DC fast charging≤ 200 A / 1000 V ≤ 200 kWOrion BMS 2

CCS Fast-Charge Kit

Add AC + DC combined-charging (CCS) fast-charge capability to an EV conversion through a single outlet. A complete system - contactor controller, CCS ECU, charge outlet, locking motor, stop switch, contactors and fuse - built around the Orion BMS 2. Choose your standard below; follow the full user guide for every safety-critical step.

Pick your CCS connector standard - it tunes the kit, lock motor and proximity-pilot resistor.

Indicative shop price, ex-VAT. Quoted per project (shipping, options).

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Before you orderThis kit only works with an Orion BMS 2, a battery ≥ 200 V, and economiser contactors (< 100 mA standby). It is designed to work only with the supplied charge outlet and locking motor. Hard limit 200 A / 1000 V. Not suitable for aviation.

Kit contents

Everything in the box. The CCS bus HV connectors are not supplied (choose a passthrough or connector to suit) - use ≥ 70 mm² cable rated for 200 A continuous, no splicing.

CCS ECU — Every component supplied in the CCS kit. © Fellten.

Contactor Controller — Every component supplied in the CCS kit. © Fellten.

Installation

Work through the mounting sequence. Design the HV architecture around a second, CCS-dedicated HV bus that's only live during fast charging - no un-switched live HV should leave the battery box.

High-voltage wiring

The contactor controller drives five contactors and taps HV sense after the battery and CCS contactors.

CCS HV bus architecture — The dedicated second HV bus for CCS, split after the main pack fuse. © Fellten.

Connectors & pin-outs

Every harness connector and its pins. HV sense: HV0 = battery (beige), HV1 = CCS inlet (black), taken after the respective contactors - polarity-critical. Search to filter.

Status & fault codes

The stop-switch LED shows charge status and, on a fault, blinks RED a number of times followed by one long BLUE.

Interactive. Click any fault row or status colour below and the stop-switch LED will play it out here. Click the button itself to run a random self-diagnostic.
state: white

Fault codes (RED blinks)

Status colours — AC / standby

Status colours — DC fast charge

Software setup

Configured through the Orion BMS Utility. Keep the HVIL open until this is done, to stop the contactors closing during setup.

Orion BMS Utility — enable Zero-EV CCS Controller — Tick “Zero-EV CCS Controller” in the Orion Utility CANbus tab. © Fellten / Ewert.

Troubleshooting

Common symptoms and where to look. Some AC/DC chargers use protocols not yet widely adopted - if one doesn't work, contact Fellten (currently Shell chargers are known-incompatible).

Documents & downloads

The full user guide, harness drawings and related guides. Links open in a new tab.

PDFCCS user guideFull install manual (PDF)Download PDFContactor-controller harnessHarness drawing (PDF)Download PDFMain harnessH2 main harness drawing (PDF)Download GUIDEOrion BMS 2 guidesBMS purchasing / wiring / operationsOpen