Advancing MOV Block Technology:

Improving Performance,
Stability & Protection

GE Pingan, Chairman
Xi’an Tian Gong Electric (TGE), China
 Advancing MOV Block Technology:
Improving Performance, Stability & Protection

GE Pingan, Chairman, Xi’an Tian Gong Electric (TGE), China

13909255175@139.com

Contents
Abstract ...................................................................................................................................... 2
1. Introduction ............................................................................................................................ 2
1.1 TGE Introduction ................................................................................................... 2
1.2 Manufacturing Process of MOV .............................................................................. 2
2.Background of TGE Technology Development ....................................................................... 3
3.Development of Performance Enhancement ........................................................................... 3
3.1 Improvement on the Main Varistor Formula & the Optimization of Sintering
Process

3.1.1 The Improvement & Optimization of Varistor Formula.......................................... 3

3.1.2 Optimization of MOV Sintering Process ............................................................... 4
3.2 The R&D of the MOV Side Glass Coating Insulation Layer .......................................... 4
3.2.1 The Glass Coating Process .................................................................................... 4
3.2.2 The Optimization of Glass Coating Sintering Process ............................................... 4
3.3 Improvement of Manufacturing Equipment .............................................................. 7
3.3.1 Development of glass coating Spraying Equipment ............................................... 7
3.3.2 Development of Aluminium Spraying Equipment ................................................. 8
3.4 Research on Operational Duty Performance -36mm diameter MOV ........................... 8
3.4.1 Description of Operating Duty Test ................................................................... 11
3.4.2 Results of Operating Duty Test.......................................................................... 12
4.The Electrical Parameter for Typical MOVs.......................................................................... 13
5. Conclusions .......................................................................................................................... 13
Reference ................................................................................................................................. 14

1
Abstract
This technical paper presents an in-depth analysis of Metal Oxide Varistor (MOV)
development and performance enhancement, with a focus on surge arrester technology.
Ground breaking improvements have been made in the insulation layer through a
low-temperature glass powder material, optimized using electrostatic powder spraying
techniques. The paper also discusses fine-tuning the sintering curve to achieve a wider
temperature range for glass coating firing, contributing to greater stability in the MOV's grain
boundary layer. Special attention is given to formula optimization, incorporating strategic
chemical additives to elevate the MOV's protective performance and robust absorption
capability. These advancements are supported by the development of specialized
manufacturing equipment such as automatic electrostatic dry glass coating and electrical arc
aluminium spraying equipment. Extensive operating duty tests, following stringent conditions
beyond standard requirements, validate the technical performance of the newly developed
MOV. The findings affirm that these resistors not only meet but exceed established
international standards, thereby enabling the design of smaller, more cost-effective surge
arresters.

1. Introduction
1.1 TGE introduction
Xi 'an Tiangong Electric Co., LTD. (TGE) is located in Xi 'an, the capital of Shaanxi Province,
China. The company has been committed to the R&D and manufacture of high-performance
Metal Oxide Varistors (MOV) for many years. At present, TGE has a complete MOV
manufacturing technology system, independent intellectual property rights, and a complete
production line for MOV. TGE covers an area of about 46,600 square meters, and the
construction area is about 70,000 square meters.

1.2 Manufacturing Process of MOV

MOV is an electronic ceramic product, the primary constituent of MOV is zinc oxide, making
up roughly 90% of the total mass. The residual 10% comprises oxide additives, which serve
multiple functions: they fine-tune the non-linear V-I characteristics, control grain growth,
maintain the electrical stability of the MOV, and facilitate the manufacturing process.
MOV's manufacturing process is divided into eight steps, which are
1) Additive production
2) Spray dry
3) MOV pressing
4) MOV binder volatilization and sintering
5) Side insulation layer production
6) Grinding and cleaning
7) Spray aluminium electrode
8) Test and quality control
The entire production cycle is about 20 days, and each manufacturing process must be accurately
controlled to produce high -quality MOV.
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2. Background of TGE Technology Development
The performance of MOV made in China, when compared with the end of last century, has been
greatly improved, and the technical performances of the MOV, such as protection level, energy
absorption capability, aging performance and high current impulse withstand performance, have
all met the standard requirements.

However, the side insulation layer is basically organic material, since the organic coating may
easily become softened when the temperature exceeds 250°C, hidden risks in the side insulation
layer such as reduction of insulation performance, deterioration of small current characteristics
and peel-off of the glaze layer, may arise in the production of the arrester whose silicone rubber is
directly contacted with the MOV.

Moreover, there is still a gap with the international advanced level in the stability of the AC MOV
(the change rate of the reference voltage after the high current impulse), especially in the stability
after the high amplitude and steep impulse impact and the polarity reversal stability in the aging
test of DC MOV, so it is urgent to improve the technology in these areas.

Therefore, it becomes particularly necessary to optimize MOV formula and develop glass
insulation layer to solve the above problems.

3. Development of Performance Enhancement

3.1 Improvement on the Main Varistor Formula & Optimization of Sintering
Process

3.1.1 The improvement of varistor formula

Formulation is the basis of performance and process. Therefore, in order to improve the
varistor performance, the improvement and optimization of the formula is the most important
basic work. TGE has mainly carried out the following formula improvements:

A. After extensive tests, TGE has selectively add new chemical elements to change the
original nine-element formula to a ten-element one. With this improvement, the grain
boundary layer of the MOV becomes more stable, the change rate of current impulse
withstand is even lower, and the original excellent protection performance of the MOV
is still preserved.
B. According to the different requirements of AC, DC and high gradient varistors, after fine
adjustment of the proportion of chemical elements, a new varistor formula is finally
worked out with excellent protection performance, strong absorption capability and
better performance stability, thus laying the foundation for varistors with stable electric
performance.

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3.1.2 Optimization of MOV Sintering Process
The cooling rate of the temperature falling period in the sintering process has a great
influence on the nonlinear coefficient of the grain boundary layer, and can affect the
processing range of the subsequent process, that is, the glass coating sintering process,
therefore, the firing curve needs to be repeatedly adjusted and optimized. TGE has made
repeated tests on the cooling speed of varistors in the range of 600-850 , and finally
determined a more excellent cooling curve, which will yield better electrical performance in
small current area and wider heat treatment temperature range, thus laying a good foundation
for the following R&D of varistor glass coating.

3.2 R&D of MOV Side Glass Coating Insulation Layer

Glass coating is the international mainstream MOV side insulation material, the glass coating
generally includes the spraying and firing process. In order to industrialize the domestic glass
coating process, we have done the following work in the past years.

3.2.1 The Glass Coating Process

We selected a low-temperature glass powder material which has high stability, outstanding
insulation and 510 vitrification temperature, applied it to the side of the MOV by
electrostatic powder spraying and slurry spraying process respectively, then sintered it and
observed its effect. After repeated tests, as a result, the coating process by electrostatic
spraying method showed a more excellent appearance and better adhesion.

3.2.2 The Optimization of Glass Coating Sintering Process

In addition to produce a glass coating coated layer with fine appearance and strong adhesion,
the glass coating sintering process can also change the internal crystal shape of the MOV, and
then stabilize the electrical performance of the MOV. Whether for normal AC MOV, DC
MOV or high gradient MOV, the heat treatment at 450-550 will affect the Bi-rich phase
transformation of the grain boundary layer, and the closely related corresponding cooling rate
is just the key factor affecting the phase transformation of the grain boundary layer. Therefore,
the optimization of the glass coating sintering process can stabilize the grain boundary layer
and improve the effect of polarity-reversal aging of DC MOV.
Through repeated tests, TGE has finally found out the appropriate temperature rise and fall
curve, the highest sintering temperature and the heat preservation time, and successfully
produced the 0.1mm uniform and dense coated glass coating layer. This insulation layer
characterizes high electrical insulation strength and mechanical strength, and is closely
combined with the MOV body.

In conclusion, by improvement of the main MOV formula, cooling curve optimization in the
sintering procedure and the optimization of the glass coating process, we successfully solved
the polarity-reversal problem in the aging of the DC MOV and improved the aging
performance of AC MOV, and at the same time, the change rate of the MOV reference
voltage after the large current impulse has been greatly reduced, especially for MOVs whose
diameter is less than 42mm, the improvement effect is more significant. Therefore, the
operating duty performance of the distribution arrester is enhanced.

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 Table 1. Comparison of aging performance of MOV before and after technology improvement

AC MOV
MOV type
D36 D42 D60 D71 D115
Test temperature(°C) 115 115 115 115 115
Time period(h) 1000 1000 1000 1000 1000
Applied voltage（U*1.414/U1mADC） 0.85 0.9 0.9 0.9 0.9
Pend/Pstart before technology
0.88 0.89 0.92 0.89 0.91
improvement
Pend/Pstart after technology
0.75 0.69 0.83 0.74 0.78
improvement

Figure 1.

The aging

characteristics

of D41H36 (with

2.5mm epoxy

glass fiber winding layer) at 90% AVR and

115°C, 2000h.

AVR stands for Arrester Voltage Ratio. The formula for AVR (η) is:

Where Uc is the applied power frequency voltage (r.m.s. value), and U1mADC is the DC
1mA reference voltage of the MO Resistor.

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 Table 2 DC D71H22.5 polarity reverse Aging Test data
Pi Power loss PI/P0
P0 0.591 1.00
P1 0.209 0.35
P2 0.389 0.66
P3 0.166 0.28
P4 0.352 0.60
P5 0.159 0.27
P6 0.58 0.98
P7 0.155 0.26
P8 0.636 1.08
P9 0.187 0.32

Time (h)
Picture 2 DC D71H22.5 polarity reverse Aging Test
Horizontal coordinates are time, vertical coordinates are power loss.

Table 3 Comparison of high current withstand of MOV before and after technology improvement
Change rate before Change rate after
High current technology technology
MOV type
withstand, 2times improvement improvement
Uref Ures Uref Ures
D36H31 100kA -5.60% 1.35% -2.44% 1.09%
D42H29.4 100kA -4.76% 1.02% -1.65% 0.85%
D60H35.4 100kA -3.24% 0.90% -1.47% 0.73%
D78H35.4 100kA -2.07% 0.21% -1.02% 0.15%

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3.3 Improvement of Manufacturing Equipment
Due to the niche industrial scale of MOV manufacturing, standardized facilities are scarce.
Most specialized production equipment is custom-designed to fit a company's unique process
requirements.

3.3.1 Development of Glass Coating Spraying Equipment

For the glass-coated MOV production line, we have developed automatic electrostatic dry
glass coating equipment. This system uses an electrostatic spraying process to apply
granulated glass powder vertically downward onto the MOV's surface. This eliminates the
non-uniformity in the glaze layer caused by gravitational effects during horizontal spraying.
Additionally, this approach ensures even heating of the internal and external glass powder
layers during the firing process, resulting in a uniform, dense, and highly adhesive fired glass
insulation layer. Unlike the slurry spraying technology used by other manufacturers, our
design incorporates two alternating spraying modules, significantly boosting efficiency. The
successful development of this equipment enhances both the effectiveness and efficiency of
glass coating application.

Figure 2. Automatic glass powder coating machine

Figure 3. Glass coating application (passivation process) – left before process, right after process

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 Figure 4. Glass coating application (passivation process) – precision of process

3.3.2 Development of Aluminium Spraying Equipment

In China and some other countries, the common aluminum spraying method for MOV
involves protecting their sides with silicone rubber rings. This creates an unsprayed margin
along the edges, resulting in uneven current distribution during impulse events and increasing
the likelihood of MOV edge breakdown. This traditional rubber ring method is complex and
inefficient. To resolve this longstanding issue, we have developed automatic electrical arc
aluminum spraying equipment. The design employs high-speed airflow along the edges
during spraying to remove molten aluminum particles, preventing edge contamination and
enabling a
rubber-ring-free process. Consequently, this full-electrode technology increases energy
absorption capability by up to 15%. Furthermore, our fast-flipping technology enables
simultaneous spraying on both sides, greatly enhancing production efficiency.

Figure 5. Aluminum Spraying Equipment –MOV before and after spraying process

3.4 Research on Operational Duty Performance -36mm Diameter MOV

Through optimization of MOV formulations, manufacturing processes, and
specialized production equipment, TGE have substantially improved the MOV' protection
level, energy absorption capability, and stability. These enhanced MOV not only meet
the standards of IEC60099-4:2014, IEEE Std C62.11-2020, and GB11032-2020, but they
also enable arrester design miniaturization and cost reduction—factors of significant
economic importance. Specifically, TGE has developed MOV with a diameter of 36mm and
a gradient of 235V/mm for distribution type arresters (Heavy Duty HD & Distribution High
DH). Subsequent sections will present the test results for these 36mm diameter MOV (D36
types).

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 Table 4 Technical parameters of glass coated D36 MOV
MOV Spec
D36H20.7 D36H31 D36H34.5
NO. Item
1 Diameter (mm) 36±0.7
2 Height (mm) 20.7±0.3 31±0.3 34.5±0.3
3 Insulation layer Glass
4 Gradient (V/mm) 235
Distribution High (DH) for IEC
5 Applicable Classification
Heavy Duty (HD) for IEEE
IEC60099-4:2014
6 Reference international standards
IEEE Std C62.11-2020
7 Nominal Discharge Current (kA) 10
8 Repetitive Charge Transfer (C) 0.4
9 Thermal Energy Qth (C) 1.1
10 1000 hours aging coefficient at 115°C ≤1.00
4/10µs high current impulse, 2 times
11 100
(kA)
2ms long duration current impulse
12 400
withstand, 20 times (A)
Recommended value of rated voltage
13 3 4.5 5
（kV）
14 Reference Voltage U1mADC (kV) 4.85±0.3 7.3±0.45 8.1±0.5
Reference Voltage at 5mA, Uref
15 3.55±0.22 5.34±0.33 5.92±0.37
(kVrms）

In order to ensure that the operating duty test conditions for the MOV are more stringent than
the heat dissipation conditions of the surge arresters, the MOV are placed in a heat-insulated
insulating cylinder. The heat dissipation characteristics are as follows:

Figure 6. Thermal dissipation characteristics

The red curve is prorated section, the black curve is the surge arrester model

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For distribution type arresters, the difference in the operating duty test procedure between
IEC60099-4:2014 and IEEE Std C62.11-2020 lies solely in the power frequency voltage applied
for 10 seconds. To verify the operating duty performance of the D36 MOV, we employed test
parameters that are more stringent than those required by the standards.
The focus is primarily on the following three points:
1. Ur is increased, and the voltage application time is extended.
2. MCOV is increased.
3. MOV preheating temperature is increased.
4. The times of high currents has been increased.

4.4.1 Description of Operating Duty Test

To demonstrate thermal stability as per international standers, Surge Arresters are required to
absorb energy from switching occurrences (Station Class) or charge transfer (Distribution Class)
from lightning activities, and then be able to thermally recover when subjected to temporary
overvoltage and subsequent sustained operating voltage conditions. This capability is verified by
the operating duty test.

Figure x. Graphical depiction of steps of the operating duty test for non-gapped distribution
arresters (source IEEE C62.11)

- Initial and Final Characterization are required to monitor any changes or

modifications of the MOV structure and Electrical Performance following the surge
duty.
- The Preconditioning is represented by the injection of a high current impulse which
is supposed to influence the characteristics of MOV towards a kind of accelerated
ageing.
- The Thermal Stress and Recovery part represents the main stage of the test. MOV
are first preheated to 60°C or more (a realistic extreme condition). Then, a charge
equivalent to lightning strikes is injected through two impulses. Subsequently, the
equivalent of the rated voltage is applied for 10 seconds (an extreme transient
overvoltage condition). Finally, we apply the MCOV (an extreme phase-to-ground
permanent voltage condition), and the temperature is continuously measured to
ensure that the system is stable and that the temperature decreases over time.

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 4.4.2 Results of Operating Duty Test

The test results indicate that the D36 MOV can successfully pass the operating duty test, even
under conditions more stringent than those specified in the standard. Therefore, D36 MOV is
suitable for use in the production of distribution type arresters for both IEC and IEEE
standards.

Table 5. Results on Operating Duty Tests for 36mm MOV type

Thermal proportional unit with two pieces of D36H22 wrapped by 2.5mm thick epoxy fiber glass
as insulating layer
Samples
Sample No. 1 2 3 4 5 6 7 8
U1mA DC (kV） 10.612 10.641 10.598 10.512 10.641 10.656 10.684 10.699
Data before the
Uref 5mA (kV） 7.88 7.9 7.87 7.81 7.9 7.91 7.93 7.94
test
U10kA (kV） 19.11 19.15 18.96 19.09 19.01 19.08 19.02 19.02

Ur (kV） 7.17 7.19 7.16 7.43 7.53 7.54 7.56 7.57

Feature
MCOV (kV） 0.8Ur 0.8Ur 0.8Ur 0.85Ur 0.85Ur 0.85Ur 0.85Ur 0.85Ur
Parameters
Ur*1.414/U1mADC 0.96 0.96 0.96 1.00 1.00 1.00 1.00 1.00
Apply 4/10µs First time 103.89 101.83 103.06 102.34 102.34 102.52 102.72 102.45
high current
102.88 101.37 102.05 101.97
（kA) Second time

Cool down to room temperature 21°C

Actual preheating temperature（°C） 75 75 75 75 75 75 75 75

8/20µs impulse first (C） 0.596 0.585 0.571 0.576 0.567 0.586 0.59 0.589
Qth=1.1C，
second (C） 0.575 0.571 0.571 0.568 0.567 0.581 0.579 0.59
single time
Qth≥0.55C total (C） 1.171 1.156 1.142 1.144 1.134 1.167 1.169 1.179

apply voltage within 100ms ≤90ms

applied voltage (kV） 7.16 7.22 7.17 7.49 7.53 7.47 7.47 7.55
Apply Ur 10S
time of duration (s） 10 15 15 20 10 10 20 20

applied voltage (kV） 5.75 5.78 5.77 6.34 6.45 6.48 6.4 6.4
Apply MCOV time of duration (s） 1800 900 1800 1800 1800 1800 1800 1800
1800s (30min) Thermal stability
OK OK OK OK OK OK OK OK
judgment
Uref5mA (kV） 7.29 7.25 7.46 7.31 7.42 7.41 7.4 7.49
Data after the
U10kA (kV） 19.72 19.68 19.31 19.58 19.51 19.38 19.38 19.35
test
Sample inspection Good Good Good Good Good Good Good Good

Uref5mA change rate (%) -7.5 -8.2 -5.2 -6.4 -6.1 -6.3 -6.7 -5.7
Test evaluation U10kA change rate (%) 3.19 2.77 1.85 2.57 2.63 1.57 1.89 1.74

Pass Criteria (%) ±5 ±5 ±5 ±5 ±5 ±5 ±5 ±5

Test results qualified qualified qualified qualified qualified qualified qualified qualified
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5. The Electrical Parameter for Typical MOVs
After a series of technical breakthroughs, the performance parameters are shown in the

following table.

Table 6 Typical specifications of MOV

Gradie ND High
Ur Iref Uref
nt A Ures(k Uref/ Ures/ curre
Type (kV (mA (kV Qrs(C)
(V/m (kA V) Ur Ur nt 2
) ) )
m) ) time

100k 8/20u 0.4

D36H31 5.02 235 10 2 5.26 13.11 1.05 2.61
A S 0

D42H29. 100k 1.0

5.14 250 10 3 5.35 12.79 1.04 2.49 2mS
4 A 0

D60H35. 100k 2.4

5.52 220 10 3 5.73 12.93 1.04 2.34 2mS
4 A 0

D70H35. 100k 3.2

5.64 220 10 5 5.76 12.69 1.02 2.25 2mS
4 A 0

D78H35. 100k 4.0

5.69 220 10 5 5.78 12.54 1.02 2.2 2mS
3 A 0

D105H2 100k 6.0

3.66 220 20 5 3.73 8.12 1.02 2.22 2mS
2.5 A 0

6. Conclusions

Although the MOV industry has existed for over 40 years and boasts numerous players,
particularly in China, meeting and exceeding performance standards in manufacturing
requires both specialized experience and focused research. TGE's initiatives have resulted in
the development of a diverse range of MOV characterized by tightly controlled
manufacturing processes. Introduction of new material elements into the MOV formulation,
along with adjustments in the proportions of existing material elements and optimizations in
the sintering process, have collectively enhanced the technical performance of MOV

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structures. Utilizing the recently developed glass coating technology has further improved
both the aging performance and stability of MOV following high-current impulses.

Advancements have also been made in the technology of manufacturing equipment,

culminating in the successful industrialization of glass-coated MOV. Furthermore, a
specialized MOV designed for heavy-duty distribution arresters has been developed.
Operating duty tests conducted under conditions more stringent than those specified by
standard requirements affirm that these technical parameters satisfy all criteria necessary for
distribution arresters.

References

- [1] Experimental Investigations of the Multiple Impulse Energy Handling Capability

of Metal-Oxide Varistors for Applications in Electrical Power Engineering - Dipl.-Ing.
Maximilian Nikolaus Tuczek

- [2] IEEE Standard C62.11-2020 - IEEE Standard for Metal-Oxide Surge Arresters for
AC Power Circuits (>1 kV)

- [3] Factors in Performance of Metal Oxide Varistors – INMR Contribution –

Jonathan Woodworth, Arresterworks

- [4]《IEC60099-4:2014 surge arresters part 4: metal oxide arresters without gaps for
A.C . systems 》

- [5]《氧化锌压敏陶瓷制造及应用》王振林、李胜涛著 M. 北京: 科学出版社, 2009

- [6]《metal oxide varistor form microstructure to micro-characteristics》何金良著

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