I've also seen this effect when testing component power supplies
(off-line switch-mode converters, 50-500W).

The problem became apparent when a customer added another EMI
filter ahead of our power supply, creating a system we didn't
anticipate.  The power supply alone passed the test, but the
additional EMI filter and power supply would not pass the
common-mode surge test.

When I sketched the AC input circuit of the composite system, I
realized the surge generator was simply pulsing into several
common-mode inductors and primary-ground capacitors - the circuit
had no load!

I set the surge generator to a relatively low voltage (200V), and
connected an oscilloscope probe from the power supply AC input
terminal to chassis.  I saw the 200V surge ring to almost 400V!
If this had been a 2kV common-mode surge, I expect that the power
supply would see about 4kV primary-ground, which it was clearly
not designed for. 

I think performing this simple test would be your best indication
of surge voltages seen in your system.  Since it involves
primary-connected components, be sure to observe proper safety
precautions.

[email protected] wrote:
>When troubleshooting surge problems on products  we often see the surge pulse 
>to
>be much higher after the line filter (testing the AC Mains with Line-Earth 
>surge
>pulses according to EN61000-4-5). 
>
>Can someone explain the science behind this and what effect the load might 
>have?
>Can this increase in the surge potential be anticipated ahead of time so proper
>clearances can be designed in?

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