Precharge Test — and — CCCV Cutoff
Current Test (DVP entries)
Nice — I added both test cases below as ready-to-drop-into your DVP. I made one
reasonable assumption: your maximum charging current = 8 A (you gave this), so I used
cutoff = 5% of I_max = 0.4 A as the CV cutoff current (common industry practice). If you
prefer a different cutoff (for example 0.1 A or 0.05 × Imax), tell me and I’ll update the values.
1) Precharge (Inrush / Soft-start) Test
Category: Electrical — Functional / Safety
Purpose: Limit inrush current into DC link / battery during connection and verify precharge
circuit (resistor, NTC, relay/contactor) works and prevents damage.
Standard reference: IEC 60065 / IEC 62368 family (practice), AIS-138 (apply equivalent
protective practice)
Test Conditions: Input 230 VAC nominal (vary 207–253 VAC optionally). Charger
connected to discharged battery simulator / bulk capacitor bank representing system DC
bus. Measure inrush with and without precharge path.
Equipment: AC source (programmable), high-speed current probe / oscilloscope, DC
electronic load or battery simulator, data logger, temperature probe, multimeter.
Test Procedure (step-by-step):
1. Configure DC bus/battery simulator to open (deep-discharge or 0 V) and connect
charger through precharge resistor and relay as per product design.
2. Set AC source to 230 VAC. Ensure oscilloscope/current probe and data logger are
ready (sample ≥10 kS/s).
3. Close AC input. Record instantaneous input inrush current and DC bus voltage
ramp-up. Record precharge resistor current and time until relay closes (if applicable).
4. After precharge completes and main contactor closes, monitor transient current spike
(if any). Repeat 3 cycles.
5. Repeat test at worst-case line (207 VAC and 253 VAC) and at elevated ambient (if
required).
Acceptance Criteria:
● Inrush current while precharge active must be below component-specified safe limit
(e.g., ≤ specified fuse/inlet rating — typically < 2–3× steady-state startup inrush); no
protective device nuisance trip.
● DC bus voltage ramps to nominal smoothly within expected precharge time
(documented in product spec).
● Relay/contactors operate only after precharge complete; no arcing or welding
observed.
● No damage to components; charger functions normally after cycles.
Records: Waveforms of inrush current, precharge time, relay by-time, ambient
temperature.
Remarks: If a NTC or active soft-start used, repeat to validate NTC heating/cooling
behaviour across
