CCS Type1 Fast Charging Kit

A complete CCS Type 1 DC fast charging kit for EV conversions, built and programmed here. It gives a converted vehicle the same rapid charging a production EV has: plug into a public DC charger, and the car and the charger negotiate and deliver current straight to the pack.

Adding DC fast charging is the difference between a conversion that is a local vehicle and one that can make a journey. On a 350 V pack this kit will take up to 70 kW, so a 10 to 90 percent charge lands at roughly 40 minutes instead of the ten hours the same pack takes on AC. The kit is the whole charging path: the inlet, the controller that talks to the charger, the contactors that carry the current, the fuse, the locking motor and the ECU that supervises the session. Type 1 is the North American inlet; the Type 2 kit is the European equivalent.

Key specifications

Features

• Turns a ten hour AC charge into roughly forty minutes on a public DC charger, which is what makes long journeys practical in a conversion
• Supplied as a complete path from inlet to pack, so there is no hunting for a compatible controller, contactor or lock motor
• ECU is potted and programmed for CCS Type 1 before it ships
• Runs the precharge circuit and can control your main HV contactors, rather than being a separate system bolted alongside them
• Supervises the session itself: it checks the pack voltage against what the BMS reports, watches the interlock loop, and opens the contactors safely if anything is wrong
• Built and tested here rather than assembled from a parts list, and documented in a 28 page guide written by the people who build it
• Hard limits of 200 A and 1000 V are set in firmware, not left to the installer

Compatibility

This kit works with an Orion BMS and will not operate without one. The BMS has to be set up in software and reporting over CAN, and the pack voltage it reports must agree with what the CCS side measures, within 20 volts. If your build uses a different BMS, talk to us before ordering.

Your pack must reach 200 V before the system will close the positive contactor, so this kit is not suitable for low voltage builds. The CCS bus carries up to 200 A continuously, so the cable and every connector on it must be rated for that, with a bend radius of at least 120 mm on the large DC cables. 70 mm2 shielded HV cable and matching lugs are the usual choice. Plan the fuse and disconnect into the same run.

For European and UK vehicles, order the CCS Type 2 kit instead. The two kits share the same user guide and differ in the inlet and the ECU programming.

In the box

• 1 x CCS Type 1 charge inlet with harness
• 1 x CCS vehicle ECU, potted and programmed for Type 1
• 1 x CCS contactor controller
• 2 x 250 A contactors
• 1 x 200 A fuse
• 1 x magnetic charge port locking motor with connector
• 1 x stop charge button with connector
• 1 x set of CCS connectors and pins for your own loom
• 4 x insulated lugs

HV cable, the fuse holder and the vehicle side wiring are not included, because they depend on your pack layout.

Downloads

The 28 page CCS Type 1 and Type 2 user guide is in the Documents tab above, along with the main harness and contactor controller harness drawings. The guide covers design considerations, mounting, the full pin out for every connector and the system matrix.