A new Algorithm for the Design of Metal Oxide

Varistor Surge Arresters

Nicolae Tarfulea Flaviu Mihai Frigura-Iliasa

Politehnica University Politehnica University
Power Systems Department Power Systems Department
Timisoara, Romania Timisoara, Romania
[email protected] [email protected]

Doru Vatau Petru Andea

Politehnica University Politehnica University
Power Systems Department Power Systems Department
Timisoara, Romania Timisoara, Romania
[email protected] [email protected]

Florin Balcu Amalia Corina Macarie

National Institute for Research and Development National Institute for Research and Development
in Electrochemistry and Condensed Matter in Electrochemistry and Condensed Matter
Timisoara, Romania Timisoara, Romania
[email protected] [email protected]

Abstract—Metal Oxide Varistors (also known as ZnO There is no algorithm generally accepted for the design of
varistors) are built in many types of overvoltage protection these varistors [3].
equipment, being one of the most common solution for surge
arresters. They have a higher non-linear dependence between This paper presents an original design solution which
voltage and current, and a relatively high heat adsorption proposes a 3 steps algorithm for integrating a dedicated varistor
capacity in case of normal overvoltage pulses. Their current is in a low voltage surge arrester.
mostly activated by temperature, so overheating can cause a
These steps are:
major damage. Researches could be carried out both for a new
material as well as for technical solutions for a new design of this 1-The electrical design;
piece of equipment, by studying heat extraction and transfer
inside a new varistor device. This paper propose a simple new 2-The thermal design;
device, used for low voltage applications, based on some 3-The compliance measurements.
supplementary brass masses added to the varistor, shaped as
cylinders. They act like heat pumps at the beginning and as
radiators at the end of the thermal process caused by a transitory II. ELECTRICAL DESIGN
overvoltage. A finite element model followed by some Electrical design is mandatory, in order to choose the
experimental measurements is also presented in order to confirm optimal height.
the new design, for permanent and transitory regimes.
This first part of the new algorithm for optimal surge
Keywords—Metal Oxide Varistors, Low Voltage, Design arresters design is an electrical estimation of the sensitivity for
Algorithm the chosen varistor. The opening voltage has to be close to the
lower overvoltage limit. When close to that parameter, we
I. INTRODUCTION notice a high risk of steady conduction, ending in a thermal
runaway [1].
Metal Oxide Varistors are successfully used for overvoltage
protection equipment at an industrial scale. The reference is the UMCOV voltage, which is the Maximum
Continuous Operating Voltage, in fact, the overvoltage limit of
Any consumer is exposed to many overvoltage phenomena, the protected equipment (formal value, obtained from the
caused mostly by lightning (a transitory overvoltage regime) or network RMS value). Domestic lines have these values: (1).
caused by internal power network faults (permanent
overvoltage regime). Metal Oxide Varistors are semiconductor
ceramic materials [2]. UMCOV = 230x1.06 = 244 V (1)

978-1-5090-2320-2/16/$31.00 ©2016 IEEE

 A 1,1 coefficient, normal for the domestic electrical III. THERMAL DESIGN
equipment could be easily used. Equation (1) becomes: Overheating could easily destroy any type of varistor, when
exposed to excessive number of shocks [3].
UMCOV = 230x1.1 = 253 V (aprox. 250 V) (2) The thermal part of the design algorithm is used in order to
establish the diameter (the heat-energy absorption capacity) of
By consequent, the peak value is (3): that varistor. It is an assessment of the thermal balance between
the heat produced inside the varistor and the heat dissipated
UmMCOV = 1.41xUMCOV = 357 (aprox. 360 V) (3) outside, in permanent and overvoltage regime [6].
A relation for this balance is given by:
The domestic protected equipment set these values. They
have to be conform with the varistor.
U n * If = Į * S l * IJ (7)
First, the URMS voltage has to be the same as UMCOV, the
overvoltage limit of the varistor. By default, URMS = 253 V Where:
(RMS value)
• Un is the nominal voltage (230 Vef);
Its peak value is UmRMS = 253 x 1.41 = 357 V
• If is the leaking current (0,1 mA);
Theoretically, UmRMS is equal to UmMCOV, and UN.
• Į is the global thermal transitivity (by convection and
Generally UN/ URMS is empirically fixed to 1.5…1.7. It is a radiation, equal with 17 W / (m2 degree));
simple and empirical relation having no physical correspondence.
• IJ is the accepted heating of the varistor (IJ(t) =
The coefficient of non-linearity, Į, for that varistor type ș –șa = 20 °C);
starts from 17 up to 20. Close to the minimal opening voltage,
limited as 358 V, for a measured 1 mA current (corresponding • Sl is the lateral heat dissipation surface. For a simple
to that varistor opening), the relation between voltage d2
augmentation ǻu and current augmentation ǻi became: disk varistor, it is S l = 2 ⋅ π ⋅ + π ⋅ d ⋅ h , where d
4
is the minimum demanded diameter, and h is its
[1/(1+ǻi)] = [UmRMS/(UmRMS + ǻu)]Į (4) height of 2.8 mm, already determined.
Relation (7) will be written as:
and:

2 ⋅ Un ⋅ If
ǻi = [(UmRMS + ǻu)/UmRMS)] Į – 1, d 2 + 2dh − =0
α ⋅ π ⋅τ (8)

ǻu = UmRMS [(1+ǻi)1/ Į – 1] (5) Taking only the positive one:

where, UN • UmMCOV = UmRMS

8 ⋅ Un ⋅ If
When doubling the current (ǻi = 1 mA), the voltage − 2 ⋅ h + 4 ⋅ h2 +
d=
α ⋅ π ⋅τ (9)
increase will be ǻu = 12.56 V Heat produced inside the
varistor will be four times higher, thermal runaway could be 2
dangerous.
And the specified diameter will be:
Voltage increase has to be limited to 3-4 V, which means
UN/ URMS = 1.55 x 1.01 = 1.56 (inside the protective envelope).
d = 4.33 mm (chosen as 5 mm) (10)
In fact, the opening voltage, from literature [6], for 230 V
domestic varistors, is established at 253 x 1.56 = 395 V (peak
value). IV. MATERIAL MEASUREMENTS AND CONFORMITY
We know that, for a standard inter-boundary junction, the In order to confirm all previous steps, some conformity
opening voltage is uN = 3.02 V (peak value) and, we know also measurements are required. For certain specific applications,
that the medium diameter of a grain is dg = 21 μm. By like IT equipment, supplied from the low voltage power
consequent, the varistor height will be established at: network, it is necessary to measure the electrical capacity of the
varistor at 50 Hz. We will present an original and efficient
procedure, applied for varistor capacity measurements, by
H = dg x UN / uN = 0.021 x 395 / 3.02 = 2.8 mm (6) using a simple digital oscilloscope.
The principle of this method is based on the non-linearity in
capacity of a certain varistor at that specified frequency.
 The specified varistor is considered as equivalent to an where:
electrical schema having a capacity CV (variable with the
applied voltage, but fixed for a certain voltage) and a resistance h = 2.8 mm (for the 230 Vef classic varistors);
RV. This schema, together with the schema for measurements is d is the diameter;
presented in Figure 2. A standard two channel digital
oscilloscope was used. The PC is recommended, but not İ0 = 8.854·10-12 F/m (the absolute air permittivity).
absolutely necessary. All results are shown in Table 1:

TABLE I. AC MEASUREMENTS AT 250 V, 50 HZ

Diameter for Icmax [A] CV [nF] İr
varistors
7 mm 1.32 ·10-5 0.14 1042
20 mm 1.13·10-4 1.07 1036
30 mm 2.57·10-4 2.38 1044

All measurements were performed at an environmental

temperature of 20 °C.
For the 7mm varistor, we notice that the average value for
İr is around 1040, like for a classic material having 5 additive
oxides, used in common AC applications. It confirms the
quality of the method involved [4].
After performing all these design features, the varistor must
be verified for compliance to:
• Measured In, the nominal current, the peak discharge
current for a 8/20 ȝs wave, according CECC 42000 Test
C2.1; It will be correlated with Imax – the maximum
Fig. 1. The electrical schema for alternative measurements current for the protected equipment;

The varistor in connected to one channel and another one is • Calculated or measured Np – the voltage level, which
reserved for measurements, by using the Rd resistance,of the could be one of those:
current passing through the varistor. The varistor was • Maximum peak value for a standard t1/t2 = 1.2/50 ȝs
permanently connected to 250 Vef (UMCOV, the maximum shock;
RMS voltage value in normal conditions). If the supplying
voltage is higher, the varistor becomes a conductor and the • The residual nominal voltage (as a maximum voltage);
resistive part of the current is higher. If the voltage is lower,
that varistor acts like an insulator, and the capacitive • The maximum clamping voltage divided to 1.15 – 1.2;
component is higher than the resistive one. All measurements
made at 50 Hz AC were performed at the Faculty of Electrical V. CONCLUSIONS
Engineering in Timisoara. This three steps algorithm used for design a specific
Generally, we can separate the two current components, Ir varistor, completed with the simple capacity test method, is
the resistive one, in phase with the main voltage, and Ic, the easy to use and to perform, with standard equipment available
capacitive one, with a 90 degrees delay. in any electrical engineering laboratory, performed even by
students. It gives information about the performances of all
The maximum capacitive current Icmax, obtained for the those materials involved and gives also a suggestion for their
maximum 90 degrees distance, when the main voltage reaches application domain.
0, has to be measured too.
The results obtained by using this design method are simple
The relation for the varistor capacity CV became: and they are totally confirmed by obtaining, for that considered
varistor, an İr which is 2.2 times lower for the first 2 oxides
material by comparing with the 5 oxides one, which has a 2.11
CV = Icmax/(Vmax ·Ȧ) (11)
higher granulation, after performing additional measurements.
They are also confirmed with the close range of values
Where Vmax = 250·1.41= 352 V, Ȧ = 314 rad/s obtained for 230 VRMS varistors. Generally, on literature, for
After obtaining the CV capacity at 50 Hz, we can measure this simple material, only values of 1000-1500 are shown.
its relative permittivity, İr for this 250 Vef voltage and 50 Hz The presented method is very simple and it could be an
frequency. The computing relation is: efficient design method both for varistor producers and users. It
is a simplified version of all the standardized procedures.
İr = (4·h·CV)/(İ0·ʌ·d2) (12)
 It could be combined with other methods, too, and it could REFERENCES
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