www.megaresistors.

com
CUS TOMIZ A BLE

$
EFFICIENT

HIGH QUALITY
 CO NT E N T S

2 Our Philosophy
What We Do

3 Product Overview

4 Neutral Grounding

5 High Resistance

6 Low Resistance

8 Dynamic Braking

10 Motor Control

 11 Harmonic Filter

12 Custom Products
Discharge Resistors
Neutral Grounding Cabinets
Custom Assemblies

13 Standards

www.megaresistors.com / 905.908.2376 1
OUR PHILOSOPHY WHAT WE DO

Our mission is to become a driving force of We build resistors.

innovation and quality in the global market for
Resistors fulfill a variety of important power system
power resistors. MegaResistors is fully committed to
needs in all industries, from preventing electrical
achieving sustainable growth for all stakeholders,
hazards and downtime due to ground faults in
including customers, employees, and society
factories, mines and hospitals to dissipating excess
in general.
energy in electrical machinery and even filtering out
Accountability is important to us, we use a certified electrical frequencies that can be harmful to wildlife.
quality management system, along with national They are an essential component to electrical safety
and international standards for every product and operation.
we design and manufacture. Our products are
Call us, visit our website, or email us to learn more
designed, verified and validated through rigorous
and see how we can satisfy your electrical resistance
inspection and testing. We know that our products
requirements.
are deployed to prevent loss of life, serious injury,
capital loss, and to help you meet statutory
requirements and workplace efficiency needs. 905.908.2376
Efficiency, reliability and quality are at the core of
our product design and production. We strive to
905.908.2377
make it easy for you to configure and to order
the product you need through quote forms,
direct email, phone and faxing. sales@megaresistors.com

www.megaresistors.com

2 www.megaresistors.com / 905.908.2376
 PRODUCT OVERVIEW

PRODUCT OVERVIEW
NEUTRAL GROUNDING
We manufacture standard and
custom made power resistors.
In the industry these types of
resistors are commonly referred to
with various names that describe
the application rather than the
resistor itself such as Neutral HIGH RESISTANCE
Grounding Resistor, Dynamic
Braking Resistor, Motor Control
Resistor etc.

PRODUC T OVERVIEW
CUSTOMIZABLE

EFFICIENT DYNAMIC BRAKING

HIGH QUALITY

MOTOR CONTROL

HARMONIC FILTER

www.megaresistors.com / 905.908.2376 3
 NEUTRAL GROUNDING

NEUTRAL GROUNDING
Also known as Neutral Earthing
NEUTR AL GROUNDING

The purpose of a NEUTRAL GROUNDING RESISTOR Advantages

is to limit the ground fault current to a safe level so that
✔ Reduced operation and maintenance expenses.
all the electrical equipment in the power system is
✔ Fast isolation of the original fault.
protected. The resistor should be the only current path
between the neutral of power transformers or power ✔ Reduced transient overvoltages.
generators and ground. ✔ Reduced physical damage on the equipment at fault.
When the neutral of a system is not grounded it is possible ✔ Simplification of ground fault location.
for destructive transient overvoltages to appear from line
✔ Increased life and protection of transformers,
to ground during normal switching of a circuit having a generators and related equipment.
line-to-ground fault. Experience has proved that these
✔ Reduced frequency of faults.
overvoltages cause aging and failure of insulation at
locations on the system other than at the point of fault. ✔ Improved service reliability.
In this way, a relatively unimportant line-to-ground fault ✔ Increased protection in the use of lightning arresters.
on one circuit may result in considerable damage to
✔ Increased safety for personnel.
equipment and interruption of service on other circuits,
not to mention the increased difficulty in finding the
original location of the problem.

A neutral grounding resistor is designed to limit the ground CUSTOMIZABLE

fault current to a safe value while at the same time letting
EFFICIENT
enough current to flow to operate the protective relays that
will alarm or clear the fault. While the disturbance lasts the HIGH QUALITY
resistor must be capable of absorbing and dissipating the
energy generated without exceeding the temperature limits
established by international standards. In this way the fault
is safely limited, isolated, and the power system is protected
against overvoltages.

4 www.megaresistors.com / 905.908.2376
 NEUTRAL GROUNDING

HIGH RESISTANCE HIGH RESISTANCE GROUNDING RESISTORS are

recommended for installations that require continuous
service even after a phase ground fault occurs.

A phase to ground fault will not cause a large current to

flow and will not trip the breakers because the neutral
grounding resistor will limit the current to a very low value,
typically 5 Amps.

For added security it is required that a suitable ground

detection device, or ground fault relay, be used to indicate
the presence of a ground fault.

Pulsing devices can be used with high resistance systems

to reduce the time required to find and remove the
ground fault.

Second ground fault protection will only trip the low priority
feeders in the case of a second ground fault allowing the rest

NEUTR AL GROUNDING
of the installation to continue uninterrupted.

This type of Neutral Grounding Resistor should limit the

fault to a value greater than the capacitive charging current
of the system to avoid overvoltages caused by intermittent
faults. While the disturbance lasts the resistor must be
capable of absorbing and dissipating the energy generated
without exceeding the temperature limits established by
national and international standards.

Optional Features
✔ Pulsing
✔ Zig-zag transformer
✔ Resistor monitoring
Advantages ✔ Second ground fault protection
✔ Continuous operation even with a phase to ground fault ✔ Network communications
✔ Reduced transient overvoltages ✔ Touchscreen operator panel

✔ Reduced physical damage on the equipment at fault ✔ Buzzer

✔ Increased life and protection of transformers, ✔ Meters and indicating lights

generators and related equipment ✔ Events Storage
✔ Reduced occurrence of faults
✔ Improved service reliability Accessories
✔ Increased safety for personnel Flexible Current Probes

www.megaresistors.com / 905.908.2376 5
 NEUTRAL GROUNDING

LOW RESISTANCE Features

• Up to 5,000 amperes and up to 115,000 volts line to neutral.

• Stainless steel nuts and bolts.

• S tainless steel and tin plated copper connectors and internal

connections for positive contact and reduced oxidation.

• Indoor or indoor-outdoor service with ventilated or

non-ventilated top and sides.

• Removable top or side covers and optional side or front doors.

• S olid or perforated bottom for protection against the entrance

of rodents, birds or accidental contact by personnel.

• High-temperature mica, porcelain and synthetic insulators.

• O
 ptional entrance and exit bushings located according to
customer’s needs.

• O
 ptional current transformers, voltage transformers and
NEUTR AL GROUNDING

relays for fault detection, mounted inside the enclosure with

optional external terminal box.

• Optional enclosure heaters, thermostats and temperature relays.

• M
 anual, test report and optional CSA code special inspection
and blue label.

• O
 ptional aluminum, stainless steel and lamacoid nameplates
and tags.

• 24 month guarantee.

Optional Features
Resistive Elements Enclosures Enclosure Materials Enclosure Mounting
Wirewound NEMA 1 Galvanized Steel **
Floor-mounting**
Edgewound NEMA 3R** Stainless Steel Wall-mounting
Stamped Grid NEMA 4 Anodized Aluminum **
Standard Models
NEMA 4X

Enclosure Features Transformers Bushings Other Features

Door with Lock Current Transformer Top Neutral Special Colors
Tamperproofing Voltage Transformer Side Neutral High Altitude
Seismic Zone Special Bracing Zigzag Transformer Top Ground Forced Cooling
Tower or Trailer Mounting Step/Down Transformer Side Ground Multiple Taps

Protection Relays Sensor resistor Heater Disconnect

Used to alarm or trip in Allows the protective relay Used in humid environments Turn off the resistive circuit
the case of a ground fault. to determine if the resistor to prevent condensation of at any time.
has failed. water into the system.

6 www.megaresistors.com / 905.908.2376
 NEUTRAL GROUNDING

Standard Models
Initial Time
Temp. Rise Type Dimensions (in) Dimensions (mm)
Current, A Rating

277 V 25 10 seconds 760°C 60-3001 22”x 22”x 13” 559 x 559 x 330 mm
50 10 seconds 760°C 60-3002 22”x 22”x 13” 559 x 559 x 330 mm
200 10 seconds 760°C 60-4002 22”x 22”x 13” 559 x 559 x 330 mm
5 Continuous 375°C 60-3006 22”x 22”x 13” 559 x 559 x 330 mm
10 Continuous 375°C 60-3008 22”x 22”x 13” 559 x 559 x 330 mm

347 V 25 10 seconds 760°C 60-3001 22”x 22”x 13” 559 x 559 x 330 mm
50 10 seconds 760°C 60-3002 22”x 22”x 13” 559 x 559 x 330 mm
100 10 seconds 760°C 60-3004 22”x 22”x 13” 559 x 559 x 330 mm
200 10 seconds 760°C 60-4003 22”x 22”x 13” 559 x 559 x 330 mm
5 Continuous 375°C 60-3008 22”x 22”x 13” 559 x 559 x 330 mm
10 Continuous 375°C 60-3010 22”x 22”x 13” 559 x 559 x 330 mm

1390 V 50 10 seconds 760°C 61-3006 45”x 50”x 23.5” 1143 x 1270 x 597 mm

NEUTR AL GROUNDING
100 10 seconds 760°C 61-3012 45”x 50”x 23.5” 1143 x 1270 x 597 mm
200 10 seconds 760°C 61-4005 45”x 50”x 23.5” 1143 x 1270 x 597 mm
400 10 seconds 760°C 61-4007 45”x 50”x 23.5” 1143 x 1270 x 597 mm
5 Continuous 375°C 61-3032 45”x 50”x 38.75” 1143 x 1270 x 984 mm
10 Continuous 375°C 61-3040 45”x 50”x 38.75” 1143 x 1270 x 984 mm

2400 V 25 10 seconds 760°C 62-3008 45”x 37”x 23.5” 1143 x 940 x 597 mm
50 10 seconds 760°C 62-3010 45”x 37”x 23.5” 1143 x 940 x 597 mm
100 10 seconds 760°C 62-3020 45”x 37”x 38.75” 1143 x 940 x 984 mm
200 10 seconds 760°C 62-4010 45”x 37”x 38.75” 1143 x 940 x 984 mm
400 10 seconds 760°C 62-4013 45”x 37”x 38.75” 1143 x 940 x 984 mm
5 Continuous 375°C 62-3056 45”x 37”x 38.75” 1143 x 940 x 984 mm
10 Continuous 375°C 62-3069 50”x 45”x 38.75” 1270 x 1143 x 984 mm
25 Continuous 375°C 62-4038 62”x 45”x 50.5” 1574 x 1143 x 1282 mm

4160 V 25 10 seconds 760°C 63-3013 45”x 37”x 38.75” 1143 x 940 x 984 mm
50 10 seconds 760°C 63-3018 45”x 37”x 38.75” 1143 x 940 x 984 mm
100 10 seconds 760°C 63-3036 45”x 37”x 38.75” 1143 x 940 x 984 mm
200 10 seconds 760°C 63-4015 50”x 45”x 38.75” 1270 x 940 x 984 mm
400 10 seconds 760°C 63-4020 50”x 45”x 38.75” 1270 x 940 x 984 mm
5 Continuous 375°C 63-3096 45”x 37”x 72” 1143 x 940 x 1823 mm
10 Continuous 375°C 63-3119 50”x 45”x 72” 1270 x 1143 x 1823 mm

8000 V 25 10 seconds 760°C 64-3025 45”x 37”x 38.75” 1143 x 940 x 984 mm
50 10 seconds 760°C 64-3036 50”x 37”x 38.75” 1270 x 940 x 984 mm
100 10 seconds 760°C 64-3069 50”x 37”x 38.75” 1270 x 940 x 984 mm
200 10 seconds 760°C 64-4029 50”x 45”x 72” 1270 x 1143 x 1823 mm
400 10 seconds 760°C 64-4038 50”x 45”x 72” 1270 x 1143 x 1823 mm
5 Continuous 375°C 64-3186 76”x 56”x 59” 1930 x 1522 x 1499 mm
10 Continuous 375°C 64-3228 81”x 61”x 73.5” 2058 x 1549 x 1867 mm

www.megaresistors.com / 905.908.2376 7
 DYNAMIC BRAKING

DYNAMIC BRAKING RESISTOR

The purpose of a DYNAMIC BRAKING RESISTOR is to slow Advantages

DY N A M I C B R A K I N G

down or to quickly stop a motor by draining excess voltage

✔ Faster braking of DC and AC motors.
and keeping it within safe tolerances. This can help to lower
the wear and tear of friction braking components, enable ✔ Lower wear and tear of friction braking components.

faster braking and eliminate the risk of a runaway due to ✔ Keep motor voltages within safe levels.
overheating. ✔ E liminate risk of a runaway due to overheated friction
When removed from a power supply, most DC motors will brakes in some motors.

act as electrical generators due to their permanent magnets. ✔ Reduce wasted time during braking.
If a resistor is then connected as a load, the energy produced ✔ Increase life of the equipment.
by the rotational inertia of the DC motor will be dissipated
✔ Improved service reliability.
by the resistor slowing down the motor. While AC motors
do not have permanent magnets in their rotors, they do have ✔ Designed to absorb thermal expansions and contractions.
an induced magnetic field created by the rotating magnetic
field in the stator. The energy lost in the stator will backfeed
into the variable frequency drive (VFD), which will rise the
voltage on the DC bus in the VFD. The greater the difference
CUSTOMIZABLE
between the output of the VFD and the rotor’s actual speed, EFFICIENT
the more energy will be fed into the VFD. If the VFD tries to
brake the motor too quickly, the voltage will rise too much HIGH QUALITY
and damage the VFD. Most VFDs will shut down as a safety
feature before this happens, and the motor will coast to
a stop by friction alone. With appropriately sized braking
resistors the motor can be stopped much more quickly
without raising the voltage to unsafe levels.

Braking resistors with smaller ohmic values will help motors

stop faster but will also dissipate more heat. This will require
the use of more mass in the resistor or a heat sink to keep
its temperature within a safe limit.

8 www.megaresistors.com / 905.908.2376
 DYNAMIC BRAKING

Features
• Terminal block normally closed thermal switch.

• Stainless steel nuts and bolts.

• Stainless steel and tin plated copper connectors and internal

connections for positive contact and reduced oxidation.

• Optional outdoor service with removable covers and ventilated

bottom screen for protection against the entrance of rodents,
birds or accidental contact by personnel.

• High-temperature mica, porcelain and synthetic insulators.

• Rated, designed, manufactured and tested according to

national and international standards.

Optional Features
Resistive Elements Enclosure Materials

DY N A M I C B R A K I N G
Wirewound Galvanized Steel**
Edgewound Stainless Steel
Stamped Grid Anodized Aluminum

Enclosures Enclosure Features

NEMA 1 ** Drip Hood
NEMA 3R Elevating Stand
NEMA 4
Optional Features
NEMA 4X
Normally open thermal switch
**
Standard Models Forced cooling

Standard Models
Type Power Dimensions (in) Dimensions (mm)
DB 2 0.1-0.8 KW 15” x 8” x 5.25” 381 x 203 x 133 mm
DB 4 0.8-1.6 KW 15” x 14” x 5.25” 381 x 356 x 133 mm
DB 8 1.6-4 KW 22” x 14” x 5.25” 559 x 356 x 133 mm
DB 16 4-8 KW 20” x 18” x 8.25” 508 x 457 x 210 mm
DB 24 8-12 KW 20” x 24” x 8.25” 508 x 610 x 210 mm
DB 18-2 12-18 KW 34.5” x 21.6” x 15” 876 x 549 x 383 mm
DB 18-3 18-27 KW 34.5” x 21.6” x 22.5” 876 x 549 x 574 mm
DB 18-4 27-36 KW 34.5” x 21.6” x 30” 876 x 549 x 762 mm
DB 18-5 36-45 KW 34.5” x 21.6” x 37.5” 876 x 549 x 953 mm
DB 18-6 45-54 KW 34.5” x 21.6” x 45” 876 x 549 x 1143 mm

www.megaresistors.com / 905.908.2376 9
 MOTOR CONTROL

MOTOR CONTROL
MOTOR CONTROL RESISTORS are used to control the
torque and speed of AC and DC motors, by limiting in-rush
current. To avoid confusion it should be noted that these
resistors are used to control power input into motors
while Dynamic Braking Resistors are used to brake and
drain energy.

These resistors are commonly used with wound-rotor motors

as an external resistor circuit. Conductors in the rotor are
connected to slip rings, these slip rings provide the contact
to the resistor circuit. By changing the level of resistance
in the circuit speed and torque can be adjusted. In other
words, higher resistance means reduced torque and speed.

For multiple levels of torque and speed control, Motor

Control Resistors use “steps” or “speeds”. Steps/speeds
MOTOR CONTROL

essentially provide intervals for levels of resistance. For most

applications, a 4-step/ 5-speed Motor Control Resistor is
recommended. 1-step/ 2-speed resistors are available, all the
way up to 10-step/11-speed. In general we recommend that Features
you use a higher number of steps if the motor is powerful • Very wide range of power and resistance ratings.
and used for large-scale purposes. Usually there will always
• Stainless steel bolts and nuts.
be one more speed level than resistor steps, because
the maximum speed is achieved with all steps cut out; • R
 ating, design, manufacturing and testing according to
national and international standards.
exceptions occur when a permanent slip resistor is required
to reduce internal heating of the motor. • 24 month guarantee.

To enable manufacturers to test resistors under the same

conditions, NEMA has defined resistor classes based on Optional Features
duty and the type of application. We use these classes
Resistive Elements Enclosure Materials
to conform to standards and making it easier for you to
Wirewound Galvanized Steel**
order your product. You can refer to the NEMA Resistor
Edgewound Stainless Steel
Applications and then the NEMA Resistor Classes to
configure the resistor required for your motor. Stamped Grid Anodized Aluminum

Enclosures
Advantages NEMA 1**
✔ Limit torque and speed of wound rotor motors to safe levels. NEMA 3R

✔ Keep motor voltages within safe levels. **

Standard Models

✔ Reduce overheating.

✔ Reduce wasted time during braking.

✔ Increase life of the equipment.

✔ Improved service reliability.

10 www.megaresistors.com / 905.908.2376
 HARMONIC FILTER

HARMONIC FILTER
HARMONIC FILTER RESISTORS are often used, in
combination with inductors and capacitors, as harmonic
frequency filters.

The purpose of these filters is to reduce distortions in

power systems, produced by non linear loads such as arc
welders, induction furnaces, variable frequency drives,
ballasts, computer equipment, phones, uninterruptible
power supplies etc., which can cause failure of motors,
transformers and switchgear through insulation breakdown,
arcing and overheating.

In a normal AC power system, supply voltage varies

sinusoidally with a fundamental frequency of 50 or 60 hertz.
When linear loads, such as resistive heaters, incandescent
lamps, constant speed induction and synchronous motors,

H A R M O N I C F I LT E R
are connected to the system, sinusoidal currents will be
drawn from the system at the same frequency as the
voltage. However when non-linear loads are connected,
a series of sinusoidal currents, called harmonics, will be Advantages
drawn at integer multiples of the fundamental frequency. ✔ Reduced neutral currents and resonance.
Many industrial and commercial electrical systems have ✔ Improved voltage stability.
capacitors installed to offset the effect of low power factor.
✔ Reduced system losses.
Most capacitors are designed to operate at a maximum of
110% of rated voltage and at 135% of their kvar ratings. ✔ Improved system reliability.

Since capacitive reactance is inversely proportional to

frequency, harmonic currents may result in capacitor banks Optional Features
overload and failure.
Resistive Elements Enclosure Materials
Wirewound Galvanized Steel**
Features
Edgewound Stainless Steel
• Very wide range of power and resistance ratings. Stamped Grid Anodized Aluminum
• Stainless steel nuts and bolts.
Enclosures Enclosure Features
• Designed for three-phase stacked or side by side installation.
NEMA 1 ** Drip Hood
• Continuous wirewound, edgewound and stamped corrosion NEMA 3R Elevating Stand
resistant elements selected to meet power rating,
inductance limits and voltage requirements0 **
Standard Models
Bushings
• Low coefficient of change in resistance with changes in Top Neutral
operating temperature
Side Neutral
• High-temperature, porcelain or synthetic insulators selected Top Ground
to meet special creepage and clearance requirements .

• Conductive parts connected to a defined potentials.

www.megaresistors.com / 905.908.2376 11
 CUSTOM PRODUCTS

DISCHARGE RESISTORS
Also known as Bleeder Resistors
DISCHARGE RESISTORS are placed in parallel with high-
voltage supplies to discharge an electric charge stored in
a capacitor or battery. This is done whenever the equipment
containing the capacitor or battery may need to be serviced
or repaired.

A discharge resistor may be either switched across the

capacitor for rapid discharge without quiescent dissipation,
or permanently connected for high reliability and low cost.
In the latter case there is a tradeoff between the time to
reach safe discharge and the quiescent power loss.

Advantages
DISCHARGE RESISTORS

✔ Faster discharge of capacitors and batteries.

✔ Personnel safety.

✔ Easier equipment handling.

✔ More control over speed of discharge.

✔ Compliance with statutory regulations.

NEUTRAL GROUNDING CABINETS

We can supply custom made generator neutral grounding
cabinets including line side and neutral side single or multiple
enclosures with neutral grounding resistors, disconnects,
bus bars, neutral formation, current and voltage transformers,
step-down transformers, arresters and capacitors.

CUSTOM ASSEMBLIES
We can create custom assemblies to your specifications.
Including load banks and other products not listed in
our catalogue.

Please do not hesitate to contact us. We can help you

meet you unique resistance needs.

12 www.megaresistors.com / 905.908.2376
 STANDARDS

All of our products are designed, built and tested according to the most recognized national and
international applicable standards.

International Organization for Standardization

The ISO develops and publishes international standards including the ISO 9001:2008 standard.

Our quality management system includes all of our fundamental processes and has been
developed according to the ISO 9001:2008 standard. It requires periodic review of the
quality management system and training and certification of our employees. It details
how we take your product requirements and turn them into products with consistent
and measurable quality, how we control our measurement of quality, how we deal with
nonconformances etc.

National Electrical Manufacturers Association

NEMA provides a forum for the standardization of electrical equipment, enabling consumers
to select from a range of safe, effective, and compatible electrical products.

S TA N DA R D S
Canadian Standards Association
The Canadian Standards Association develops standards and installation codes in multiple
areas including management, construction, electrical, energy and the environment.
CSA offers global solutions for product testing and certification that help streamline access
to markets in North America and around the world.

Institute of Electrical and Electronics Engineers

The IEEE Standards Association (IEEE-SA) is a leading developer of global industry standards
in a broad-range of industries, including Power and Energy.

International Electro Technical Commission

The IEC is a world’s leading organization for the preparation and publication of International
Standards for all electrical, electronic and related technologies.

Underwriters Laboratories
UL is a global independent safety science company with more than a century of expertise
innovating safety solutions.

UL certifies, validates, tests, verifies, inspects, audits, advises, educates and collaborates to
establish standards that create level playing fields and work to develop new pathways for
the latest innovations.

www.megaresistors.com / 905.908.2376 13
 15-2430 Lucknow Drive, Mississauga
ON L5S 1V3 Canada

905.908.2376

905.908.2377

sales@megaresistors.com

www.megaresistors.com

Your best choice for power resistors

©2016 MegaResistors Corp.