vibration Resistance | 5--200Hz, 1g, 98m/s² | No Visible Structural Damage |
| Resistance to Soldering Heat | Terminals Immersed in 350±5°C Solder for 3 Seconds | ΔR ≤ ±(1%R + 0.05Ω) |
| Solderability | Terminals Immersed in 235±5°C Solder for 5 Seconds | Solder Coverage ≥95% |
Note: All performance data are obtained under standard laboratory test conditions in accordance with GB/T 5792 to ensure consistent quality and reliable product performance.
| Comparison Item | DUFEW Inverter Corrugated Resistor | General Purpose Power Resistor |
|---|---|---|
| Primary Application | Designed specifically for VFD dynamic braking and regenerative energy dissipation | Designed for continuous power dissipation and general-purpose electrical circuits |
| Operating Duty | Short-time, high-energy pulse operation with intermittent duty cycles | Continuous or steady-state operation |
| Selection Method | Resistance selected according to inverter specifications; power rating calculated based on braking duty cycle | Selected according to continuous power dissipation requirements |
| Overload Capability | Withstands up to 10× rated power for 5 seconds, ideal for regenerative braking | Limited overload capability; not suitable for repeated high-energy pulses |
| Heat Dissipation | Corrugated ribbon structure provides a large cooling surface for efficient heat transfer | Conventional winding offers limited cooling efficiency |
| Operating Temperature | Surface temperature up to 300°C with 350°C heat-resistant coating | Typically below 200°C depending on resistor type |
| Voltage Spike Suppression | Corrugated winding helps reduce switching voltage spikes and improves inverter stability | No optimization for voltage spike suppression |
| Mechanical Reliability | Stainless steel terminals and brackets provide excellent vibration resistance for heavy-duty industrial equipment | Standard construction intended for general electrical applications |
| Typical Applications | Elevators, cranes, rolling mills, servo systems, injection molding machines, conveyors | General electronic equipment, power supplies, lighting circuits, and industrial control systems |
A: An inverter braking resistor is specifically designed to absorb regenerative energy generated during motor deceleration. Unlike standard power resistors, it operates under short-duration, high-energy pulse conditions and is optimized for intermittent braking duty rather than continuous power dissipation.
A: The resistance value should follow the inverter manufacturer's recommended specification, while the power rating should be selected according to the braking frequency, braking time, duty cycle, and motor power. If you are unsure, DUFEW's engineering team can recommend the appropriate model based on your application.
A: It is generally not recommended. Different inverters may have different braking voltages and operating sequences. Sharing a resistor may result in unstable operation or insufficient braking performance. If a shared resistor is required, both the resistance value and power rating must be carefully calculated.
A: Yes. We provide OEM and ODM manufacturing services, including customized resistance values, power ratings, dimensions, terminal styles, mounting brackets, and complete solutions based on customer drawings or technical specifications.
A: It is designed for standard VFD braking applications where high overload capability and efficient heat dissipation are the primary requirements. A Non-Inductive Corrugated Resistor is recommended for high-frequency PWM circuits, energy storage systems, and applications where extremely low inductance is critical.
A: Inverter braking resistors are widely used in elevators, cranes, hoists, rolling mills, injection molding machines, conveyors, textile machinery, automated production lines, servo drive systems, and renewable energy equipment.
DUFEW provides high-quality Inverter Corrugated Resistors for industrial automation, renewable energy, and motor drive applications worldwide. Whether you require a standard product or a fully customized solution, our engineering team is ready to support your project with professional recommendations and fast production.
- OEM & ODM Manufacturing
- Customized Resistance Values
- Custom Power Ratings (50W--10kW)
- Custom Dimensions & Mounting Options
- Technical Selection Support
- Stable Bulk Production
- Fast Global Delivery
Contact DUFEW today to discuss your application or request a competitive quotation.
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