How to Convert a CCS1 Inlet Equipped Vehicle to NACS

As the EV industry shifts toward the North American Charging Standard (NACS), CCS1-equipped vehicle owners are racing to upgrade their cars for broader charging access. At Fiver New Energy Co., Ltd., we specialize in manufacturing custom NACS charge ports and providing tailored solutions for tech-savvy enthusiasts ("geeks") looking to future-proof their EVs. This guide walks you through the conversion process, with actionable insights and expert support from our team.

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Why Convert from CCS1 to NACS?  

Expanded Charging Network: Access to NACS-compatible charging stations, including 15000+ Tesla Superchargers.
Compact Design: NACS connectors are more compact (40% smaller) and user-friendly compared to the bulky CCS1 design.
Industry Transition: Major automakers like Ford and GM are transitioning to NACS, making it the future standard in North America

For DIYers: Need a custom NACS charge port? Our team designs SAE J3400-compliant hardware with plug-and-play adaptability for seamless integration.

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Key Differences Between CCS1 and NACS      

1. Communication Protocols

   • DC Fast Charging: Both CCS1 and NACS use ISO 15118 for PLC-based communication.
   • AC Charging: CCS1 uses SAE J1772, while NACS aligns with J1772 under SAE J3400, ensuring interoperability.

2. Physical Design

• CCS1: Combines J1772 AC inlet with two DC pins for fast charging.
• NACS: Uses a single, compact connector for both AC and DC charging.

Steps to Convert CCS1 to NACS     

1. Hardware Modifications

• Replace the Charge Inlet:
  Install a NACS-compatible charge port, ensuring proper alignment of pins (AC/DC, ground, proximity, and control pilot).
• Rewiring:
  Map NACS pins to the vehicle’s onboard charger (OBC) and battery management system (BMS):
  • AC pins (L1/L2/N) to the OBC.
  • DC pins (+/-) to the BMS/DC contractors.
• Safety Systems:
  Update proximity detection (PP) and control pilot (CP) circuits to match NACS/J3400 requirements.

2. Software Modifications

• Communication Protocols:
  Ensure the vehicle’s OBC and BMS support ISO 15118 for DC charging and SAE J1772 for AC charging.
• Charging Logic:
  Adjust software to recognize the NACS connector and switch between AC/DC modes.
• Safety & Diagnostics:
  Reprogram fault detection for NACS-specific scenarios (e.g., thermal events, pin alignment).

3. Certification and Testing

• Ensure the modified vehicle meets SAE J3400, UL 2251, and FCC regulations for safety and EMI compliance.
• Conduct rigorous testing to validate charging performance, safety, and reliability.

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Practical Challenges and Solutions      

1. Cost: Hardware and software modifications can be expensive.
   • Solution: Consider using a NACS to CCS1 adapter or wait for OEM-supported retrofits.
2. Interoperability: Public CCS1 chargers won’t connect to a NACS inlet without an adapter.
   • Solution: Use Tesla’s Magic Dock or third-party adapters to access Superchargers.
3. Warranty: Modifications may void the vehicle’s warranty.
   • Solution: Wait for automaker-approved retrofits to retain warranty coverage.

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Alternatives to Full Conversion

1. Adapters:
   • Tesla Magic Dock and third-party adapters (e.g., Lectron) allow CCS1 vehicles to charge at NACS stations.
2. OEM Retrofits:
   • Major automakers plan to offer NACS adapters for existing CCS1 vehicles starting in 2024.

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Conclusion

Converting a CCS1-equipped vehicle to NACS is a technically demanding but rewarding process that unlocks access to a broader charging network and future-proofs your EV. While DIY conversions are possible, using adapters or waiting for OEM solutions is often more practical and cost-effective. As the industry transitions to NACS, widespread compatibility and support will continue to improve, making this conversion a worthwhile investment for EV owners.