(Engineering FAQ: HVC High Voltage Resistors as Caddock Alternatives)

Abstract

As demand grows for diversified electronic component supply chains, HVC (High Voltage Components) high-voltage thick film resistors are becoming the preferred alternative to Caddock products. This document compiles 12 key engineering questions and provides a comprehensive analysis from electrical compatibility and performance benchmarking to supply chain strategy. All data is based on laboratory measurements and industry application cases, helping R&D engineers and purchasing managers achieve low-risk replacement.

1. Electrical and Mechanical Compatibility

Q1: Can HVC resistors directly replace Caddock MG/TF/TG series in terms of electrical parameters?

A: Yes, they are fully compatible.

HVC strictly benchmarks key parameters against mainstream Caddock series during the design phase:

• Resistance range: Covers 100Ω to 100GΩ.
• Operating voltage: Up to 40kV (axial) / 100kV (rod).
• Key metrics: Using a ruthenium-based thick film process, HVC's voltage coefficient (low VCR) and temperature coefficient (±25 to ±50 ppm/°C) match Caddock. In about 95% of high-voltage divider and precision medical applications, direct replacement is possible without circuit redesign.

Q2: Are there differences in package dimensions? Can they achieve drop-in replacement?

A: HVC achieves true pin-to-pin compatibility.

Package options match Caddock, with lead spacing tolerances within ±0.1mm.

• Example: HVC MG715 (PF series) uses the same 19.05mm length and 3.56mm diameter as Caddock MG715.
• Improvement: Optimized termination; measured end-electrode adhesion improves by about 15% in high-voltage arcing tests.

Q3: Do high-frequency characteristics meet RF and pulse application requirements?

A: Yes, HVC offers non-inductive design options.

For RF and fast-pulse applications, internal structure is optimized to reduce parasitics:

• Structure: Archimedean spiral trimming or planar non-inductive printing.
• Measured performance: At 100MHz, HVC non-inductive parts match Caddock impedance behavior for RF attenuators, radar power supplies, and high-voltage switching circuits.

2. Performance Benchmark and Advantages

Q4: What about long-term load stability (load life stability)?

A: HVC exceeds typical industry requirements.

After 1000 hours of 85°C / 85% RH accelerated aging:

• HVC HVR series: Average resistance drift < 0.25%.
• Industry expectation: Often < 1.0%.
• Principle: High-density glass glaze and nanoscale grain-boundary engineering reduce moisture-induced film degradation.

Q5: What are the advantages in pulse handling?

A: HVC emphasizes surge-resistant design.

Micron-scale functional particles in the paste increase thermal diffusion rate by about 40%.

• Data: In X-ray generators and laser drive supplies, HVC parts tolerate short (e.g. 10µs) surges at about 5× rated power, improving life under repetitive discharge.

Q6: What is TCR consistency?

A: Laser trimming supports batch consistency.

Standard TCR grades align with Caddock:

• Precision: ±25 ppm/°C (benchmarking Caddock TF)
• Standard: ±50 ppm/°C (benchmarking Caddock MG/TG)
• Data: From −55°C to +155°C, TCR linearity suits precision instruments.

3. Quick Selection Guide for Popular Models

0.5W – 1W Precision Instrument Grade

Caddock Model	Power	Voltage Rating	Resistance Range	Dimensions (mm)	HVC Alternative Model	Match Rating
MG650	0.5W	600V	200Ω–5MΩ	7.95×2.39	HVR-BOP-3.5×8-5M00-F-25-600	✅ Perfect Match
MG660	0.6W	1kV	400Ω–10MΩ	12.70×2.39	HVR-BOP-3.5×13-10M0-F-25-1k	✅ Perfect Match
MG680	0.8W	2kV	600Ω–20MΩ	19.05×2.39	HVR-BOP-3.5×19-20M0-F-25-2k	✅ Perfect Match
MG710	1.0W	4kV	800Ω–50MΩ	25.40×2.39	HVR-BOP-3.5×25-50M0-F-25-4k	✅ Perfect Match

1W – 3W Medium Power Supply Grade

Caddock Model	Power	Voltage Rating	Resistance Range	Dimensions (mm)	HVC Alternative Model	Match Rating
MG715	1.0W	2kV	400Ω–50MΩ	19.05×3.56	HVR-BSP-7×19-50M0-F-25-2k	✅ Perfect Match
MG720	2.0W	6kV	1kΩ–150MΩ	38.10×3.56	HVR-BSP-7×38-150M-F-25-6k	✅ Perfect Match
MG730	3.0W	6kV	500Ω–250MΩ	38.10×6.10	HVR-BSP-7×38-250M-F-25-6k-HD	✅ High Power Density

5W – 15W High Voltage Load Grade

Caddock Model	Power	Voltage Rating	Resistance Range	Dimensions (mm)	HVC Alternative Model	Match Rating
MG745	5.0W	15kV	1kΩ–500MΩ	76.20×6.10	HVR-BSP-7×76-500M-F-25-15k	✅ Performance Upgrade
MG810	10.0W	25kV	1kΩ–1.25GΩ	127.0×8.00	HVR-BSP-7×127-1G25-F-25-25k	✅ High Redundancy
MG815	15.0W	30kV	1kΩ–2GΩ	152.4×8.89	HVR-BSP-7×152-2G00-F-25-30k	✅ High Redundancy

4. HVC Part Numbering System

HVR-[Series]-[Tube Diameter × Tube Length]-[Resistance Value]-[Tolerance]-[Temp Coefficient]-[Voltage]

Code	Meaning	Example
HVR	High voltage resistor prefix	HVR-BSP-7×19
BSP/BOP	φ7mm / φ3.5mm ceramic tube	BSP-7×19, BOP-3.5×8
Resistance value	5M00 = 5MΩ, 1G25 = 1.25GΩ	10M0, 500M
Tolerance	D = ±0.5%, F = ±1%, J = ±5%	F
TCR	25 = ±25ppm/°C, 50 = ±50ppm/°C	25
Voltage	600 = 600V, 2k = 2kV, 15k = 15kV	6k

Ordering example: Replace MG715-10M-1% → HVR-BSP-7×19-10M0-F-25-2k

5. Typical Alternative Case Studies

Caddock P/N	HVC Alternative	Key Technical Upgrades
MG715-10M-1%	HVR-BSP-7×19-10M0-F-25-2k	1:1 form-fit, ±25ppm low TCR drift
MG720-100M-1%	HVR-BSP-7×38-100M-F-25-6k	Enhanced pulse withstand, suitable for X-ray systems
MG810-1G-1%	HVR-BSP-7×127-1G25-F-25-25k	Ultra-high resistance, research-grade stability

6. Supply Chain and Procurement Strategy

Q7: What are MOQ and lead time?

A: HVC offers more flexible supply than many Western brands.

• MOQ: 50 pcs minimum (Caddock often requires ~1000), lowering NPI barriers.
• Samples: Free engineering samples from 5 pcs during development.
• Lead time: Typically 4–6 weeks; urgent builds can compress to about 2 weeks.

Q8: Is off-the-shelf inventory available?

A: Yes, with global stocking.

HVC maintains inventory in Shenzhen and major distribution hubs for common values (e.g. 10MΩ, 100MΩ, 1GΩ). Compared with Caddock's 12–16 week cycles, HVC can support regional direct supply.

7. Quality Certification and Industry Compliance

Q9: Do products meet medical and industrial requirements?

A: Yes.

• Medical: Aligns with high-voltage insulation expectations of IEC 60601-1; used in defibrillators, CT scanners, and similar equipment.
• Industrial: RoHS and REACH compliant.

Q10: What about the quality system?

A: Industrial/military-grade discipline.

• Inspection: 100% DC withstand and short-time overload (STOL) testing.
• Standards: Methods follow MIL-STD-202 and IEC 60115.
• Traceability: Lots traceable to raw materials.

8. Typical Application Selection Guide

Q11: How to select parts for PV / energy-storage inverters?

A: Use HVC Power Film (PF) series.

For DC-link dividers, 100ppm/°C-class TCR and derating curves align with Caddock MG.

• Anti-PID: Packaging materials are optimized for Anti-PID performance under 1500VDC-class bias.

Q12: What about extreme environments (e.g. downhole exploration)?

A: Use HVC high-temperature high-voltage series.

For oilfield logging and similar cases, extended temperature options reach +175°C and higher, with shock and vibration qualification for downhole reliability.

9. Popular Model Cross-Reference

For Caddock end-of-life or shortage situations, contact HVC for cross-referenced part numbers, datasheets, quotes, and samples.

Series Cross-Reference Guide

Caddock Original Series	HVC Corresponding Series	Replacement Highlights	Typical Applications
Type MG / MX	HVC Power Film	High power density, axial leads, high voltage withstand	HV power supplies, X-ray systems
Type TG	HVC HV Stick	Rod-style package, ultra-high resistance, non-inductive options	Mass spectrometry, HV probes
Type TF	HVC Precision	Precision flat package, low TCR	Precision dividers, metrology
Type USG	HVC Ultra-Stable	Excellent long-term stability (<50ppm/year)	Research-grade analyzers

MG Series Quick Selection (Compatibility Notes)

0.5W – 1W Precision Instrument Grade

Caddock Model	Power	Max Working Voltage	Resistance Range	Size (L × D)	HVC Replacement Note
MG650	0.5W	600V	200Ω – 5MΩ	7.95 × 2.39 mm	Fully compatible
MG660	0.6W	1,000V	400Ω – 10MΩ	12.70 × 2.39 mm	Fully compatible
MG680	0.8W	2,000V	600Ω – 20MΩ	19.05 × 2.39 mm	Fully compatible
MG710	1.0W	4,000V	800Ω – 50MΩ	25.40 × 2.39 mm	Fully compatible

1W – 3W Medium Power Supply Grade

Caddock Model	Power	Max Working Voltage	Resistance Range	Size (L × D)	HVC Replacement Note
MG715	1.0W	2,000V	400Ω – 50MΩ	19.05 × 3.56 mm	Fully compatible
MG720	2.0W	6,000V	1kΩ – 150MΩ	38.10 × 3.56 mm	Fully compatible
MG730	3.0W	6,000V	500Ω – 250MΩ	38.10 × 6.10 mm	Recommended alternative

5W – 15W High Voltage Load Grade

Caddock Model	Power	Max Working Voltage	Resistance Range	Size (L × D)	HVC Replacement Note
MG745	5.0W	15kV	1kΩ – 500MΩ	76.20 × 6.10 mm	Fully compatible
MG810	10.0W	25kV	1kΩ – 1.25GΩ	127.0 × 8.00 mm	Long-life build option
MG815	15.0W	30kV	1kΩ – 2GΩ	152.4 × 8.89 mm	Ultra-HV option

Typical Replacement Cases (Reference)

Caddock P/N (in use)	HVC Recommended (Ref.)	Key Technical Upgrades
TF020R	HVC-PR-0.5W-1K	Stable ruthenium-based paste; flat package improves heat dissipation
TG931-10M-1%	HVC-HVS-1W-10M	Optimized VCR; improved linearity under high voltage
MG715-2M-1%	HVC-PF-1.5W-2kV	Enhanced pulse withstand for switched-mode applications
USG series	HVC-US-3W-5kV	Designed for analyzers; extremely low annual drift

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