EMC Surge Immunity Test System of 6kv Surge Generator

Core Test Principle of Surge Generator and Application Value of 6kv Gear

A surge generator is a highly integrated automatic EMC test device. Its core principle is to generate standard combination wave pulses through an energy storage circuit to simulate two types of high-energy transient interference: first, high-voltage shocks induced by indirect natural lightning on power lines and signal lines; second, voltage and current surges formed by startup and shutdown switching of large-capacity inductive and capacitive loads on power grids. The equipment outputs 1.2/50μs open-circuit voltage waveform and 8/20μs short-circuit current waveform, which are applied to the power supply and internal connecting wires of equipment under test (EUT). The tester observes whether the equipment malfunctions or hardware breaks down to evaluate the surge withstand capability of products.

The 6kv surge generator is a mainstream model widely used in the industry. Its 6kV output voltage covers the type test grades of most civil and industrial electronic products, matching standard test gears of 4kV and 6kV, and can complete surge tests required for mandatory certifications such as CCC, CE and CQC. Models above 6kV are mostly used for outdoor high-power power equipment, while models below 6kV are only applicable to small low-voltage consumer electronics with insufficient versatility. As a standard 6kv surge generator, LISUN SG61000-5 features continuously adjustable output voltage from 0 to 6kV and maximum output current of 3kA. A built-in coupling decoupling network enables common-mode and differential-mode surge tests for single-phase power ports without additional supporting equipment.

Figure: Surge tester

Parameter Comparison of Full Series LISUN SG61000 Surge Generators

Table 1 Core Specification Comparison of LISUN SG61000 Series Surge Generators

As a benchmark model of 6kv surge generator, the standard SG61000-5 is equipped with an Android LCD touch screen. The surge times are programmable from 1 to 9999, supporting automatic switching of positive and negative polarities, and adjustable synchronization and asynchronous phase shift from 0° to 360°. It is uniquely equipped with built-in voltage and current attenuation probes and an oscilloscope, allowing real-time viewing of standard 1.2/50μs and 8/20μs waveforms on the screen without external instruments, greatly reducing supporting test costs. The overall dimension is 44×45×35cm with gross weight about 30kg. The built-in 4-wire symmetrical coupling decoupling network supports single-phase AC240V/16A testing without extra CDN.

Standardized Test Procedure of 6kv Surge Generator

Based on the working mechanism of surge generator for simulating transient interference, SG61000-5 forms a standardized test process:
• Preparation of Equipment and Supporting Tooling: Match with PD-E01 surge protection device, SG-DESK test bench and isolation transformer, reliably ground the equipment and check wiring of coupling decoupling network;
• Test Parameter Setting: Select 6kV test gear, set output impedance of 2Ω/12Ω, define surge times, polarity and synchronization phase, and call standard 1.2/50μs and 8/20μs waveforms;
• EUT Clamping and Power Supply: Connect EUT to built-in CDN, supply power via isolation transformer and close the test protection cabin to avoid high-voltage safety risks;
• Automatic Surge Impact Test: The equipment outputs pulses fully automatically, and the touch screen records voltage and current waveforms in real time;
• EUT Failure Judgment: After the test, inspect EUT functions, power circuits and lightning protection components. The product is qualified without restart, breakdown or permanent damage.

Applicable Industries and Standard Compliance Advantages

LISUN SG61000-5 6kv surge generator supports testing of all types of electrical and electronic products, covering home appliances, LED lighting, industrial controllers, medical equipment, new energy small household appliances, security monitoring and other fields. The equipment fully complies with universal domestic and international surge immunity standards including GB/T17626.5, IEC61000-4-5 and EN61000-4-5. The output test waveforms and data are recognized by third-party laboratories and certification bodies.

Compared with simple surge equipment, the 6kV model features wider voltage coverage, enabling multi-grade tests without replacing different devices. The built-in waveform observation function judges waveform distortion in real time to guarantee accurate test data. It can be expanded with external power line and communication line CDN to adapt to surge detection of three-phase equipment and communication ports, realizing multi-purpose machine and lowering laboratory equipment procurement costs.

Conclusion

The 6kv surge generator is the core test equipment to meet EMC surge immunity certification requirements of most electronic products. Relying on the test principle of surge generator to simulate high-energy transient interference, it can accurately reproduce surge shocks caused by lightning induction and power grid load switching. With advantages of continuously adjustable output from 0 to 6kV, built-in oscilloscope, fully automatic touch control system and integrated coupling decoupling network, the standard LISUN SG61000-5 balances test accuracy, easy operation and standard compatibility. It is widely applied in enterprise R&D laboratories, third-party testing institutions and quality inspection institutes, providing a stable and standardized test solution for lightning protection circuit optimization and EMC compliance testing of electrical and electronic products.