Fully Automatic Surge Testing Machine in EMC Immunity Test

Abstract
Surge testing machine is a highly integrated full-automatic electromagnetic compatibility (EMC) test equipment. Its core function is to simulate high-energy transient interference caused by natural lightning induction and switching of large-capacity inductive and capacitive loads. It is used to evaluate the immunity of power cords and internal connecting wires of electrical and electronic equipment to such interference, and provide a standardized test environment for the compliance detection of equipment electromagnetic immunity. Taking LISUN SG61000‑5 series surge testing machine as the research object, this paper expounds its working principle, technical parameters, applicable standards, system configuration and engineering application. Combined with measured parameters, it illustrates the key role of the equipment in EMC certification, R&D verification and quality control, providing a reference for model selection and test implementation in related industries.

Figure: Surge tester

Introduction

In industries such as electric power, communication, industrial control, household appliances and new energy, electrical and electronic equipment operate in a complex electromagnetic environment for a long time, and are extremely vulnerable to high-energy transient surge shocks caused by lightning induction, power grid switching and load mutation. These shocks will lead to device breakdown, interface burnout, data disorder, system downtime and even safety accidents. To uniformly evaluate the surge immunity of equipment, domestic and international authorities have issued core standards for surge (impulse) immunity test, and surge testing machine is the core equipment to realize standardized tests.

LISUN SG61000‑5 surge testing machine is designed for general and high-voltage surge test requirements, with output voltage ranging from 0 to 20kV. It is compatible with standard combination waves and communication waves, equipped with built-in coupling-decoupling network and waveform monitoring unit. It can automatically complete standardized tests with multi-polarity, multi-phase shift and multi-times, and is widely used in 3C certification, type test, R&D pre-test and factory inspection, serving as key equipment to ensure the electromagnetic safety of equipment.

Working Principle and Test Value of Surge Testing Machine

Surge testing machine adopts high-voltage pulse forming and impedance matching network to output standard 1.2/50μs open-circuit voltage wave and 8/20μs short-circuit current wave. It injects surge accurately into power lines or signal lines through coupling-decoupling network (CDN), to simulate transient interference in real working scenarios.

Core Test Value
• Immunity Verification: Evaluate the electrical withstand capability and structural safety of power cords and connecting wires under high-energy transient shocks.
•  Defect Location: Identify weak links including insufficient insulation, poor protection, bad grounding and circuit design defects.
•  Compliance Access: Meet mandatory certification requirements of GB/T 17626.5, IEC 61000‑4‑5, EN 61000‑4‑5 and other mainstream standards.
• Service Life Prediction: Simulate full-life surge stress to improve long-term reliability and market competitiveness of products.

The equipment supports line-to-line and line-to-ground coupling, automatic positive/negative polarity switching, 0°‑360° synchronous/asynchronous phase shift control, providing consistent, controllable and traceable test conditions for laboratories and production lines.

Core Technical Parameters of LISUN SG61000‑5 Surge Testing Machine

LISUN SG61000‑5 series surge testing machine covers multiple voltage levels and waveform configurations, suitable for power port and communication port tests. The key parameters are shown in the table below:

 Applicable Standards and Compliance Capacity

LISUN SG61000‑5 surge testing machine strictly complies with the following standards, covering mainstream certification requirements worldwide:

Domestic Standard: GB/T 17626.5 Electromagnetic compatibility (EMC) – Testing and measurement techniques – Surge immunity test

International Standards: IEC 61000‑4‑5, EN 61000‑4‑5

The output waveform, impedance, voltage/current accuracy, coupling mode and test procedure of the equipment fully meet the standard requirements. It can be directly used for CNAS, CMA, 3C, CE, FCC and other compliance tests, providing authoritative support for product market access.

System Configuration and Safety Supporting Equipment

To ensure test accuracy and operation safety, LISUN provides a complete supporting scheme for SG61000‑5 surge testing machine:
• Coupling-Decoupling Network: Equipped with built-in single-phase/4-wire CDN; external power port CDN61000‑5P and communication port CDN61000‑5C are optional.
•  Isolation and Safety Protection: Isolation transformer ITEU‑SP4K/ITUS‑SP2K, surge test protection device PD‑E01 and special test desk SG‑DESK are recommended to reduce high-voltage risks, ensure reliable grounding and interference isolation.
•  Waveform Monitoring: Built-in voltage/current attenuator probes and electronic oscilloscope, which can directly display 1.2/50μs and 8/20μs waveforms on the touch screen without external instruments, improving test efficiency and accuracy.

Functional Advantages and Application Scenarios

Core Functional Advantages
• High Precision Full Range: Voltage and current error ≤±5%, waveform error ≤±20%, fully meeting certification-level test requirements.
• Full Automatic Test: One-key setting of polarity, surge times, phase shift and interval on touch screen, automatic test execution and data recording.
• Multi-waveform and Multi-impedance: Covers standard combination waves and communication waves, suitable for power, control and communication interface tests.
• High-voltage Safety Design: High-voltage models adopt cabinet structure with interlock protection, equipped with complete safety devices, suitable for long-term laboratory use.
• Proven Market Reliability: The equipment has been sold and verified in the market for more than ten years, with a complete after-sales service system and stable performance.

Typical Application Fields
Surge testing machine has become an indispensable standard equipment in industrial quality control and EMC laboratory. LISUN SG61000‑5 series is widely used in household appliances & power supplies, industrial control & electric power, information & communication, automotive electronics, new energy and other industries, to complete surge immunity pre-test and certification test of power lines, communication lines and control circuits, and detect EMC design hazards in advance.

Conclusion

Surge testing machine is an indispensable standard equipment for electromagnetic compatibility test of electrical and electronic equipment. It can scientifically evaluate the surge immunity of equipment, locate design defects and support product compliance access by accurately simulating lightning and power grid transient surges. As a mature and reliable surge testing machine, LISUN SG61000‑5 series has the advantages of wide voltage coverage, standard waveform output, full-automatic control, built-in monitoring and complete safety supporting facilities. It meets the multi-scenario requirements from general 6kV to high-voltage 20kV, and complies with mainstream domestic and international standards, making it the preferred equipment for R&D, certification and quality inspection.

It is recommended that users select the appropriate surge testing machine and matching CDN, isolation and protection devices according to interface type, target voltage level, standard requirements and safety specifications, to ensure standardized, safe and effective surge tests, and comprehensively improve the electromagnetic reliability of products.