Technical Whitepaper: How to Design a Precharge Circuit for Hybrid and Electric Vehicle Applications


Precharge circuits are essential for applications with capacitive loads that can result in high inrush currents during power up.

Current spikes of thousands of amps can easily damage system components such as causing contactors to weld closed.

In hybrid or electric vehicle applications, a precharge circuit may be used every time the vehicle is turned on.

In this 13-page technical whitepaper, Brian Munari, Business Development Manager and Andrew Schneer, Applications Engineer (both from HVOR Electrification, Sensata Technologies) explain why and how to design a Precharge circuit.

The following topics are covered:
Overview and benefits of using precharge circuits
How to design a precharge circuit
Using a precharge circuit
How precharge circuits typically fail
The difference between “wet” vs “dry” switching contactors
Component guide for precharge circuit solutions including GIGAVAC’s P195 and GV210 precharge contactors as well as main contactors like the GV350, GV200 and HX460

Download whitepaper on the website

TT Electronics WPRT Series – Wirewound Ceramic Power Resistors, ideal for EV/HEV Pre-Charge

WPRT series gives designers a high overload power resistor for current regulation with a range of connection and mounting options tailored to automotive use.

Robust construction, Flameproof case, Wirewound resistor element
10 to 50 watts continuous, Up to 250W for 10s overload, Up to 500J fast surge rating
AEC-Q200 qualified, RoHS compliant
Resistance values typically 0R1 to 1K5, tolerance 5%

Download datasheet on the website

For more information contact Nijkerk Electronics.

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