intermovtive PRPC501-A Manual 

Auburn, CA 95602 Phone: (530)-823-1048 Fax: (530)-823-1516 Page 1 of 13 An ISO 9001:2008 Registered Company PRPC501-A Programmable Relay Power Center See PRPC Programming Utility software for latest list of supported vehicles 2009-2014 Ford E-Series and F-Series Contact Intermotive for additional applications Introduction The Programmable Relay Power Center provides access to a broad range of vehicle data such as MPH, RPM, Park Brake, Service Brake, temperatures, transmission range, accelerator pedal, doors, lights, door locks, ABS, MIL, etc. Specific data is vehicle dependent, and by running the PRPC Programming Utility software (free download from www.intermotive.net), available information on a particular chassis can easily be determined. The PRPC provides 8 configurable relay outputs, eight configurable low current outputs (1/2A Max), and six configurable beepers. The Programmer allows logical combinations (AND, OR, =, >, <) of various vehicle data to control an output. For example, one output can be programmed to go active when ECT>230 OR TFT>250 AND RPM>300 (any numeric values can be used). This could drive a high temperature dash indicator. Another output could be programmed to drive a warning buzzer/lamp when the vehicle speed exceeds some limit, such as 70mph. Electric doors can be disabled unless certain safety conditions are met and so on. There are also ten general purpose inputs, one analog input, and one dedicated ignition input that can be used as part of the programmable logic. PRPC Programming U lity Instruc ons (Used for configuring the programmable outputs, beepers and inputs) Requirements: • Java Runtime Environment (v1.7.0 or later) must be installed on your computer prior to running this utility. Most PC’s already have Java installed. The most recent version can be obtained for free at http://java.com/en/download/manual.jsp. • The PRPC Programming Utility. This is a free Intermotive software program that will need to be loaded on your PC. The files are available from the download page at www.intermotive.net. It is recommended that an “InterMotive” folder be created to store the files. • USB to Serial cable (part# s-h37a1) is included in the a-IPU kit and is a one-time purchase. This kit is required for all programming and is recommended to be kept in a central location. Once PRPC Programming Utility has been run and the specific configuration has been created, it can be downloaded onto the PRPC501-A module(s) with the Programming Utility.

can be found at: http://www.ftdichip.com/Drivers/VCP.htm 2. To install the programming utility, unzip the PRPC Programming Utility folder to your local hard drive. 3. Create a shortcut on the desktop if necessary, but do not separate the PRPC Programming Utility.exe file from the rxtxSerial.dll file! 4. Plug in the USB cable (Part# s-h37a1) prior to starting the application. 5. Double click the PRPC Programming Utility.exe file to launch. 6. This screen will come up. If the program does not launch, close all applications and reinstall the Java Runtime Environment and the PRPC Programming Utility. Setting the PRPC Programming Utility Pin Configurations: To view a video on tips for configuring the module, go to www.Intermotive.net 1. Under the “Home” tab select the model year, manufacturer, model, and engine size of the vehicle the PRPC will be in- stalled in. 2. Click the “Create Configuration” button. 3. This screen will come up. 4. Configure as desired. See the following page for more infor- mation. Press the Enter button after each entry. Note: CTO can only be programmed on LCO5 (J4-5). 2.2 Hz per MPH can only be programmed on LCO6 (J4-6). 5. Select “Save Configuration” under the “File” tab. 6. Enter a configuration name (Max. 16 characters) and click “OK”. 7. Review the configuration summary and click “Save Configuration”. 8. Enter a filename and choose a location that will be easy to locate. 9. Under the “File” menu, select “Save Configuration Summary”. 10. Double click the .ims file previously configured. 11. Enter Company Name, phone number, and notes and click the ‘OK’ button. Note: Enter the vehicle model year, model, and engine in the notes section. 12. Enter a file name and click the ‘Save’ button. 13. Click the ‘Open File’ button. 14. Right click on summary and select ‘Print’. 15. Cut the printed label and place it in the bag attached to the PRPC module. InterMotive Inc. 13395 New Airport Rd. Auburn, CA 95602 Phone: (530)-823-1048 Fax: (530)-823-1516 Page 2 of 13 www.intermotive.net [email protected] PRPC501-A-090314-INS

Auburn, CA 95602 Phone: (530)-823-1048 Fax: (530)-823-1516 Page 3 of 13 www.intermotive.net [email protected] PRPC501-A-090314-INS Setting Pin Mode— PRPC Application Software Momentary: Output follows condition set but with a turn on delay, and a turn off delay. Setting ‘On Delay’ and ‘Off Delay’ to zero causes the output pin to simply “follow” the condition set being true (ON) and false (OFF). Latching: This mode will latch an output pin ON, starting ‘On Delay’ seconds after the conditions are met, and will keep it ON even after the conditions are no longer true. It will then latch the output OFF, following ‘Off Delay’ seconds after the conditions are met again. It can be thought of as toggle On/toggle Off. The simplest use would be when using a momentary button as the only input condition and setting the Delays to zero. Thus a load could be turned on by pushing a momentary button, and turned back off by pushing the button a second time. Time Hold: The output pin goes ON after the conditions become true, and stays ON for the selected ‘On Time’, regardless of the conditions. Off Time is Not Applicable. Time Delay: Output is turned ON after the selected ‘delay’ time after the conditions are met. It stays on for selected ‘On time’, regardless of input conditions. Flashing—Momentary: Used for creating a flashing output. When conditions are met, output flash- es. When conditions are no longer met, flashing stops. Flashing ON and OFF times (duty cycle) are controlled by entering the following values. Flashing - Latching: Same as above, except flashing will continue after conditions are no longer true, and will stop when conditions become true again—toggle ON, toggle OFF. Duty cycle is con- trolled by the ON and OFF times.

The InterMotive “a-IPU” kit is sold separately and allows pro- gramming the PRPC on your desktop. It consists of a 12VDC wall adapter and download cable and works with the PRPC program- ming software utility. Note: Do not have the PRPC Programming Utility opened until instructed to do so. 1. Plug the Module Desktop Power/Ground Supply inverter into a 120V AC power source. 2. Locate the 6-Pin Female connector on the module but do not connect the AC adapter to the PRPC module until indicated in the following steps. 3. Plug the phone jack end of the download cable into the J8 COMM port of the PRPC module and the USB end into your PC. J8 COMM Port Loading your previously created Configuration file into the PRPC: Open the PRPC Programming Utility. Under the “Home” tab on the PRPC Programming Utility, choose the COM Port the USB cable is connected to. Note: This can be determined on Windows XP by right-clicking on ‘My Computer’ and selecting ‘Properties.’ From this window select the ‘Hardware’ tab and click on ‘Device Manager.’ In the De- vice Manager window, expand the ‘Ports’ menu and the download cable will display as ‘USB Serial Port.’ Click the ‘Open File’ button. 1. Open the PRPC*.ims or configuration file to load on the PRPC501-A module. (This file must already be loaded on the computer). 2. Click the load button on the computer screen. “Waiting” will come up next to the progress bar. This means the program is waiting for the power to be plugged into the PRPC module. 3. Plug in the 6 pin connector of the power adapter into the PRPC501-A module. The progress bar on the computer screen will display status as the configuration loads and takes approximately 2 seconds or less. Configuration is loaded once the screen says “DONE” and programming is complete. 4. To verify that the correct data was loaded into the module, disconnect the 6 pin connector from the module and press the ‘Get” button on the screen. Plug in the 6 pin connector and the information will be displayed. To program another module with the same configuration file, start with step 2. InterMotive Inc. 13395 New Airport Rd. Auburn, CA 95602 Phone: (530)-823-1048 Fax: (530)-823-1516 Page 4 of 13 www.intermotive.net [email protected] PRPC501-A-090314-INS

1. Locate the vehicles OBDII Data Link Connector. It will be mounted below the lower left dash panel. 2. Remove the mounting screws for the OBDII connector. Plug the Red connector from the PRPC Data Link Harness into the vehicle’s OBDII connector. Ensure the connection is fully seated and secure with the supplied wire tie. 3. Mount the pass-through connector from the PRPC Data Link Harness in the former location of the vehicle’s OBDII connector. 4. Secure the PRPC Data Link harness so that it does not hang below the lower dash panel. NOTE: Do NOT plug the Data Link harness into the 6-pin connector on the PRPC501-A module. This will be done at a later step. Disconnect the battery before proceeding with the installation. PRPC501 Module Find a suitable location to mount the PRPC501 module. Do not mount the module where it will be exposed to excessive heat. Do not mount the module until all wire harnesses are routed and secure. The last step of the installation is to mount the module. InterMotive Inc. 13395 New Airport Rd. Auburn, CA 95602 Phone: (530)-823-1048 Fax: (530)-823-1516 Page 5 of 13 www.intermotive.net [email protected] PRPC501-A-090314-INS PRPC Power Lug Connect a 65A fused VBAT source to the 1/4” power bolt. The PRPC is designed for a maximum cable size of 2 AWG for this power connec- tion. Installer must provide strain relief on cable outside of the PRPC’s enclosure. It is recommended that the strain relief is within 6” of the enclosure. The absence of strain relief could result in damage to the module. IMPORTANT—READ BEFORE INSTALLATION It is the installer’s responsibility to route and secure all wiring harnesses where they cannot be damaged by sharp objects, mechanical moving parts and high heat sources. Failure to do so could result in damage to the system or vehicle and create possible safety concerns for the operator and passengers. Avoid placing the module where it could encounter strong magnetic fields from high current cabling connected to motors, solenoids, etc. Avoid radio frequency energy from antennas or inverters next to the module. Avoid high voltage spikes in vehicle wiring by always using diode clamped relays when installing upfitter circuits.

Connector J18 contains 6 of the PRPC’s 11 fused output pins. These 6 fused output pins are connected to 4 configurable relay outputs. Each relay output is capable of 15 Amps maxi- mum. Configurable relay output 4 is shared by fuses 4A, 4B, and 4C. When added together the sum of these three fuses must not exceed 20 Amps. Note that the placement of fuse 3 will determine whether the output is active high or active low. The use of fused outputs 4A, 4B, or 4C is recommended for higher current loads. The PRPC module has an absolute maximum current rating of 65 Amps. The 6 fused output pins on connector J18 are defined as follows: • Pin #1 (White wire) Configurable Relay Output 4, Fuse 4C, Active High • Pin #2 (White wire) Configurable Relay Output 4, Fuse 4B, Active High • Pin #3 (White wire) Configurable Relay Output 4, Fuse 4A, Active High • Pin #4 (White wire) Configurable Relay Output 3, Fuse 3, Fuse Selectable Active High/Low • Pin #5 (White wire) Configurable Relay Output 2, Fuse 2, Active High • Pin #6 (White wire) Configurable Relay Output 1, Fuse 1, Active High Connect the desired outputs to vehicle equipment as needed. Tape up unused leads. 6 Pin Output Back of Connector InterMotive Inc. 13395 New Airport Rd. Auburn, CA 95602 Phone: (530)-823-1048 Fax: (530)-823-1516 Page 6 of 13 www.intermotive.net [email protected] PRPC501-A-090314-INS The default configuration for the relay outputs on J18 are as follows: • Pin #1 (White wire), • Pin #2 (White wire), • Pin #3 (White wire), • Pin #4 (White wire), Left Turn Signal On • Pin #5 (White wire), Key On • Pin #6 (White wire), Low Beams or High Beams 2-Pin PRPC Connector Connector J20 contains the two black ground wires for relay output fuse sensing, motor reversing, and low true relay outputs. This is not an optional connection. The wires in this connector must be attached to a good chassis ground for the system to function properly. 1 2 3 4 5 6 Right Turn Signal On

• Pin #1 (White wire) IN1 or IN2 Active • Pin #2 (White wire) IN2 Active • Pin #3 (White wire) IN1 Active • Pin #4 (White wire) • Pin #5 (White wire) InterMotive Inc. 13395 New Airport Rd. Auburn, CA 95602 Phone: (530)-823-1048 Fax: (530)-823-1516 Page 7 of 13 www.intermotive.net [email protected] PRPC501-A-090314-INS 5-Pin PRPC Connector Pin-Out Definition Connector J17 contains 5 of the PRPC’s 11 fused output pins. These 5 fused output pins are connected to 4 configurable relay outputs. Each relay output is capable of 15 Amps maximum. Configurable relay output 5 is shared by fuses 5A and 5B. When added together the sum of these fuses must not exceed 20 Amps. Note that the placement of fuse 6 will determine whether the output is active high or active low. The use of fused outputs 5A or 5B is recommended for higher current loads. The PRPC module has an absolute maximum current rating 65 Amps. The 5 fused output pins on connector J17 are defined as follows: • Pin #1 (White wire) Configurable Relay Output 8, Fuse 8, Active High • Pin #2 (White wire) Configurable Relay Output 7, Fuse 7, Active High • Pin #3 (White wire) Configurable Relay Output 6, Fuse 6, Fuse Selectable Active High/Low • Pin #4 (White wire) Configurable Relay Output 5, Fuse 5B, Active High • Pin #5 (White wire) Configurable Relay Output 5, Fuse 5A, Active High Connect the desired outputs to vehicle equipment as needed. Tape up unused leads. 5 Pin Output Back of Connector ECT > 230F or TFT > 250F 1 2 3 4 5

Connector J4 contains the PRPC’s 8 low current output pins. Each output is rated at 1/2A and is intended to drive relay coils or other low current loads. Note that Pin 8 of the eight outputs is ac- tive low (ground) while the rest are active high (12V). Note: when driving relays, a diode- protected type must be used. InterMotive recommends DigiKey #PB682-ND Relay. The 8 outputs are defined as follows: • Pin #1 (Yellow wire) Configurable Output, Active High • Pin #2 (White wire) Configurable Output, Active High • Pin #3 (Brown wire) Configurable Output, Active High • Pin #4 (Gray wire) Configurable Output, Active High • Pin #5 (Blue wire) Configurable Output, Active High • Pin #6 (Green wire) Configurable Output, Active High • Pin #7 (Orange wire) Configurable Output, Active High • Pin #8 (Pink wire) Configurable Output, Active Low* Connect the desired outputs to vehicle equipment as needed. Tape up unused leads. When connecting to relays, use relays with appropriate kick-back suppression, such as Digikey #PB682-ND. Unsuppressed relays will induce very high voltage spikes throughout modern vehicles sensitive computer electronics and should not be used, per Ford, GM, SAE, etc. The default configuration for the 8 outputs are as follows: • Pin #1 (Yellow wire) Trans Range=Reverse - Flashing Momentary, 2 seconds On, 2 seconds Off • Pin #2 (White wire) Transmission = Park • Pin #3 (Brown wire) Left Turn Signal • Pin #4 (Gray wire) Right Turn Signal • Pin #5 (Blue wire) CTO* • Pin #6 (Green wire) Any Door Open • Pin #7 (Orange wire) Vehicle Speed > 76 • Pin #8 (Pink wire) Engine Running *CTO = ((RPM/2)*#Cyl) = pulses per minute. E.G. 600rpm = 2400 (8 cylinders) 8 Pin Output Back of Connector InterMotive Inc. 13395 New Airport Rd. Auburn, CA 95602 Phone: (530)-823-1048 Fax: (530)-823-1516 Page 8 of 13 www.intermotive.net [email protected] PRPC501-A-090314-INS

Connector J3 contains the PRPC’s 12 discrete wire inputs. There are 3 configurable active high/ low, 7 active low inputs, 1 analog input, and 1 dedicated ignition input. These inputs have their own internal pull up/pull down resistors so they can be left floating when not used or not active. These inputs can be used as part of the programmable logic to configure the output pins. • Pin #1 - (Yellow/Black stripe) Input 1, Configurable Active high/low • Pin #2 - (Brown/White stripe) Input 2, Configurable Active high/low • Pin #3 - (White/Black stripe) Input 3, Configurable Active high/low • Pin #4 - (Green/White stripe) Input 4, Active low • Pin #5 - (Gray/Black stripe) Input 5, Active low • Pin #6 - (Purple/White stripe) Input 6, Active low • Pin #7 - (Blue/White stripe) Input 7, Active low • Pin #8 - (Pink/Black stripe) Input 8, Active low • Pin #9 - (Black/White stripe) Input 9, Active low • Pin #10 - (Orange/Black stripe) Input 10, Active low • Pin #11 - (Tan/Black stripe) Input 11, Analog • Pin #12 - (Red/White stripe) Input 12, Dedicated Ignition Connect inputs as needed. Tape up unused input wires. InterMotive Inc. 13395 New Airport Rd. Auburn, CA 95602 Phone: (530)-823-1048 Fax: (530)-823-1516 Page 9 of 13 www.intermotive.net [email protected] PRPC501-A-090314-INS 12 Pin Input Back of Connector Beeper Definition - The PRPC501 has 6 unique beeper logic conditions and sounds. Default Configuration: Beeper 1: Low pitch, fast, 10 beeps when VBAT < 11.75V Beeper 2: High pitch, medium, when ECT > 230F or TFT > 250F Beeper 3: High pitch, continuous, when any I/O fuse is blown Beeper 4: Medium pitch, medium, when the SB and Gas Pedal are depressed Beeper 5: Medium pitch, medium, when VSS > 0 and PB is On Beeper 6: High pitch, medium, when VSS > 76

Auburn, CA 95602 Phone: (530)-823-1048 Fax: (530)-823-1516 Page 10 of 13 www.intermotive.net [email protected] PRPC501-A-090314-INS Initial Installation Power-Up: The following sequence must be performed prior to mounting the PRPC501-A module. The initial installation is completed as follows: 1. Ensure the Data Link harness 6 pin connector is NOT connected to the PRPC501 module. 2. Turn the vehicle key on, engine off 3. Insert the Data Link harness 6 pin connector into the PRPC501 module. 4. The PRPC’s red fuse LEDs will “scroll” if the VIN is not recognized. Reconnect the vehicle battery PRPC501-A Module Mounting Ensure all the harnesses are properly connected and routed. Mount the PRPC501 module as described on page one. Verify the module is in an area away from any external heat sources (engine heat, heater ducts, etc.), and secure using screws or double sided tape.

1. Turn the ignition ON to wake up and initialize the PRPC module. 2. With the conditions met, ensure that all desired outputs are responding correctly per their programmed condition set (e.g., output 5 goes high when engine is running). The PRPC is properly installed only if it passes the above tests. If any irregular operational issues persist, recheck the condition set configuration. Contact InterMotive at 530-823-1048 for technical assistance. InterMotive Inc. 13395 New Airport Rd. Auburn, CA 95602 Phone: (530)-823-1048 Fax: (530)-823-1516 Page 11 of 13 www.intermotive.net [email protected] PRPC501-A-090314-INS Diagnostics Relay Outputs: Each relay has an associated on-board green LED that indicates when the relay coil is active. These green LEDs can be thought of as conditions met indicators. In addition each fused output has an on-board red fuse blown LED. These red LEDs are processor controlled. If the module is not in diagnostics mode and a blown fuse is detected on a configured output the associated on-board red LED will illuminate. No fuse sensing is done on outputs that are not configured to turn on. Low Current Outputs: To enter LCO diagnostic mode, momentarily press the red test button on the module (look for “TEST” on the printed circuit board) ONE time with the ignition on. The on-board yellow status LED will blink once every second in this diagnostic mode. The on-board red fuse LED’s will light when a corresponding LCO is active: Output Trouble Codes: If there is an issue with one of the PRPC outputs, the red fault LED will flash a three digit code while in diagnostic mode. A 1-1-1 code means everything is working properly. The second digit flashed will correspond to the output number and the third digit will indicate the specific problem. Fuse LED 1 2 3 4A 4B 4C 5A 5B LCO # 1 2 3 4 5 6 7 8 J4 Pin # 1 2 3 4 5 6 7 8 1’st Digit (Output Type) 2 - PRPC LCO 3 - PRPC Relay 2’nd Digit (Output Number) LCO Relay # 3’rd Digit (Specific Problem) • 2 - Output fault (overcurrent or overvoltage) • 3 - Invalid data (The data associated with the output is invalid) • 4 - Data timed out (The data associated with the output has timed out) • 5 - Unsupported data (The data associated with the output is not supported on the current vehicle)

controlled based on the module’s configuration created using the Intermotive PRPC Programming Utility program. When the key is turned OFF, the PRPC501 module will go into a low power sleep mode . This may take up to TEN minutes, and the LED’s on the module will go out once in sleep mode. Other vehicle activity such as opening doors, inserting key in the ignition, etc. may delay sleep mode. InterMotive Inc. 13395 New Airport Rd. Auburn, CA 95602 Phone: (530)-823-1048 Fax: (530)-823-1516 Page 12 of 13 www.intermotive.net [email protected] PRPC501-A-090314-INS Inputs: To enter Input diagnostic mode, momentarily press the red test button on the module (look for “TEST” on the printed circuit board) TWO times with the ignition on. The on-board yellow status LED will blink twice every second in this diagnostic mode. The on-board red fuse LED’s will light when a corresponding Input is active: Fuse LED 1 2 3 4A 4B 4C 5A 5B Input # 1 2 3 4 5 6 7 8 J3 Pin # 1 2 3 4 5 6 7 8 6 9 9 7 10 10 8 12 12 Scrolling LED’s: This may indicate one of the following errors: • LED’s scrolling sequentially one at a time indicates that an invalid or incomplete VIN was captured. • LED’s scrolling from the middle outward indicates a configuration error. This can be the result of configuring the PRPC for one chassis, but installing it in a different chassis. PCB Temperature Load Shedding: The PRPC monitors on-board temperature in three different locations. If any one of the readings exceeds a predetermined temperature threshold the module will shed one relay load every 2 minutes to regulate heat. The outputs where the temperature readings are highest will be shut off first. If at any time a temperature reading is 5C above the predetermined temperature threshold the module will shed one relay load every second until all relays are off. If this sequence is triggered the module will beep 5 times in about 30 seconds at high pitch before shedding any output.

If the PRPC fails any step in the Post Installation Test, review the installation instructions and the loaded configuration by running the Graphical User Interface application. If necessary, call InterMotive technical support @ (530) 823-1048. PRPC501-A-090314-CAD