InterMotive H-EVO506-A Installation Instructions

Introduction

The InterMotive H-EVO506-A product is designed for the Ford F250-F600 chassis. It enables automatic engine start and stop functionality to charge the vehicle's OEM 12V battery and/or an auxiliary battery system. This allows for unattended operation, enhancing security. The module features several field-programmable parameters that can be customized. Installation utilizes "plug & play" connectors that interface directly with factory OEM connectors, reducing installation time and improving reliability. The module incorporates internal safeguards and functional preconditions for safe operation, along with diagnostic functions for troubleshooting.

Note: Not for use on chassis with Push to Start ignition systems.

Important Safety Information

IMPORTANT - READ BEFORE INSTALLATION

Installers are responsible for routing and securing all wiring harnesses to prevent damage from sharp objects, moving parts, or high heat. Improper installation can lead to system or vehicle damage and safety concerns. Avoid placing the module near strong magnetic fields or high-voltage cabling. Use diode-clamped relays and solenoids for upfitter circuits to prevent high voltage spikes.

CAUTION

All electronic products are susceptible to Electrostatic Discharge (ESD). Ground yourself before handling the module or harnessing by touching chassis ground (e.g., the barrel of a cigarette lighter).

Installation Instructions

EVO506 Module Installation

Preparation: Disconnect the vehicle battery before starting.

Mounting: Remove the lower dash panel below the steering column. Select a mounting location away from excessive heat sources (engine, heater ducts). Ensure routed harnesses do not interfere with the tilt steering column in its lowest position. Leave sufficient slack in harnesses for module removal if needed. Do not mount the module until all wire harnesses are routed and secured. The final step is to mount the module itself.

Shift Lock Connection

Locate the OEM 4-pin connector C2008. Remove the OEM connector and plug it into the mating 4-pin connector T-harness supplied with the EVO506. Then, plug the remaining male connector into the OEM cavity.

Ignition Switch Connections

1. Remove the left side trim piece using a trim removal tool. This piece is secured by several clips and a "tree" plug.
2. Remove the dash upper trim using a trim removal tool. This piece is attached by multiple clips.
3. Remove three (3) 7mm screws securing the Instrument Panel Surround to the dash.
4. Lower the steering column. Pull the Instrument Panel Surround away from the dash, noting any securing clips. Connector C250, located on the bottom side of the ignition switch, will become accessible. Plug the mating ends of the InterMotive ignition harness into the ignition switch and the OEM harness.
5. Route the harness to the mounting location of the EVO506 module.

Data Link Harness Installation

The Ford Super Duty features an OEM Gateway module located behind the center console, adjacent to the SYNC 4 module. Access this module by following these steps:

1. Remove the RH instrument panel trim using a trim removal tool, starting from the ignition switch area towards the silver clip. Opening the glove compartment may provide better access.
2. Using a trim removal tool, detach the upper right corner of the lower steering column close-out panel and set it aside.
3. Remove four (4) 7mm bolts located at the top of the center stack.
4. Release clips on both sides of the center stack using a trim removal tool and carefully move the center stack away from its mounting points.
5. Disconnect the two connectors located behind the center stack.
6. Detach the push-mount cable tie from its bracket and move the cable out of the way.
7. Remove four (4) 7mm bolts and move the bracket away from the mounting points to access the Gateway Module, which is located behind the bracket.
8. Disconnect the Gateway Connector by pressing down on the tab and pulling the connector away from the module.
9. Install the Data Link Harness between the Gateway Module and the disconnected Gateway Connector.
10. Route the 6-pin connector of the Data Link Harness to the mounting location of the EVO506 module.
11. After installing the Data Link Harness, proceed with the installation instructions for the key fob box, key fob harness, SEIC harness, and Monitor Mode LED harness. Reverse the panel removal steps to reassemble the vehicle's interior.

Key Fob Box Installation

A spare key fob must be modified and placed into the provided enclosure to enable the H-EVO506-A system to function with the key removed from the ignition. Ensure the key fob is programmed before installation.

1. Press the silver button to flip the key out.
2. Orient the fob with the Ford logo facing up. Insert a flathead screwdriver into the slots and use leverage to pop off the back cover.
3. Remove the star screw using a T6 Torx screwdriver.
4. Gently pry apart the two halves of the fob, possibly using needle-nose pliers inserted into the fob and slowly opened.
5. Remove the switchblade key, battery, and the silver loop (optional).
6. Reassemble the key fob.
7. After installing the larger antenna coil, route its harness to the key fob box mounting location. Remove the key fob box cover and insert the key fob into the ring on the key fob box harness.
8. Place the key fob into the bottom of the key fob box, routing the harness towards the side hole. Insert the rubber grommet into this hole.
9. Replace the box cover and secure it with the four included screws. Plug the 3-pin connector into the mating connector on the key fob harness.
10. Install the larger antenna coil from the key fob box harness around the OEM Immobilizer Coil by sliding it over the ignition lock cylinder.
11. Connect the 3-Pin H-EVO506-A Molex connector from the key fob harness to J13 of the module.
12. Find a suitable location below the steering column to mount the key fob box, ensuring space for the H-EVO506-A module as well.

Stationary Elevated Idle Control (SEIC) Harness

Fast Idle: The fast idle system adjusts engine idle RPM to increase electrical and mechanical output. By default, gas engines idle at 1500 RPM and diesel engines at 1200 RPM.

Fast Idle SEIC Connections:

For 2023+ Ford Super Duty models, Fast Idle is controlled via the CAN network. The following connections are required:

1. Locate the Customer Access 25-pin harness behind the passenger kick panel.
2. The mating 25-pin pigtail is included with the vehicle and can be found in the glovebox.
3. Using solder and heat shrink, connect the following wires:
   • Diesel: InterMotive SEIC harness White/Brown wire to OEM 25-pin pigtail White/Brown wire.
   • Gas: InterMotive SEIC harness Green/Violet wire to OEM 25-pin pigtail White/Brown wire.
   • Connect InterMotive SEIC harness Yellow/Green wire to OEM 25-pin pigtail Yellow/Green wire (Pin 7).
   • Connect InterMotive SEIC harness Green wire to OEM 25-pin pigtail Green/White wire (Pin 5).
4. Plug the Yellow/Green wire from the InterMotive SEIC Harness into the configured SEIC output of the 4-way dual row connector, J5-Pin 4.

Monitor Mode Push Button LED Installation (S-H84KX)

The kit includes a switch with an LED that illuminates when Monitor Mode is active.

1. Drill a 16mm (0.630") hole in the desired mounting location.
2. Route the harness through the hole to mount the switch:
   • Remove the lock nut from the switch.
   • Pull the harness through the hole.
3. Slide the lock nut onto the harness and secure it to the back of the switch.
4. Connect the 4-pin (Black) connector of the S-H84KX harness to the mating connector on the EVO506 main harness.

Final Steps

Verify that the following connections and installations have been completed:

• Data Link Connector installed.
• Key fob modified, inserted into key fob box, and key fob box mounted. The 3-pin Molex connector (J13) is plugged into the EVO506 module.
• Ignition Switch connectors are plugged into the ignition switch and the EVO506 main harness.
• Shift Lock harness is plugged into the Shift Lock connector (C2008).
• SEIC harness is mounted and connected to the vehicle SEIC connector and plugged into the EVO506 main harness.
• LED control button is mounted and plugged into the EVO506 main harness.

Make the following connections from the H-EVO506 main harness to the H-EVO506 module:

• 4-Pin connector to J8.
• 4-Pin Molex connector to J5.
• 8-Pin Molex connector to J4.
• 16-Pin Molex connector to J7.

Make the following connections from the key fob harness to the H-EVO506 module:

• 3-Pin connector to J13.

Make the following connections to the H-EVO506 harness:

• 2-pin Molex connector from the auxiliary battery system to the main harness connector.

Note on Main Harness (840-00320): The dark green wire senses auxiliary battery voltage. The pink wire indicates when the engine is running. The brown wire is for an optional discrete hood switch input.

Reconnect Vehicle Battery: With the key in the RUN position, plug the free end of the H-EVO506 Data Link harness into J11 of the H-EVO506 module.

Once all connections are made, installation is complete. Before reinstalling panels, perform all post-installation checks and verify correct module operation.

Module Operation

The H-EVO506 module can auto-start the vehicle under specific conditions to keep the OEM and auxiliary batteries charged. Auto-start functions are initiated based on three events:

1. OEM Battery Monitoring: If the OEM battery's State-of-Charge (SoC) or voltage drops below a programmed set point, the engine starts. The module continues monitoring; once the battery reaches a programmed level, a configurable timer starts. The engine stops after the timer expires.
2. Auxiliary Battery Monitoring: If configured, the module monitors auxiliary battery voltage. If it drops below a programmed set point, the engine starts. Once the auxiliary battery reaches a programmed level, the engine auto-stops.
3. 12V Start Trigger: If configured, the EVO506 communicates with a Battery Management System and receives a 12V start trigger. The engine starts when the trigger is received and auto-stops when the trigger is removed.

Note: The module monitors either event 2 or event 3, not both. Both OEM and auxiliary batteries must be fully charged for the engine to auto-stop.

Fast Idle

After an auto-start, the engine runs at a higher speed for optimal charging. Engine speed is set by an SEIC input voltage, typically 1500 RPM for gas engines and 1200 RPM for diesel engines. For different idle speeds, the SEIC harness resistor may need replacement. Consult the Ford Body Builder's Layout guide for resistor charts.

Fast Idle is a Ford-controlled feature requiring specific preconditions:

• Vehicle must be in PARK.
• Vehicle speed must be 0 MPH.
• Engine Coolant Temperature (ECT) must be between -7°C and 110°C (20°F to 230°F).
• Service brake and accelerator pedals must not be pressed.
• Engine must be at a stable idle speed.

VIN Scroll and Monitor Mode

VIN Scroll

Upon initial power-up (hard boot), the H-EVO506 module reads the vehicle's VIN to confirm compatibility. If power is applied without the key in RUN, the module performs a VIN scroll (LEDs blink ascending then descending) before entering a sleep state. Turning the key to RUN allows the module to verify the VIN and operate.

Monitor Mode

For engine start/stop control, the H-EVO506 must be in "Monitor Mode". This mode is entered by pressing and holding the control button for a programmed duration, provided the following preconditions are met:

• Vehicle in PARK.
• Service Brake released.
• Parking Brake applied.
• Hood Closed.
• Fuel Level above configured value.
• Key in the RUN position (if using push button).
• Engine coolant temp (ECT) below the "shutdown ECT" configured value.

When Monitor Mode is active, the Monitor Mode button LED illuminates continuously. The key can be removed from the ignition. The instrument cluster powers on, and a 30-second timer begins. The module monitors the OEM and auxiliary batteries. If both batteries are above their set points when the timer expires, dash lights turn off, and monitoring continues. If battery levels drop below set points, or a 12V start trigger is received, dash lights turn on, and the engine auto-starts/high-idles.

Monitor Mode Operation Details

A configurable engine-run timeout dictates how long the engine runs after each auto-start, stopping when batteries are charged or the timeout expires.

LED Status: A continuous LED on the Monitor Mode button indicates normal operation. Blinking indicates an error or unwanted state. Four states are defined:

• Engine failed to start after 3 tries.
• Engine failed to stop after 3 tries.
• Engine prematurely stopped.
• Service brake applied while in Monitor Mode (anti-theft).

Error states can be exited by turning the key to CRANK. Auto-start/stop is disabled until Monitor Mode is reset by exiting and re-entering.

Exiting Monitor Mode: Achieved by pushing and holding the Monitor Mode button or pressing the fob unlock button three times. If the engine is running, it will shut off first.

Battery Force Charge: In Monitor Mode, pressing the Monitor Mode button three times within 3 seconds starts the engine and Fast Idle to top off battery charge. The engine shuts off once batteries are fully charged. Fast Idle charging also terminates if the engine run timer expires or fuel level is low.

Configuration Parameters

The H-EVO506's operation is controlled by several parameters, which can be modified using an InterMotive download cable and a laptop. Contact InterMotive for download cable availability.

Available parameters include:

• OEM battery SoC trip point: Engine auto-starts when OEM battery SoC falls below this level. Default: 45%.
• OEM charge restore point: Module starts extended timer when voltage reaches this level. Default: 90%.
• OEM battery low voltage trip point: Engine auto-starts when OEM battery falls below this level. Default: 11.8V.
• OEM charge restore point (voltage): Module starts extended timer when voltage reaches this level. Default: 13.5V.
• Extended charge time: Duration engine runs after OEM restore point. Default: 1200 sec (Range: 10-3600 sec).
• Fast Idle engine speed: Default: 1850 RPM (Range: 950-2000 RPM).
• Monitor Mode lockdown time: Time before auto-start/stop is restored after service brake application. Default: 300 sec (Range: 10-600 sec).
• Push Button Latency: Minimum button hold time for activation. Default: 2 sec (Range: 2-10 sec).
• Shutdown ECT: Max coolant temp to prevent engine shutdown and Monitor Mode exit. Default: 110°C (230°F).
• Maximum ECT: Max coolant temp for Fast Idle operation. Default: 106°C (219°F) (Range: 65°C-110°C / 149°F-230°F).
• Minimum ECT: Min coolant temp for Fast Idle operation. Default: -10°C (14°F) (Range: -10°C-15°C / 14°F-59°F).
• Auxiliary Battery low voltage trip point: Engine auto-starts when auxiliary battery falls below this level. Default: 49.9V (Range: 40V-60V).
• Auxiliary Battery charge restore point: Module auto-stops engine when voltage reaches this level. Default: 57V (Range: Low limit-60V).
• Low Fuel Level threshold: System will not enter monitor mode if fuel level is below this value. Default: 25% (Range: 0-100%).
• Engine-Run Timeout Value: Max allowable time engine runs on a single auto-start. Default: 60 minutes (Range: 50-120 minutes).

Diagnostics

The H-EVO506 module features diagnostic functions using module LEDs and a red test button.

LED Indicators:

• LEDs F1-F4: Indicate if an adjacent fuse is blown.
• LEDs 1-4 and "ST": Display status information based on the selected diagnostic page. The "ST" LED blinks the current page number (e.g., one blink for page 1, two for page 2). There are 7 defined pages. If "ST" LED is OFF, the other 4 LEDs indicate a Monitor Mode error.

Navigating Diagnostic Pages: Press the red test button to cycle through pages sequentially. Forward (1-7) requires the Park Brake applied; reverse (7-1) requires the Park Brake released.

Page Information (Pages 1-6):

• Page 1 (Module Inputs 1-4): LED1: Control Button, LED2: 12V Trigger Start Req, LED3: Hood Closed, LED4: OFF/RUN Key Position.
• Page 2 (Module Inputs 5-7): LED1: Start/Stop Trig Type, LED2: Aux Battery Low Request, LED3: Crank Key Position, LED4: Monitor Mode LED.
• Page 3 (LCO Outputs): LED1: LCO1 (Ignition Crank), LED2: LCO2 (unused), LED3: LCO3 (+12V, engine running), LED4: LCO4 (optional +12V SEIC Output).
• Page 4 (Relay 1-4): LED1: Relay 1 (Shift Lock), LED2: Relay 2 (Key ACC), LED3: Relay 3 (Key RUN), LED4: Relay 4 (Ignition Power).
• Page 5 & 6: Internal Use Only.

Page 7: Temporarily modifies operational parameters for testing (e.g., Extended charge time to 15 sec, Engine OverRev to 1700 RPM, Monitor Mode lockdown time to 10 sec). Values reset upon power cycle.

Post Installation Checks

After ensuring all connections are properly made to the module, ignition switch, hood latch, and auxiliary battery system, verify that the engine starts using the OEM key and that the vehicle operates correctly.

Monitor Mode Testing

Initial Setup: Vehicle stopped, in PARK, ignition ON, engine OFF, hood closed, parking brake applied, service brake released.

1. Press and hold the Monitor Mode button for at least 2 seconds. The button LED should illuminate, indicating Monitor Mode is active and the module is monitoring battery status or 12V input.
2. Press and hold the Monitor Mode button again to turn the LED OFF and exit Monitor Mode.
3. Apply the Parking Brake, shift out of PARK, then press and hold the Monitor Mode button. Verify the module does not enter Monitor Mode. Release the button.
4. Place the vehicle back in PARK, apply and hold the Service Brake, then press and hold the Monitor Mode button. Verify the module does not enter Monitor Mode. Release the button.
5. Release the Service Brake, open the hood, and press and hold the Monitor Mode button. Verify the module does not enter Monitor Mode. Release the button.
6. Close the hood. Repeat step 1 with the key in the RUN position. The module should enter Monitor Mode.
7. Turn the key to OFF and remove it.
8. Turn on vehicle loads (e.g., headlights) to draw down the OEM battery. When the battery reaches the preset point, verify the engine automatically starts.
9. With the engine running, confirm Fast Idle is enabled after a few seconds, with RPMs stabilizing.
10. Verify the engine runs for the expected duration and then stops automatically. (Test run time can be adjusted via diagnostic feature on Page 14).
11. Repeat steps 8 and 9. With the engine running at Fast Idle, apply the Service Brake and verify:
    • Fast Idle is disabled.
    • The engine stops.
    • The Monitor Mode button LED starts blinking.
12. Observe that the button LED continues blinking for a period before returning to a continuous ON status. During blinking, auto start/stop is disabled.
13. With the engine OFF, draw down the auxiliary battery or trigger a 12V start request from an external Battery Management System (BMS).
    • If monitoring auxiliary battery voltage directly, verify the engine starts and runs at Fast Idle until the auxiliary battery voltage reaches the preset level.
    • If receiving a 12V request signal, verify the engine starts and runs at Fast Idle while the signal is active (+12V) and shuts OFF when the signal becomes inactive (0V).
14. Press and hold the Monitor Mode button again to turn the LED OFF. In this state, auto start/stop is deactivated. Verify this by drawing down the OEM battery (step 8); the engine should not auto-start.
15. Verify alternate Monitor Mode activation by pressing the fob LOCK button three times.
16. Verify alternate Monitor Mode deactivation by pressing the fob UNLOCK button three times.

If the module fails any step, review installation instructions and connections. For assistance, contact InterMotive Technical Support at (530) 823-1048.

Submit product registration at www.intermotive.net.

Wiring Diagram Description

The wiring diagram (Page 19) illustrates the connections for the H-EVO506-A module. Key components and connections include:

• Module Connectors: J13, J10, J8, J5, J4, J7, J11, J1, SW1.
• Harnesses: Main Harness (Part #840-00320), Data Link Harness, Key Fob Harness (Part #840-00110 Rev 02), SEIC Harness (Gas Part #840-00296, Diesel Part #840-00058), Monitor Mode Switch Harness (Part #S-H84KX), Optional Hood Switch Harness (Part #S-ESB400-A).
• Key Connections: Battery Voltage (Red), CAN 1 High/Low (Lt Blue/Violet), CAN 2 High/Low (Dk Green/Brown), Ground (Gray), Key Fob Antenna (Orange/Red), Shift Lock (Lt Blue), Ignition Switch (Violet, Orange, Yellow, Gray/Orange, Blue, VIOLET/WHITE, VIOLET, BLACK/WHITE, GRAY/ORANGE, BLACK/WHITE, VIOLET, BLACK/WHITE), Start/Stop Input (+12V) (VIOLET), Auxiliary Battery Input (40-60V) (DK GREEN), Hood Switch (BROWN, RED), LED Push Button (+12V Engine Running Output, SEIC Output, +12V).
• Module Ports: J13 (3-Pin Key Fob), J11 (Data Link), J8 (4-Pin), J5 (4-Pin Molex), J4 (8-Pin Molex), J7 (16-Pin Molex).
• OEM Connections: OEM Ignition Switch, OEM Shift Lock Connector, OEM Gateway Module, OEM Gateway Harness.

Refer to the specific steps in the installation instructions for detailed connection procedures.