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High Voltage Relay Wiring – with Precharge
Below is the recommended HV wiring setup for systems using 3 relays and precharge functionality:
Relay Wiring Diagram
🧩 Components:
HV Battery: Provides the main power
HV Fuse: Protects the system from overcurrent
HV Relays (3 total):
Precharge Relay: Connects via precharge resistor to slowly charge input capacitors
Positive Relay: Main high-side connection to the load
Negative Relay: Switches the low side (Battery -) to GND
Precharge Resistor: Limits inrush current when first connecting to the inverter
Current Shunt: Measures total current flow
Inverter / Load: Final consumer of the HV power
Chassis connection (E pin): Must be connected to battery chassis – ideally with 2 separate wires
🔌 BMS HV Connector Pins:
B+ / B-: Connect directly to the battery
O+ / O-: Connected after the relays, represents the output side
E: Earth/Chassis connection
⚠️ Important: The precharge path must always lead through the shunt to ensure current measurement during precharge.
The positive and negative relays must remain open during precharge phase and close only after precharge completes.
👉 This wiring ensures proper current monitoring and safe soft-start of the system.