PRC505-A Programmable Relay Power Center
“
Specifications:
- Product Name: PRC5xx*-A Programmable Relay Power Center
(Ford) - Manufacturer: InterMotive Inc.
- Model: PRC5xx-A
- Enclosure Options: PRC5xx-A (full enclosure), PRC5xx-AX (low
profile enclosure) - Supported Vehicles: Ford E-Series, Ford F-Series (F250 to
F750), Ford Transit, and more (refer to the manual for full
list) - Firmware Compatibility: PRPCs with firmware version 4.65 or
higher
Product Usage Instructions:
Installation:
- Ensure you have the correct version of PRPC for your Ford
vehicle. - Follow the installation instructions provided by InterMotive
for proper setup. - Connect the PRPC to the Intermotive CIM, FlexSpeak, or
FlexFlash system using a LIN harness if applicable.
Programming:
- Use the FlexTech Programming Utility software for the latest
list of supported vehicles. - Connect the PRPC to your PC via the J8 COM Port using the
appropriate cable. - Load your configuration file into the PRPC using the
InterMotive Download Manager software.
Contact Information:
If you have any questions or need assistance, contact
InterMotive Inc. at the provided phone number or email address.
FAQ:
Q: How do I know which version of PRPC is compatible with my
Ford vehicle?
A: Refer to the manual for the list of supported vehicles and
their corresponding PRPC versions. If unsure, contact InterMotive
for assistance.
Q: What should I do if my vehicle or model year is not listed
as supported?
A: Reach out to InterMotive for information on additional
applications or compatibility updates.
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An ISO 9001:200185 Registered Company
PRC5xx*-A Programmable Relay Power Center (Ford)
See FlexTech Programming Utility software for latest list of supported vehicles See below for a current list of supported Ford vehicles Contact InterMotive for additional applications
Introduction The Programmable Relay Power Center (PRPC) is the core module in the FlexTech System and 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. The PRPC provides 8 configurable relay outputs, eight configurable low current outputs (1/2A Max), and six configurable beepers. 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. 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. Depending on the version of PRC5xx-A that you have there could also be motor reversing hardware included, see the table on the next page.
PRPCs with firmware 4.65 or higher can be connected to the Intermotive CIM, FlexSpeak and FlexFlash system using a LIN harness. For more information, see the appropriate instructions (CIM, FlexSpeak, or FlexFlash).
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PRC Versions and the vehicles they currently support Make sure that the version of PRPC you are installing is the correct one for your Ford vehicle. There may be new vehicles or model years added. If you don’t see your vehicle or model year below, please check with InterMotive.
PRC505-A PRC550-A B-PRC505-A*
Without Motor Reversing With Motor Reversing Without Motor Reversing
B-PRC550-A* With Motor Reversing
(2009-2019 E-Series) (2011-2016 F250 – F550) (2016-2019 F650/750)
(2009-2019 E-Series) (2011-2016 F250 – F550) (2016-2019 F650/750) (2017-2022 F250 – F550) (2021-2022 F650/750) (2021-2026 Ford E-Series) (2020-2025 Ford Transit) (2017-2022 F250 – F550) (2021-2022 F650/750) (2021-2026 Ford E-Series) (2020-2025 Ford Transit)
G-PRC505-A** G-PRC550-A** H-PRC505-A**
Without Motor Reversing With Motor Reversing Without Motor Reversing
PRC507-A
Without Motor Reversing
PRC557-A
With Motor Reversing
PRC509-A
Without Motor Reversing
PRC559-A
With Motor Reversing
(2022-2025 Ford Transit w/Sync4) (2022-2025 Ford Transit w/Sync4) (2023-2024 F250-F600)
(2014-2019 Transit) (2014-2019 Transit) (2015-2020 F-53/F-59 6.8L)
NOTE: Ambient Air Temperature is not available on F-53 or F-59, so the heater boost trigger for AFIS will not work on
these vehicles.
(2015-2020 F-53/F-59 6.8L)
* Uses the Ford 24-pin Data Link Harness ** Uses the Ford 26-pin Data Link Harness
(See page 5 for installation instructions)
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PRC5xx Enclosures The PRC5xx-A comes in a full enclosure that has openings on the side for access to the connectors. This gives full protection for the board. The PRC5xx-AX comes in a low profile enclosure that gives backing support and insulation to the board while allowing air flow over the board.
Motor Reversing vs Non Motor Reversing Operation In general, all of the relay outputs on the PRPC are of the single-pole-single-throw, normally open (Form A) type. They are open circuits when not activated. When activated, they provide 12V to the output (or optionally ground for Relay 3 and Relay 6). In order to provide motor reversing operation, the PRC550/557/559 versions have different relays for Relay 1, Relay 2, Relay 7, and Relay 8. These are singlepole-double-throw, with both normally open and normally closed inputs (Form C). Relay 1 with Relay 2 forms a motor reversing pair (also Relay 7 with Relay 8). To use these outputs in this way requires selecting “Motor Reversing” in the configuration. If selected for Relay 1 it is also selected for Relay 2 (selecting for Relay 7 also selects for Relay 8). If motor reversing is selected, then the software in the PRPC will not allow Relay 1 and Relay 2 (Relay 7 and Relay 8) to be activated at the same time. If motor reversing is not selected in the configuration, these outputs are independent outputs that provide 12V when activated and ground when deactivated.
Optional Add-On modules There are a number of additional modules that can be connected to the PRPC using a LIN cable. The PRPC then interfaces with these devices to extend the functionality of the FlexTech system. Please refer to the instructions for each module for its installation and operation. · Switch Backer Board, SBB4 or SBB8. These boards monitor four or eight switches and provide a
programmable indicator light for each. They also provide a backlight and have two 1 A and four 0.5 A Low Current Outputs (LCOs). All functions are controlled by the PRPC. A total of two Switch Backer Boards of either size can be used together on the PRPC. · Expansion Board, EXP401. This board has four 10 A fused relay outputs, four 1 A LCO outputs, and four active low inputs which expand the capability of the PRPC. All functions are controlled by the PRPC. Two Expansion Boards can be used together. · Gateway, A-G500 for use with PRC505/507/550/557. This activates the Intelligent Lift Interlock System (ILIS) for wheelchair lift operation, and the Advanced Fast Idle System (AFIS). · Gateway, A-G501 for use with B-PRC505/550 on 2021 Ford E-Series and 2020 Ford F250-F550 Gas engines only. This activates the Intelligent Lift Interlock System (ILIS) for wheelchair lift operation, and the Advanced Fast Idle System (AFIS). · A-G501-G for use with B-PRC505/550 for 2020 and newer Ford F250-F600 6.7L Diesel engine. This activates the Intelligent Lift Interlock System (ILIS) for wheelchair lift operation, and the Advanced Fast Idle System (AFIS). · Gateway, A-G515 for use with the B-PRC505/550 on 2020 Ford Transit. This activates the Intelligent Lift Interlock System (ILIS) for wheelchair lift operation, and the Advanced Fast Idle System (AFIS). · Gateway, A-G509 for use with PRC509/559. This activates the Intelligent Lift Interlock System (ILIS) for wheelchair lift operation, and the Advanced Fast Idle System (AFIS). · Gateway with Brakemax, A-GB500 for use with PRC505/507/550/557. This activates the ILIS for wheelchair lift operation, and includes Brakemax operation which automatically puts the vehicle in Tow Haul mode at start up. · Advanced Fast Idle System, ACM401-A. This is used to activate fast idle operation when a full gateway is not installed. · Pre-Trip Inspection Module, PTM505-A/B. This module is a stand-alone module, but it can Communicate with the PRPC when an inspection is active so that the PRPC can activate lights that it is controlling.
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J8 COM Port
Desktop Programming the PRPC
The InterMotive “a-IPU” kit is sold separately, and allows programming the PRPC on your desktop. It consists of a 12VDC wall power supply and a download cable (see photo at right, the 2 short adapter cables are for other products), and works with the InterMotive Download Manager software utility. This software is a free download from www.intermotive.net/ downloads.html. Note: Do not have the InterMotive Download Manager opened until instructed to do so. 1. Plug the 12VDC wall supply into a 120V AC power source. 2. Locate the 6-Pin Female connector on the module (J19, DLC) but do
not connect the 12VDC wall supply to the PRC5xx-A module until indicated in the following steps. 3. Plug the phone jack end of the download cable into the J8 COM port of the PRC5xx-A module and the USB end into your PC.
J19 DLC Loading your previously created Configuration file into the PRPC: 1. Open the InterMotive Download Manager software. Choose the COM Port the USB cable is connected to.
Note: The COM Port can be determined in the Device Manager window. This window is found as follows: · For Windows XP — Right-click on `My Computer’ and select `Properties’. From this window select the
`Hardware’ tab and click on `Device Manager’. · For Windows 7 — In the Start menu select `Control Panel’. From this window select `Device Manager’. In the Device Manager window, expand the `Ports’ menu and the download cable will display as “USB Serial Port (COMxx)” where xx is a 1 or 2 digit number. Select this COMxx port in the software.
2. Click the `Open File’ button. 3. Open the PRPC—-.ims configuration file (that you received back from InterMotive) to load on the
PRC5xx-A module. (This file must already be loaded on the computer). Click the `Load’ button on the computer screen. “Waiting” will
come up below the progress bar. This means the program is waiting for the power to be plugged into the PRC5xx-A module. Plug the 6 pin connector of the 12VDC wall supply into J19 (DLC) on the PRC5xx-A module. The progress bar on the computer screen will display status as the configuration loads and takes only a few seconds. The configuration is loaded once the screen says “DONE” and programming is complete. 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.
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Installation Instructions
Disconnect the battery before proceeding with the installation. 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 or 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.
PRC5xx-A Module Find a suitable location to mount the PRC5xx-A 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. There is a drawing on the last page of these instructions that shows where each connector is located on the module. Consider this when picking the location and orientation of the module and the wiring harnesses such that connecting and mounting of the module does not stress the wiring harnesses.
NOTE: Do NOT plug the Data Link harness into the 6-pin connector on the PRC5xx-A module after installing the Data Link Harness. It will be done at a later step. Do not extend the extension harness, under any circumstances.
Data Link Harness (6-pin connector) 1. Locate the vehicle’s 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. 5. Skip to PRPC Power Lug section, bottom of Page 9
Ford 24-pin Data Link Harness (6-pin connector)
1. Locate the vehicles Gateway Module. It will be mounted below the
lower left dash panel.
2. Remove the harness behind the Gateway module by pressing the
locking tab and pulling outward.
3. Plug the Female side of the Intermotive Gateway
Gateway Module
Harness into the back of the Gateway module. Ensure the
connection is fully seated and secured by the locking tab.
4. Plug the Male side of the Intermotive Data Link Harness into the
Gateway harness.
5. Secure the PRPC Gateway harness so that it does not hang below
the lower dash panel.
6. Skip to PRPC Power Lug section, bottom of Page 9
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Gateway Harness
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Gateway Plug and Play Harness (Transit w/Sync4) 1. Locate the vehicles Gateway Module. It will be mounted behind the glove
compartment. 2. Press the tabs inward on the sides of the glove
compartment and fully lower it. 3. Remove the 3 nuts securing the Gateway module to the vehicle. 4. Remove the 26-pin connector from the side of the Gateway
module and plug into the mating connector on the G-PRC5XX harness. 5. Plug the male 26-pin connector from the G-PRC5XX harness into the Gateway module. 6. Reinstall the Gateway module and the glove compartment. 10. Run the 6-pin connector of the datalink harness to the mounting location of the module. 11. Skip to PRPC Power Lug section, bottom of Page 9
Ford 26-pin Data Link Harness Installation The 2023+ Ford F250-F600 has an OEM Gateway module located on the other side of the SYNC 4 module, which is behind the center console. Follow the steps below to access it:
1. Remove the RH instrument panel trim using a trim removal tool. The trim starts at the ignition switch and ends at the silver clip. The glove compartment can be opened to better access the back side of the trim.
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Data Link Harness Installation F250-F600 (Cont.) 2. Using a trim removal tool, pop out the upper
right corner of the lower steering column close out panel. Position it away from the center stack.
3. Remove the 4 bolts (Size: 7mm) located at the top of the center stack.
4. Release the clips on both sides of the center stack using a trim removal tool. Position the center stack away from the mounting points.
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Data Link Harness Installation F250-F600 (Cont.) 5. Disconnect the 2 connectors behind the center stack
6. Detach the push-mount cable tie from the bracket and position the cable out of the way.
7. Remove the 4 bolts (Size: 7mm) and position the bracket away from the mounting points to access the Gateway Module. The Gateway Module is located behind the bracket.
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Data Link Harness Installation F250-F600 (Cont.) 8. Disconnect the Gateway Connector by pressing
down on the tab and pulling the connector away from the module.
9. Install the Datalink Harness between the Gateway Module and the disconnected Gateway Connector.
10. Run the 6-pin connector of the datalink harness to the mounting location of the module.
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 connection. 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.
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2-Pin PRPC Connector Connector J20 contains the two black ground wires for relay output fuse sensing, motor reversing (if available), and low true relay outputs. This is not an optional connection. The wires in this connector must be attached to a good bare metal chassis ground for the system to function properly.
1
2
6-Pin PRPC Connector Pin-Out Definition
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 maximum. The placement of fuse 3 will determine whether that output is active high or active low. 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. The use of fused outputs 4A, 4B, or 4C is recommended for higher current loads. The PRC5xx-A module has an absolute maximum current rating of 65 Amps. The 6 fused output pins on connector J18 are defined as follows:
Relay # 4C 4B 4A 3 2 1 Pin # 1 2 3 4 5 6
1 2 3 4 5 6
6 Pin Output
Pin Numbers for the mating connector looking from the back (wire side)
· Pin #1 – Configurable Relay Output 4, Fuse 4C, Active High · Pin #2 – Configurable Relay Output 4, Fuse 4B, Active High · Pin #3 – Configurable Relay Output 4, Fuse 4A, Active High · Pin #4 – Configurable Relay Output 3, Fuse 3, Fuse Selectable Active High/Low · Pin #5 – Configurable Relay Output 2, Fuse 2, Active High (Motor Reversing if available) · Pin #6 – Configurable Relay Output 1, Fuse 1, Active High (Motor Reversing if available) Connect the desired outputs to vehicle equipment as needed.
The default configuration for the relay outputs on J18 is as follows:
Pin #
Mode
Selected
PRC505/550/507/557
Ig/Vb Off On
Conditions
Configuration Mode Ig/Vb
Off
PRC509/559
On
Conditions
1 Mom Ign 0 0
Mom Ign 0 0
2 Mom Ign 0 0 Right Turn Signal = On Mom Ign 0 0 IN 4 (J3-4) = Active
3 Mom Ign 0 0
Mom Ign 0 0
4 Mom Ign 0 0 Left Turn Signal = On
Mom Ign 0 0 IN 3 (J3-3) = Active
5 Mom Vbat 15s 0 Key = On
Mom Vbat 15s 0 Key = On AND Virtual Output #1* = Off
6 Mom Ign
0 0 Low Beams = On OR High Beams = On
Mom Ign
0 0 Park Brake = On
* See the description of Virtual Outputs and the default configuration on page 11.
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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:
Relay # 8 Pin # 1
7 6 5B 5A 2 34 5
1
2
3
4
5
5 Pin Output
Pin Numbers for the mating connector looking from the back (wire side)
· Pin #1 – Configurable Relay Output 8, Fuse 8, Active High (Motor Reversing if available) · Pin #2 – Configurable Relay Output 7, Fuse 7, Active High (Motor Reversing if available) · Pin #3 – Configurable Relay Output 6, Fuse 6, Fuse Selectable Active High/Low · Pin #4 – Configurable Relay Output 5, Fuse 5B, Active High · Pin #5 – Configurable Relay Output 5, Fuse 5A, Active High Connect the desired outputs to vehicle equipment as needed.
The default configuration for the relay outputs on J17 is as follows:
Pin #
Mode
Selected
PRC505/550/507/557
Ig/Vb Off On
Conditions
Configuration Mode Ig/Vb
Off
PRC509/559
On
Conditions
1 Mom Ign 0 0 Virtual Output #2* = On
Mom Ign 0 0 Input #1 = Active OR
Input #2 = Active
2 Mom Ign 0 0 Input #2 = Active
Mom Ign 0 0 Input #2 = Active
3 Mom Ign 0 0 Input #1 = Active
Mom Ign 0 0 Input #1 = Active
4 Mom Ign 0 0 ECT > 230F OR TFT > 250F Mom Ign 0 0 ECT > 230F OR TFT > 250F
5 Mom Ign 0 0
Mom Ign 0 0
* See the description of Virtual Outputs and the default configuration on page 11.
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8-Pin PRPC Connector Pin-Out Definition Connector J4 contains the PRPC’s 8 low current output (LCO) 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 active low (ground) while the rest are active high (12V). Note: when driving relays, a diode-protected type must be used. InterMotive recommends Digi-Key #PB682-ND Relay. The 8 outputs for PRC505/550/507/557 versions are defined as follows:
· Pin #1 – Configurable Output (LCO #1), Active High
· Pin #2 – Configurable Output (LCO #2), Active High
· Pin #3 – Configurable Output (LCO #3), Active High
· Pin #4 – Configurable Output (LCO #4), Active High · Pin #5 – Configurable Output (LCO #5), Active High · Pin #6 – Configurable Output (LCO #6), Active High · Pin #7 – Configurable Output (LCO #7), Active High
8 7 6 5 4 3 2 1
8 Pin Output
Pin Numbers for the mating connector looking from the back (wire side)
· Pin #8 – Configurable Output (LCO #8), Active Low For the PRC509/559 versions LCO outputs 1, 2, 3, 5, 6, and 7 are as described above. LCO output 4 is still active high, but requires that 12V to be connected to J4 pin 8 in order to operate. Therefore there is no LCO output 8. When using the Gateway add-on with PRC509/559 versions LCO output 4 will not be available. It is used by the ILIS function (shift lock), and any configuration that may be done for LCO output 4 will be ignored. Connect the desired outputs to vehicle equipment as needed. When connecting to relays, use relays with appropriate kick-back suppression, such as Digi-Key #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 low current outputs on J4 is as follows:
Selected Configuration
Pin #
Mode
PRC505/550/507/557
Ig/Vb Off On
Conditions
PRC509/559
Mode Ig/Vb Off On
Conditions
1 FlMom Ign 2s 2s Trans Range = Reverse
FlMom Ign 2s 2s Trans Range = Reverse
2 Mom Ign 0 0 Trans Range = Park
Mom Ign 0 0 Trans Range = Park
3 Mom Ign 0 0 Left Turn Signal = On 4 Mom Ign 0 0 Right Turn Signal = On
Mom Ign 0 0 Fuel Level < 25%
Mom Ign 0 0 Light–Check Engine = On (If Available)
5 Mom Ign NA NA CTO* 6 Mom Ign 0 0 Any Door = Open 7 Mom Ign 0 0 Vehicle Speed > 76 8 Mom Ign 0 0 Engine Running = True
Mom Ign NA NA CTO* Mom Ign 0 0 Engine Running = True Mom Ign 0 0 Vehicle Speed > 76
Not Available
*CTO = ((RPM/2)*#Cyl) = pulses per minute. E.G. 600rpm = 2,400 (8 cylinders)
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12-Pin Input Connector Definition 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 – Input 1, GUI Configurable Active High/Low
· Pin #2 – Input 2, GUI Configurable Active High/Low
· Pin #3 – Input 3, GUI Configurable Active High/Low · Pin #4 – Input 4, Active low · Pin #5 – Input 5, Active low · Pin #6 – Input 6, Active low
12 11 10 9 8 7 6 5 4 3 2 1
12 Pin Input
· Pin #7 – Input 7, Active low
· Pin #8 – Input 8, Active low
· Pin #9 – Input 9, Active low · Pin #10 – Input 10, Active low · Pin #11 – Input 11, Analog
Pin Numbers for the mating connector looking from the back (wire side)
· Pin #12 – Input 12, Dedicated Ignition Connect inputs as needed.
Beeper Definition
The PRC5xx-A has 6 unique beeper logic conditions and sounds to allow custom warnings.
The default configuration for the 6 beepers is as follows:
* See the description of Virtual Outputs and the default configuration on the next page.
Beeper
#
Pitch
Mode (Pulse)
IGN/ VBAT
Selected Configuration
PRC505/550/507/557/509/559
# of Beeps or Time
Conditions
1
Low
Fast Ign hot
10
Virtual Output #1* = On
2
High Medium Ign hot Continuous ECT > 230F OR TFT > 250F
3
High Continuous Ign hot
10
Any Fuse Blown
4 Medium Medium Ign hot Continuous Service Brake = On AND Gas Pedal Position = Open
5 Medium Fast Ign hot Continuous Vehicle Speed > 0 AND Park Brake = On
6
High
Fast Ign hot Continuous Vehicle Speed > 76 mph
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Virtual Outputs Definition The PRC5xx-A has 3 Virtual Outputs that can be used to extend the logic for controlling outputs. These outputs exist only internally to the firmware on the board. They can be used as inputs to the logic for any of the actual outputs. They can even be looped back to their own input logic or that of any other virtual output. This last capability gives the PRPC the unique ability to create very complex control logic that could not be done with the actual inputs and outputs alone. The default configuration for the PRPC has an easy to understand example of the use of a virtual output. In the configuration table on the previous page, beeper 1 is set to give an alarm whenever the battery voltage is below about 11.8 V. Without the availability of virtual outputs, beeper 1 would be set to activate when VBAT < 11.8V. If the voltage is fluctuating between 11.70V and 11.85V, for example, the beeper would be constantly activated and de-activated every time the voltage changed. This could cause this alarm to be of little value. Instead, the default configuration uses virtual output 1 to turn on beeper 1 as seen in the table on the previous page. The default configuration for virtual output 1, as shown in the table below, gives a hysteresis effect to the alarm. Virtual output 1 is looped back to its input to latch the output on until VBAT returns to more than 12V. This way the alarm will start sounding when VBAT drops below about 11.8V and will continue to sound until VBAT returns to higher than 12V.
Virtual Output
# Mode Ign/Vbat Off On
Selected Configuration PRC505/550/507/557
Conditions
Results
Mom Ign hot 10s 10s (Vbat < 11.75V OR Virtual Output #1 = Output comes on when Vbat
ON) AND Vbat < 12.1875V
< 11.75V and stays on until
1
Vbat returns to 12.1875V or
higher
2
Mom Ign hot 5s 0 Input #2 = Active
3
None
Output On and stays on 5s after Input #2 goes Inactive Output Off
Virtual Output
# Mode Ign/Vbat Off On
Selected Configuration PRC509/559
Conditions
Mom Vbat hot 0 0 (Vbat < 11.8V OR Virtual Output #1 =
1
ON) AND Vbat < 12V
Results
Output comes on when Vbat < 11.8V and stays on until Vbat returns to 12V or higher
2
None
3
None
Output Off Output Off
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Phone: 530-823-1048 Fax: 530-823-1516 Page 14 of 21
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PRC5xx-A-031025-INS
Finishing the Installation and Testing Operation
Module Mounting 1. Ensure all the harnesses are properly routed with strain relief where needed. 2. Mount the PRC5xx-A module as described on page two. 3. Verify that the module is in an area away from any external heat sources (engine heat, heater ducts,
etc.).
Connect the Harnessing: The following sequence should be performed prior to reconnecting the vehicle battery: 1. Connect each of the harness connectors to the corresponding connector
on the PRC5xx-A. Each connector has a different number of pins and will only fit into the connector on the board with the same number of pins. Do not use force to insert a connector. 2. Install fuses in the fuse holders of a value that will allow sufficient current for the load. The maximum fuse size is 15A. 3. The vehicle battery may now be reconnected.
Post Installation Testing 1. Turn the ignition ON to wake up and initialize the PRPC module. 2. If the red LEDs are scrolling sequentially it indicates that the VIN is either not been found or is not valid.
In this case turn the ignition off and then press and hold the red test button on the PRPC while turning the ignition back on. This will cause the PRPC to look for a new VIN. In most cases this will solve the problem. If it continues please contact InterMotive. 3. Ensure that all desired outputs are responding correctly per their programmed set of conditions in the PRPC configuration (For example, depending on the actual configuration, PRPC relay 4 activates when the engine is running).
The PRC5xx-A is properly installed only if it passes the above tests. If any irregular operational issues persist, recheck the set of conditions in the PRPC configuration.
Contact InterMotive at 530-823-1048 for technical assistance.
PRPC Operation: Turning the vehicle ignition ON will wake up and initialize the PRC5xx-A module. Outputs are controlled based on the module’s configuration created using the InterMotive FlexTech Programming Utility program. When the key is turned OFF, the PRC5xx-A 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.
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.
InterMotive Inc. 12840 Earhart Ave. Auburn, CA 95602
Phone: 530-823-1048 Fax: 530-823-1516 Page 15 of 21
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PRC5xx-A-031025-INS
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.
Status Displays and 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 LED to indicate when the fuse is blown. 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 performed on outputs that are not configured to turn on.
Diagnostics Operation There are 8 “pages” of diagnostic displays that can be selected. Each page displays a different status using the red Fuse LEDs. Each status page is described below. In addition, when in any of the pages, the red FAULT LED will blink a fault code if there are any problems. The fault codes are described on page 16. Selecting the Page: The page to be displayed is selected by pressing and releasing the TEST button (you must have the ignition on – in normal operating mode). When pressing this button, hold it down for about 1 second before releasing it (holding longer than 1 second is not going to cause a problem). To select page 3 starting from normal operating mode, press and release the test button three times. To move from page 1 to page 5, press and release the test button 4 times. The amber STATUS LED will blink the page number alternately with the FAULT LED which is now blinking the fault code. If there are no faults detected, the fault code is three slow blinks of the fault LED. To return to normal operation, move to page 8 then press and release the test button one more time. All LEDs will then return to normal operation with fault and status off.
PAGE 1: Status display of the Low Current Outputs To enter LCO display mode, momentarily press the red test button once with the ignition on. The on-board amber status LED will repeatedly blink once to indicate page 1. The on-board red fuse LED’s will light when a corresponding LCO is active as shown in the table below (fuse LEDs 6, 7, & 8 are not used):
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
InterMotive Inc. 12840 Earhart Ave. Auburn, CA 95602
Phone: 530-823-1048 Fax: 530-823-1516 Page 16 of 21
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PRC5xx-A-031025-INS
PAGE 2: Status display of the Inputs To enter input display mode, momentarily press the red test button twice with the ignition on. The on-board amber status LED will repeatedly blink twice to indicate page 2. Note that input 11 is an analog input and cannot be shown in this display. The on-board red fuse LED’s will light when a corresponding input is active as shown in the table below:
Fuse LED 1
2
3
4A
4B
4C
5A
5B
6
7
8
Input #
1
2
3
4
5
6
7
8
9
10
12
J3 Pin #
1
2
3
4
5
6
7
8
9
10
12
PAGE 3: Display of CAN, ILIS, and AFIS Status To enter CAN, ILIS, and AFIS display mode, momentarily press the red test button three times with the ignition on. The on-board amber status LED will repeatedly blink three times to indicate page 3. The on -board red fuse LED’s will light to indicate the status of these activities as shown in the table below:
LED
Indicates
1
ILIS/AFIS loop processing
2
CAN1
3
CAN2
4A
AFIS Functions Active
4B
AFIS Input 6 Trigger Active (Only if Configured)
4C
LIFT DOOR (Input 10)
5A
AUX DOOR (Input 9)
5B
SHIFT LOCK INPUT (Input 8)
6
LIFT INHIBIT (Input 7)
7
ACTIVE COMMAND MODE
PAGE 4: AFIS RPM Adjust To enter AFIS RPM Adjust mode, momentarily press the red test button four times with the ignition on. The on-board amber status LED will repeatedly blink four times to indicate page 4. In this page, the RPM for the fast idle can be adjusted by grounding input 6. Each time input 6 is grounded Fuse 4A red LED will light and the RPM for AFIS will increase by 50. If the increment causes the idle exceed the maximum idle setting, the idle rpm is set to 900. The max fast idle RPM for gas engines is 2,000 and for diesel engines it is 1,600. The initial default values are 1,500 for gas and 1,200 for diesel.
PAGE 5: Heater Boost RPM Adjust To enter Heater Boost RPM Adjust mode, momentarily press the red test button five times with the ignition on. The on-board amber status LED will repeatedly blink five times to indicate page 5. In this page, the RPM for the fast idle for heater boost can be adjusted by grounding input 6. Each time input 6 is grounded Fuse 5A red LED will light and the RPM for will increase by 50. The limit and default values are the same as above in diagnostic page 4.
InterMotive Inc. 12840 Earhart Ave. Auburn, CA 95602
Phone: 530-823-1048 Fax: 530-823-1516 Page 17 of 21
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PRC5xx-A-031025-INS
PAGE 6: Switch Backer Board Inputs To enter Switch Backer Board Input display mode, momentarily press the red test button six times with the ignition on. The on-board amber status LED will repeatedly blink six times to indicate page 6. The on-board red fuse LED’s will light when a corresponding SBB input is active as shown in the table below (fuse LEDs 6, 7, & 8 are not used):
Red Fuse LED
1
2
3
4A
4B 4C 5A 5B
Input
SW1A|SW1B|SW1C|GPI1 SW2A|SW2B|SW2C|GPI2 SW3|GPI3 SW4|GPI4 SW5 SW6 SW7 SW8
Also in this mode each relay is activated by the SBB inputs. This is a good way to confirm that all relays are functioning properly.
Relay Input
1
2
3
4
5 6 7 8
SW1A|SW1B|SW1C|GPI1 SW2A|SW2B|SW2C|GPI2 SW3|GPI3 SW4|GPI4 SW5 SW6 SW7 SW8
PAGE 7: Expander Board Inputs To enter Expander Board Input display mode, momentarily press the red test button seven times with the ignition on. The on-board amber status LED will repeatedly blink seven times to indicate page 7. The onboard red fuse LED’s will light when a corresponding EXP input is active as shown in the table below (only fuse LEDs 1, 2, 3, & 4A are used):
Fuse LED Input
1 GPI1
2 GPI2
3 GPI3
4A GPI4
PAGE 8: Output Trouble Codes
To enter the Trouble Code display mode, momentarily press the red test button eight times with the ignition on. The on-board amber status LED will repeatedly blink eight times to indicate page 8. The on-board red fuse LED’s will light showing a pattern that can be decoded to give a fault code number. This can be interpreted by calling InterMotive Support.
As mentioned before, the red fault LED will be blinking the trouble code when any of the 8 pages is selected. The fault LED blinks out the three digit code alternatively with the Status LED which is blinking the page number. When everything is working properly, the fault LED will be blinking 3 times rather slowly. This is a code of 1-1-1 which means NO fault.
When there is a fault, the LED first blinks a number that tells where in the PRPC the fault is coming from
(LCOs, Relays, Beepers, etc.). This will blink from 2 to 15 times (11 to 14 not used), note this count. There
will then digit will
be a then
brief blink
pause before the 2nd digit (the same time as between blinks and will be one of the following: 1, 2, 3, 4, 5, 7, or 15. Note
ftohristh2end1c-o1u-1ntc. oTdhee)r.eTwheill 2nd
again there
be are
a brief some
optahuesrecobdeefosrewhtheere3trdhedi3gridt.cTohuent3hrdadsigaitdwiffiellruesnut amllyeainndinicga.tAegwahinic, hnootuetpthuitstchoeufnatu. ltThiseon,
but
following is an example of a full fault code. It indicates that relay number 4 has an output fault: 3-2-4.
Don’t worry about getting the count right the first time. The fault count will repeat alternating with the page count on the Status LED so you will have plenty of time to see the counts over and over to get it right. Only 1 fault will be shown. If there are more than 1 fault in the board, only the highest priority fault will be shown. The fault codes are listed in the table on the next page. The beginning of the table shows lowest priority faults. The end of the table shows the highest priority faults.
PAGE 9 & 10 Contact Intermotive for information regarding these pages.
InterMotive Inc. 12840 Earhart Ave. Auburn, CA 95602
Phone: 530-823-1048 Fax: 530-823-1516 Page 18 of 21
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PRC5xx-A-031025-INS
Definition of Fault Code Counts
Fault Code What The Code Means
Fault Code What The Code Means
1-1-1 2-2-(LCO #) 2-3-(LCO #) 2-4-(LCO #) 2-5-(LCO #) 2-7-(LCO #) 3-2-(Relay #) 3-3-(Relay #) 3-4-(Relay #) 3-5-(Relay #) 3-7-(Relay #) 4-2-(Beeper #) 4-3-(Beeper #) 4-4-(Beeper #) 4-5-(Beeper #) 4-7-(Beeper #) 5-4-1 5-4-2 5-4-3 5-5-1 5-5-2 5-5-3 6-1-(LCO #) 6-2-(LCO #) 6-3-(LLED #) 6-4-(LLED #) 6-5-1 6-5-2 6-5-3
No Fault, operating normally PRPC-LCO-Output Fault* PRPC-LCO-Invalid Timeout** PRPC-LCO-Invalid Receive Data*** PRPC-LCO-Invalid Unsupported**** PRPC-LCO-Unknown Error PRPC-Relay-Output Fault* PRPC-Relay-Invalid Timeout** PRPC-Relay-Invalid Receive Data*** PRPC-Relay-Invalid Unsupported**** PRPC-Relay-Unknown Error PRPC-Beeper-Output Fault* PRPC-Beeper-Invalid Timeout** PRPC-Beeper-Invalid Receive Data*** PRPC-Beeper-Invalid Unsupported**** PRPC-Beeper-Unknown Error PRPC-AFIS-No Security PRPC-AFIS-BCM No Security PRPC-AFIS-Scantool Detect PRPC-CAN1 Error PRPC-CAN2 Error PRPC-MCZ33879 Error SBB1-LCO Fault-LCO # SBB1-LCO Invalid Receive Data-LCO # SBB1-Load LED Fault-LLED # SBB1-Load LED Invalid Receive Data-LLED # SBB1-MCZ33879 Error SBB1-VN7140 Error SBB1-MAX13362 Error
7-1-(LCO #) 7-2-(LCO #) 7-3-(LLED #) 7-4-(LLED #) 7-5-1 7-5-2 7-5-3 8-1-(LCO #) 8-2-(LCO #) 8-3-1 8-4-1 8-7-15 9-1-(LCO #) 9-2-(LCO #) 9-3-1 9-4-1 9-7-15 10-1-1 10-2-1 10-1-2 10-2-2 10-1-3 10-2-3 10-1-4 10-2-4 10-1-5 10-2-5 15-15-1
SBB2-LCO Fault-LCO # SBB2-LCO Invalid Receive Data-LCO # SBB2-Load LED Fault-LLED # SBB2-Load LED Invalid Receive Data-LLED # SBB2-MCZ33879 Error SBB2-VN7140 Error SBB2-MAX13362 Error EXP1-LCO Fault-LCO # EXP1-LCO Invalid Receive Data-LCO # EXP1-MCZ33879 Error EXP1-Low Battery Voltage EXP1-PCB Temperature Fault EXP2-LCO Fault-LCO # EXP2-LCO Invalid Receive Data-LCO # EXP2-MCZ33879 Error EXP2-Low Battery Voltage EXP2-PCB Temperature Fault LIN-No Communications-PTIM LIN-Receive Error-PTIM LIN-No Communications-SBB1 LIN-Receive Error-SBB1 LIN-No Communications-SBB2 LIN-Receive Error-SBB2 LIN-No Communications-EXP1 LIN-Receive Error-EXP1 LIN-No Communications-EXP2 LIN-Receive Error-EXP2 PRPC-PCB Temperature Fault
* Output fault (overcurrent or overvoltage) ** Data timed out (The data associated with the output has timed out) *** Invalid Data (The data associated with the output is invalid) **** Unsupported Data (The data associated with the output is not supported on the current vehicle)
InterMotive Inc. 12840 Earhart Ave. Auburn, CA 95602
Phone: 530-823-1048 Fax: 530-823-1516 Page 19 of 21
*U.S. Patent #9,469,261
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PRC5xx-A-031025-INS
Customer Supplied Harnessing Molex Connector # 39012080 Suggested Terminal # 39000038 / 39000077
If GTWY Activation equipped
A-GB500-$$ only *LCO4 = Tow Haul/Overdrive
LCO1 (12V)
1
LCO2 (12V)
2
LCO3 (12V)
3
LCO4 (12V)*
4
LCO5 (12V)
5
LCO6 (12V)
6
LCO7 (12V)
7
LCO8 (GROUND) 8
Part#
S-H33AX – PRC505/550
S-H133DX – B-PRC505/550
InterMotive Supplied Plug and Play Data Link Harness
840-00197 – G-PRC505/550 840-00294 – H-PRC505/550 S-H33TX – PRC507/557 S-H94AX-$$ – Ext Harn
(Battery Voltage)
RED
1
(CAN 1 High)
YELLOW
2
(CAN 2 High)
GREEN
3
(Ground)
GRAY
4
(CAN 1 Low)
BROWN
5
(CAN 2 Low)
BLUE
6
Customer Supplied Harnessing Molex Connector # 39012120 Suggested Terminal # 39000038 / 39000077
Input 1 (GUI Configurable Active High/Low)
1
Input 2 (GUI Configurable Active High/Low)
2
Input 3 (GUI Configurable Active High/Low)
3
Input 4 (Active Ground)
4
Input 5 (Active Ground)
5
Input 6 (Active Ground)
6
Input 7 (Active Ground)
7
Input 8 (Active Ground)
8
Input 9 (Active Ground)
9
Input 10 (Active Ground)
10
Analog (0.0 – 15.9V)
11
Dedicated Ignition Input
12
InterMotive Supplied with Flextech accessories
J3 INPUT J5 LIN
7
6
Test Button
Board Output MAX 65 amp
1
2
J8 COMM
STATUS FAULT
J4 LCO J19 DLC
3
44 4 ABC
4
+
Fuse Max 15A
Simultaneous output not to exceed 20 amp
Simultaneous output not to exceed 20 amp
5
55 AB
J18
123
J17
J20
Module Part# S-M1521-08 – PRC505-AX S-M1521-06 – PRC507-AX S-M1521-21 – PRC550-AX S-M1521-26 – PRC557-AX
Customer Supplied Harnessing Molex Sabre Connector # 44441-2006 Suggested Terminal # 43375-0001
6
Relay 1
Motor Reversing on PRC550/557
5
Relay 2
Non-Motor Reversing on PRC505/507
4
Relay 3 (Fuse Selectable – Sinking or Sourcing)
3
Relay 4a
2
Relay 4b
1
Relay 4c
2
Ground Customer Supplied Harnessing
Molex Sabre Connector # 44441-2002
1
Ground Suggested Terminal # 43375-0001
5
Relay 5a
4
Relay 5b
3
2
Relay 7
Motor Reversing on PRC550/557
1
Relay 8
Non-Motor Reversing on PRC505/507
Customer Supplied Harnessing Molex Sabre Connector # 44441-2005 Suggested Terminal # 43375-0001
678
8
Green Relay
Beeper LED’s
Red Fuse LED’s
Submit product registration at www.intermotive.net
If the PRPC fails any step in the Post Installation Test, review the installation instructions
and the loaded configuration by running the FlexTech Programming Utility application. If necessary, call
InterMotive technical support @ 530-823-1048.
PRC5xx-A-031025-INS
Customer Supplied Harnessing Molex Connector # 39012080 Suggested Terminal # 39000038 / 39000077
LCO1 (12V)
1
LCO2 (12V)
2
LCO3 (12V)
3
LCO4 (12V)*
4
LCO5 (12V)
5
*For High True on LCO4
LCO6 (12V)
6
apply 12v to Pin 8
LCO7 (12V)
7
(any logic other than shift lock) Attach to 12V* 8
InterMotive Supplied Part#
Plug and Play
S-H33AX – PRC509/559
Data Link Harness S-H94AX-$$ – Ext Harn
(Battery Voltage)
RED
1
(CAN 1 High)
YELLOW
2
(CAN 2 High)
GREEN
3
(Ground)
GRAY
4
(CAN 1 Low)
BROWN
5
(CAN 2 Low)
BLUE
6
Customer Supplied Harnessing Molex Connector # 39012120 Suggested Terminal # 39000038 / 39000077
Input 1 (GUI Configurable Active High/Low)
1
Input 2 (GUI Configurable Active High/Low)
2
Input 3 (GUI Configurable Active High/Low)
3
Input 4 (Active Ground)
4
Input 5 (Active Ground)
5
Input 6 (Active Ground)
6
Input 7 (Active Ground)
7
Input 8 (Active Ground)
8
Input 9 (Active Ground)
9
Input 10 (Active Ground)
10
Analog (0.0 – 15.9V)
11
Dedicated Ignition Input
12
InterMotive Supplied with Flextech accessories
J3 INPUT J5 LIN
7
6
Test Button
Board Output MAX 65 amp
1
2
J8 COMM
STATUS FAULT
J4 LCO J19 DLC
3
44 4 ABC
4
+
Fuse Max 15A
Simultaneous output not to exceed 20 amp
Simultaneous output not to exceed 20 amp
5
55 AB
J18
123
J17
J20
Module Part# S-M1521-07 – PRC509-AX S-M1521-03 – PRC559-AX
Customer Supplied Harnessing Molex Sabre Connector # 44441-2006 Suggested Terminal # 43375-0001
6
Relay 1
Motor Reversing on PRC559
5
Relay 2
Non-Motor Reversing on PRC509
4
Relay 3 (Fuse Selectable – Sinking or Sourcing)
3
Relay 4a
2
Relay 4b
1
Relay 4c
2
Ground Customer Supplied Harnessing
Molex Sabre Connector # 44441-2002
1
Ground Suggested Terminal # 43375-0001
5
Relay 5a
4
Relay 5b
3
2
Relay 7
Motor Reversing on PRC559
Non-Motor Reversing on PRC509
1
Relay 8
Customer Supplied Harnessing Molex Sabre Connector # 44441-2005 Suggested Terminal # 43375-0001
678
8
Green Relay
Beeper LED’s
Red Fuse LED’s
Submit product registration at www.intermotive.net
If the PRPC fails any step in the Post Installation Test, review the installation instructions
and the loaded configuration by running the FlexTech Programming Utility application. If necessary, call
InterMotive technical support @ 530-823-1048.
PRC5xx-A-031025-INS
Documents / Resources
 |
INTERMOTIVE PRC505-A Programmable Relay Power Center [pdf] Installation Guide PRC505-A, PRC550-A, B-PRC505-A, PRC505-A Programmable Relay Power Center, PRC505-A, Programmable Relay Power Center, Relay Power Center, Power Center |