Modular Design and Intelligent Integration Applied to Surge Testing Equipment

Introduction

During power grid operation and outdoor service environment, transient high voltage surge generated by lightning induction and switching of large-capacity inductive or capacitive loads may cause equipment breakdown, system crash and communication failure of electronic devices. Surge testing equipment reproduces standard surge pulses to complete immunity evaluation, which is mandatory to satisfy requirements of GB/T 17626.5, IEC 61000‑4‑5 and EN 61000‑4‑5.

Conventional surge testing equipment is restricted by single output range, complicated waveform switching and mandatory external oscilloscope connection, leading to poor flexibility for multi-grade testing scenarios. Adopting modular structure, LISUN SG61000‑5 series surge testing equipment realizes wide-range voltage and current output together with multiple standard waveforms. With integrated probes and virtual oscilloscope and full-process LCD touch operation, the equipment guarantees waveform precision, simplified operation and reliable test data, becoming mainstream configuration for EMC laboratories focusing on power supply, communication, industrial control and home appliance industries. 

Figure: Surge tester

Modular Design and Multi-Range Output Performance

Modularization is mainstream technical solution for modern surge testing equipment, enabling flexible combination and expansion of high voltage unit, energy storage unit, coupling network and control unit to balance versatility and scalability. Built upon modular architecture, LISUN SG61000‑5 series covers full test scenarios from low-power laboratory evaluation to high-power industrial verification, with maximum output specification of 0~30kV voltage and 0~15kA current to fulfill strict severity level tests for diversified products.

The series consists of SG61000‑5SB, SG61000‑5, SG61000‑5H‑SP, SG61000‑5H15‑SP, SG61000‑5H20‑SP and SG61000‑5C. Different output capacity is realized via module configuration: low voltage models apply to conventional consumer electronics and home appliances; high voltage versions target outdoor electrical products, power equipment and communication devices; dedicated communication module is customized for 10/700μs telecom surge test. Modular design reduces maintenance cost and facilitates function upgrade along with updated testing standards.

Standard Waveform Output and Parameter Accuracy

The core performance of surge testing equipment lies in standardized waveform output to ensure repeatable and comparable test results. Complying with GB/T 17626.5 and IEC 61000‑4‑5, SG61000‑5 provides two groups of combined waveforms for power port and communication port testing separately.

Combined Waveform 1 for Power Port Test
Open-circuit voltage waveform: 1.2/50μs±20%; Short-circuit current waveform: 8/20μs±20%; Available output impedance: 2Ω, 12Ω, 500Ω.

Combined Waveform 2 for Communication Port Test
Open-circuit voltage waveform: 10/700μs±20%; Short-circuit current waveform: 5/320μs±20%; Available output impedance: 15Ω, 40Ω.

Rising edge, half-peak duration and amplitude tolerance are controlled within standard allowance to maintain consistent surge injection and avoid misjudgment caused by waveform distortion.

Core Technical Specifications of SG61000‑5 Series Surge Testing Equipment

The following specification table demonstrates comprehensive performance including modular structure, wide output range, multi-waveform compatibility and high measuring precision.

Built-in Probe and Oscilloscope: Innovative Design for Simplified Test Process

Traditional surge testing equipment requires external high voltage probes and independent oscilloscope for waveform monitoring, resulting in complicated wiring, extra space occupation, parasitic interference and potential safety hazard during high voltage operation. LISUN SG61000‑5 series adopts innovative integrated design with built-in voltage & current attenuator probes and electronic oscilloscope. No extra external measuring instrument is required; voltage and current surge waveform can be displayed in real time on LCD touch screen to check amplitude, front edge and half-peak value against standard specification, improving testing efficiency and operation safety significantly.

This integrated solution cuts procurement and wiring cost of external oscilloscope and high voltage probes, eliminates waveform distortion introduced by peripheral instruments. Operators can complete parameter setup, waveform checking, cycle setting and start-stop control via touch panel. Synchronized surge output and waveform monitoring ensures every impulse complies with standard requirement, and the stable embedded system supports long-term continuous aging test.

Intelligent Functions and Safety Protection Design

SG61000‑5 series surge testing equipment improves usability and safety via intelligent configuration to satisfy high-efficiency and stable operation of EMC laboratories. Synchronous or asynchronous phase triggering with precise 0°~360° adjustment is available for AC power port testing. Automatic polarity switching enables unattended sequential test after presetting total surge cycles.

Comprehensive protection including overvoltage, overcurrent, overheat and door-open power cut is equipped, cooperating with safety cabinet and isolation transformer to protect operators. Internal or external CDN (Coupling Decoupling Network) is optional for single-phase, three-phase and telecommunication line tests for multi-port DUT. All test records can be stored and exported to meet documentation audit requirement of accredited laboratories.

Standard Compliance and Application Fields

LISUN SG61000‑5 series surge testing equipment fully conforms to GB/T 17626.5‑2019, IEC 61000‑4‑5:2014 and EN 61000‑4‑5. It is widely applied in R&D and QC test of power adapters, battery chargers, switching power supplies, industrial power units, home appliances, smart home products, outdoor lighting, security equipment, communication terminals, routers, optical modems, base station hardware, industrial controllers, inverters, sensors, automotive electronics and third-party accredited EMC laboratories.

Conclusion

With modular structure, LISUN SG61000‑5 series surge testing equipment realizes full-range output coverage up to 0~30kV and 0~15kA and generates certified 1.2/50μs,10/700μs open-circuit waveforms and 8/20μs,5/320μs short-circuit waveforms in accordance with global mainstream surge immunity standards. Benefiting from innovative built-in voltage/current attenuator probes and embedded oscilloscope plus LCD touch control, the equipment removes dependence on extra external instruments to streamline testing workflow and enhance measuring accuracy and operational safety.

Featuring high integration, stable performance and friendly operation, this surge testing equipment fulfills test requirements for product development, quality inspection and certification assessment, delivering reliable technical solution for lightning surge immunity validation of electrical and electronic products and becoming preferred test instrument for modern EMC laboratories.