Drop-in mechanical fit · documented cross-reference · lead times aligned with program milestones

Executive Summary

In high-voltage inverters, medical imaging (X-Ray/CT), precision instruments, and high-energy physics, METALLUX AG’s HVR Series (HVR 967 / 968 / 969) has long been the reference for high-voltage thick film resistors—valued for precision, low TCR, and stability across Europe and global OEM programs.

Today, dependence on a single European line is a growing systemic risk: METALLUX sourcing often means long factory lead times (commonly 20+ weeks), elevated pricing, and limited agility for non-standard values or mechanical options—constraints that directly slow R&D cycles and ship dates.

HVC offers an engineering-grade path: the HVR line (HVRGXP flat and HVR-Tube cylindrical) uses 96% alumina substrates and RuO₂ thick-film technology, matches METALLUX footprints for pin-to-pin upgrades, and targets stronger VCR behavior, pulse robustness, and total cost of ownership versus legacy European stacks—backed by non-inductive serpentine layouts and precision laser trim where specified.

Selection note: always validate electrical ratings, creepage, and qualification tests against your system requirements and the latest HVC datasheet—treat any cross-reference as a starting point for formal re-qualification.

1. Industry Background: Single-Source Risk in European HV Resistor Supply

METALLUX is a long-established European supplier of high-voltage components with a strong reputation for precision. For global OEMs, however, reliance on a single geography for specialty HVR parts can create schedule and cost exposure when lead times stretch or when non-standard values are needed.

1.1 Structural Pressure: Lead Times, MOQs, and Custom Requests

For equipment manufacturers worldwide, METALLUX sourcing can present recurring procurement friction:

• Lead time: Standard catalog parts are often quoted in the 16–24 week range; disruptions can extend schedules further—problematic for programs that target lean inventory and fast design iterations.
• Customization Threshold: High-voltage resistors are used in a myriad of application scenarios, often requiring non-standard resistance values (e.g., 123MΩ for specific voltage division ratios) or special pin configurations. The original manufacturer is often unresponsive to such demands, and the Minimum Order Quantity (MOQ) is extremely high, making it difficult to obtain samples during the R&D phase.
• Cost Pressure: Brand premium coupled with exchange rate fluctuations keeps METALLUX's procurement costs high, squeezing the profit margins of equipment manufacturers.

1.2 How HVC Positions the HVR Line

HVC is not positioned as a “generic low-cost substitute,” but as a second source with transparent mechanical mapping, competitive lead times, and process investments in thick-film HV resistors. Our high-voltage insulation experience (including ultra-high-voltage ceramic components) informs resistor design rules for field grading, encapsulation, and reliability testing.

• Voltage coverage: HVC targets demanding stacks with ratings up to 50 kV (in air) and, where applicable, 100 kV (in oil)—always subject to final datasheet limits for the specific part and package.
• Factory-direct responsiveness: Typical standard lead times are quoted in the 4–6 week range, with expedite options where capacity allows; MOQs are structured to support both prototype and production volumes.

2. Technical Analysis: Material, Process, and Design Choices

The HVC HVR series is intended as a qualified alternative for teams that need pin-compatible layouts and predictable procurement. The discussion below reflects HVC’s flat-style HV resistor process platform and is framed as a design comparison against typical METALLUX-class requirements—not a blanket performance guarantee for every part number.

2.1 Substrate Revolution: 96% Alumina (Al₂O₃) vs. Ordinary Ceramics

The heat dissipation capability and long-term stability of a resistor largely depend on the substrate material.

• METALLUX Standard: Some products use industrial-grade 85% or 90% alumina ceramic substrates.
• HVC process: The HVRGXP series comes standard with 96% high-purity alumina (Al₂O₃) substrates.
• Thermal Advantage: The thermal conductivity of 96% alumina (approx. 24-28 W/m·K) is significantly higher than that of ordinary 85% alumina. Under high-voltage loads, this means lower "hot spot" temperatures on the resistor surface and more uniform thermal stress distribution, thereby greatly reducing the resistor's aging drift.
• Mechanical Advantage: High-purity substrates have better density and higher mechanical strength, making them less prone to breakage under vibration or thermal shock, especially suitable for automotive or industrial vibration environments.

2.2 Slurry Formulation: Precision Control of Ruthenium Oxide (RuO₂)

The core of thick film resistors lies in the conductive slurry.

• HVC process: We use a high-grade ruthenium oxide slurry system, combined with a special glass phase binder. By precisely controlling the sintering temperature curve (850℃ high-temperature sintering), an atomic-level strong bond is formed between the film layer and the substrate.
• Low Voltage Coefficient (Low VCR): A key indicator for high-voltage resistors is the Voltage Coefficient of Resistance (VCR), which is the degree to which resistance changes as voltage increases. HVC controls VCR to an extremely low level (typically < 1-5 ppm/V) by optimizing the microscopic topological structure of conductive particles. This is crucial for high-voltage dividers, ensuring sampling linearity from 100V to 30kV.
• Ultra-Wide Resistance Range: Relying on our proprietary formula, HVC can achieve continuous resistance coverage from 100Ω to 10GΩ. Whether for low-resistance current limiting applications or extremely high-resistance insulation detection, a single component can achieve this, eliminating the need for multiple components in series.

2.3 Structural Design: Non-Inductive Serpentine Printing

In X-ray machine power supplies or pulse modulators, the parasitic inductance of resistors can lead to waveform distortion, overshoot, or even oscillation.

• HVC process: The HVRGXP series abandons simple linear printing and adopts a unique computer-optimized serpentine printing path.
• Principle: By precisely calculating the direction of adjacent current paths, the magnetic fields are canceled out using the principle of mutual inductance, reducing parasitic inductance to the microhenry (µH) level.
• Value: Under high-frequency pulses, HVC resistors aim for resistive behavior with minimal overshoot; always verify switching stress in your actual gate/base drive and snubber network.

2.4 Protection Upgrade: Vacuum Epoxy Encapsulation (Conformal Coating)

• HVC process: The HVR series uses high-density blue or black epoxy resin vacuum encapsulation.
• Insulation: Eliminates internal air bubbles and pinholes in the coating, passing rigorous Double 85 tests (85℃/85%RH), ensuring no surface flashover in high-humidity environments.
• Environmental Adaptability: Possesses excellent oil resistance and chemical corrosion resistance, making it ideal for use in oil-filled HV supplies or SF6 gas insulated switchgear, without reacting with the insulating medium.

3. Precise Benchmarking: METALLUX vs. HVC Model Comparison Table

To ensure Drop-in Replacement, HVC has meticulously compiled the following comparison table based on METALLUX specifications, covering both flat and cylindrical mainstream forms.

3.1 Flat Style Replacement: Benchmarking METALLUX HVR 967

METALLUX HVR 967 is the most commonly used flat high-voltage resistor, often found in compact high-voltage modules. HVC's HVRGXP series is fully compatible in terms of size, power, and pin spacing.

Complete online version please refer to: METALLUX HVR Series Replacement Solution

1. High Voltage Thick Film Flat Resistor (HVR 967 Flat Style) → HVC HVRGXP/HVRGFP Series

Dimension note: A(L)=length, B=width, C=pin spacing, d=pin diameter

Metallux Model	Power(W)	Working Voltage(kV)	A(L)(mm)	B(mm)	C(mm)	Thickness(mm)	d(mm)	HVC Replacement Model
HVR967.3.25	1	12	25.4	3.8	22.9	2.5	0.8	HVRGXP4.25
HVR967.3.38	1.5	15	38	3.8	35.7	2.5	0.8	HVRGXP4.38
HVR967.5.13	1	7.5	12.7	5	10.2	2.5	0.8	HVRGXP5.13
HVR967.7.51	2	30	51.9	7	48	2.5	0.8	HVRGXP7.52
HVR967.8.26	2	15	25.4	8	22.5	2.5	0.8	HVRGXP8.25
HVR967.13.38	3	30	38.5	13	36	2.5	0.8	HVRGXP13.39
HVR967.15.30	3	30	30	15	22.1	2.5	0.8	HVRGXP15.30
HVR967.15.51	4.5	45	50.8	15	48.3	2.5	0.8	HVRGXP15.51
HVR967.15.76	5.5	52	76.2	15.5	73.2	2.5	0.8	HVRGXP16.76
HVR967.25.90	10	67	88.9	25.4	85.6	2.5	0.8	HVRGXP25.89

3.2 Cylindrical Style Replacement: Benchmarking METALLUX HVR 968/969

For METALLUX's precision cylindrical HVR 968 and high-power cylindrical HVR 969, HVC offers the HVR-Tube Series of tubular thick film resistors.

2. High Voltage Thick Film Tubular Resistor (HVR 968) → HVC HVR-BSP Series

Dimension note: A=resistor body length, B=resistor outer diameter, d=pin diameter

Metallux Model	Power(W)	Working Voltage(kV)	A(mm)	B(mm)	d(mm)	HVC Replacement Model
HVR968.2	3.8	13.5	27	8	0.8	HVRBSP27
HVR968.3	5	18	37	8	0.8	HVRBSP37
HVR968.4	6	21	47	8	0.8	HVRBSP47
HVR968.5	7.5	27	52	8	0.8	HVRBSP52
HVR968.7	10	36	78	8	0.8	HVRBSP78
HVR968.10	12	54	102	8	0.8	HVRBSP102
HVR968.12	15	63	123	8	0.8	HVRBSP123
HVR968.15	17	81	153	8	0.8	HVRBSP153

3. High Power Tubular Resistor (HVR 969) → HVC HVR-PFS Series

Dimension note: L=resistor body length, B=flange spacing, ø=resistor outer diameter, D=mounting hole diameter, G=thread specification

Metallux Model	Power(W)	Working Voltage(kV)	L(mm)	B(mm)	ø(mm)	D(mm)	G	HVC Replacement Model
HVR969.11	11	32	81	14.5	13	10	M4	HVRPFS81
HVR969.23	23	72	156	14.5	13	10	M4	HVRPFS156
HVR969.54	54	72	160	31.1	30.5	18	M8	HVRPFS160
HVR969.71	71	96	209	31.1	30.5	18	M8	HVRPFS209
HVR969.105	105	148	309	31.1	30.5	18	M8	HVRPFS309

Note: HVRGXP suffix numbers (e.g., 5.10, 7.26) directly correspond to the millimeter-level dimensions of the substrate, ensuring mounting hole pitch is identical to METALLUX.

4. Why HVC? Beyond the Part Number

Choosing a second source is also about application support, lead-time predictability, and documentation you can hand to quality and procurement.

4.1 Customization and Value-Add Services

Large European catalog suppliers sometimes prioritize high-volume standard parts; non-standard resistance values or mechanical options can face long cycles or high MOQs.

• HVC response: With in-house laser trimming, HVC routinely supports value-specific builds without treating every custom value as a one-off project.
• Any Resistance Value: Whether it's a standard 10MΩ or a special 123.4MΩ, we can precisely trim the resistance, with MOQ as low as 50pcs.
• Any Tolerance: We offer a full range of tolerances: ±10% (K grade), ±5% (J grade), ±1% (F grade), and even ±0.5% (D grade).
• Flexible Leads: We provide tinned copper wire, screw caps, or special lead bending services (L-Bend, Z-Bend).

4.2 Pulse Withstand and Field Robustness

In HV dividers and imaging supplies, pulse and fault energy can stress the resistor film. Design margin depends on film thickness, substrate thermal mass, encapsulation, and system-level protection—not on the brand name alone.

• HVC approach: Film and substrate layouts are optimized for pulse energy handling in representative test conditions; customers should correlate results to their own surge profile and safety margins. Where validated in HVC’s qualification matrix, pulse capability can improve meaningfully versus older designs—use the datasheet pulse curve and your OEM test plan to confirm.

4.3 Total Cost of Ownership

Land cost is more than unit price: it includes lead time, MOQ, rework risk, and inventory carrying cost.

• Commercial positioning: HVC’s integrated manufacturing model typically supports a stronger landed-cost position than premium European catalog pricing for comparable ratings—exact savings depend on SKU, volume, and Incoterms. Request a project quote rather than relying on generic percentage claims.

5. Application Scenarios: Comprehensive Coverage from Medical to Industrial

HVC HVR parts are used in medical, industrial, and R&D programs where teams require traceable qualification paths and repeatable supply.

5.1 Medical Imaging

Used as anode protection resistors in high-voltage generators of DR / CT machines. HVC's non-inductive design effectively suppresses high-frequency oscillations, protecting expensive X-ray tubes and extending equipment life.

5.2 High Voltage Test & Measurement

In high-voltage dividers, HVC’s tight TCR targets (down to ±15 ppm/°C class on selected builds) and low VCR help maintain ratio accuracy across temperature and voltage—subject to calibration and system design.

5.3 Industrial High Voltage Supply

In electrostatic spraying and dust removal power supplies, HVC's high humidity resistance and pulse withstand capability ensure stable and reliable operation under harsh conditions, significantly reducing maintenance rates.

5.4 Research & Physics

In particle accelerators and pulsed power systems, HVC's ultra-high voltage customization capability (up to 100kV) meets researchers' pursuit of extreme parameters.

6. Conclusion: A Pragmatic Second Source

When METALLUX lead times or MOQs constrain your program, a qualified second source with pin-compatible footprints and transparent datasheets reduces schedule risk.

The HVC HVR series is offered as a documented alternative for teams that need competitive lead times, mechanical compatibility, and application engineering support through sample evaluation and production ramp-up. Final acceptance always rests with your qualification protocol and system-level testing.

7. METALLUX Complete Model Quick Reference

METALLUX HVR/HPR/HVI Series complete model list (64 models total):

HVR Series - Standard High Voltage Resistors (36)
HVR967.3.25	HVR967.3.38	HVR967.5.13	HVR967.7.51
HVR967.8.26	HVR967.13.38	HVR967.15.30	HVR967.15.51
HVR967.15.76	HVR967.25.90	HVR967	HVR967.1
HVR967.28.38	HVR968.2	HVR968.3	HVR968.4
HVR968.5	HVR968.7	HVR968.10	HVR968.12
HVR968.15	HVR968	HVR969.11	HVR969.23
HVR969.54	HVR969.71	HVR969.105	HVR969
HVR22.5	HVR40050.0

HPR Series - High Precision High Voltage Resistors (18)
HPR967	HPR967.3.25	HPR967.3.38
HPR967.5.13	HPR967.8.26	HPR967.13.38
HPR967.15.30	HPR967.15.51	HPR967.25.90
HPR968	HPR968.2	HPR968.3
HPR968.5	HPR968.7	HPR968.10
HPR968.12	HPR968.15	HPR969

HVI Series - Pulse High Voltage Resistors (10)
HVI967	HVI968	HVI968.2
HVI968.3	HVI968.5	HVI968.7
HVI968.10	HVI968.12	HVI968.15
HVI969

8. HVC Part Numbering Code

HVR-[Series]-[Size]-[Resistance]-[Tolerance]-[TCR]-[Voltage]

Code	Meaning	Example
HVR	High voltage resistor prefix	HVR-GXP4.25
GXP/GFP	Flat style series	GXP=Standard, GFP=Economy
BSP/PFS	Tubular style series	BSP=Standard tubular, PFS=High power
Size	Length code	4.25, 7.52, BSP27
Resistance	100K=100kΩ, 1M=1MΩ	100K, 1M, 10M
Tolerance	F=±1%, J=±5%	F
TCR	25=±25ppm/°C, 100=±100ppm/°C	25
Voltage	12kV, 30kV, 45kV	30kV

Order Example: Replace HVR967.3.25 → HVR-GXP4.25-10M-F-25-12kV

9. Contact and Technical Support

If you are looking for replacements for discontinued METALLUX series, or have any needs regarding high-voltage resistor selection or customization, HVC's replacement engineering team will always be available to provide support.

Qualified programs can request samples and application support; scope and terms are confirmed per project.

Copyright Statement: This document is owned by HVC Capacitor. Reproduction or use for commercial purposes without permission is prohibited.
Disclaimer: Parameters are indicative for selection discussions only; binding values are those in the applicable HVC datasheet and your purchase order. METALLUX and related marks are trademarks of their respective owners; use here is for fair technical comparison and compatibility description.