Technical Characteristics and Application Research of Lightning Surge Simulator

1. Introduction

During the operation of power systems and electronic and electrical equipment, high-energy transient surge interference can be generated by natural lightning induction and switching of large-capacity inductive and capacitive loads. Such interference easily causes equipment circuit breakdown, functional failure or even permanent damage, seriously affecting the stability and service life of equipment. As a special testing device for simulating surge interference, the lightning surge simulator can generate standardized surge waveforms in accordance with EMC standards to systematically evaluate the surge immunity of equipment, making it a critical instrument in product development, quality certification and factory inspection.

Traditional lightning surge simulators have problems such as single specification, scattered test functions and the need for numerous external auxiliary instruments, which are difficult to adapt to the diversified test requirements of different industries and equipment. The complicated operation process also increases the probability of test errors. The LISUN SG61000-5 lightning surge simulator, developed by LISUN to address industry pain points, adopts a modular design concept to achieve flexible coverage of voltage and current output specifications. It integrates standard waveform output and real-time waveform monitoring, greatly improving the efficiency and accuracy of surge immunity tests. Fully compliant with international and domestic standards such as GB/T 17626.5 and IEC 61000-4-5, the equipment is widely used in surge immunity testing in electronics, electrical, communication, new energy and other fields, becoming a high-quality solution in the EMC testing field.

2. Core Design Features of LISUN SG61000-5 Lightning Surge Simulator

2.1 Modular Design for Full-Range Test Requirements

The core design highlight of the LISUN SG61000-5 lightning surge simulator is its modular architecture. Through the combination and configuration of different functional modules, it achieves full-range coverage of voltage and current output specifications, meeting diversified surge test requirements from low-voltage and small-current to high-voltage and large-current. The basic models cover an output range of 0~4.8kV/0~2.4kA to 0~6kV/0~3kA. High-voltage models including SG61000-5H-SP, SG61000-5H15-SP and SG61000-5H20-SP can achieve accurate outputs of 0~10kV/0~5kA, 0~15kV/0~7.5kA and 0~20kV/0~10kA respectively. Customized single-phase 30kV and three-phase 20kV models further increase the output voltage to 0~30kV with current matching up to 0~15kA, making them ideal for surge testing of high-voltage and high-power equipment.

Modular design is not only reflected in the flexible configuration of voltage and current output modules, but also includes standardized configuration of auxiliary modules such as coupling-decoupling networks (CDN) and isolation transformers. The equipment is equipped with a built-in AC240V/16A single-phase CDN and 4-wire symmetrical CDN, and supports optional external power line CDN61000-5P and communication line CDN61000-5C. It can be flexibly combined according to the type and input specifications of the equipment under test (EUT), realizing surge coupling tests for different interfaces such as power lines and communication lines, truly achieving “one equipment covering full-scenario tests”.

2.2 Multi-Standard Waveform Output for Accurate EMC Test Compliance

The standardization of surge waveforms is the core technical indicator of a lightning surge simulator. The LISUN SG61000-5 lightning surge simulator fully supports surge waveform output specified by international standards, and can flexibly switch between open-circuit voltage and short-circuit current waveforms according to test requirements, accurately matching the surge immunity test requirements of different equipment.

Mainstream models can stably output 1.2/50μs±20% open-circuit voltage waveforms and 8/20μs±20% short-circuit current waveforms. This combination wave is the standard waveform for power line and data line surge testing, which can accurately simulate the transient surge characteristics caused by natural lightning. The dedicated model SG61000-5C is suitable for communication equipment testing, outputting 10/700μs±20% open-circuit voltage waveforms and 5/320μs±20% short-circuit current waveforms, perfectly matching the test standards for communication line surge interference. All waveform parameter deviations are controlled within ±20%, far exceeding general industry requirements, ensuring the accuracy and authority of test data.

Meanwhile, the equipment supports free switching of surge polarity, enabling positive, negative and fully automatic polarity tests. Phase shift adjustment covers 0°~360° asynchronous and synchronous tests, simulating the impact of surge interference on equipment at different voltage phases and comprehensively evaluating equipment surge immunity. The number of surges can be freely set from 1 to 9999 times, meeting the requirements of continuous surge impact tests and accurately simulating scenarios where equipment encounters multiple surge interferences during actual operation.

2.3 Integrated Test Function Greatly Simplifies Test Operation

To solve the problem that traditional lightning surge simulators require external oscilloscopes, attenuators and other instruments for waveform monitoring, the LISUN SG61000-5 lightning surge simulator adopts an integrated functional design. It is newly upgraded with a built-in voltage and current attenuator probe and electronic oscilloscope, realizing real-time monitoring and accurate display of surge waveforms without any additional external instruments, greatly simplifying the test operation process.

The equipment is equipped with a high-definition LCD touch screen and built-in Android operating system. Testers can directly set all parameters such as voltage, current, waveform, surge count, polarity and phase shift through the touch screen. During testing, the output surge waveform curve can be viewed in real time, intuitively grasping key parameters such as rising edge, duration and peak value of the waveform, and timely detecting and adjusting waveform deviations. The built-in voltage and current attenuator probe can accurately attenuate high-voltage and large-current surge signals, ensuring stable and accurate signal collection by the oscilloscope and avoiding instrument damage and data errors caused by signal overload. The integrated design not only reduces the connection links of test instruments and test errors caused by improper line connection, but also saves laboratory space and improves the convenience and efficiency of testing.

2.4 High-Safety Design Ensures Test Operation Safety

The testing process of the lightning surge simulator involves high voltage and large current, so the safety design of the equipment is particularly important. The LISUN SG61000-5 lightning surge simulator is equipped with a complete safety protection system and supports the configuration of a variety of safety supporting equipment, fundamentally ensuring the safety of testers and test equipment. The equipment itself has functions such as high-voltage warning, overcurrent protection and overvoltage protection. When the output parameters exceed the set range, the equipment will automatically cut off the output to avoid damage to the tested equipment caused by overload surge signals. Meanwhile, it is recommended to use with LISUN dedicated surge test protection device PD-E01, which can effectively isolate the tested equipment and prevent reverse impact of high-voltage surges. It can accommodate tested equipment of 700*440*392mm, and special specifications can be customized to meet the test protection needs of equipment of different sizes. In addition, the equipment can be optionally equipped with SG-DESK surge test desk and EUT isolation transformer to further improve the safety and standardization of the test process.

3. Core Technical Parameter Table of LISUN SG61000-5 Lightning Surge Simulator

Model	Open Circuit Voltage Waveform	Short Circuit Current Waveform	Output Impedance	Output Voltage Range	Output Current Range	Operation Mode	Core Application Scenarios
SG61000-5SB	1.2/50μs±20%	8/20μs±20%	2Ω, 12Ω	0~4.8kV±5%	0~2.4kA±5%	LCD Touch Screen + Android	Low-voltage small electronic equipment
SG61000-5	1.2/50μs±20%	8/20μs±20%	2Ω, 12Ω	0~6kV±5%	0~3kA±5%	LCD Touch Screen + Android	General electronic & electrical equipment
SG61000-5H-SP	1.2/50μs±20%	8/20μs±20%	2Ω, 12Ω, 500Ω	0~10kV±5%	0~5kA±5%	LCD Touch Screen + Android	Medium & high-voltage industrial equipment
SG61000-5H15-SP	1.2/50μs±20%	8/20μs±20%	2Ω, 12Ω, 500Ω	0~15kV±5%	0~7.5kA±5%	LCD Touch Screen + Android	High-voltage high-power equipment
SG61000-5C	10/700μs±20%	5/320μs±20%	15Ω, 40Ω	0~6kV±5%	0~150A±5%	LCD Touch Screen + Android	Communication equipment & line testing
SG61000-5H30-SP (Custom)	1.2/50μs±20%	8/20μs±20%	2Ω, 12Ω, 500Ω	0~30kV±5%	0~15kA±5%	LCD Touch Screen + Android	Ultra-high voltage equipment custom test

4. Industry Applications of LISUN SG61000-5 Lightning Surge Simulator

4.1 Electronic and Electrical Industry

Power lines and control lines of household appliances, consumer electronics and small industrial electrical appliances are vulnerable to lightning surge interference, leading to internal circuit damage and functional failure. The basic models SG61000-5SB and SG61000-5 of the LISUN SG61000-5 lightning surge simulator can achieve surge output of 0~6kV/0~3kA, accurately simulating surge interference in low-voltage power supply environments. They evaluate the surge immunity of refrigerators, air conditioners, washing machines, routers and other equipment, ensuring stable operation when encountering surge interference in actual use and meeting EMC certification requirements for household appliances.

4.2 Communication Equipment Industry

Communication lines of communication base stations, switches, optical fiber transceivers and other communication equipment are susceptible to lightning-induced surges, resulting in data transmission interruption and equipment damage. The dedicated model SG61000-5C can output communication-specific surge waveforms of 10/700μs open-circuit voltage and 5/320μs short-circuit current, perfectly matching the surge test standards for communication lines. It can perform surge coupling tests on RJ45, optical fiber interfaces and other communication equipment interfaces, evaluating the immunity of equipment communication lines and ensuring the stability and continuity of communication networks.

4.3 New Energy and Power Equipment Industry

New energy and power equipment such as photovoltaic inverters, charging piles, high and low voltage distribution cabinets operate outdoors or in industrial environments for a long time, with a high probability of encountering lightning surges. As high-voltage and high-power equipment, they have stricter requirements for surge immunity. The high-voltage models of the LISUN SG61000-5 lightning surge simulator can achieve surge output of 0~30kV/0~15kA, simulating high-energy surge interference caused by strong lightning. They comprehensively evaluate the circuit protection capability of new energy and power equipment, avoiding equipment shutdown, fire and other safety accidents caused by surge interference.

4.4 Industrial Control Industry

PLC, frequency converters, servo motors and other industrial control equipment are the core of industrial production, and their surge immunity directly determines the stable operation of production lines. The LISUN SG61000-5 lightning surge simulator supports synchronous/asynchronous testing with phase shift from 0° to 360°, simulating the impact of surge interference on industrial control equipment at different voltage phases. Through optional external coupling-decoupling networks, it can perform comprehensive surge tests on power lines, control lines and communication lines of equipment, ensuring trouble-free operation of industrial control equipment in complex industrial electromagnetic environments and improving the reliability of production lines.

5. Application Value and Industry Development Trend of Lightning Surge Simulator

As a new-generation modular lightning surge simulator, the core application value of the LISUN SG61000-5 lightning surge simulator lies in comprehensive coverage of test requirements and great improvement of test efficiency. The modular design breaks the limitation of single specification of traditional equipment. Through the configuration of different modules, it can meet all surge test requirements from low voltage to high voltage, from conventional equipment to customized equipment, reducing equipment procurement costs for enterprises. The integrated waveform monitoring function eliminates the complicated operation of external instruments, reduces test preparation time and operation errors, and improves test efficiency. The accurate standard waveform output and complete safety protection design ensure the accuracy of test data and the safety of the test process, providing scientific and authoritative test basis for product development, improvement and quality certification.

With the development of electronic and electrical equipment towards miniaturization, intelligence and high power, and the continuous upgrading of EMC standards, the development of lightning surge simulators presents a trend of modularization, intelligence and integration. In the future, lightning surge simulators will further optimize the modular architecture, realize the standardization and generalization of more functional modules, and improve equipment adaptability. In terms of intelligence, IoT and big data technology will be integrated to realize remote collection, analysis and management of test data, creating an intelligent test platform. In terms of integration, it will further integrate multiple EMC test functions such as surge test, electrostatic discharge test and electrical fast transient burst test, realizing “one machine with multiple functions” and providing users with a more comprehensive EMC test solution.

6. Conclusion

As a high-precision, intelligent and multi-purpose modular testing equipment, the LISUN SG61000-5 lightning surge simulator realizes full-range output of 0~30kV voltage and 0~15kA current with modular design. It fully supports standard output of open-circuit voltage waveforms such as 1.2/50μs and 10/700μs, as well as short-circuit current waveforms such as 8/20μs and 5/320μs. Its built-in voltage and current attenuator probe and electronic oscilloscope, combined with LCD touch screen operation, realize integrated and intelligent surge testing, greatly simplifying the test operation process and ensuring the accuracy and standardization of test waveform parameters. Equipped with a complete safety protection system and diverse supporting equipment, the equipment further improves the standardization and convenience of testing while ensuring test safety.

As a professional lightning surge simulator compliant with international and domestic standards such as GB/T 17626.5 and IEC 61000-4-5, the LISUN SG61000-5 not only meets the surge immunity testing needs of electronics, electrical, communication, new energy, industrial control and other industries, but also provides important support for product development, improvement and quality certification through scientific test data. Under the background of increasingly stringent EMC requirements, the LISUN SG61000-5 lightning surge simulator has become an important equipment in the EMC testing field with its advanced design concept, excellent technical performance and wide application scenarios, and has important practical significance for promoting the improvement of product surge immunity and the development of the EMC testing industry.

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