Resistors are rated by the value of their resistance and the electrical power given in watts, (W) that they can safely dissipate based mainly upon their size. Every resistor has a maximum power rating which is determined by its physical size as generally, the greater its surface area the more power it can dissipate safely into the ambient air or into a heatsink. The power rating of MVR series up to 50W with heat sink. TO-220 and TO-247 resistors are rated 30 watts to 140 watts with heat sinks.
A resistor can be used at any combination of voltage (within reason) and current so long as its “Dissipating Power Rating” is not exceeded with the resistor power rating indicating how much power the resistor can convert into heat or absorb without any damage to itself. The Resistor Power Rating is sometimes called the Resistors Wattage Rating and is defined as the amount of heat that a resistive element can dissipate for an indefinite period of time without degrading its performance.
The power rating of resistors can vary a lot from less than one tenth of a watt to many hundreds of watts depending upon its size, construction and ambient operating temperature. Most resistors have their maximum resistive power rating given for an ambient temperature of +70℃ or below. The power rating of Micrhom Electronics' MELF resistor ranges from 0.2 watt to 3 watts, while the ones of Nual series ranges from 5 watts to 300 watts.
As the dissipated resistor power rating is linked to their physical size, a 1/4 (0.250)W resistor is physically smaller than a 1W resistor, and resistors that are of the same ohmic value are also available in different power or wattage ratings. Carbon resistors, for example, are commonly made in wattage ratings of 1/8 W, 1/4 W, 1/2 W, 1W, and 2 Watts.
Generally speaking the larger their physical size the higher its wattage rating. However, it is always better to select a particular size resistor that is capable of dissipating two or more times the calculated power. When resistors with higher wattage ratings are required, wirewound resistors are generally used to dissipate the excessive heat.
