Increasing resistor reliability: essential maintenance tips

From railways to renewable energy and marine applications, resistors are essential components of many electrical and mechanical systems. However, failing to maintain your resistors can threaten their reliability, leading to reduced functionality and potential safety issues. So, what can be done to extend resistor lifespan and ensure optimal performance?

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Resistor technology is constantly evolving. Innovation in materials and design has led to improved performance and new industry applications. Without these advancements, many renewable technologies needed to meet net-zero targets would be unviable. Dynamic braking resistors (DBRs), for example, protect battery electric vehicle engines with regenerative braking systems and support energy output in renewable applications like tidal power and wind turbines.

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The impact of damaged resistors ?

Damaged resistors can put a strain on the entire system, risking decreased efficiency and reduced lifespan for both the resistor and other components. A damaged resistor may experience a reduction in its stated resistance value, taking it beyond the specified tolerance range. This can result in voltage spikes and even complete circuit failure, especially in high-voltage applications, leading to serious safety hazards.

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Keeping dry: moisture management ??

According to HSB, moisture is responsible for 17.4 per cent of electrical failures, making it the second biggest cause after loose connections. This presents a particular challenge in tidal and maritime applications where chlorides in seawater can corrode resistors. Selecting the right material, such as 316-grade stainless steel, which offers better resistance to chlorides, is essential. Additionally, using electrical enclosures with appropriate IP ratings can help protect against moisture exposure.

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Handling the heat: overheating prevention???

When resistors become coated in dust or dirt, their ability to dissipate heat effectively is compromised, leading to overheating. Overheating can damage internal components and presents a fire risk. To prevent this, ensure the resistor's cooling system is up to scratch. Water cooling and convection cooling are effective methods, with water cooling being particularly efficient for high continuous power requirements.

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The importance of proactive maintenance ??

Proactive maintenance is crucial in extending resistor lifespan. Regular inspections allow for early detection of moisture, dust, or dirt, and help mitigate risks to performance. Maintenance routines should include removing accumulated particulates using suitable cleaning methods and continuously monitoring the operating environment and temperature to ensure protection measures are effective.

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Cressall's complementary maintenance service?

Cressall offers a complementary maintenance service with the purchase of all its off-the-shelf and custom resistors. This service extends the working life of resistors and helps avoid the financial and time investment of recommissioning, designing, and delivering replacements. Ensuring regular maintenance not only enhances performance but also safeguards the safety and functionality of the entire system.

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Ignoring the need to maintain resistors can worsen their performance and affect the safety and functionality of the entire system. By putting the right systems in place and undertaking regular proactive maintenance, you can ensure that your resistors work effectively now and well into the future.

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To learn more about Cressall's resistor maintenance service, visit our website.