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Notes: Littelfuse Varistor Design Examples
Notes: Littelfuse Varistor Design Examples
NOTES
Littelfuse
Varistor Design Examples
This note is meant to be a guide for the so some suppression must be added. It is 3000
UL1449 CORD CONNECTED
user in selecting a varistor by describing desirable to use the built-in impedance of 2000
AND DIRECT PLUG-IN
CATEGORY
common application examples, and illus- the coil to drop the remaining voltage, so 1500
V130LA2
trating the solution process to determine the suppressor would best be applied as
PROTECTION AGAINST 129V. The closest voltage rating available is PEAK AMPERES 8/20µs WAVESHAPE
600
It is desired to prevent failure of the power about 30Ω is derived from the inductive
– 5kV sin 105„ t X age of from 325V to 380V, depending on PEAK AMPERES 8/20µs WAVESHAPE
e-10-5 t the model size, as shown in Figure 2a and Figure 2b. V130LA Varistor V-I Characteristics
Figure 2b.
Figure 1a. Transient Generator
IV
Revising the estimate, I=(2500V-
VARISTOR CURRENT
12
The circuit shown in Figure 4. experiences tive and is equal to I M .This assumes that the
10
failures of the rectifiers and SCR when the primary copper resistance, leakage reactance
8
transformer primary is switched off.The and equivalent core resistive loss compo- 6
manufacturer has tried 600V components nents are small compared to LM .This is a 4
f = 50...60Hz
with little improvement. valid assumption for all but the smallest 2
ARMATURE
V pri Figure 6. Magnetizing current of transformers with low sili-
R1 X L = -----------
M I NL con steel core
330k SPEED
CONTROL and
FIELD
i M = I NL
The designer needs to know the total After determining voltage and peak current, +
28V
CC
RC
CC = STRAY CAPACITANCE
energy stored and the peak current trans- energy and power dissipation requirements DC
L = RELAY COIL INDUCTANCE
RC = RELAY COIL RESISTANCE
must be checked. For the given example, the
single pulse energy is well below the
ZP ZS
V130LA20B varistor rating of 70J at 85˚C FIGURE 8. RELAY CIRCUIT
N
maximum ambient temperature. Average
IM
MUTUAL power dissipation requirements over idling Figure 8. Relay Circuit
INDUCTANCE
VPRIMARY REPRESENTED LM VSECONDARY
BY IRON CORE power are not needed because of the non- When relays or mechanical switches are
repetitive nature of the expected transient. used to control inductive loads, it is neces-
IDEAL
TRANSFORMER
20mH 50
τ = L/R C = ---------------- = 210 s 200mH V+
95
The supply is set at 25mA to represent the VC 26V
t
model, the number of allowable pulses peak motor current in normal 120V AC IC
exceeds 100 million. operation. As switch S1 was opened, the 470
Problem the highest RF detector output (shown in Figure 14a. Basic solenoid circuit
Switching of a small timer motor at 120V, the lower trace) is 32V.
60Hz, was causing serious malfunctions of an VC = COLLECTOR
electronic device operating from the same A 26V V+ VC EMITTER VOLTAGE
200V/cm
0
power line. Attempts were made to observe V+
26V
the transient noise on the line with an oscil- IC
t
IV IC
loscope as the first step in curing the
B
problem. Observed waveforms were
t
20V/cm
“hash,” i.e., not readily identifiable. IV
0
200 s/cm
Noise in an electromechanical system is a UPPER V1: 200V/cm LOWER V RF: 20V/cm
t
commonly experienced result of interrupting t: 0.2ms/cm Figure 14b. Solenoid circuit with varistor protection
current by mechanical contacts. When the Figure 12. Unprotected Contacts
switch contacts open, a hot cathode arc when the transistor base is grounded (turn-
may occur if the current is high enough. On Obviously, some corrective action should be ing “off ”).The inductor forces current to
the other hand, low current will permit taken and the most effective one is that flow until the energy stored in its field is
switch opening without an arc, but with ring- which prevents the repeated breakdown of dissipated.This energy is dissipated in the
ing of circuit resonances. As a consequence, the gap. Figure 13 shows the waveform of reverse bias condition of the transistor and
voltages can exceed the contact gap break- V1 (upper trace) and VRF (lower trace) for is sufficient to cause breakdown (indicated
down resulting in a replica of the old spark the same test conditions with a Littelfuse by a sudden collapse of collector voltage
gap transmitter. It is the low current Varistor, type V130LA10A, connected during the pulse).
case that produces the most serious noise directly across the switch terminals.The
disturbances which can result in malfunctions varistor completely eliminates the relaxation
oscillations by holding the voltage below the Solution
or damage to electrical equipment.These This condition can be eliminated either by
pulses cause noise problems on adjacent gap breakdown voltage (about 300V) while
dissipating the stored energy in the system. shunting the transistor with a suppressor or
lines, trigger SCRs and triacs, and damage by turning it on with a varistor connected
semiconductors. In addition, they can disrupt collector-to-base.The first method will
microprocessor operation causing memory considerably reduce the demands upon the
to be lost and vital instructions to be missed. safe operating area (SOA) of the transistor. If
200V/cm
0
the voltage is kept below its breakdown
Solution level, all energy will be dissipated in the
A test circuit (Figure 11) was set up with suppressor.The latter method will cause the
lumped elements replacing the measured 0 transistor to once again dissipate the stored
10V/cm
circuit values.The motor impedance was 200 s/cm energy, but in the forward-bias state in which
simulated by R1 , L1 , and C1 , and the AC
UPPER V1: 200V/cm LOWER V RF: 20V/cm the transistor can safely dissipate limited
t: 0.2ms/cm
line impedance by L2 and C 2 . A DC source amounts of energy.The choice is determined
Figure 13. Varistor protected contacts
allowed repeatable observations over the by economics and reliability. A suppressor
connected collector-emitter (C-E) will be
PROTECTION OF TRAN- more expensive than one connected C-B,
5 H S1 SISTORS SWITCHING since it is required to absorb more energy,
L2
4 POLE
0.2 200
20 100 1,000 10,000 Frequently, the cause of motor failures can 230VRMS LINE - LINE 2 POLE
IMPULSE DURATION (µs) 100
be traced to insulation breakdown of the 80
4 POLE HA3
2
105 10
200 102 106 from external sources.This section deals 8
6
100 with the self-generated motor transients 10 20 40 60 80 100 200
MOTOR (hp)
400 600 800 1000
50
due to motor starting and circuit breaker
Figure 18. Stored energy curves for typical delta-connection
20 operation. induction motor
10
INDEFINITE NOTES:
5
In the case of DC motors the equivalent 4. Delta connected at 60Hz.
2
circuit consists of a single branch.The 5. Energy at maximum torque slip speed.
1 6. See Figure 20 for varistor circuit placement.
20 100 1,000
IMPULSE DURATION (µs)
10,000 magnetic stored energy can be easily
Figure 15b. ZA Series V18ZA3 to V68ZA10 (14mm)
calculated in the armature or field circuits
using the nameplate motor constants. With As an aid in selecting the proper operating
7mm V39ZA1 would not be limited to a AC induction motors the equivalent voltage for Littelfuse Varistors,Table 1 gives
cumulative number of pulses. magnetic motor circuit is more complex guidelines for wye-connected and delta-
and the circuit constants are not always connected motor circuits at different
In cases where the peak current is greater given on the motor nameplate.To provide a line-to-line applied voltages. Figure 20
and intersects with the recommended guide for motor protection, Figures 17, 18, provides guidance in proper placement of
pulse life curves, the designer must deter- 19 were drawn from typical induction the varistor.
mine the maximum number of operations motor data. While the actual stored energy
expected over the life of the circuit and will vary according to motor frame size and
confirm that the pulse life curves are not construction techniques, these curves
S O O G GS O CO C O O S
200
4 POLE V321HA32 series varistor will meet this
230VRMS LINE - LINE 2 POLE requirement.The HA series Littelfuse Figure 21. Crowbar circuit
100
80 3 2 Varistor provides a greater margin of safety,
4 POLE HA
11
60
V5 although the PA series Littelfuse Varistor The supply shown can provide 2A RMS of
40 0
2 POLE A4 0
27
5P
1 0P
A8 fully meets the application requirements. short-circuit current and has a 1A circuit
V V5
2/
20 HA
3 Three varistors are required, connected breaker. A C106D SCR having a 4A RMS
71
V2
directly across the motor terminals as capability is chosen.Triggering will require at
10
8 shown in Figure 20. least 0.4V gate-to-cathode, and no more
6
10 20 40 60 80 100 200 400 600 800 1000
MOTOR (hp) than 0.8V at 200A at 25˚C ambient.
Figure 19. Stored energy curves for a typical motor with
stalled rotor
NOTES: Solution
7. 60Hz, see Figure 20 for varistor circuit placement. VL-L Check the MA series Littelfuse Varistor
8. Energy at start, i.e., SLIP = 1. specifications for a device capable of
9. Induction motor.
10. 2, and 4 pole motors.
supporting 240V peak.The V270MA4B can
handle √2 (171V RMS ) = 242V. According
Interruption of motor starting currents to its specification of 270V ±10%, the
1
presents special problems to the user as VVARISTOR = -------VL —L V270MA4B will conduct 1mA DC at no
3
shown in Figure 19. Since the stored Figure 20a. Wye connected
less than 243V.The gate-cathode resistor
magnetic energy values are approximately FIGURE 20A. WYE CONNECTED can be chosen to provide 0.4V (the mini-
10 times the running values, protection is mum trigger voltage) at 1mA, and the SCR
difficult at the higher horsepower levels. will not trigger below 243V.Therefore, R GK
Often the motor is started by use of a should be less than 400.The highest value
reduced voltage which will substantially VL-L
5% tolerance resistor falling below
reduce the stored energy. A reduction in
M 400 is a 360 resistor, which is selected.Thus,
starting current of a factor of two results in RGK is 378 maximum and 342 minimum.
a fourfold reduction in stored energy. If a Minimum SCR trigger voltage of 0.4V
reduced voltage starter is not used, then a requires a varistor of 0.4V/378, or 1.06mA
decision must be made between protection VVARISTOR = VL-L for a minimum varistor voltage of ≈245V.
for the run condition only, and the condi- The maximum voltage to trigger the circuit
Figure 20b. Delta connected
tion of locked rotor motor current. For is dependent upon the maximum current
most applications, the starting condition can the varistor is required to pass to trigger
be ignored in favor of selecting the varistor the SCR. For the C106 at 25˚C, this is
for the worst-case run condition. Power Supply Crowbar determined by calculating the maximum
Occasionally it is possible for a power current required to provide 0.8V across a
supply to generate excessively high voltage. parallel resistor comprised of the 360 RGK
Problem An accidental removal of load can cause selected and the equivalent gate-cathode
To protect a two-pole, 75hp, 3φ , 460V damage to the rest of the circuit. A simple SCR resistor of 0.8V/200A, since the C106
RMS line-to-line wye-connected motor safeguard is to crowbar or short circuit the requires a maximum of 200A trigger
from interruption of running transients. supply with an SCR.To provide the trigger- current.The SCR gate input resistance is 4k
ing to the SCR, a high-voltage detector is and the minimum equivalent gate-cathode
Specific Motor Data Is Not Available needed. High voltage avalanche diodes are resistance is the parallel combination of 4k
effective but expensive. An axial leaded and RGK(MIN) , or 360Ω -5%, 342.The
Littelfuse Varistor provides an effective, parallel combination is 315Ω.Thus, I VARIS-
Solution inexpensive substitute.
Consult Figure 17 along with Table 1. TOR for maximum voltage-to-trigger the
Standard varistors having the required volt- C106 is 0.8V/315, or 2.54mA. According to
age ratings are the 320VRMS rated models. Problem the specification sheet for the V270MA4B,
This allows a 20% high-line voltage condi- In the circuit of Figure 21, the voltage, with- the varistor will not exceed 330V with this
tion on the nominal 460V line-to-line out protection, can exceed twice the current.The circuit will, therefore, trigger at
voltage, or 266V line-neutral voltage. Figure normal 240V peaks, damaging components between 245 and 330V peak, and a 400V
17 shows a two-pole 75hp, wye-connected downstream. A simple arrangement to rated C106 can be used.The reader is
induction motor, at the running condition, crowbar the supply is shown. cautioned that SCR gate characteristics are
sensitive to junction temperatures, and The second category is that of surges This latter mode of stress may result in the
a value of 25˚C for the SCR temperature produced by nearby lightning strokes.The eventual open-circuiting of the device due
was merely chosen as a convenient value severity of a lightning stroke is characterized to melting of the lead solder joint.
for demonstrating design procedures. in terms of its peak current.The probability
of a direct stroke of a given severity can be When the device fails in the shorted mode
The maximum energy per pulse with this determined. However, since the lightning the current through the varistor becomes
waveform is determined as approximately current divides in many paths, the peak limited mainly by the source impedance.
1/2 x K x IPK x VPK x t (duration of 1/2 current available at an AC outlet within a Consequently, a large amount of energy can
wave pulse), or 0.52mJ for this example. building is much less than the total current be introduced, causing mechanical rupture
Since the voltage does not drop to zero in of the stroke.The standard impulse used to of the package accompanied by expulsion
this case, the SCR remains on, and the represent lightning and to test surge of package material in both solid and
varistor sees only one pulse; thus, no protective devices is an 8/20µs current gaseous forms. Steps may be taken to mini-
steady-state power consideration exists. waveshape as defined by ANSI Standard mize this potential hazard by the following
C68.2, and also described in ANSI/IEEE techniques: 1) fusing the varistor to limit
General Protection of Standard C62.41-1991 and IEC 60664-1. high fault currents, and, 2) protecting the
Solid State Circuitry surrounding circuitry by physical shielding,
A third category of surges are those or by locating the varistor away from other
Against Transients On produced by the discharge of energy stored components.
117VAC Lines in inductive elements such as motors and
Problem transformers. A test current of 10/1000s
waveshape is an accepted industry test
Series and Parallel
Modern electronic equipment and home impulse and can be considered representa- Operation of Varistors
appliances contain solid state circuitry that tive of these surges. In most cases the designer can select a
is susceptible to malfunction or damage varistor that meets the desired voltage
caused by transient voltage spikes.The Although no hard-and-fast rules can be ratings from standard catalog models.
equipment is used in residential, commer- drawn as to the category and severity of Occasionally the standard catalog models
cial, and industrial buildings. Some test surges which will occur, a helpful do not fit the requirements either due to
standards have been adopted by various guideline can be given to suggest varistors voltage ratings or energy/current ratings.
agencies and further definition of the envi- suitable in typical applications. When this happens, two options are avail-
ronment is underway by the IEEE and other able: varistors can be arranged in series or
organizations. The guideline of Table 2 recognizes consid- parallel to make up the desired ratings, or
erations such as equipment cost, equipment the factory can be asked to produce a
The transients which may occur on residen- duty cycle, effect equipment downtime, and “special” to meet the unique application
tial and commercial AC lines are of many balances the economics of equipment requirement.
waveshapes and of varying severity in terms damage risk against surge protection cost.
of peak voltage, current, or energy. For Series Operation of
suppressor application purposes, these may
be reduced to three categories. Failure Modes and Varistors
Varistor Protection Varistors are applied in series for one of
Varistors are inherently rugged and are two reasons: to provide voltage ratings in
First, the most frequent transient might be
conservatively rated and exhibit a low fail- excess of those available, or to provide a
the one represented by a 30kHz or
ure rate.The designer may wish to plan voltage rating between the standard model
100kHz ring wave.This test surge is defined
for potential failure modes and the resultant voltages. As a side benefit, higher energy
by an oscillatory exponentially decaying
effects should the varistor be subjected to ratings can be achieved with series
voltage wave with a peak open circuit volt-
surge currents or energy levels above its connected varistors over an equivalent
age of 6kV.This wave is considered
rating. single device. For instance, assume the
representative of transients observed and
application calls for a lead mounted varistor
reported by studies in Europe and North
with an VRMS rating of 375VAC and
America.These transients can be caused Failure Modes having a ITM peak current capability of
by distant lightning strikes or distribution Varistors initially fail in a short-circuit mode 6000A.The ITM requirement fixes the varis-
line switching. Due to the relatively high when subjected to surges beyond their tor size. Examining the LA series
impedance and short duration of these peak current/energy ratings.They also voltage ratings near 375VAC , only 320V
transients, peak current and surge energy short-circuit when operated at steady-state and 420V units are available.The 320V is
are lower than the second and third cate- voltages well beyond their voltage ratings. too low and the 420V unit (V420LA40B)
gories.
results in too high a clamp voltage (VC of
APPLICATION TYPE DUTY CYCLE LOCATION EXAMPLE SUGGESTED MODEL 1060V at 100A). For a V130LA20B and a
Light Consumer Very Low A Mixer/Blender V07E130 or V10E130
Consumer Low A Portable TV/Electronics V14E130
V250LA40B in series, the maximum rated
Consumer Medium A Home Theater, PC V14E130, V20E130 voltage is now the sum of the voltages, or
Light Industrial/Office Medium B Copier, Server V20E130, V20E140 380V.The clamping voltage,VC , is now the
Industrial Medium B Motors, Solenoid, Relay V20E140, V131HA32
sum of the individual varistor clamping volt-
Industrial High B Large Computer Motor Control V131DA40 or DB40
Industrial High B Elevator Control Heavy Motors V151DA40 or DB40
ages, or 945V at 100A.The peak current
capability is still 6500A but the energy
Table 2. Littelfuse varistor selection guideline for 117VAC applications
rating is now the sum of the individual SERIES PARALLEL
energy ratings, or 200J. Objective Higher voltage capability. Higher Current Capability
Higher energy capability. Higher Energy Capability
Non-Standard voltage capability.
In summary, varistors can be connected in Selection Required No Yes
series providing they have identical peak Models Applicable All, must have same ITM rating. All models
current ratings (I TM), i.e., same disc Application Range All voltages and currents. All voltages - only high currents, i.e., >100A.
diameter.The composite V-I characteristic, Precautions ITM ratings must be equal. Must be identical voltage rated models.
Must test and select units for similar V-I characteristics.
energy rating, and maximum clamp voltages
Effect on Ratings Clamp voltages additive. Current ratings function of current sharing as determined graphically.
are all determined by summing the respec- Voltage ratings additive. Energy ratings as above in proportion to current sharing.
tive characteristics and/or ratings of the Current ratings that of single device. Clamp voltages determined by composite V-I characteristic of matched units.
Energy WTM , ratings additive. Voltage ratings that of single unit.
individual varistors.
Table 3. Checklist for series and parallel operation of varistors
1000
LIMIT SAMPLE Some guidelines for series and parallel
800 operation of varistors are given in Table 3.
PEAK VOLTAGE (V)
600
500
400
300
LOWER BOUND (20%)
200 SAMPLE UNIT
MODEL V251BA60
TA = -40oC TO 85oC
100
0.1 0.5 1 5 10 50 100 500 1000 5000 10000 Littelfuse, Inc.
PEAK CURRENT (A) 800 E. Northwest Highway
Figure 22. Parallel operation of varistors by graphical tech- Des Plaines, IL 60016
nique www.littelfuse.com
Specifications, descriptions and illustrative material in this literature are as accurate as known at time of publication, but are
subject to change without notice. Littelfuse is a registered trademark of Littelfuse Incorporated.
EC638 Copyright © 2001 Littelfuse, Inc., All Rights Reserved. Printed in U.S.A. JANUARY 2002