21, rue d’Artois, F-75008 PARIS A2 – 303 CIGRE 2006

http : //www.cigre.org

Long-Time Experiences of ZnO Varistor Application in Power Transformers and

OLTC's

P. Heinzig*, W. Knorr, C. Ploetner

SIEMENS AG, PTD T
Germany

A. Krämer, M. Kölbl
Maschinenfabrik Reinhausen GmbH
Germany

SUMMARY

Transformers are exposed to various electrical stresses during service. Transient over voltages caused
by switching operations and lightning impulses can result in severe stresses on the internal insulation.
Such over voltages are normally limited to allowable values by surge arrestors at the line terminals.
However, excessive over voltages inside the transformer can occur if the exciting over voltage has the
same frequency as a natural frequency of a winding or a winding section. In such cases the over
voltage excites a resonance oscillation inside the relevant winding section with high amplitudes that
can damage the insulation. To avoid this effect several methods are known. The classical method is the
installation of a so called “snubber circuit” which consists of a resistor and a capacitance that are
connected from terminals to ground or in parallel to a winding section. More effective is the usage of
nonlinear resistors like ZnO elements.
These elements work independently of the occurring frequencies because they limit the voltage to a
certain value by absorption of energy. Transformer manufacturers have used ZnO elements for more
then 20 years to protect regulating windings and current limiting reactors in tertiary circuits, both of
which are subject to oscillations.

The Report shows detailed investigations of the usage of ZnO elements containing:
• Application possibilities in Transformers and OLTC
• Function
• Design criteria’s
• Long time service experience and stability
Based on the design criteria’s hundreds of transformers have been in service with ZnO protected
windings without any problems caused by the ZnO elements. This is a result of the quality control
process of the specific elements used and very conservative design rules which are based on detailed
investigations in the past.
The results of long time tests for more than 16 years show that proper limitation of continuously AC
guarantees a stable thermal service of ZnO elements under hot oil.

*E-Mail:peter.heinzig@siemens.com 1
Because the ZnO elements are connected in parallel to a winding section, the continuous voltage
across this section stresses them during the whole life. The minimal number of series-connected ZnO
elements will be determined based on this voltage. Hence, the residual voltage increases also by the
number of series connected elements. Due to this fact the ratio between clamping voltage and
allowable continuously AC stress determines the occurring over voltage during impulse or resonance
voltages.
The achievable protection by ZnO arrestors will be shown for different stresses and also in comparison
to proper designed “snubber circuits”.
Additionally some constructive examples of ZnO arrangements inside transformers and OLTC
compartment for different applications will be shown. These include both arrangements decently
located to the winding block and accessible arrangements in a separated oil compartment.
Within the insulation system of an OLTC the distance between the tap in service and the pre-selected
tap requires over voltage protection in most of the applications. Both under normal operation and
when testing the transformer with lightning impulse voltages, transient over voltages can appear on
this insulation distance. The magnitude of these over voltages is mainly determined by the oscillations
of the transformer windings and by the OLTC position during testing.
Today OLTC's for small and medium power transformers are mainly protected by using spark gaps.
ZnO elements are used in high power transformers or in transformers, where the service conditions
would cause frequent response of the spark gaps. The benefits for such applications are:
• Limiting of the over voltage without delay
• Limiting of the over voltage at a constant response threshold
• Reproducible behavior during impulse testing and in service
• No wear or significant ageing over the lifetime of the diverter switch
• Easy access during OLTC maintenance

The paper will deal in detail with the fundamentals of the application of ZnO's in OLTC for power
transformers as well as the good service experience of those elements over the last 25 years.

KEYWORDS

Zink-Oxide-Varistors, Winding-Protection, On-Load-Tap-Changer, Reliability

1. APPLICATION RANGE FOR ZNO-VARISTORS

External over voltages are normally limited to allowable values by surge arrestors at the line terminals.
Nevertheless, excessive over voltages can occur inside the transformer.
In the case of occurrence of a lightning impulse at the terminals, the internal windings parts are
stressed by voltage gradients produced by the traveling wave and by oscillations in parts of the
windings. These stresses of the insulation can be precisely calculated by modern design tools and the
insulation can be designed accordingly [1]. The related performance of the transformers is proven by
lightning impulse tests.
Switching operations in the system can lead to the occurrence of voltage oscillations at the terminals
of transformers. If such an oscillation voltage has a frequency which is close to the natural frequency

2
of a winding or a winding section voltage-amplitudes can be generated across certain parts of the
insulation inside the transformer. It is not economical to design the insulation of the transformer to
withstand all possible stresses generated by switching oscillations at all possible frequencies. Even a
design for a specified resonance frequency is not usual, as it may be difficult to predict the resonant
frequency of the system, or the resonant frequency of the system may change due to changes of the
electrical characteristics of the system.
For damping of impulse and oscillating voltage stress across the insulation two methods are very
common: installation of a so called “snubber circuit” or installation of ZnO varistors.
The classical method consists of the installation of a so called “snubber circuit” which consists of a
resistor and a capacitance that are connected from terminals to ground or in parallel to a winding
section (see fig. 1a). During Impulse stresses, a small damping of the amplitude of the oscillations
inside the transformer can be achieved. More pronounced is the reduction of the amplitudes of
oscillations at resonant frequencies.
4 4

ZnO
5

ZnO
5 6
ZnO
7
ZnO

6 8
regulating winding

regulating winding
ZnO

9
ZnO

7 ZnO-elements 10
ZnO

11
ZnO

Snubber circuit 1 x u step

8 12
ZnO

13
ZnO
R

9 14
a) winding protection by b) winding protection by
"Snubber circuit" ZnO-elements
Figure 1: Measures to reduce overvoltages inside a winding

More effective is the usage of nonlinear ZnO varistors (see fig.1b). These elements can assure a
substantial damping of the amplitudes of the oscillations during lightning impulse stress as well as
during the occurrence of oscillations with frequencies close to the resonant frequencies of winding
parts.
Due to the extreme non-linearity of the characteristic curve ZnO varistors absorb little energy at power
frequency voltage levels and damp the much higher voltage amplitudes of the transient oscillations.

2. RELIABILITY CONSIDERATIONS

Siemens has made very detailed investigations about the usage of ZnO varistors in transformers [2, 3].
Hundreds of transformers are in service with ZnO protected windings without any indication of
problems caused by the ZnO varistors.
This was achieved mainly due to:
– strict control of the ZnO varistor elements
– proper design of the elements-assembly
– very safe design rules that are based on long-time investigations.

3
Due to the fact that the ZnO varistors are connected in parallel to a winding section, the AC voltage of
the winding stresses the ZnO varistors continuously. The number of series-connected ZnO elements
will be determined based on this voltage.
To confirm the design rules and get confidence about the long-term effects Siemens has investigated
the behavior of several ZnO elements for more than 15 years under hot transformer oil at different
operating voltages û1 û2, û3 and û4.(see fig. 2). This investigation has shown that the ohmic loss
increase of the ZnO varistors depends of the applied voltage. Up to an applied voltage with an peak
value û2 a stabilization of the power consumption in the last years has been recorded after a rise-time
of the loss in the first 4 years. Therefore the peak voltage û2 has been chosen as a limit for the
admissible amplitude of the applied power frequency voltage across the ZnO varistor element in
service. The continuous over-excitation of the transformer is also taken into account in the design
stage.

250
û4
200
Loss in mW

150

û3
100

Design Voltage û2
50
û1

0
1985 1990 1995 2000 2005 Year

Figure 2: Measured power consumption of ZnO elements over time

The ZnO elements are arranged inside a pressboard tube (see fig. 3), which is normally mounted next
to the winding or to the tap changer. This assembly, together with the above described design rules,
allow maintenance-free operation during the lifetime of the transformer.

Pressboard Tube

Screening-Ring

Spring

ZnO-Elements

Connection wire

Figure 3: ZnO elements assembly

4
3. APPLICATION AREA OF ZNO VARISTORS
ZnO varistors have been used for more than 20 years to protect mainly tapping windings of
transformers and the insulation of reactors connected in tertiary systems.
In the tap windings of power transformers, where the tapping range is up to d 25% the ratio between
the maximum impulse voltage and the operating power frequency voltage of the tap winding is quite
high. Therefore the voltage amplitudes can be reduced up to 50% using ZnO varistors in case of
transformers with windings in star connection as well as in transformer with windings in delta
connection (see figures 4 and 5).
Maximum impulse
voltage amplitude

Pow er Transformers Furnace Transformers

across Tap
Windings

0 20 40 60 80 100
Tapping Range %

Envelope of the maximum voltage w ithout varistor

Maximum voltage across the ZnO-varistors

Figure 4: Maximum voltage across tap windings of transformers in star-connection with and without
ZnO varistors
Maximum impulse
voltage amplitude

Pow er Transformers Furnace Transformers

across Tap
Windings

0 20 40 60 80 100
Tapping Range %

Envelope of the maximum voltage w ithout varistor

Maximum voltage across the ZnO-varistors

Figure 5: Maximum voltage across tap windings of transformers in delta-connection with and without
ZnO varistors
In transformers where the tapping range is high, like furnace transformers and the windings are
arranged in delta connection, the ratio between the maximum impulse voltage and the operating power
frequency voltage of the tap winding is lower (see fig. 5). Therefore the ZnO varistors would not
provide a mentionable reduction of the amplitude of the impulse voltage in the tap winding. In this
case it is more economical to use the “snubber circuit” described before.
Reactors which are connected in tertiary systems have a low operating voltage drop at rated current.
But in case of transferred impulse surges to the tertiary system the impulse voltage across the reactor
can be quite high. A proper reduction of the transferred impulse voltage can be achieved using ZnO
varistors which are connected in parallel to the reactor (see fig. 6).

5
 3W2 3V2 3U2

3W1 3V1 3U1

3W3 3V3 3U3

3W2 3V2 3U2

Figure 6: ZnO varistors in parallel to a current limiting reactor in a delta connected winding

4. LONG TIME EXPERIENCE OF ZNO VARISTOR APPLICATION IN ON-LOAD

TAP-CHANGERS (OLTCS)
Within the insulation system of an OLTC the distance between the tap in service and the pre-selected
tap requires over-voltage protection in most of the applications. Both under normal operation and
when testing the transformer with lightning impulse voltages, transient over voltages can appear on
this insulation distance. The magnitude of these over voltages is mainly determined by the oscillations
of the transformer windings and by the OLTC position during testing. Especially in winding
arrangements with a coarse and tap winding extremely high voltage stresses occur at this insulating
distance during impulse testing when the OLTC is in mid position.
Fig. 7 shows the principal winding arrangement. Under chopped wave stress a maximum of 40% of
the incoming wave can appear across the distance between the tap in service and the pre-selected tap.
It is easy to understand that diverter switches cannot be designed for such withstand voltages. The
distance between the tap in service and the pre-selected tap must be adapted by means of over-voltage
protection to deal with the stress.
There are two possibilities for the over voltage protection in the diverter switch. OLTCs for small and
medium power transformers are mainly protected by using spark gaps. For high power transformers as
well as for all transformers where the service conditions would cause frequent response of the spark
gap, non-linear resistors are the better over voltage protection solution for the distance between the tap
in service and the pre-selected tap. During the last 25 years non-linear resistors made of Zinc Oxide
(ZnO) have been in use in OLTCs for power transformers with a very good service experience.
ZnO varistors are very fast limiting elements. The residual voltage varies in a small range because of
the high non-linearity of the ZnO elements (the varistor voltage increases between 1 mA and 10 kA
just about the factor 2).
The ZnO varistors applied to the diverter switch of the OLTC are connected across one tap of the tap
winding. Thus they are continuously stressed with the AC step voltage, but at this voltage level
(UStep, max. = 4000 V) there is no significant leakage current flowing through the varistor. For the surge
arresters several single ZnO-elements are connected in series. In some cases also the transition
resistors of the diverter switch are connected in series to the ZnO varistors to get a well-balanced ratio
between impulse current and residual voltage.
The values of the impulse currents stressing the ZnO varistors during transient over-voltages are of
great importance for the life expectancy of the varistors. They are dependant on the transformer data
and design. For the purpose of calculating the surge current, it is necessary to know the surge
impedance. In order to receive these surge impedance values, distribution measurements on several
numbers of transformers with different ratings and designs were performed.

6
Such transformer voltage current characteristics can be described as follows:

U a0 = U 0 − I a0 ⋅ Z S

with Ua0: residual voltage between the tap in service and the pre-selected tap
U0: max. voltage stress at this insulating distance without over voltage protection
Ia0: impulse current caused by the voltage stress
ZS: surge impedance

Impulse
stress

coarse winding

Ua 0

U0 Transformer-
tap Characteristic
winding

Arrester-
Characteristic
Operating
Ua point
0

Ia 0

Fig. 7: Winding arrangement with coarse and Fig. 8: Voltage current characteristics of a
tap winding, OLTC in mid position transformer and of the ZnO arrester

In fig. 8 the voltage current characteristics of a transformer and of the ZnO arrester are schematically
shown. The crossing point determines the operating point of the arrester.
In case of OLTCs the arresters with a series connection of ZnO elements and transition resistors are
designed in such a way that no impulse currents of more than 3 kA will arise. In case of the used
distribution type varistors, these stresses will not cause any problems, as it is shown in fig. 9. The
usability of the varistors under hot transformer oil must be proven and is usually confirmed by the
manufacturer of the ZnO elements. Before assembling the arrester the voltage at 1 mA DC of each
ZnO element is measured and recorded. This value serves as a reference for future measurements (e.g.
service checks).
As a part of the diverter switch, the arresters are easy accessible during the OLTC maintenance work,
which is periodically carried out on the on-load tap-changer. The voltage at 1 mA DC will be
measured and recorded at each maintenance check. This measured value will be compared with the
reference value mentioned before.
A decrease of the 1 mA DC voltage affects the operation voltage of the varistor with the consequence
that the leakage current increases. For the application in OLTC a reduction up to 10% of the 1 mA DC
voltage was established as a tolerable variation. In that case the leakage current will not reach values
that may cause a thermal runaway.

7
 Lightning impulse current [kA] 100

Air (RT)
Oil (100°C)
Oil (120°C)

10
1 10 100
Operation times

Fig. 9: Lightning impulse current (4/10 µs) versus number of discharge withstand characteristics. (An
extrapolation of the curves above for impulse currents of 3 kA (4/10 µs) leads to about 7.000
operations for use under Oil at 120°C).

69,27%
20% 100%

17,88%
18% 90%

16% 80%

14% 70%

Cumulative percentage
12% 60%
Percentage

10% 50%

8% 7,26% 40%

6% 30%

4% 20%

1,96% 1,68%
2% 10%
,56% ,84%
,00% ,28% ,28% ,00%
0% 0%
≤?-6% -5% -4% -3% -2% -1% 0% 1% 2% 3% >3%
Deviation of the 1 mA DC voltage

Fig. 10: Deviation of the 1 mA DC voltage of surge arresters with 2 - 7 ZnO elements after 6 years of
service (average time)

8
In the first applications in the early 1980s some arresters with ZnO elements showed deviations
greater than the desired 10% of the 1 mA DC voltage. The cause was found in the manufacturing
process of the ZnO elements and could be eliminated. After this improvement the quality of the ZnO
varistors could be kept constant on a high level until today. This good experience is depicted in
figure 10. The results shown are based on about 1750 ZnO elements assembled in more than 360
arresters and are gained from measurements on about 130 OLTCs commissioned in 1983 and later. It
can be easily taken from this figure that the deviation of the 1 mA DC voltage varies between –6% and
+3% for all measured ZnO elements. That shows that the deviation of the 1 mA DC voltage is only
half as much as the limit would allow, which is a remarkable hint for the good quality and service
stability of the used varistors.

75% 100%

61,54%
60% 80%

Cumulative percentage
45% 60%
Percentage

28,21%
30% 40%

15% 20%

5,13%
2,56% 2,56%
,00% ,00%
0% 0%
≤ -4% -3% -2% -1% 0% 1% > 1%
Deviation of the 1 mA DC Voltage

Fig. 11: Deviation of the 1 mA DC voltage of surge arresters with 2 - 7 ZnO elements after 13 years of
service (average time)
Some of the above mentioned varistors were measured a second time after additional 7 years (average
time) of service. Fig. 11 shows the results from these measurements. The deviation in percentage is
related to the factory measurements 13 years (average time) ago. These results are based on about 180
ZnO elements assembled in 39 arresters from 13 OLTCs. Also this measurement shows no significant
deviation of the 1 mA DC voltage. Due to this excellent behaviour ZnO arresters never caused
problems within the OLTC with respect to ageing phenomena.

5. CONCLUSIONS
The ZnO varistors are valuable devices for effective protection of transformer windings against all
kinds of transient over voltages caused by lightning strokes, faults, switching operations and resonance
conditions. The use of these varistors can strongly be recommended in all cases where they lead to a
more economical design.
In summarizing it can be pointed out also that the experience with ZnO varistors used as over-voltage
protection in OLTCs is excellent. The life expectancy of the ZnO elements is at least in the same
dimension as the lifetime of the transformer (more than 30 years).
Safe design rules for ZnO application must be based on long-term investigations and experience.

9
BIBLIOGRAPHY

[1] W. Müller, E. Buckow. “Numerische Berechnung der Resonanzschwingungen von

Transformatorenwicklungen (Siemens Forschungs- und Entwicklungsberichte Bd. 13
(1984))
[2] W. Knorr, W. Müller and W. Peschke. “The use of ZnO Varistors in Transformers”
(Elektrizitätswirtschaft Bd. 85 (1986))
[3] W. Knorr, W. Peschke and B. Thies. “The behavior of Zink Oxide Devices in Hot
Transformer Oil” (Elektrizitätswirtschaft Bd. 84 (1985))

10