CCS Type 2 Fast Charging Kit

A complete CCS Type 2 DC fast charging kit for EV conversions, built and programmed here. It gives a converted vehicle the same rapid charging a production EV has, and because Type 2 carries AC and DC through one inlet, it also feeds your onboard charger from the same socket.

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 alone. 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 and runs precharge. Type 2 is the European and UK inlet; the Type 1 kit is the North American 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
• One inlet handles both AC and DC, so the vehicle needs a single charge port rather than two
• Supplied as a complete path from inlet to pack, so there is no hunting for a compatible controller, contactor or lock motor
• Runs the precharge circuit and can control your main HV contactors, rather than being a separate system bolted alongside them
• Designed to mount inside the HV battery enclosure, which keeps the high current run short
• ECU is potted and programmed for CCS Type 2 before it ships
• Hard limits of 200 A and 1000 V are set in firmware, not left to the installer
• Built and tested here, and documented in a 28 page guide written by the people who build it

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 pack voltage over CAN, because precharge decisions are made on that value. If your build uses a different battery management system, 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 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.

For North American vehicles, order the CCS Type 1 kit instead. The two kits share the same user guide and differ in the inlet, the lock motor and the ECU programming.

In the box

• 1 x CCS Type 2 charge inlet with connectors and 3 metre AC tails
• 1 x CCS vehicle ECU, potted and programmed for Type 2
• 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, the ECU mounting screws (three M8) 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, the system matrix and the fault codes.