Step 7 – Onboard charging system

Install the onboard charger (OBC) and Type 2 charge inlet. A Type 2 (IEC 62196) socket allows 7.4kW single-phase or 22kW three-phase AC charging. Proper earth fault protection and isolation monitoring is mandatory.

Procedure

1. Select charge port location — original fuel filler position is ideal
2. Cut mounting hole and install Type 2 inlet with weatherproof seal
3. Mount onboard charger (OBC) near battery pack
4. Wire OBC AC input to charge inlet (L1, L2/N, L3, PE)
5. Connect OBC DC output to battery via contactor and fuse
6. Connect pilot signal (CP) and proximity pilot (PP) to VCU
7. Program VCU charge sequence: CP negotiation → contactor → charge
8. Install earth leakage circuit breaker (ELCB) in charge wiring
9. Install charge status LED indicator visible from outside
10. Wire BMS communication to OBC via CAN bus
11. Test charging with EVSE at 16A before attempting 32A
12. Verify charge stops at target SOC (80% for daily use)

Safety warnings

1. Charge inlet must be properly earthed — ground fault is electrocution risk
2. Never charge with a damaged cable or in standing water
3. Install proper RCD in home charging circuit
4. Charging generates hydrogen gas — ensure ventilation

Pro tip

Retain the original fuel cap door for the Type 2 inlet for a cleaner appearance. Many converters use a custom laser-cut adapter to fit the socket in the original fuel filler recess.