Mansoura University

Faculty of Engineering
Electrical Power & Machine Dept.

HIGH VOLTAGE RESISTORS

By
Khaled Ibrahim Abdul Aziz
Section 3

Supervised By
Assoc. Prof. Dr. Ebrahim A. Badran
 Abstract
Several different types of resistor exist. When it comes to HV power the
resistor must have high voltage rating to withstand the power; this report
offers the main types of high voltages resistors including the construction,
advantages and disadvantages, and application of each one.

Table of Contents
1. Introduction ......................................................................................................................... 2
2. Carbon film resistors ........................................................................................................... 2
3. Metal Oxide resistors........................................................................................................... 3
4. Surge metal glaze resistors .................................................................................................. 3
5. References ............................................................................................................................ 4
1. Introduction
A resistor refers to an element in the architecture of electronics that hinders
the flow of electricity. An increase in the resistance value will require an
increase in the applied voltage to maintain a constant electrical current.
Resistors with high voltage rating are suitable for HV systems and precise
applications. There are many types of high voltage resistors that
manufacturers provide. The main types of these resistors are:
2. Carbon film resistors
Carbon film resistors are a fixed form type resistor. They are constructed out
of a ceramic carrier with a thin pure carbon film around it, which functions
as resistive material.

2.1 Construction
The carbon film resistor is made by placing the
carbon film on a ceramic substrate. The carbon film
blocks some amount of electric current. The ceramic
substrate acts as the insulating material to the heat or
electricity. Hence, the ceramic substrate does not
allow heat through them. Therefore, these resistors
can withstand at higher temperatures without any
damage. Metallic end caps are fitted at both ends of
the resistive material. The leads made of copper are joined at two Figure 1
ends of these metallic end caps. The resistive element of the
carbon film resistor is coated with epoxy for protection. It uses thin film
technology.

2.2 Advantages and disadvantages

Carbon film resistors are a significant improvement on carbon composition
resistors with less noise generated. They are cheap and have low tolerance
with wide operating range. However, they are not commercially available
compared to other types and high negative temperature coefficient of
resistance.

2.3 Applications
Typical use for carbon film resistors is in high voltage and temperature
applications. Operating temperatures are up to 15kV with a nominal
temperature of 350°C. Examples are high voltage power supplies, radar, x-
rays and laser
2
3. Metal oxide film resistor
The metal oxide film resistor is a type of fixed resistor, which uses metal
oxide film as the resistive element to limit the flow of electric current to
certain level. The film is constructed by using the tin oxide.

3.1 Construction
The metal oxide film resistor is made by coating the
ceramic core with metal oxide such as tin oxide. The
antimony oxide is added to the tin oxide to increase its
resistivity. The resistivity of the metal oxide film is
mainly depending on the amount of antimony oxide
added to the tin oxide.
The film made of tin oxide and antimony oxide acts as
the resistive element to the electric current. Hence,
metal oxide film restricts the electric current to certain
level. The ceramic core acts the insulating material to
the electricity. Hence, the ceramic core does not allow Figure 2
heat through it. Thus, these resistors can withstand at high
temperatures. They use thick film technology.

3.2 Advantages and disadvantages

They can operate at higher temperatures, high surge and overload capability,
produce low noise, provide high stability and reliability. They also have
small size with low cost. However, they have poor properties for low values
and tolerance

3.3 Applications
They are used in applications where stability and uniformity of
characteristics are desired such as automotive electronics and industrial
applications. They are also used as high voltage dividers where precision is
not important, load resistors and bleeder resistors.

4. Surge metal glaze resistors

metal glaze resistor is a type of fixed resistor, which uses glass powder and
metal particles (silver and palladium) mixture to restrict the flow of electric
current to certain level. which are used in series with circuit elements that
might experience arcs or intentional transients.

3
4.1 Construction
A metal glazed film is deposited on a high-grade ceramic
body. After that caps are applied to the rods and tinned
electrolytic copper wires are welded to these end caps.
The resistors are coated with a light-blue lacquer which
provides electrical, mechanical and climatic protection.
The encapsulation is resistant to all cleaning solvents
according to IEC 60068-2-45. Figure 3

4.2 Advantages and disadvantages

High pulse-loading capability, good replacement for carbon composite
resistors, lead (pb)-free solder contacts, and high stability.

4.3 Applications
In overload and high voltage pulse hazard circuits (TV-sets, monitors), high
power electronic ballasts

5. References
[1] P.F Van Oorschot , and J.W. Pustjens. The Resistor Guide. 2nd edition
[2] Shaik, Asif. “Carbon Film Resistor.” Physics and Radio Electronics, www.physics-
and-radio-electronics.com
[3] Panasonic, Metal (Oxide) Film Resistors, 02 sep 2014

[4] Vishay BCcomponents, High Voltage Surge Metal Glaze Leaded Resistor, 18 Jul
2008