“Fast Charging for Electric Vehicles: A Step-by-Step Guide to Installing the Fellten CCS Fast Charging Kit

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Installing a DC Fast Charging kit in your electric vehicle can be a challenging but rewarding process. By following these steps and ensuring safety throughout the installation, you can enjoy faster charging times and a more convenient electric vehicle ownership experience. In this article, we will guide you through the process of installing a DC Fast Charging kit in your electric vehicle.

Understanding Electric Vehicle Charging

Electric vehicles have batteries that deplete as they are used and need recharging. There are three primary levels of charging:

  1. Level One Charging: This is usually done from a regular household outlet (110 volts, 10-15 amps). The electric vehicle supply equipment does not convert it to direct current (DC), so the onboard charger in the vehicle handles the conversion.
  2. Level Two Charging: This type of charging is done at home or away from home and can deliver 30-50 amps. Level Two Charging uses alternating current (AC) and still requires the onboard charger to convert it to DC.
  3. DC Fast Charging (Level Three Charging): This type of charging is not typically done at home and uses specific units set up in parking lots. DC Fast Charging can deliver up to 200 amps and does not require an onboard charger, as it fills up the batteries directly with DC.

Different Types of DC Fast Charging

There are two main types of DC Fast Charging:

  1. CHAdeMO: This standard was popular with the Nissan Leaf and other early electric vehicles but is now being phased out.
  2. CCS (Combined Charging System): This standard combines AC and DC charging elements, offering a combined charging output. Most electric vehicles other than Tesla use the CCS Fast Charging standard.

Before we begin, let’s review the components of a typical DC Fast Charging kit:

  1. Contact controller
  2. 200 amp fuse
  3. Two additional contactors
  4. Fast charging plug with locking motor
  5. Communication plug
  6. CCS VCU (Vehicle Control Unit)

Step 1: Preparation

Before installing the kit, ensure that your electric vehicle is compatible with the selected DC Fast Charging kit. Make sure you have all the necessary tools and safety equipment, such as gloves, safety glasses, and a multimeter.

Step 2: Locate the High Voltage Area

Determine the location of the high-voltage area in your electric vehicle. This is where the battery, inverter, and other high voltage components are typically located.

Step 3: Install the Contact Controller and Fuse

Install the contact controller and 200 amp fuse in the high voltage area. Secure the components using brackets or straps, and ensure they are properly insulated.

Step 4: Connect the Contactors

Connect the additional contactors to the contact controller. These contactors will manage the high voltage circuits during the charging process.

Step 5: Install the Fast Charging Plug

Install the fast charging plug in a suitable location, ideally near the charging port. Secure the plug and ensure that it is connected to the vehicle’s high voltage circuits.

Step 6: Connect the Communication Plug

Connect the communication plug to the vehicle’s control systems. This plug allows the fast charging kit to communicate with the vehicle, providing essential information such as battery status and charging speed.

Step 7: Install the CCS VCU

Install the CCS VCU in the high voltage area. Connect the VCU to the communication plug and the vehicle’s control systems, ensuring proper communication between the fast charging kit and the vehicle.

Step 8: Wiring and Testing

Perform all necessary wiring according to the fast charging kit’s instructions. Double-check all connections for correct polarity and tightness. Once the installation is complete, test the fast charging kit using a compatible DC Fast Charging station.

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