Varistores 01 06 2010

The Surges…
•…How to protect
your electronics with
Apr-08 Sébastien CHADAL Varistor 2008

I. Basics
II. Construction of Varistors
III. Parameter of a varistors
IV. Selection of Varistors
V. Applications
VI. ESD Varistors
VII. ESD Applications
VIII.ESD Varistor selection
IX. Layout
Sébastien Chadal
I. Basics

Over Voltages: Sources
• atmospheric discharges
Æ when, how often, how strong???
Varistors
• « industry caused » discharges
Æ switching activities:
not destroying, but repeating
• electrostatic discharges
Æ between: ● human + material ESD Suppressors
ESD
● material + material

Atmospheric Discharges
Atmospheric caused over voltages: flash
9 Direct Impacts (Fire…)
9 Phenomenon of indirect impacts through connected wires
You don‘t know how big the energy of this over voltage will be

Industry Caused Discharges
« industry caused » discharges

Switching activities with capacitors or inductors :
9 transformers,
9 motors,
9 relays…
- is seldom destructive,
but it will repeatedly appear
- causes high-frequently
(transient) wire failures

Why Over Voltage Protection?

WESURGE products
Disk Varistors – high voltage and energy:

– Power supply: industry facilities, washing
machines, pumps,…
– Activation units for: motors, pumps, facilities,…
• SMD Varistors - low voltage

– Activation units for: motors, pumps, facilities,…
– Protection of single components, LCD-Displays,
AC/DC low voltage distribution,…
• ESD Varistors – very low voltage, low capacitor,

almost no energy:
– Protection for electrostatic discharge
– Components with wires to the environment
– Signal lines (I/O): USB, CAN, RS232, FireWire,…
• TVS* protection for E.S.D

- Very low capacitor
*Transient Voltage Suppressor
IEC 61643-1

Lightning Arrestor

Why do we need a Standardized Curve Progressions ?
Simulation of random phenomena

Repetivity of the test, to compare the effectiveness of the
different solution
Test for the approval of the product

Standardized Curve Progressions
Standardized curve progressions are used at EMC-tests and for

the specification of varistors. Examples: EN 61000-4-5
Voltage progression (1,2/50µs)

Rise time: 1.2 µs
Decay time to half value: 50 µs
Four test level : 0,5 - 1- 2 and 4 kV
Positive and negative voltage
Between 0 and 360°
1 time per minute minimum
5 tests on each polarity
Current progression (8/20µs)

Rise time: 8 µs
Decay time to half value: 20 µs
Current : 0,25 to 2 kA

Varistor: Functionality
varistor Æ the over-pressure valve in the electric circuit
U-I Graph for SMD-Varistor 825 42 350

Varistors are 7
LOAD
voltage ILeakage 6
dependent
5
resistors
Current [mA]
4
(VDR).
3
LOAD 1
IWithstanding
0
30 40 50 60 70
Voltage [V]

Calculation of Energy and Power Dissipation
The energy in watt-seconds / joule is calculated with followed formula:

W (J) = U (V) • I (A) • t (s)
W = 4000 V • 816 A • 42•10-6 s = 137 J
To compare with a square pulse
W = 4000 V • 2000 A • 20•10-6 s = 160 J
At one impact per minute Pmax is: WORSE CASE

P (W) = W (J) / t (s) U Open Circuit
P = 137 J / 60 s = 2.28 W
Square pulse I short Circuit
P = 160 J / 60 s = 2.60 W
9 Tip to approximately estimate the size of a varistor:

9 Calculate with a square pulse (U and I are constant during the pulse)!
Comparison of Over Voltage Protection Devices
Over voltage caused Over voltage caused by
by fast transients to high energy
Component:
Gas Tube Ignition

(Trisil) Ignition
?
Varistor
Diode Short Circuit

(Supressor, Transil)
like Zener-Diode with better
surge resistance
Advantages ÙDisadvantages
1-Tube Gaz 2-Varistors
Advantages Advantages
- high current absorption - cheap component
- low clamping voltage - big range of voltages
- low leakage current - fast response time
Disadvantages <= 5µsec for SMD components
- long ignition time <= 50 µsec for THT components
- desactivating voltage of ~70V, Disadvantages
so you can‘t use this part at low voltages - capacitance for THT varistors
- response time for THT varistors, to slow
That means the voltage must be lower than 70V, that for ESD discharges
the gas tube goes to high ohmic resistance! - lifetime ends perhaps with open circuit
3 - Transil Fast
Advantages transcient
- cheap
- fast
- stable voltage in conductive mode
Disadvantages High
- low current absorption, to low for industry
caused switching activities
- lifetime ends with short circuit energy
Advantages of SMD varistors…
• Compare to semiconductor ( Surge suppressor)
• = Bidirectionnel Component
• + Great endurance with the repetitive shocks
• + strong capacity of low in wave 8/20µs
• = Large choice of operating voltage
• = high speed response
• + very weal leakage current
• + Broad choice of intrinsic capacity
• = Low attenuation of the signal (Low capacity)
• + Same layout as SMD component
• = Relfow soldering (Jedec 260°C / 20 s)

Different name for varistor
VDR (Voltage Dependant Resistor)

MOV (Moving Oxyde Varistor)
GEMOV « GE General Electric »
SIOV « Siemens »
TVS (Transient Voltage Suppressor)

Equivalent circuit
Serial Resistance
Capacitance
Inductor
“Operating"-Resistance.
Rs = Serial resistance
Cv = Capacity between the several grains
….. is caused by the granular structure
L = lead inductor

II. Construction

Technologies of the varistors
Constitution:
The varistors are electronic components intended to chop
overpressures. They are carried out with metallic oxide powders
agglomerated by sintering

Disk Varistors: Production
Production
Sintering is a metallurgic process at which the powder Powder

formed materials are pressed together under high pressure
and high temperatures.
The sintering temperature must be lower than the melting
temperature of the material powder, so the material will
Pressure
keep in solid state.
That’s important to get an porous material!
°C

Disk Varistors: Production
Production
metal powder (ZnO) is pressed and sintered (MOV = Metal Oxid Varistor)
a metal layer is coated on each side
the pins are soldered
coating for isolation and protection of the component is layered
coating
sintered body metallizing pins

SMD Varistors: Technology
ceramic SMD multilayer body
small sizes (0402 – 2220)
fast response time (< 0,5 ns)
low capacitance

Disk Varistors: Safety Approvals
WESURGE Disk-Varistors are conformable with:
- CSA N° XUHT8.E244196
- UL N° XUHT2.E244196
- VDE N° 40010687 & 40010688
Annotation: SMD-Varistors are not conformable with safety approvals,

because their working voltage is lower than 75V.
Also at our competitors!

View into the varistor
• Varistors are built of ZnO grains, with a Ø from 10 to 100 µm

• A varistor is a series and parallel connection of many microvaristors
• Double disk thickness follows double voltage
• Double disk diameter follows quad current (A=pi*r2)
Microvaristor
3,5V
I
100µA
Task
• The bare disk of 820 54 271 1

has a thickness of 1.7mm
Size Varistor Clamping Break-Down
Voltage Voltage Voltage
14 mm 275 Vrms 710 V ?
• The grain size 12,7µm, what is the varistor breakdown Voltage ?
disc thickness 1.7mm

VVar = *VVar per grain = * 3.5V = 430V
Grain − size 12,7 µm

III. Parameters of the varistors

Varistors – Operation - Parameters

Varistor: Functionality
varistor Æ the over-pressure valve in the electric circuit
Functionality
Varistors are voltage dependent resistors (VDR).
Charge
ILeakage
This interdependence is symmetric and not linear.
If you put on an continuously increasing voltage at the

varistor, its resistance will change in a small range
very fast. The resistance will get from high-resistance
(some MegOhm) to low-resistance (few Ohm).
Charge
IWithstanding

U/I-Graph: Overview
max. Current
+I
ITM
Current @ Clamping Voltage
IP
0,1mA or 1mA
Leakage Current
IN
ID
+U
VM VN VC
Clamping Voltage
Varistor Breakdown Voltage
Max. Operating Voltage

Max. Operating Voltage
Max. Operating Voltage VM

+I
ITM
Is the max. allowed voltage between IP
the two pins.
IN
ID
+U
Defined for direct current VDC VM VN VC
and alternating current VRMS.
Should be 15%-20% above nominal operating voltage of device!!!

Varistor Breakdown Voltage
Varistor Breakdown Voltage VN

+I
ITM
The voltage, from which the current IP
rises exponentially
IN
ID
+U
The Varistor Voltage is always VM VN VC
measured in VDC at a defined current IN

(1 mA).
User for standardization of varistors. Not needed for varistor selection

Max. Clamping Voltage
Max. Clamping Voltage VC

+I
The maximum voltage that occurs if a ITM
current of 8/20µs is applied to the IP

varistor.
IN
The declaration is made for a ID
+U
specified typical current Ip “V@ A”, VM VN VC
e.g. 710V @ 50 A).
Must be smaller than withstanding voltage of protected device.

Varistor voltage – Clamping voltage
•Operating Volatge +I
20 VRMS or 26 VDC ITM
Voltage Varistor 33V IP
IN
ID
+U
VM VN VC

•Voltage Varistor 33V
•Operating Volatge
? •20 VRMS or 26 VDC
VC = 73 v
=> 73 V can be mesure
à1A
VN = 33 v just behind the varistor
At 1 mA

Withstanding Surge Current
Withstanding Surge Current ITM
+I
ITM
Is the max. current which IP
the varistor can withstand.
IN
Æ more is better ID
+U
VM VN VC
Current Curve
Determines the size of varistor.

Withstanding Surge Current - Derating
Withstanding Surge Current

Derating
The Withstanding Surge Current
is dependent on the size and the
number of replications of pulses.
With a 120µs Wave, the value is

going down by a factor of 10 when
a series of 100 pulses is applied
to the varistor.
Ex: for a wave of 120µ

Imax 50 A drop to 5A
Withstanding Surge Energy vs. Size
• Disk Varistors:
Energy 10/1000 <=: 20J 56J 90J 225J 382J
Diameter: 5mm 7mm 10mm 14mm 20mm
• SMD Varistors:
Energy 10/1000 <=:0,05J 0,1J 0,3J 1,1J 1,4J 4,2J 12J
Size: 0402 0603 0805 1206 1210 1812 2220
These values are for reference. They don’t substitute any test!!!
Order Code and Packaging
820 54 271 1
823 57 050 220
Tolerance
Type: @ Disk:
820: Disk 1: 10%
823: ESD 2: 20%
825: SMD 3: 30%
5: 5%
6: 15%
7: 25%
Series: Operating Voltage:
0: ULC Disk+SMD: Capacitance
1: LC Vrms @ ESD Suppr.:
3: Basic xx*10^x xx*10^x

Size @Disk: Size @ SMD&ESD:
4: HighSurge 1: 10mm 0: 0805, 0508 ESD:
5: Power (Std) 2: 20mm 1: 1206, 0612 Vdc
8: Array 4: 14mm 2: 2220 Xx*10^x
5: 5mm 3: 1210
7: 7mm 4: 1806
5: 1812
6: 0603
7: 0402:
IV. Selection of a Varistor

Varistor Selection - Summary
• Max. operating voltage should be 15-20% above the

operating voltage of protected device
• Size of varistor is driven by max. current

Î estimation through nominal current of protected device
• Max. clamping voltage must be lower than withstanding

voltage of protected device
Î max. clamping voltage rises with operating voltage
Æ physical legality
• Intrinsic capacity, taking account for the protection of the

data line.
• …in every case you have to test the solution

Technical Characteristics: Summary
Functionality
+I
ITM
IP
IN
ID
+
VM VN VC
Varistor Max. Withstanding Energy Capaci-

max. Operating Saf
Order Code Breakdown Clamping Surge Current Power @ tance @
Voltage
Betriebsspannung Appro
Voltage Voltage @ 8/20µs 10/1000µ 1kHz
Ø14mm s

Task
• Select for your customer a Ref Size Vrm Enrergy Surge Power
(mm) (V) (J) Current (W)
surge protection for
(A)
820412711 10 275V 80 3500 0,4
– 230V power supply
820442711 14 275V 155 6000 0,6
– max. current = 0,5kA
– max. energy = 60J 820522711 20 275V 624 6500 1
• What you need: sele

– 230 + 15-20% Æ 275Vrms c t th
e sm
– Surge current must be higher alles
t pos
than 500A sible
– Energy must be higher than par t
60J
– Î 820 41 271 1

Task
• Select a surge protection for Ref Size Vrm Enrergy Surge Power
(mm) (V) (J) Current (W)
(A)
– 230V power supply 820412711 10 275V 80 3500 0,4
– max. current = 0,5kA
820442711 14 275V 155 6000 0,6
– max. energy = 60J
– one surge every minute 820522711 20 275V 624 6500 1
• What you need sele

– same conditions as before ct th
– 1 Surge every 1 minute = every
e sm
all e
60 Seconds st p
Æ calculate the max. oss
ibl ep
dissipating power Energy 60J J art
Pmax = = = 1 = 1W
Time 60s s
– Î 820 52 271 1
V. Applications

Varistors - Applications
•Basics

Perfect Protection (here: Telephone System)
Expensive data and telecommunication applications are multi-level

protected. So the weaker component is kept from demolition.
The protection components are decoupled by inductors or resistors.
Gas Tube Varistor Suppressor

current up to 10 kA 2 kA 0,2 kA
response time < 500 ns < 25 ns < 10 ns

Varistor Applications
Protection of low-voltage and signal lines
Attention! Application against bias is only allowed with additional fuses in series connected
Varistors - Applications
•Main power supply 115 / 230 et 400 Vrms
•Disk varistors : 5 to 20 mm

Varistances - Applications
•Power supply : 3,3 to 56 Vdc or Vac
•Disk varistors 5 to 20 mm or SMD varistor 0805 – 1206 -1210 - 1812

-2220

Protection of inductors and switching devices
The varistor should only protect one component of the electric

circuit. It‘s always that component, which is connected parallel
with the varistor.
Protection of switching devices
The varistor should only protect one component of the electric

circuit. It‘s always that component, which is connected parallel
with the varistor.
Varistances - Applications
•Protections des alimentations photovoltaïques
•De part leur installation, les panneaux photovoltaïques sont

particulièrement exposés aux risques de foudroiement…
Photovoltaic Cell
Fuse
DC AC
Converter
Serial P arallel
Mounting
Fuse

VI. ESD Varistors
ESD – Electrostatic Discharge

WESURGE Range
• Standard and High Energy Disc Varistors
• Standard and High Energy SMD Varistors
• SMD Varistors for ESD protection with

• low intrinsic capacitance
• TVS* for ESD protection with

• ultra low intrinsic capacitance
The Electrostatic Discharge E.S.D.
• The electrostatic discharges are generated by the ionization of

materials (frictions).
• Discharges between materials (especially in production)
• Discharges by contact (user)
• Consequences:
• Unreliability or destruction of
components.
• More often,trouble of materials.

EMC Test: IEC 61000-4-2

Test Procedures
• HBM: Human Body Model

• MM: Machine Model
• CDM: Charge Device Model
• FCDM: Field Induced Charge Device Model
Human Body Model

Air Discharge Contact Discharge
move discharge unit to component discharge unit is in contact
with component

Trigger Voltage vs. Max. Clamping Voltage
Trigger Voltage
Max. Clamping Voltage
ESD Suppressor Varistor

ESD Varistor Applications
•Why to protected I/O
•IEC 61000-4-2 ESD test are

between 8 to 15 kV
•ESD IC internal protection are
maximum 3 to 4 kV !

ESD Suppressor
Comparison of Components

Comparison with other protection devices
• WESURGE Disk Varistors

– robust
– bidirectional
• WESURGE SMD Varistors
– and fast ( < 1ns)
– Low capacitance
• WESURGE ESD Suppressors
– and very fast( < 0.5ns)
– and low and specified capacitance
• Zener Diodes
– Fast ( 2 - 4 ns), but low energy absorption
– unidirectional
– strong derating at temperatures over 40°C
• IC integrated protection devices
– fast, but low energy absorption
– ESD Pulse can couple into IC Æ IC must be rebooted
– are made for voltages up to 2-3 kV, but not for 15 kV as the ESD Suppressors
Comparison of ESD Pulses
ESD Pulse
ESD Suppressor
short circuit

Difference ESD Suppressor ↔ Diode
Diode
ESD Suppressor

ESD SMD Varistors Technology
ZnO multilayer ceramic body
• Small sizes (0402 – 0603 – 0805)
• Very fast response time (< 0.1 to 0.5 ns)
• Low or very low capacitance (100 to 2 pF)
• Big resilience in the repetitive shocks

• High transient current capability
• Very wide choice of operating voltage
• Ultra fast response time
• Very low leakage current
• Choice of the intrinsic capacity

TVS* ESD Ultra Low Capacitance
•New polymer technology for ESD protection
NEW
• Al2O3 alumine ceramic substrat
• Pd/Ag internal electrode
• Polymer technology
• Ag/Ni/Sn electrode termination
• High temperature protection Ultra low intrinsic capacitor (0,2 pF)
Low Clamping voltage (17 to 30 V)
Ultra fast response time (<0.1 to 0.5 ns)
Very low leakage current (<0.01 µA)

TVS ESD Ultra Low Capacitance
•Insertion loss 1 MHz to 3 GHz
NEW

ESD Suppressor
Applications

Applications for ESD Suppressors
• Protections is needed at:
– all communication interfaces
• Examples:
– Modems, DSL-Router Interfaces
– LAN I/O Ports
– USB, FireWire Ports
– Bus-Systems e.g. CAN-Bus
– Keyboards, Head-Sets, Antennas
– DVI, HDMI
– …
• ICs have often a withstanding voltage of 100 - 150V

• Beginning at 1kV a human can feel an ESD pulse
Î IC breaks down, and you don’t feel it
Applications WE-VE

•Low level I/O ESD protection

•Low Capacitance SMD Varistors 0402 – 0603 – 0805 & array

•High speed data ESD protection
•Low Capacitance SMD Varistors 0402 – 0603 – 0805 &
array

Protection of USB 2.0
WE-VS
Thermal
Fuse
WE-CNSW
WE-VE WE-VE

Protection of LVDS
WE-CNSW
WE-CNSW
WE-CNSW
WE-CNSW
WE-VE WE-VE WE-VE WE-VE WE-VE WE-VE WE-VE WE-VE WE-VE

•High speed data ESD protection
•Selection examples
Rate or Rise Time Capacitance Value P/N

Type
Frequency WESURGE
0603 / 5 Vdc / 0.2 pF
USB 2.0 480 Mbits 0,5 à 0,6 ns < 4 pF 823 06 050 029
823 81 120 029 (Array)
0603 / 5 Vdc / 5 pF
USB 1.1 12 Mbits 4 à 20 ns 5 à 10 pF 823 56 050 050
Bus CAN High- 0603 / 12 Vdc / 10 pF

1 Mbits 70 à 250 ns 5 à 10 pF
Speed 823 56 120 100
0402 / 5 Vdc / 56 pF
RS232 & IrDA1.0 115,2 kbits 1,8 à 8 µs 10 à 100 pF 823 57 050 560
0603 / 5 Vdc / 100 pF

Audio 20 Hz à 20 kHz 0,05 à 50 ms 10 à 100 pF 823 56 050 101

ESD TVS Applications
•DVI & HDMI audio video ESD protection

Firewire IEEE 1394 - Schnittstelle
•EMI & ESD combined I/O protection
Common Mode Filter

WE-CNSW oder WE-SLx
ESD-Varistors:
823 06 050 029
823 07 050 029 WE-VEA „ULC“
823 81 120 029 823 81 120 029

ESD TVS Applications

ESD Suppressor
Selection

Signal Voltage
• VDC of ESD Suppressor must be higher than VDC of device
• The higher the frequency, the lower must be the capacitance
• Choose not a too small cap,

because than the trigger voltage is too high
data rate
• The fundamental frequency f =
2

Trigger Voltage vs. Capacitance
Trigger-Voltage vs. Capacitance
500 0
Trigger Voltage
Insertion Loss
450 5
400 10
Insertion Loss [dB] @ X MHz

350 15
300 20
Umax [V]
250 25
200 30
150 35
100 40
50 45
0 50
0,01 0,1 1 10 100 1000 10000
Capacitance [pF]
RS-XXX
2.0 1.1
Insertion Loss vs. Frequency: WE-VE “ULC”
typical insertion loss WE-VE Ultra Low Cap
1
0
Insertion Loss [dB]
-1
-2
-3
-4
-5
0,01 0,1 1 10 100 1000 10000
Frequency [MHz]
RS-XXX
1.1 2.0
Layout

Synergies WE Components

How to implant varistors?
• Board Designing…
• Don't forget some rules !
…Track and pad widely sized
Ground plan

•Board Designing…
•Don't forget some rules !
Metallic
Metallic Frame
Standoff
Ground plan

• Put varistors near I/O
OK OK
IC
Transfo

•One TVS by line or one array of 4 TVS…

•What strategy do you choose?
L=?

Varistor Sample Kits

Varistor Flyer

SMD Varistors Kit
•P/N : 825999
More of 2.000 pieces!
Booklet with characteristics

and applications.
Standard, High Energy, ESD
LC & ESD ULC range:
• 0402 à 2220 & Arrays
• 39 Part Number
• 15 to 60 pieces by value

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The Surges…

Apr-08 Sébastien CHADAL Varistor 2008

Apr-08 Sébastien CHADAL Varistor 2008

Apr-08 Sébastien CHADAL Varistor 2008

Apr-08 Sébastien CHADAL Varistor 2008

« industry caused » discharges

Apr-08 Sébastien CHADAL Varistor 2008

Apr-08 Sébastien CHADAL Varistor 2008

Disk Varistors – high voltage and energy:

• SMD Varistors - low voltage

• ESD Varistors – very low voltage, low capacitor,

• TVS* protection for E.S.D

Apr-08 Sébastien CHADAL Varistor 2008

Apr-08 Sébastien CHADAL Varistor 2008

 Simulation of random phenomena

Apr-08 Sébastien CHADAL Varistor 2008

Standardized curve progressions are used at EMC-tests and for

Voltage progression (1,2/50µs)

Current progression (8/20µs)

Apr-08 Sébastien CHADAL Varistor 2008

varistor Æ the over-pressure valve in the electric circuit

U-I Graph for SMD-Varistor 825 42 350

Apr-08 Sébastien CHADAL Varistor 2008

 The energy in watt-seconds / joule is calculated with followed formula:

 At one impact per minute Pmax is: WORSE CASE

9 Tip to approximately estimate the size of a varistor:

Gas Tube Ignition

Diode Short Circuit

• Compare to semiconductor ( Surge suppressor)

Apr-08 Sébastien CHADAL Varistor 2008

 VDR (Voltage Dependant Resistor)

Apr-08 Sébastien CHADAL Varistor 2008

Apr-08 Sébastien CHADAL Varistor 2008

Apr-08 Sébastien CHADAL Varistor 2008

Apr-08 Sébastien CHADAL Varistor 2008

Sintering is a metallurgic process at which the powder Powder

Apr-08 Sébastien CHADAL Varistor 2008

sintered body metallizing pins

Apr-08 Sébastien CHADAL Varistor 2008

 ceramic SMD multilayer body

 small sizes (0402 – 2220)

 fast response time (< 0,5 ns)

Apr-08 Sébastien CHADAL Varistor 2008

WESURGE Disk-Varistors are conformable with:

- VDE N° 40010687 & 40010688

Annotation: SMD-Varistors are not conformable with safety approvals,

Apr-08 Sébastien CHADAL Varistor 2008

• Varistors are built of ZnO grains, with a Ø from 10 to 100 µm

• The bare disk of 820 54 271 1

• The grain size 12,7µm, what is the varistor breakdown Voltage ?

disc thickness 1.7mm

Apr-08 Sébastien CHADAL Varistor 2008

Apr-08 Sébastien CHADAL Varistor 2008

Apr-08 Sébastien CHADAL Varistor 2008

varistor Æ the over-pressure valve in the electric circuit

Varistors are voltage dependent resistors (VDR).

If you put on an continuously increasing voltage at the

Apr-08 Sébastien CHADAL Varistor 2008

Varistor Breakdown Voltage

Max. Operating Voltage

Apr-08 Sébastien CHADAL Varistor 2008

Max. Operating Voltage VM

Simulation of random phenomena

The energy in watt-seconds / joule is calculated with followed formula:

At one impact per minute Pmax is: WORSE CASE

VDR (Voltage Dependant Resistor)

ceramic SMD multilayer body

small sizes (0402 – 2220)

fast response time (< 0,5 ns)

3: Basic xx10^x xx10^x