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Hongyi Electronics
Resistors for Rail & Transit
Traction · Braking · Filter · Earthing · EN 50155 / EN 45545

Resistors for Rail & Transit

Rolling-stock and traction substations rely on heavy-duty resistors at every energy-conversion stage: dynamic braking grids dissipate up to 4 MW per car during regenerative-blending failures, line filters smooth the DC catenary, earthing resistors set a defined fault-current path, and harmonic filters compensate the 16⅔ Hz / 50 Hz traction transformer. Components must satisfy EN 50155 (electronic equipment), EN 50124 (insulation coordination), EN 50121-3-2 (EMC) and the fire & smoke standard EN 45545-2 HL2/HL3 with halogen-free materials. Mechanical shock and vibration follow EN 61373 Category 1 Class B. Hongyi supplies edge-wound stainless and FeCrAl grid resistors, IP54-enclosed cement and aluminum-housed designs, with 30-year service-life dossiers for OEMs like CRRC, Alstom and Siemens Mobility.

Key Requirements

Key Requirements

  • EN 50155 electronic equipment compliance (temp, EMC, supply variation)
  • EN 45545-2 HL3 fire & smoke with halogen-free, low-toxicity materials
  • EN 61373 Cat 1 Cl B shock 5 g / vibration 0.1–150 Hz
  • Braking grid pulse 4 MW for 30 s, continuous 200 kW per car
  • 30-year design life with replaceable element modules
How to Select

How to Select

  1. Match the braking-grid resistance to motor EMF / DC-link voltage profile (typically 0.5–5 Ω)
  2. Confirm HL3 oxygen index (LOI ≥ 32) and smoke density (Ds ≤ 300)
  3. Specify natural-convection cooling for under-car installation; forced air for roof-top
  4. Validate insulation 2.5 kV AC + Um per EN 50124-1 OV4 / PD3
  5. Demand type-test certificate from accredited lab (TÜV / Lloyd's / CNAS)
Recommended Products

Recommended Products

Wirewound Resistors
Wirewound Resistor

Wirewound Resistors

High-precision, low-noise wirewound resistors for measurement and current sampling

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Cement Resistors
Cement Resistor

Cement Resistors

Cost-effective power-sampling and current-limiting resistors with vertical / horizontal mounting

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High-Voltage Resistors
High Voltage Resistor

High-Voltage Resistors

Professional resistors for high-voltage pulse, discharge, X-ray and HV measurement

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Resistor Boxes
Resistor Box / Cabinet

Resistor Boxes

Integrated resistor cabinet solutions for industrial braking and energy dissipation

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Related Applications

Related Applications

Dynamic Brake · Auxiliary Converter · Earth-Fault · EN 50155 Compliant

Resistors for Rail Traction & Electric Trains

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Dynamic Braking · Regen Energy Dissipation · IEC 60322 Compliant

Braking Resistors for VFDs / AC Drives

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Regenerative Energy Dissipation · EN 81-20 · IEC 60204-32

Braking Resistors for Elevators & Cranes

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Aluminum housed, cement and wirewound resistors side by side — Hongyi Electronics

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Frequently asked questions

Are your rail braking resistors EN 45545-2 HL3 certified?
Yes. Our edge-wound stainless and FeCrAl grid families have been tested by TÜV Süd to HL3 requirement set R26 (electronics) including ISO 5660-1 cone calorimeter, ISO 5659-2 smoke density and NF X70-100 toxicity. Insulators use silicone-free ceramic / mica boards; cabling and connectors are halogen-free per IEC 60754. Certificates are available for inspection during type-test.
Can you supply a complete dynamic-braking resistor cabinet for a 25 kV AC EMU?
Yes. We deliver fully assembled IP54 / IP65 cabinets with edge-wound stainless grids, blower (or natural-convection), PT100 thermal sensors, contactor and rupture disc. Typical cabinet ratings: continuous 1.2 MW, peak 4 MW for 30 s, working voltage 3.6 kV DC. Cabinets ship with type-test report, FAT protocol, EC declaration and 30-year service-interval plan. CRRC and Alstom approved drawings are on file.
How do you handle vibration and shock testing for under-car installation?
Under-car resistors are tested to EN 61373 Category 1 Class B: 5 hours sinusoidal sweep 5–150 Hz with 0.1 g² /Hz PSD, plus 5 g shock 30 ms half-sine in all 6 directions. Post-test we verify resistance shift < 1%, insulation > 100 MΩ at 1 kV, and no mechanical cracks via dye penetrant. Test reports are accepted by CRRC, Stadler and Hitachi Rail acceptance committees.
What is the expected service life of your braking grid resistors?
Design life is 30 years / 1.5 million braking cycles based on a typical metro duty profile (100 cycles per day, 30 s peak followed by 5 min cooling). The grid element itself can be exchanged in the depot after 15 years if duty doubles; insulators and frame are sized for the full 30 years. We provide an in-service inspection checklist and oxide-layer photo reference for visual condition-based maintenance.
Sample Request

Sample Request

Standard samples are provided free of charge in reasonable quantities (shipped within 2–3 business days). Custom samples are delivered within 2–4 weeks. Please use the form on the right to tell us:

  • Company and contact details
  • Target part number or key specs (power / resistance / package)
  • Application scenario and estimated annual volume
  • Shipping address and expected delivery date
📧 You can also email us directly at [email protected] / 13650089870
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Online Inquiry

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