A precharge circuit charges the DC-link capacitor to the battery voltage, minimizing the inrush current caused when the main contactors close. For the health of the main contactors the inrush is minimized as too high of inrush can cause the contacts to weld together, rendering them defective. Figure 1-1. Precharge Configurations
The goal of the precharge circuit is to limit inrush current at system power-up. Depending on the system voltage, the capacitance value, and the intended design, precharge can take as little as a few milliseconds or as long as several seconds.
Assume that the resistance value of the pre-charging resistor is above 30Ω, and the loop voltage is assumed to be 300 V. At this time, the maximum loop current is also Just 10A, the capacity of the pre-charge relay is above 10A, and the pre-charge circuit is safe.
Since the precharge circuit is directly connected to the battery, both the contactor and the resistor must be rated for full battery voltage. The precharge contactor and resistor must also be able to handle the precharge current and power dissipation.
The precharge circuit is commonly found on the positive leg, but it could just as easily be installed on the negative leg. Since the precharge circuit is directly connected to the battery, both the contactor and the resistor must be rated for full battery voltage.
Smart precharge circuits include a timer to abort the precharge if the voltage does not reach a certain level within a prescribed period of time. Some also include a counter so that only a certain number of precharge events can occur within a certain window of time to prevent the resistor from overheating.
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