MCS 2000W to 4000W Series Metal Clad Resistors

What are the MCS 2000W to 4000W Series Metal Clad Resistors?

The MCS 2000–4000 is a high-power wire-wound metal clad resistor housed in an extruded aluminium enclosure, engineered for applications that demand sustained high-power dissipation, robust mechanical construction, and a wide resistance range in a compact chassis-mount form factor. Available in four power ratings — 2000W, 2500W, 3000W, and 4000W (on heatsink) — the MCS series is one of the highest continuous-power metal clad resistors in the RMS range, making it the preferred choice where braking, load-dump, or pre-charge duty cycles impose sustained rather than purely pulsed thermal loads.

The resistance range of 0.1Ω to 9kΩ (inductive) is exceptionally broad, covering everything from low-impedance braking choppers and snubber circuits to high-impedance pre-charge and bleed resistor applications in EV charging infrastructure and industrial drives. A non-inductive winding option (0.1Ω to 4kΩ) is available for RF-sensitive circuits and fast-switching snubber applications where parasitic inductance must be minimised. Three tolerance classes — ±1%, ±5%, and ±10% — are offered, with a temperature coefficient not exceeding ±260ppm/°C.

The extruded aluminium housing provides both structural rigidity and an integral heatsink surface, bolting directly to a chassis panel or external heatsink to dissipate the high continuous thermal loads that 2kW–4kW operation generates. Dielectric withstanding voltage is rated at AC 2500V for 1 minute (5mA leakage), and insulation resistance is guaranteed at 100MΩ at 500Vdc — both significantly higher than standard industrial resistor requirements, reflecting the MCS's suitability for high-voltage DC bus and EV infrastructure environments. Heat resistance is verified at 180°C for 2 hours, confirming stability under prolonged thermal stress.

Braking & pre-charge application note: In motor drive and inverter systems, the MCS is connected across the DC bus through a braking chopper to absorb regenerative energy during deceleration, clamping bus voltage and protecting drive electronics from overvoltage faults. In EV charging and energy storage applications, the MCS's broad high-ohmic resistance range makes it equally suitable as a pre-charge or bleed resistor, safely controlling inrush current into large DC link capacitors before main contactor closure. Its sustained power rating — rather than pulse-only capability — means it can handle the longer charge cycles associated with high-capacity battery systems and stationary energy storage.

Model: MCS
Resistor type: High Power Braking
Description: Industrial
Power Rating:2kW-4kW
Resistance (Ω): 0.1~9k
Tolerance (%): ±1, ±5, ±10
TCR (ppm/C):

Model: IRH, IRV, ULH, ULV
Resistor type: Metal clad resistor
Description: UL/CE, aluminum housed, chassis mounted
Power Rating: 60W~500W
Resistance (Ω): 0.1~6.8k
Tolerance (%): ±0.5, ±1, ±2, ±5, ±10
TCR (ppm/C): 260 Max.

Model: LFH
Resistor type: Horizontal metal clad
Description: Industrial
Power Rating: 300W-2kW
Resistance (Ω): 0.1~7k
Tolerance (%): ±1, ±5, ±10
TCR (ppm/C):

Model: IRV, ULV, IRM, ULM600-1200
Resistor type: Metal clad resistor
Description: UL/CE, aluminum housed, chassis mounted
Power Rating: 600W-1.2kW
Resistance (Ω): 0.1~175
Tolerance (%): ±1, ±2, ±5, ±10
TCR (ppm/C): 260 Max.

Model: SFH/SFV
Resistor type: Metal clad resistor
Description: Industrial
Power Rating: 60W~200W
Resistance (Ω): 0.1~2.2k
Tolerance (%): ±1, ±5, ±10
TCR (ppm/C):