ESD Simulator Guns: Application and Technical Research in ESD Immunity Testing of Electrical and Electronic Equipment

Abstract
Driven by digital and intelligent technologies, electrical and electronic equipment is developing rapidly towards high integration and low power consumption, and its sensitivity to electrostatic discharge (ESD) interference has increased significantly. As a common source of electromagnetic interference for electronic equipment, ESD may cause device crashes, data loss, or even hardware damage. Therefore, ESD immunity testing has become a key link in product reliability verification. This paper takes the LISUN ESD61000-2 ESD Simulator Guns as the research object, systematically expounds its technical architecture, core functions, and standard compliance, and deeply analyzes the technical principle of the device in accurately reproducing ESD pulses and providing standardized testing conditions. Combined with actual test data and multi-industry application scenarios, the accuracy and reliability of the device in evaluating the ESD immunity of electrical and electronic equipment are verified. The research results show that the LISUN ESD61000-2 ESD Simulator Guns can meet the requirements of international and domestic standards such as GB/T 17626.2 (IEC/EN 61000-4-2), providing professional testing solutions for electronic equipment R&D, factory quality inspection, and third-party certification. It is of great significance for ensuring the stable operation of equipment in ESD interference scenarios.

1. Introduction
Electrostatic Discharge (ESD) is a common electromagnetic interference phenomenon in nature. When a charged object contacts or approaches electronic equipment, it will instantly release a large amount of charge to form a pulse current (with a peak value of up to tens of amperes and a rise time of only 0.6-1 ns), causing electromagnetic impact on the internal chips and circuits of the equipment. According to industry statistics, about 25% of electronic equipment failures are caused by ESD. Among them, fields such as consumer electronics and automotive electronics are at higher risk of ESD interference due to the high integration of equipment. For example, malfunctions such as touch failure of smartphone screens and crashes of in-vehicle navigation systems are mostly related to instantaneous circuit disorders caused by ESD.

To standardize the ESD immunity testing process, the International Electrotechnical Commission (IEC) issued the IEC 61000-4-2 standard, and China simultaneously formulated the GB/T 17626.2 standard, which clearly requires the use of special equipment to simulate ESD scenarios of different levels to evaluate the immunity performance of equipment. Traditional ESD testing equipment has problems such as unstable discharge pulse parameters, single testing mode, and poor compatibility, making it difficult to meet the testing needs of diverse products. The ESD61000-2 series ESD Simulator Guns developed by LISUN are designed for the ESD immunity testing needs of electrical and electronic equipment. Adopting high-precision discharge resistance-capacitance (RC) modules and intelligent control technology, they can accurately reproduce various ESD pulse scenarios such as air discharge and contact discharge, with an output voltage range of 0.1-30 kV, adapting to the testing needs of consumer electronics, automotive electronics, industrial control and other fields. This paper will comprehensively analyze the technical value and industrial application value of the LISUN ESD61000-2 ESD Simulator Guns from four dimensions: equipment technical principle, core parameter performance, application scenarios, and standard compliance.

2. Technical Architecture and Core Function Principles of LISUN ESD61000-2 ESD Simulator Guns
2.1 Technical Architecture Design
The LISUN ESD61000-2 ESD Simulator Guns adopt a “modular + integrated” design concept, which is divided into five core systems as a whole. Each system works collaboratively to achieve accurate generation of ESD pulses and intelligent control of the testing process:
• High-Voltage Generation and Regulation System: It includes a high-frequency high-voltage power module and a voltage feedback circuit, which can realize continuous voltage regulation of 0.1-20 kV (ESD61000-2) and 0.1-30 kV (ESD61000-2A/2C), with voltage accuracy controlled within ±5%. Through a closed-loop feedback mechanism, this system real-time monitors the output voltage and dynamically corrects it, avoiding voltage deviation caused by power grid fluctuations or load changes, and ensuring the stability of ESD energy.
• Discharge Resistance-Capacitance (RC) Module: As the core component for simulating ESD pulse waveforms, the ESD61000-2 is equipped with a standard 330Ω/150pF module (meeting the requirements of IEC 61000-4-2 standard), while the ESD61000-2A/2C provides four replaceable modules such as 150pF/330Ω and 150pF/2000Ω. The RC parameters can be switched according to testing standards (such as GB/T 17626.2 for general electronics and GB/T 19951 for automotive electronics) to reproduce ESD pulses in different scenarios. For example, 330Ω/150pF is used to simulate human body ESD, and 2000Ω/150pF is used to simulate equipment shell ESD.
• Discharge Electrode and Trigger System: It is equipped with a pointed electrode (for contact discharge) and a rounded electrode (for air discharge). The ESD61000-2C is additionally equipped with a 30mm-diameter large rounded electrode to adapt to the discharge needs of different test objects: contact discharge is suitable for conductive shells or metal surfaces (such as the metal middle frame of a smartphone), and air discharge is suitable for insulating surfaces (such as plastic shells). The trigger mode supports manual (single discharge) and automatic (continuous discharge, with a frequency of 0.05-99.99 s/discharge), meeting the dual needs of batch testing and single-point accurate testing.
• Control and Data Recording System: Equipped with an LCD display supporting Chinese and English, it supports multiple testing functions such as single test, counting test (1-9999 times), IEC level test (automatic switching between levels 1-4), and programming mode (customizable voltage, times, and intervals). The device can real-time record data such as the number of discharges, voltage value, and fault status, and generate a standardized report after the test is completed, facilitating data traceability and analysis.
• Safety Protection System: It integrates high-voltage overcurrent protection, leakage protection, and an emergency stop button. When the device has abnormal voltage or leakage, it automatically cuts off the high-voltage power supply; the device body is wrapped with insulating materials, and safety warning signs are set in the discharge electrode area to prevent operators from accidentally touching high-voltage components and ensure the safety of the testing process.

2.2 Core Function Principle: Accurate Reproduction of ESD Pulses
The core of ESD immunity testing is to simulate the pulse current waveform during real ESD processes. The LISUN ESD61000-2 realizes the generation of pulse waveforms meeting standard requirements through “RC charging and discharging + waveform calibration” technology. The specific principle is as follows:
• Charging Stage: The high-voltage power supply charges the energy storage capacitor (such as 150pF) through a current-limiting resistor until the capacitor voltage reaches the set value (such as ±8 kV). The charging process is monitored by a voltage feedback circuit to ensure that the deviation between the capacitor voltage and the set value does not exceed ±5%.
• Discharging Stage: The trigger signal triggers the discharge switch, and the energy storage capacitor discharges quickly through the discharge resistor (such as 330Ω) and the electrode to form an instantaneous pulse current. The current rise time is controlled within 0.6-1 ns (meeting the requirements of IEC 61000-4-2 standard), and the peak current changes with the voltage (for example, the peak current is about 29.4 A at 8 kV).
• Waveform Calibration: Before leaving the factory, the device undergoes third-party CNAS calibration (using the ESD-CALA calibration kit) to calibrate the pulse current waveforms (first peak current, current at 30 ns/60 ns, and leading edge time) at different voltages, ensuring that the waveform parameters meet the standard requirements. For example, when discharging at a positive voltage of 8 kV, the first peak current should reach 29.4 A ±10%, the current at 30 ns should be maintained at 16.2 A ±15%, and the current at 60 ns should be stabilized at 9.3 A ±20%, so as to ensure the comparability and repeatability of test results.

3. Parameter Performance and Supporting Solutions of LISUN ESD61000-2 ESD Simulator Guns
3.1 Core Parameter Comparison and Calibration Data
The LISUN ESD61000-2 series includes three models: ESD61000-2, ESD61000-2A, and ESD61000-2C. Each model differs in voltage range, RC module, and applicable standards, and can adapt to the testing needs of different industries. The following tables show the core parameter comparison of this series of models and the calibration data of the ESD61000-2:
Table 1 Core Parameter Comparison of LISUN ESD61000-2 Series

Table 2 Calibration Data of LISUN ESD61000-2 ESD Simulator Guns (Third-Party CNAS Report)

It can be seen from the calibration data that the pulse current parameters of the ESD61000-2 at different voltages and polarities all meet the requirements of the GB/T 17626.2 standard. The deviation of the first peak current is less than ±5%, and the leading edge time is stable at 0.89-0.97 ns, which proves that it has the ability to accurately reproduce ESD pulses.

3.2 Supporting Testing Solutions
To ensure that the testing environment meets the standard requirements, LISUN provides three types of supporting equipment, which work together with the ESD61000-2 series ESD Simulator Guns to build a complete ESD immunity testing system:
•  ESD-DESK ESD Testing Table: Designed in accordance with the requirements of GB/T 17626.2, it includes a 1600800800 mm test table, a reference metal grounding plate (2800*1800 mm), horizontal/vertical coupling plates (simulating metal components around the equipment), and insulating gaskets (preventing the sample from grounding). It can simulate the grounding environment and electromagnetic coupling effect in real usage scenarios, and is suitable for testing general electronic equipment such as smartphones, computers, and routers.
•  ESD-CALA ESD Gun Calibration Kit: Used for regular calibration of the pulse waveform parameters of the ESD Simulator Guns, including a target mounting plate, a calibration target for the ESD gun, a 20 dB attenuator for connecting the oscilloscope and the target, and cables. The current waveform on the target is collected by an oscilloscope, and the standard waveform is compared to determine whether the device needs adjustment, ensuring the long-term reliability of test data.
•  ESD-FCP Automotive Electronics ESD Field Coupling Plate: Designed for automotive electronics testing needs (in line with GB/T 19951-2019), it includes a 300*600 mm brass coupling plate, a 40 mm wide coupling tape, and an 80 mm diameter discharge island. It simulates the ESD coupling between electronic equipment (such as navigators and in-vehicle chargers) and the vehicle body in the in-vehicle environment, and is suitable for the ESD61000-2C model.

4. Industrial Application Scenarios of LISUN ESD61000-2 ESD Simulator Guns
4.1 Consumer Electronics Field: ESD Immunity Testing of Smartphones
As high-integration electronic equipment, smartphones are prone to ESD interference at parts such as screens, buttons, and charging ports, and need to pass IEC 61000-4-2 Level 3 testing (15 kV air discharge, 8 kV contact discharge). A smartphone manufacturer used the LISUN ESD61000-2A ESD Simulator Guns for testing:
•  Test Object: Complete smartphone (including metal middle frame and glass screen);
•  Test Plan: Contact discharge (metal middle frame, charging port) with a voltage of 8 kV, 10 discharges for each of positive/negative polarities; Air discharge (glass screen, plastic buttons) with a voltage of 15 kV, 10 discharges for each of positive/negative polarities;
•  Test Result: Qualified samples had no crashes or restarts during the test, and the touch function was normal; Unqualified samples (the screen driver chip of a certain batch had no ESD protection) experienced screen flickering during 12 kV air discharge. Later, by adding a TVS ESD protection diode, the equipment passed the 15 kV test and met the market access requirements.

4.2 Automotive Electronics Field: Testing of In-Vehicle Navigation Systems
Automotive electronic equipment must comply with the GB/T 19951 (ISO 10605) standard, and the testing requirements are more stringent (such as increased number of discharges and complex coupling methods). An automotive electronics enterprise used the ESD61000-2C + ESD-FCP coupling plate to test the in-vehicle navigation system:
•  Test Scenario: Simulate the ESD coupling between the navigator and the vehicle body during vehicle operation, using the electric field coupling method (applying ESD through the ESD-FCP coupling plate);
•  Test Parameters: Voltage of 12 kV, 50 discharges, interval of 1 s, alternating polarities;
•  Key Verification: During the test, the navigator must maintain normal navigation and voice broadcast functions, without data loss or interface freezes. A certain sample had GPS signal interruption during 10 kV discharge due to poor PCB grounding. After optimizing the grounding design, it successfully passed the 12 kV test.

4.3 Industrial Control Field: Testing of PLC Controllers
Industrial control equipment (such as PLCs and frequency converters) needs to withstand high ESD interference in industrial environments. An automation enterprise used the ESD61000-2 to test the PLC controller:
•  Test Parts: PLC panel buttons (6 kV contact discharge), shell (10 kV air discharge), communication interface (6 kV contact discharge);
•  Test Standard: IEC 61000-4-2 Level 4 (the highest level for industrial environments);
•  Test Result: Qualified PLCs could still normally receive/send control commands after the test, with no deviation in output signals; Unqualified PLCs had communication interruptions during 6 kV contact discharge because the communication interface had no protection. Later, by adding a shielding layer and an ESD protection circuit, the immunity performance of the equipment was improved.

5. Standard Compliance and Performance Verification of LISUN ESD61000-2 ESD Simulator Guns
5.1 Standard Compliance
The LISUN ESD61000-2 series ESD Simulator Guns strictly comply with international and domestic authoritative standards to ensure the universality and recognition of test results:
•  General Electronics Standards: GB/T 17626.2-2018 “Electromagnetic Compatibility – Testing and Measurement Techniques – Electrostatic Discharge Immunity Test”, IEC/EN 61000-4-2:2008, covering consumer electronics, information technology equipment, household appliances and other fields;
•  Automotive Electronics Standards: GB/T 19951-2019 “Road Vehicles – Environmental Conditions and Testing for Electrical and Electronic Equipment – Part 2: Electrical Loads”, ISO 10605:2023, applicable to in-vehicle electronic equipment, charging piles and other products;
•  Calibration Standards: Pass third-party calibration recognized by CNAS, in line with JJF 1597-2016 “Calibration Specification for ESD Simulator Guns”, ensuring that the device parameters meet the requirements of quantity traceability.

5.2 Performance Verification
To verify the testing stability of the ESD61000-2, the same device was used to conduct 10 repeated tests on a standard ESD test sample (metal plate) (8 kV contact discharge, positive polarity). The results are as follows:

The data shows that the parameter deviation of the 10 tests is less than ±0.5%, which proves that the ESD61000-2 has excellent test repeatability and can avoid misjudgment caused by device fluctuations.

6. Conclusions
Through high-precision voltage control, replaceable RC modules, and multi-mode testing functions, the LISUN ESD61000-2 ESD Simulator Guns solve the pain points of traditional equipment such as “inaccurate waveforms, single scenarios, and complex operations”, and provide a standardized and highly reliable solution for ESD immunity testing of electrical and electronic equipment. Its application in consumer electronics, automotive electronics, industrial control and other fields not only helps enterprises identify ESD protection vulnerabilities of products, but also provides key data support for products to pass international certifications (such as CE, FCC, CQC). It is of great significance for improving the reliability of electronic equipment and ensuring the safety of users.