Avcon to J1772 conversion
We have successfully converted an EVI Avcon Model # ICS200-B Intelligent Talking Charging Station from the large Avcon plug to the new J1772 connector. Here at Pioneer, we have two of the old style Avcon charging stations. Occasionally one of them got used on Rich's truck. We tested both of the units first to make sure they were working right. One of them did not work. After several frustrating hours, I found a small Anderson type connector inside the unit that was partially disconnected. One wire connection of the two was not making contact. Once that was found and fixed, the unit worked as it should, charging Rich's truck. Next we tested the Clipper Creek Model DS-100 J1772 charging station which we presumed is a properly functioning unit. Not having an OEM EV in the shop, we relied on an adapter box (J1772 to Nema 14-50) to test the charging station. It did not work. All the literature we could find on the pilot wire connection said it is pin 4. The adapter box we bought had the pilot wire connected to pin 5. A quick fix and all was working correctly. We tested the Clipper Creek unit with the fixed adapter box and a Rudman PFC 50 charger. It worked to perfection. Next we plugged the J1772 connector into the Porsche Boxster we are working on. (Also with a PFC 50) and it worked as expected. Now, knowing that the adapter box and the Porsche work with a J1772, we were ready to tackle the Avcon conversion. For your info, don't try to disassemble the Avcon connector. It is totally glued together and the cord is potted into it. Just cut the cable off. The cable has three # 10 wires (red, black, green) and a # 14 blue wire. There is also a white faux wire to round out the shape of the cable. The three # 10 wires are connected as usual and the blue wire is the pilot wire which is connected to pin 4 of the J1772 connector head. The resistor/diode in the adapter box and the system in the Porsche also was able to turn on the talking Avcon station.
John Emde
Pioneer Conversions
