Performance of Zinc Oxide-Vanadium Pentoxide Varistors in Medium Voltage Surge Arresters
Performance of Zinc Oxide-Vanadium Pentoxide Varistors in Medium Voltage Surge Arresters
Keywords: Advanced functional materials; Metal oxides; ZnO-V2O5 varistors; Medium voltage surge arresters.
Metal oxide varistor (MOV) discs (Ø28 mm × 12 mm) made of 97.5 mol.% zinc oxide (ZnO), and 0.5 mol.% each of vanadium
pentoxide (V2O5), tin (IV) oxide (SnO2), antimony(III) oxide (Sb2O3), cobalt(II, III) oxide (Co3O4), and chromium(III) oxide (Cr2O3)
additives were produced using powder metallurgy. The obtained MOVs were polycrystalline with high density. This study focused on
analyzing the microstructure and mechanical and electrical properties of the MOVs. The developed MOVs had a fine-grained
microstructure with an average ZnO grain size of about 10 μm. The Ag-coated MOV discs tested in a range of 100 – 1300 V ac
exhibited a leakage current of 0.033 – 1.420 mA and a minimum varistor voltage of 2.37 ± 0.15 kV. After conducting functional tests
on Ag-coated MOVs installed in polymer-housed surge arresters, it was found that they are suitable for use in medium voltage
arresters with a nominal voltage (Un) of 25 kV, a continuous operating voltage (Uc) of 12 kV and a leakage current (IL) of 1 mA.
1 National Institute for Research and Development in Electrical Engineering ICPE-CA (INCDIE ICPE-CA) Bucharest, 313 Splaiul Unirii
Street, 030138, Bucharest, Romania
2 MAIRA MONTAJ SRL, 38A Inovatorilor Street, 012417, Bucharest, Romania
(b)
Fig. 9 – a) SEM secondary electron (SE) image (5000 ×) of an unfractured
surface of MOVs; b) corresponding EDS spectrum.
In Fig. 10, it is noticed that V, Sb, and Sn are mostly of pores in varistors. As expected, MOVs with higher density
located at the ZnO GBs, while Co and Cr are associated with and a more homogeneous microstructure exhibited better
both ZnO grains and GBs. The elemental content of the mechanical and electrical properties.
prepared MOVs determined from the EDS analysis (Fig. 9) Sedghi et al. [36] disclosed Vickers hardness values of 125
matched the designed content, although slightly reduced for and 251 respectively for ZnO-Bi2O3-Sb2O3-CoO-Cr2O3-
some metal elements. The decrease in V and Sb can be MnO-based varistors manufactured with powder metallurgy
attributed to the partial volatilization of V2O5 and Sb2O3 with and micron and nano-sized ZnO powders. However,
lower melting points than the sintering temperature of MOVs comparing their material properties is challenging due to
(1 200 °C) [2]. V2O5 is known to exhibit high vapor pressure numerous factors affecting the properties of ZnO-based
(≥ 290 Pa) at temperatures over 1 500 K (~1 227 °C), leading varistors [2] and limited data consistency across literature
to its evaporation during sintering at elevated temperatures studies.
[27]. Sb2O3 can also vaporize at high temperatures [28].
3.3. ELECTRICAL CHARACTERISTICS
Moreover, in ZnO-based varistors, it has been found that
ZnO, Bi2O3 and Sb2O3 are the key oxides controlling the The newly developed varistors demonstrated a significant
sintering reactions at high temperatures, leading to the varistor effect. When subjected to a low voltage of 500 V
formation of secondary phases [29,30]. The remaining MO DC, the varistors exhibited a high resistance of 230 MΩ,
additives used in MOVs can be solidly dissolved in ZnO and indicating a non-conductive state. Increasing the applied
incorporated into various secondary phases [30]. The voltage to 1000 V dc decreased the resistance to 110 MΩ,
vaporization resistance of ZnO-Bi2O3-based systems doped indicating a transition to a conductive state. This substantial
with 0.36 – 0.72 mol∙% Bi2O3 and 0.72 – 1.44 mol∙% Sb2O3 decrease in resistance suggests the ability of the prepared
increased at high sintering temperatures (1 000 – 1 250 °C) ZnO-V2O5-based varistors to protect against voltage surges.
[30]. A similar trend was observed for ZnO-V2O5-based Table 2 outlines the electrical characteristics of the ZnO-
systems doped with 0.25 – 0.5 mol∙% V2O5 and V2O5-based varistors measured under ac voltages.
2 mol∙% Sb2O3 and sintered at 1 200 °C. The resulting Table 2
varistors exhibited a main ZnO phase and a Zn7Sb2O12 spinel Electrical properties of the ZnO-V2O5-based varistors under ac voltages
secondary phase, which inhibited ZnO grain growth and MOV Voltage (UAC) Uc med
improved microstructure and electrical properties [12,32]. sample 100 V 200 V 250 V 500 V 1000 V 1300 V (kV)
The density and performance of the newly developed no. Leakage current IL (mA)
ZnO-V2O5-based varistors were enhanced mainly due to S1 0.037 0.072 0.088 0.157 0.537 1.200 2.40
S2 0.038 0.075 0.090 0.142 0.583 1.420 2.20
V2O5, which acted as a sintering aid. During sintering in air
S3 0.033 0.062 0.073 0.111 0.365 1.020 2.50
at 1 200 °C, forming a V-rich liquid phase facilitated the Mean ± 0.036 ± 0.070 ± 0.084 ± 0.137 ± 0.495 ± 1.213 ± 2.37 ±
dispersion of ZnO and other MO particles, promoting GB SD 0.003 0.007 0.009 0.023 0.115 0.200 0.15
migration, densification, and enhancing solid-state diffusion
processes. Literature studies on ZnO-based varistors doped At lower ac voltages of 100 V to 250 V, the ZnO-V2O5-
with 0.5 – 1 mol∙% Bi2O3 or V2O5 also confirmed that liquid- based varistors exhibited good electrical behavior with low
phase sintering induces a ZnO grain boundary structure, leakage current (IL) values of 0.033 – 0.090 mA (Table 2),
leading to nonlinear behavior in varistors [2,33]. indicating their ability to maintain a high resistance state.
In Fig. 10, both the V-rich and the Zn-Co-Sb-O secondary Upon increasing the ac voltage to 500 V, the varistors
phases are observed to segregate at the ZnO GBs. The exhibited neutral electrical behavior, with average IL values
segregation of insoluble Sb2O3 at the ZnO GB regions occurs of 0.137 ± 0.023 mA. However, at higher ac voltages of
due to the larger ionic radius of Sb3+ cations (0.076 nm) than 1 000 V and 1 300 V, the varistors displayed poor electrical
that of Zn2+ cations (0.074 nm) in the ZnO host lattice. Other behavior, suggested by significantly increased IL values
metal cations used as dopants in ZnO have ionic radii of (0.365 – 1.420 mA). Additionally, the average values of the
0.069 nm (Sn4+), 0.0615 nm (Cr3+), 0.0545 nm (Co3+), and minimum varistor voltage in ac (Uc med) of 2.37 ± 0.15 kV
0.054 nm (V5+), all smaller than Zn2+ cations (0.074 nm) with also confirm the good electrical performance of the newly
a coordination number of VI [34]. These metal cations developed varistors, indicating their ability to protect against
generate more donor states, which improves electron voltage surges at the industrial frequency of 50 Hz.
conduction, increases nonlinearity, and reduces the leakage
current of ZnO-based varistors [2].
3.2. MECHANICAL CHARACTERISTICS
The newly developed ZnO-V2O5-based varistors
exhibited an instrumented hardness (HIT) of 2.77 ± 0.20 GPa,
a Vickers hardness of 261 ± 16 HV, and an elastic modulus
(EIT) of 128 ± 7 GPa. The mechanical properties of these
varistors are comparable to those of several commercial
ZnO-Bi2O3-based varistor blocks (4 kV, class 1) with an
average ZnO grain size of 6 – 8 µm [35]. Yoshimura et al.
[35] reported hardness values ranging from 1.89 ± 0.09 GPa
to 2.26 ± 0.05 GPa, and elastic modulus values between
104.9 ± 1.0 GPa and 115.4 ± 1.8 GPa. The variation in these
properties mostly resulted from differences in the type and
content of secondary phases and the volume fraction and size Fig. 11 – Plots of ac voltage and current waveforms over time for a MOV.
5 Magdalena-Valentina Lungu et al. 187
Figure 11 presents plots of ac voltage and current surge [1]. The resistive current also increased around 3.1
waveforms over time, recorded using a Fluke 435-II analyzer times, up to 22 mA, with a temperature rise from 15 °C to
in single-phase (A) with neutral mode (AN) at nominal 77 °C. When subjected to voltages of 12 kV and 15 kV for
setting (voltage of 1 kV, current of 1 A, frequency of 50 Hz). 6 min., the MOVs attained maximum temperatures of 18 °C
It shows a voltage dip event, characterized by a rapid and 26 °C respectively. These MOVs exhibited temperature
deviation from the nominal voltage, captured 187 ms into ac increases of about 3 to 4. times lower than the maximum
testing of MOVs. However, no transient events were temperature of 77 °C observed at the higher applied voltage
observed during ac testing of MOVs for 1 minute. The (20 kV). This means lower applied voltages result in less
maximum root mean square (RMS) current (Arms) was 0.008 stress on the MOVs and, consequently, lower temperature
A, while the maximum RMS voltage (Vrms ph-n) was 1.31 kV rises. Additionally, the resistive current decreased
under AN mode, indicating overvoltage conditions considerably within 6 min. testing, with maximum IR values
compared to the nominal voltage. The absence of transient of 2.1 mA at 27 °C for 15 kV and 0.91 mA at 18 °C for
events despite overvoltage conditions suggests the efficiency 12 kV. Particularly, under a voltage of 12 kV, the resistive
of these MOVs in suppressing voltage spikes during testing. current exhibited minimal variation, ranging between
Figures 12 and 13 depict temperature-time and resistive 0.90 mA and 0.91 mA. This steady behavior indicates
current-temperature relationships during ac testing of MOVs superior electrical and thermal stability of the MOVs at
within gapless surge arresters, maintaining constant voltages 12 kV. Therefore, the MOVs are suitable for continuous
(Uc) of 12 kV, 15 kV, and 20 kV, respectively. operation at 12 kV due to their proven reliable performance
under this voltage level.
Table 3 presents electrical testing results conducted on
MOVs installed in three polymer-housed gapless surge
arresters. Un designates the nominal voltage, Uc represents
the continuous operating voltage, K denotes the leakage
current (IL) correction factor (K = 0.8 at 20 °C), and IR max
indicates the maximum resistive current at 20 °C (Fig. 14).
Table 3
Technical characteristics of the ZnO-V2O5-based varistors determined
under real operating conditions within gapless MO surge arresters
Sample Tests in DC Tests in AC T K Uc Tfinal
No. Un IL Uc IL IR max (°C) (kV) (°C)
(kV) (mA) (kV) (mA) (mA) in DC
S1 25.8 NA 20 2.5 20 20 0.8 40 42
S2 26.0 NA 20 2.4 20 20 0.8 41 40
S3 25.5 NA 20 2.5 20 20 0.8 40 41
Fig. 12 – Variation of the temperature versus time during ac testing of Mean ± 25.8 ± NA 20 2.5 ± 20 20 0.8 40.3 ± 41 ±
MOVs in gapless surge arresters at 12 kV, 15 kV, and 20 kV. SD 0.4 0.1 0.7 0.7
As the applied voltage increases from 12 kV to 20 kV, the After conducting functional tests on Ag-coated MOVs
temperature and resistive current (IR) of the MOVs exhibited installed in polymer-housed surge arresters, it was found that
a considerable rise over time. This rise suggests that higher they are suitable for use in medium voltage arresters with a
applied voltages increased stress on the MOVs, resulting in nominal voltage (Un) of 25 kV, a continuous operating
higher temperatures and greater resistive currents. The voltage (Uc) of 12 kV, and a leakage current (IL) of 1 mA.
temperature surge was very pronounced under a voltage of
20 kV, with the MOVs reaching a temperature of 77 °C 4. CONCLUSIONS
within 5 min. of ac testing, about 5.1 times higher than the Disc-shaped MOVs made of 97.5 mol∙% ZnO,
initial temperature (15 °C). This temperature rise was mainly 0.5 mol∙% V2O5 as the varistor-forming oxide, and
due to the increased energy dissipation within the MOVs as 0.5 mol∙% each of SnO2, Sb2O3, Co3O4, and Cr2O3 additives
they absorb and dissipate excess electrical energy during the were manufactured through powder metallurgy (PM). The
188 Zinc Oxide-Vanadium pentoxide varistors in surge arresters 6
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