How to use the lightning surge simulator to do the surge test

What is a lightning surge simulator:
Lightning surge simulator is a device that can generate high voltage and high current transient pulses, used to simulate lightning strikes and other sudden electromagnetic interference situations, in order to test and evaluate the tolerance and anti-interference ability of electronic equipment and power systems.

Working principle of lightning surge simulator:
The lightning surge simulator usually consists of a capacitor with a discharge switch and a discharge inductor. During the experiment, the capacitor is charged at a slower rate. When the capacitor is fully charged, the discharge switch begins to conduct, causing the charge on the capacitor to be released into the discharge inductance at an extremely fast rate, generating extremely high voltage and current transient pulses.

Application of lightning surge simulator:
The lightning surge generator is mainly used for anti-interference testing and evaluation of electronic equipment and power systems. For example, electronic products need to undergo lightning surge testing before production to verify whether they can work properly in lightning environments and whether they can prevent faults caused by sudden electromagnetic interference.

What is lightning surge test:
The causes of surge testing are switching transients and lightning transients in the power system; The purpose of surge immunity testing is to establish a common benchmark to evaluate the performance of electrical and electronic equipment when subjected to surges (impacts).

Lightning surge test is a surge (impact) immunity test that simulates the pulse interference generated by lightning coupling, startup and shutdown of high-power equipment, power supply failure, etc. It tests the ability of the product’s power protection device to absorb surge pulses, or the pulse interference generated by startup and shutdown of high-power equipment, power supply failure, etc. It also tests the ability of the product’s power protection device to absorb surge pulses.

According to the standard IEC61000-4-5 surge impulse immunity test, the general requirement is that the lightning surge generator simulates a 1.2/50us voltage waveform, 8/20us current waveform, and a combination wave (voltage waveform 10/700us current waveform 5/320us). The coupling network couples the waveform to the tested circuit to achieve the experimental purpose. The experimental level is divided into levels 1,2,3,4 and X based on the severity of the voltage. Among them, X and are open stages, and the corresponding voltage intensity for each stage is shown in Table 1. The application range of the severity level depends on the environment (excellent resistance testing lamp laboratory) and installation conditions.

Lightning surge simulator surge test method:
The causes of surges are switching transients and lightning transients in the power system; The intention of surge immunity testing is to establish a common benchmark to evaluate the functionality of electrical and electronic equipment when subjected to surges (impacts). According to the general requirements of IEC61000-4-5 surge impulse immunity test, the lightning surge generator simulates a 1.2/50us voltage waveform, an 8/20us current waveform, and a combination wave (voltage waveform: 10/700us, current waveform: 5/320us). Through a coupling network, the waveform is coupled to the circuit under test, achieving the test purpose.

Lightning surge simulator surge test level:
The test levels are divided into levels 1, 2, 3, 4, and X based on the severity of voltage, with X and X being open levels. The corresponding voltage intensity for each level is shown in Table 1. The scale of strict level application depends on the environment (the environment that may be affected by surges) and device conditions, and is generally classified according to the following conditions:

Level 1: A well maintained environment, such as the control room of a factory or power plant.
Level 2: An environment with certain maintenance, such as a factory without strong disturbance.
Level 3: general electromagnetic interference environment, no special device requirements are specified for equipment, such as cable network of general devices, industrial workplaces and Electrical substation.
Level 4: environment seriously disturbed, such as civil overhead lines, and high voltage Electrical substation without maintenance.
Level X: Special level, determined by negotiation between the user and the manufacturer. The specific level of product selection is generally determined by the product specifications.

Lightning protection test for LED lighting fixtures:
Standard for surge testing of lighting fixtures:
GB/T 18595 “Electromagnetic Compatibility Immunity of General Lighting Equipment”
GB/T 17626.5, IEC 61000-4-5, EN 61000-4-5 “Electromagnetic Compatibility Testing and Measurement Techniques – Surge (Impact) Immunity Test”
The requirements of GB/T18595 on electromagnetic immunity apply to lamps and their related equipment, such as low-voltage power supply or battery powered bulbs, accessories and lamps.

Lamp surge test requirements:
The surge test of lighting fixtures shall be conducted in accordance with GB/T 17626.5, and the test levels are as follows:
1. Self ballasted lamps and semi lamps
Waveform data: 1.2/50us;
Test level: line to line ± 0.5kV, line to ground ± 1.0kV.
2. Luminaires and independent accessories with input power ≤ 25W
Waveform data: 1.2/50us;
Test level: line to line ± 0.5kV, line to ground ± 1.0kV.
3. Luminaires and independent accessories with input power greater than 25W
Waveform data: 1.2/50us;
Test level: line to line ± 1.0kV, line to ground ± 2.0kV.

Precautions for surge test of lightning surge generator:
1. When using an oscilloscope, it is advisable to add a blocking transformer for power supply to avoid lightning surge back surge voltage from affecting the oscilloscope power supply test. Lightning surge back surge is generally set at 8%.
2. Ensure that the lightning surge generator is grounded firmly.
3. The power supply for the differential probe is preferably powered by a barrier transformer to eliminate external interference with the test items.
4. It is recommended to use a barrier transformer for EUT power supply, or perhaps choose an air switch with a large leakage protection.
5. The safety of laboratory operation is the primary direction. (Lightning surges have high voltage and high current tests, which have certain risks) During the test, try not to touch the wiring direction. When the lightning surge generator triggers discharge, do not touch any connecting lines. In case of emergency, press the emergency stop button directly, and the instrument will actively remove the high voltage voltage.

The SG61000-5 is an automatic surge generator (also called lightning surge immunity test, combination wave generator, surge current generator/surge voltage generator, combined surge voltage and current generator) . 

Figure: Surge generator

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