EMC Design Fundamentals: Safe Use of Varistors and Common Mode Chokes in Mains and Data-Line Filters

Electromagnetic interference (EMI) remains one of the key challenges in modern electronics, affecting both signal integrity and the reliable operation of power and data systems. In low‑voltage and mains applications, varistors and common mode chokes are two of the most important passive components for overvoltage protection and EMC filtering, yet they are also frequently misunderstood and mis‑applied.

This article distills the main engineering insights from a Würth Elektronik technical webinar on EMC design fundamentals, focusing on how to select and use varistors and common mode chokes safely and effectively in real‑world designs.

Key features and benefits

Varistors and common mode chokes work together within typical mains and low‑voltage EMC filters to limit surge and ESD stress and to suppress common‑mode noise without degrading the desired power or data signal. A typical single‑phase mains filter will contain a fuse holder, varistor, discharge resistor, common mode choke, and X/Y capacitors, with each component contributing a distinct protection or filtering function.

Varistors (both through‑hole disc types and multilayer SMD types) provide fast, non‑linear clamping of overvoltage events, diverting surge energy away from sensitive circuitry once the voltage exceeds their breakdown region. Common mode chokes, built from at least two windings on a shared ferrite or nanocrystalline core, present high impedance to common‑mode currents while leaving differential‑mode currents largely unaffected, helping designs pass CISPR/IEC EMI limits without compromising power or signal integrity.

Key Takeaways

Surge and transient environment overview

International EMC standards define different overvoltage phenomena that protection components must withstand and mitigate:

From an energy perspective, ESD has the highest voltage but significantly lower energy than surge and EFT, while EFT bursts can reach energy levels around one joule when many pulses are combined into a burst. This difference in waveform characteristics is central to selecting appropriate protection components and understanding their stress profiles over lifetime.

OvervoltageVoltageCurrentRise timePulse lengthEnergy
Surge0.5–4 kV0.1–2 kA @ 2 Ω load1.25 µs50 µs10–80 J
EFTB0.5–4 kV10–100 A @ 50 Ω load5 ns15 ms100–1000 mJ
ESD4–15 kV1–50 A @ 50 Ω load0.8 ns60 ns1–10 mJ

Typical applications

Varistors and common mode chokes appear in a wide range of applications, from AC mains filters to low‑voltage DC power and high‑speed data interfaces.

In all of these use cases, proper placement of protection and filter elements—especially locating the common mode choke close to the connector—helps prevent noise from propagating into or out of the PCB, improving both EMC performance and system robustness.

ApplicationsProbable Noise SourceMain Frequency (reference)CMC benefit
Power supplies, IoT, LED driversActive Switching100 kHz – 1 MHzBlocks CM Noise along cables
Cameras, robotics, PoEInrush / Capacitive Load< 1 kHzDampens overshoot and ringing
InstrumentationGround loop or floating reference500 kHz – 50 MHzSuppresses CM
Power + DataFast buses: USB, WiFi, CAN10 MHz – 500 MHzReduces Common mode coupling of digital signals on DC line
IndustrialEMI from Motors/ Relays10 kHz – 5 MHzIsolates DC line from inductive noise sources

Technical highlights

Varistor structure and behaviour

A classic disc varistor consists of three main layers: an outer epoxy insulation, internal silver or copper electrodes, and a zinc oxide ceramic core formed from many grains. At the microscopic level, the grains act as conductive regions and the grain boundaries act as barriers to current flow. When the applied voltage is low, only leakage current flows through the device; once the voltage across the electrodes becomes sufficiently high, the barriers break down and current can flow across many grain boundaries, rapidly increasing current in the clamping region.

The I–V characteristic of a THT varistor can be divided into four regions:

Multilayer varistors (MLV) share the same zinc‑oxide grain conduction mechanism but use multiple interdigitated silver electrodes in an SMD stack, giving a much smaller package size.

Compared to THT discs, multilayer types have lower working voltage range, lower maximum surge current and energy capability, but faster response time and significantly lower capacitance—important in data‑line ESD protection.

TVS diodes and snapback effects

TVS diodes provide an alternative surge and ESD protection technology based on silicon p–np\text{-}np-n junctions. A typical device comprises a semiconductor chip, protective plastic package, and copper leads connected to the junction.

In unidirectional TVS diodes, forward conduction starts once the forward voltage exceeds about 0.6–0.7 V, while in reverse direction the diode remains in leakage up to its working voltage and then transitions into breakdown when the reverse voltage reaches a specified threshold. From breakdown up to the maximum rated current, the diode clamps voltage while allowing substantial current flow.

Some TVS diodes exhibit a snapback effect: the device requires an additional voltage above nominal breakdown to trigger a parasitic transistor formed in the package and PCB environment, after which the clamping voltage drops and follows a curve with lower voltage at a given current than a standard diode. This behaviour yields better protection (lower clamping voltage at equal current), at the cost of requiring an extra activation voltage that is generally negligible relative to typical transient pulse amplitudes.

SerieTHT varistorMultilayer varistorTVS Diode
MountTHTSMDSMD
VDCV_{DC}VDC​ (V)18–14703.3–855–440
IpeakI_{\text{peak}}Ipeak​ (A)100–1000010–2000.6–326.1
WmaxW_{\text{max}}Wmax​ (J)0.7–6200.02–1.10
C (pF)35–1210070–36001–20000
Reaction time<25 ns<1 ns<1 ns

ESD protection and capacitance vs insertion loss

In the ESD protection domain, manufacturers offer multiple families of TVS diodes and multilayer varistors, grouped into standard, high‑speed, and super‑speed areas. The primary differentiator among these families is capacitance: standard types have the highest capacitance, high‑speed intermediate, and super‑speed the lowest. Lower capacitance is critical for high‑speed data‑line applications because it directly affects insertion loss and resonance behaviour.

Insertion loss depends predominantly on impedance, which in turn depends on resistance, inductance, and capacitance of the component. For these low‑inductance ESD devices, resistance remains almost constant with frequency and inductance is negligible, so capacitance dominates.

IL(dB)=−20log10⁡|1−Γ|IL(dB) = -20 \log_{10} \left| 1 – \Gamma \right|
Γ=Zin−Z0Zin+Z0\Gamma = \frac{Z_{\text{in}} – Z_{0}}{Z_{\text{in}} + Z_{0}}
IL=Insertion loss,Zin=Input impedance,Z0=Characteristic impedanceIL = \text{Insertion loss}, \quad Z_{\text{in}} = \text{Input impedance}, \quad Z_{0} = \text{Characteristic impedance}

Higher capacitance lowers the resonance frequency and increases insertion loss from that point upward, potentially causing data errors. Design examples provided in the webinar relate typical data‑line frequencies (such as USB or Ethernet bands) to recommended capacitance ranges for ESD suppressors, helping designers choose appropriate low‑capacitance parts for their interface class.

ComponentSurgeEFT/BurstESDReaction timeCapacitance
GDT – Gas discharge tubeXµs1 pF
MOV – Metal Oxide VaristorX>25 ns10 p–10 nF
MLV – Multilayer VaristorXX<1 ns70 p–14 nF
TVS Diode – Transient Voltage SuppressionX<1 ns0.1–30 pF
TVSP Diode – TVS PowerXXX<1 ns20–2000 pF
ESD SuppressorX<1 ns0.2–100 pF
Data lineData rateFrequencyRec. capacitance for ESD device
RS 232115.2 kbit/s57.6 kHz<56 pF
100 kbit/s50 kHz
I²C400 kbit/s200 kHz<56 pF
1 Mbit/s500 kHz
RS 4223.4 Mbit/s1.7 MHz
5 Mbit/s5 MHz<10 pF
RS 48512 Mbit/s6 MHz<22 pF
CAN500 kbit/s6 MHz
USB 1.112 Mbit/s6 MHz<10 pF
USB 2.0480 Mbit/s240 MHz<2 pF
USB 3.2 Gen 1×15 Gbit/s2.5 GHz<0.5 pF
USB 3.2 Gen 2×110 Gbit/s5 GHz<0.35 pF
USB 3.2 Gen 2×220 Gbit/s
USB 4 Gen 220 Gbit/s<0.2 pF
USB 4 Gen 340 Gbit/s
SATA 1.01.5 Gbit/s750 MHz<1 pF
SATA 2.03 Gbit/s1.5 MHz<1 pF
SATA 3.06 Gbit/s3 GHz<0.6 pF
Ethernet IEEE 802.3u 100BASE-TX100 Mbit/s125 MHz digital CLK<6 pF
Ethernet IEEE 802.3ab 1000BASE-T1 Gbit/s31.25 MHz UTP<3 pF
Ethernet IEEE 802.3az 10GBASE-T10 Gbit/s417 MHz<2 pF
LVDS1.325 Gbit/s<2 pF
HDMI 1.38.16 Gbit/s3.2 GHz (165 MHz)<0.5 pF
HDMI 1.48.16 Gbit/s810 MHz (160 MHz)<0.5 pF
HDMI 2.014.4 Gbit/s6 GHz (600 MHz)<0.3 pF
HDMI 2.142.6 Gbit/s12.8 GHz (600 MHz)<0.25 pF
DisplayPort 1.18.64 Gbit/s1.35 GHz (270 MHz)<0.6 pF
DisplayPort 1.217.28 Gbit/s2.7 GHz (270 MHz)<0.6 pF
DisplayPort 1.325.92 Gbit/s4.32 GHz (810 MHz)<0.3 pF
DisplayPort 1.425.92 Gbit/s4.05 GHz (810 MHz)<0.3 pF

Common mode vs differential mode in chokes

Common mode chokes rely on the difference between common‑mode and differential‑mode currents:

A common mode choke has at least two windings on a shared core. In common mode, the currents in both windings generate co‑directional magnetic fields, increasing flux and presenting high impedance that blocks common‑mode noise. In differential mode, currents produce opposing magnetic fields that largely cancel, leaving the choke with very low impedance for the desired signal. This field cancellation explains why, under normal operating conditions, common mode chokes do not saturate even at high differential‑mode currents, unlike single‑winding inductors.

Measurement data presented in the webinar show that common mode chokes saturate quickly when driven in pure common mode, but in differential mode the effective flux remains near zero and saturation is negligible. Given that common‑mode noise currents are usually only in the microampere to milliampere range, this saturation behaviour rarely poses a design problem.

Winding styles and parasitics

Two main winding styles are used in common mode chokes:

Closer coupling between windings (bifilar) minimizes the stray field and leakage inductance, which is desirable in many data‑line chokes where low differential‑mode impedance is required. Sectional winding, used widely in mains chokes, increases leakage inductance and parasitic capacitances, which can be exploited to provide some differential‑mode attenuation at higher frequencies without significantly affecting the fundamental mains frequency (50/60 Hz).

Design examples show that even with identical nominal inductance and core material, different winding geometries lead to significantly different attenuation curves versus frequency. Frame‑core chokes with separated chambers reduce parasitic capacitances and shift resonance to higher frequencies; toroidal chokes may have different parasitic distributions. For power‑line filters, the combination of winding style, parasitic capacitances, and leakage inductance can be tuned so that a single common mode choke attenuates both common‑ and differential‑mode noise, potentially eliminating the need for a separate differential‑mode inductor.

Core materials and impedance profiles

The webinar compares similar‑size toroidal common mode chokes using different core materials:

Although three chokes in the example all share a nominal inductance of 1 mH, their impedance and attenuation curves differ significantly across the frequency spectrum. The number of turns required to achieve the same inductance also differs between materials, affecting copper loss and size. This demonstrates that choosing a common mode choke purely by inductance is inadequate; designers should consult impedance or attenuation vs frequency curves and match these to the noise spectrum they need to suppress.

CorematerialNumber of turnsWirediameter in mmInductance in mH
MnZn120,61,00
Nanocrystalline130,55,00
NiZn130,50,11

Design‑in notes for engineers

Selecting and placing varistors

When selecting a varistor for surge protection:

In practice, varistors age as they are repeatedly subjected to surges: material degradation at zinc‑oxide grain boundaries weakens barrier properties, increasing leakage current over time. Engineers can monitor varistor health by periodically measuring leakage current or the I–V curve; a significant increase in leakage compared to new devices is a strong indication that replacement is advisable. Capacitance change with age is expected to be modest and primarily of theoretical interest, assuming electrode spacing remains unchanged.

Parallel connection of varistors is generally discouraged because small differences in clamping voltage and leakage current cause current to concentrate in the “weakest” varistor, which then absorbs most of the energy and fails first. Instead, designers should select a single varistor with suitable surge rating for the application or consider series combinations where appropriate and supported by datasheet guidance.

ESD suppressor selection and data‑line impact

For ESD protection on data lines:

Insertion loss becomes especially critical for very sensitive or small‑signal data interfaces. Designers should correlate interface baud rates or spectral content with recommended capacitance ranges from the manufacturer’s tables, then validate the chosen ESD component through S‑parameter simulations or lab measurements if possible.

Common mode choke selection and data sheet interpretation

When selecting common mode chokes, engineers should:

IEC 60938 Safety Requirements

Mains supply nominal voltage line-to-neutral150 V300 V600 V1000 V
AC voltage150 V300 V600 V1000 V
DC voltage250 V450 V900 V1500 V
Between live parts of different polarity1,5 mm2,5 mm3,0 mm5,5 mm

Designers should avoid comparing components solely at a single inductance value from datasheets. Instead, it is better to examine plots of inductance vs frequency and impedance/attenuation vs frequency, ensuring the nominal inductance is defined in a frequency region where test equipment accuracy is acceptable and where frequency effects are minimal. Manufacturers often reference IEC test frequency recommendations (e.g., using 10 kHz for inductors of 1 mH and above), which help align measurements across different product families.

Winding style, leakage inductance, and mixed filters

For power‑line filters:

For data and DC line filters:

Lifetime, ageing, and portfolio updates

The webinar highlights ongoing portfolio evolution and reliability improvements:

For long‑life applications, engineers should combine datasheet lifetime derating graphs with their specific surge/ESD environment and consider periodic leakage‑current monitoring on varistors and similar devices during maintenance intervals.

Technical highlights summary table

The following table summarizes some of the key component characteristics discussed in the webinar, as a quick design reference. Exact numerical values should be taken from the relevant manufacturer datasheet.

Component typeKey functionStrengths in practiceLimitations / caveats
THT disc varistorSurge clamping on mains/DCHigh energy handling, wide voltage range, simple integrationHigher capacitance, ageing increases leakage
Multilayer SMD varistorESD/surge on data & low‑power linesFast response, low capacitance, small footprintLower surge current and energy capability
TVS diode (unidirectional)ESD/surge, especially low‑voltage railsSharp breakdown, precise clamping, SMD form factorNarrow clamping region, some variants show snapback
TVS diode with snapbackImproved ESD clampingLower clamping voltage at same current, better protectionNeeds extra trigger voltage, behaviour PCB‑dependent
Common mode choke, sectional windingMains and power filtersHigh common‑mode impedance, useful differential‑mode attenuation via leakage, good insulationLarger stray field, higher parasitics
Common mode choke, bifilar windingData and low‑voltage filtersLow leakage inductance, minimal differential‑mode impedance, compactLess suited to meeting large creepage/clearance distances
Standard capacitance ESD familyGeneral‑purpose interfacesRobust protection for moderate data ratesHigher insertion loss at high frequencies
Super‑speed ESD familyHigh‑speed serial linksMinimal insertion loss, preserved signal integrityLower energy handling, careful layout required

All performance values and limits in this table are intended only as qualitative guidance; exact ratings depend on specific series and part numbers according to manufacturer datasheets.

Conclusion

After working through this webinar’s content, a design engineer or component buyer should be able to map real‑world surge, EFT, and ESD environments onto suitable varistor and TVS families, understand how common mode chokes differentiate between noise modes and desired signals, and interpret datasheet parameters such as breakdown voltage, rated current, inductance vs frequency, and creepage/clearance distances in a safety and EMC context. By paying attention to winding style, core material, parasitic capacitances, and placement on the PCB, engineers can turn common mode chokes from generic catalogue inductors into carefully tuned filter elements that address both common‑ and differential‑mode noise at relevant frequencies.

For practical next steps, designers should review manufacturer application notes on mains filter design and common mode chokes, consult updated series information (such as new CAN‑oriented chokes and high‑voltage variants), and cross‑check lifetime and thermal derating curves against their expected surge environment and ambient temperatures. Purchasers can use this understanding to distinguish between components chosen purely on inductance or voltage rating and those selected for frequency‑appropriate impedance profiles and lifetime performance, improving both EMC compliance and long‑term reliability of the systems they support.

FAQ

What is the main difference between surge, EFT and ESD in EMC design?

Surge (IEC 61000‑4‑5) is a high‑energy, low‑frequency overvoltage event typically associated with lightning and large switching transients. EFT/B (IEC 61000‑4‑4) consists of many lower‑energy, high‑repetition pulses caused by switching inductive loads in industrial environments. ESD (IEC 61000‑4‑2) features very high voltage but relatively low energy and low repetition, arising from contact or air discharges between charged bodies. These differences in waveform shape, energy and repetition are critical when specifying protection components and test levels.

When should I use a THT disc varistor instead of a multilayer SMD varistor?

THT disc varistors are preferred in mains and higher‑energy DC applications where surge pulses can be large and the circuit has enough space for a relatively bulky component. They offer higher surge current and energy handling, plus a wider working voltage range. Multilayer SMD varistors are better suited to compact boards and data or low‑power lines, where transient energy is lower and fast response with low capacitance is more important than maximum surge capability.

How do I select the working voltage of a varistor for a mains or DC line?

The working voltage should be at least about 25% higher than the maximum normal operating voltage of the circuit. This ensures the varistor remains in the leakage region under normal conditions and only begins to conduct significantly when an overvoltage occurs. Designers should also verify that the maximum surge current and energy ratings match the worst‑case surge and EFT test levels and expected number of events over the product lifetime.

Why is capacitance so important for ESD protection on high‑speed data lines?

In low‑inductance ESD suppressors, capacitance largely determines impedance and thus insertion loss at high frequencies. Higher capacitance lowers the resonance frequency and increases insertion loss above that point, which can distort eye diagrams and increase bit error rates on interfaces such as USB or Ethernet. Low‑capacitance TVS diodes or multilayer varistors are therefore preferred for high‑speed lines to maintain signal integrity while still providing adequate ESD protection.

What makes a common mode choke different from a simple series inductor?

A common mode choke has at least two windings on a shared core. In common mode, currents in both windings flow in the same direction and their magnetic fields add, creating high impedance to block noise. In differential mode, currents flow in opposite directions and their fields cancel, leaving low impedance for the desired signal or power. This field cancellation means that, under normal operating conditions, common mode chokes do not saturate like single‑winding inductors carrying the same differential‑mode current.

How do winding style and core material affect common mode choke performance?

Bifilar or multifilar winding places windings side‑by‑side, minimizing stray fields and leakage inductance, which is ideal for data‑line chokes where low differential‑mode impedance is required. Sectional winding separates windings into distinct chambers, increasing leakage inductance and parasitic capacitances, which can be exploited to attenuate high‑frequency differential‑mode noise in mains filters. Core material (manganese‑zinc, nickel‑zinc, nanocrystalline) sets the effective attenuation bandwidth and resonance behaviour, so engineers should compare impedance or attenuation vs frequency curves rather than relying on inductance alone.

Where should I place common mode chokes and varistors on my PCB for best EMC performance?

Common mode chokes should be placed as close as possible to connectors and system boundaries to prevent noise from entering or leaving the PCB. Varistors and TVS diodes used for surge and ESD protection should also be located near the source of overvoltage events, such as input connectors or exposed pins, with short traces to minimize parasitic inductance. This placement strategy helps contain interference at the edges of the system and reduces stress on downstream components.

How‑to: Combine varistors, TVS diodes and common mode chokes in a mains EMI filter

  1. Step 1 – Define EMC and safety requirements

    Determine required surge, EFT and ESD immunity levels, conducted emission limits and applicable insulation standards for the mains filter.

  2. Step 2 – Select a suitable THT varistor for surge protection

    Choose a disc varistor with working voltage above the mains peak, appropriate surge and energy ratings, and a package that meets creepage and clearance requirements on your PCB.

  3. Step 3 – Add TVS or multilayer varistors for ESD and fast transients

    For sensitive low‑voltage nodes or data ports, select low‑capacitance TVS diodes or multilayer varistors to handle ESD and fast transients without degrading signal integrity.

  4. Step 4 – Choose a common mode choke tuned to the noise spectrum

    Select a sectional‑wound mains common mode choke whose attenuation vs frequency curve covers the dominant common‑ and differential‑mode noise frequencies while leaving 50/60 Hz unaffected.

  5. Step 5 – Complement with X and Y capacitors and discharge resistor

    Add appropriately rated X capacitors across line and Y capacitors to protective earth, together with a discharge resistor, following manufacturer application notes for single‑phase line filters.

  6. Step 6 – Place components and verify performance in EMC testing

    Arrange the fuse, varistor, common mode choke, capacitors and resistors in a compact mains filter section, then validate performance against surge, EFT, ESD and conducted EMI tests, adjusting values as needed.

Source

This article is based on engineering information presented in a Würth Elektronik technical webinar titled “EMC Design Fundamentals: How to Use Varistors and Common Mode Chokes Safely,” including the accompanying transcript and linked application documentation from the manufacturer.

References

  1. EMC Design Fundamentals: How to Use Varistors and Common Mode Chokes Safely (Würth Elektronik YouTube webinar)
  2. ANP015 – 1‑Phase Line Filter Design (Würth Elektronik application note)
  3. Catalogue and tutorial – Common Mode Chokes (Würth Elektronik)
  4. Mains Filter Guide poster (Würth Elektronik)
  5. ANP146 – Theoretical background and practical applications of WE‑CMDC common mode chokes (German)
  6. Würth Elektronik eiSos – Product overview
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