Introduction to Surge Immunity Testing
Surge immunity testing is a critical component of electromagnetic compatibility (EMC) evaluations, ensuring that electronic and electrical equipment can withstand transient voltage disturbances caused by lightning strikes, power switching, or electrostatic discharge. The LISUN SG61000-5 Surge Generator is a precision instrument designed to simulate these high-energy transients in compliance with international standards such as IEC 61000-4-5, EN 61000-4-5, and GB/T 17626.5.
This article explores the technical design principles of surge generators, the operational methodology of the SG61000-5, and its applications across diverse industries, including lighting fixtures, medical devices, automotive electronics, and power equipment.
Fundamentals of Surge Generator Circuit Design
High-Voltage Pulse Generation Mechanism
A surge generator circuit consists of several key components:
- Energy Storage Capacitor (Cs) – Stores the high-voltage charge before discharge.
- Waveform Shaping Network (Rs, Ls) – Controls the rise time and decay of the surge pulse.
- Coupling/Decoupling Network (CDN) – Ensures the surge is applied to the equipment under test (EUT) without backfeeding into the power supply.
- Triggering Circuit – Initiates the discharge process with precise timing.
The SG61000-5 employs a hybrid pulse-forming network (PFN) to generate both 1.2/50 μs voltage surges (open circuit) and 8/20 μs current surges (short circuit), replicating real-world transient conditions.
Waveform Compliance and Calibration
The surge waveform must adhere to strict tolerances as defined by IEC 61000-4-5:
| Parameter | Open Circuit Voltage (1.2/50 μs) | Short Circuit Current (8/20 μs) |
|---|---|---|
| Rise Time | 1.2 μs ±30% | 8 μs ±20% |
| Duration | 50 μs ±20% | 20 μs ±20% |
The SG61000-5 features automatic waveform verification, ensuring test repeatability and compliance with regulatory requirements.
LISUN SG61000-5 Surge Generator: Key Specifications
Technical Parameters
- Voltage Range: 0.5–6 kV (adjustable in 0.1 kV steps)
- Current Range: 0.25–3 kA
- Polarity: Positive, negative, or alternating
- Phase Synchronization: 0°–360° with respect to AC mains
- Repetition Rate: Single shot or up to 1 surge per minute
- Coupling Modes: Line-to-line, line-to-ground, and differential mode
Advanced Features
- Integrated CDN for AC/DC Power Ports – Eliminates the need for external decoupling networks.
- Digital Control Interface – Supports remote operation via PC for automated test sequences.
- Real-Time Monitoring – Displays surge voltage, current, and waveform parameters.
Industry-Specific Applications
Lighting Fixtures and Industrial Equipment
Surge testing ensures that LED drivers and industrial control systems remain operational after power grid disturbances. The SG61000-5 verifies compliance with IEC 61347 for lighting and IEC 60204 for machinery safety.
Medical Devices and Household Appliances
Medical equipment, such as patient monitors, must resist surges to prevent malfunction. The SG61000-5 tests according to IEC 60601-1-2, while household appliances follow IEC 60335.
Automotive and Rail Transit
Electric vehicles (EVs) and railway signaling systems require surge immunity per ISO 7637-2 and EN 50121. The SG61000-5’s high-current capability ensures robust validation.
Communication and IT Equipment
Telecom base stations and servers undergo surge testing per ITU-T K.21 and IEC 61000-4-5. The generator’s phase synchronization feature simulates surges at vulnerable points in the AC cycle.
Competitive Advantages of the SG61000-5
- Precision Waveform Generation – Exceeds standard tolerances for accurate testing.
- Multi-Standard Compliance – Covers IEC, EN, GB/T, and industry-specific requirements.
- User-Configurable Test Sequences – Enables automated multi-pulse testing for reliability validation.
- Enhanced Safety Mechanisms – Includes overvoltage protection and interlock circuits.
FAQ Section
Q1: What is the difference between a combination wave generator and a ring wave generator?
A combination wave generator produces 1.2/50 μs voltage and 8/20 μs current surges, while a ring wave generator simulates oscillatory transients (100 kHz ring wave per IEC 61000-4-12). The SG61000-5 is a combination wave generator.
Q2: How often should surge testing be performed on industrial equipment?
Testing should be conducted during product development, certification, and periodically in production to ensure continued compliance with EMC standards.
Q3: Can the SG61000-5 test DC-powered devices?
Yes, the generator supports both AC and DC coupling modes, making it suitable for automotive and renewable energy applications.
Q4: What is the maximum cable length for remote triggering?
The SG61000-5 supports remote triggering via optical isolation, with recommended cable lengths under 10 meters to minimize signal degradation.
Q5: Does the SG61000-5 include self-diagnostic functions?
Yes, the device performs automatic waveform calibration and fault detection before each test cycle.
