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  • Does anyone have experience with High Voltage DC Testing?

    Julian Cross

    Julian Cross

    @hCKNKn6
    Updated: Feb 12, 2026
    Views: 400.7K

    Does anyone here have experience with High Voltage DC testing? I work in Automotive Validation Testing, focusing on Test Equipment design, DAQ, and LabVIEW for typical automotive products. Our current tests involve voltages under 16V and peak current draws up to 40A, with most products drawing less than 5A peak.

    With the rise of electric vehicles, we're now getting customer requests for designs that handle 240-800VDC with different current draw requirements.

    Can anyone recommend literature or resources for design guidelines on high voltage DC testing, including safety considerations?

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  • Kaustubh Katdare

    @thebigk • 3h

    Interesting question. Moving from sub-16V systems to 240–800VDC is not just a voltage jump. It’s a different engineering category.

    At 800VDC, your primary problem is not measurement. It’s energy control and fault containment.

    A few things I’d think about early:

    1. Isolation strategy first, instrumentation second Design around reinforced isolation between HV and LV domains. This includes:
    • Isolated DC supplies
    • Isolated DAQ inputs
    • Fiber or isolated comms
    • Proper creepage and clearance per IEC 60664

    Don’t retrofit isolation later. It has to be foundational.

    1. Arc and fault energy

    DC arcs don’t self-extinguish like AC. That changes protection philosophy. Look into:

    • Fast HV contactors with pre-charge circuits
    • Proper bleeder resistors
    • DC-rated fuses and breakers
    • Arc flash risk assessment even in lab environments

    IEC 61010 and NFPA 70E are worth reviewing for lab setups.

    1. Measurement considerations

    Shunt resistors at 800V systems need careful placement and isolation amplifiers. Hall-effect or closed-loop current sensors are often safer.

    For voltage sensing, use precision HV dividers rated for transient overvoltage. Also evaluate CAT ratings depending on where this equipment connects.

    1. Pre-charge and inrush

    EV loads often have large DC link capacitors. Without controlled pre-charge, your test rig becomes the failure point.

    1. Interlocks and procedural safety

    You’ll need:

    • Door interlocks
    • HV present indicators
    • Discharge verification before access
    • Clear LOTO procedures

    Even in validation labs, treat it like industrial power equipment.

  • Kaustubh Katdare

    @thebigk • 3h

    For literature:

    • TI and Analog Devices both have solid application notes on isolated measurement and high-voltage sensing.

    • UL 2231 and ISO 6469 are useful for EV safety context.

    • “High Voltage Engineering Fundamentals” by Kuffel is more academic but useful for understanding insulation and breakdown behavior.

    • Also review OEM battery test system design guides from companies like Chroma or Keysight. Their manuals often expose practical architecture decisions.

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