TEKONSHA 90920 Prodigy iD Brake Controller Instruction Manual

90920

BRAKE CONTROL
Instruction and Operating Manual

Electronic Brake Control with EDGE™
For 2, 4, 6 and 8 brake (or 1–4 axles) applications

READ THIS FIRST:
Read and follow all instructions carefully before installing or operating the PRODIGY iD. Keep these instructions with the Brake Control for future Reference.

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Scan QR Code For French or Spanish Language Instructions and Enter Part Number 90920.

Important Facts to Remember

1. WARNING The PRODIGY iD may be operated with reduced performance if the Dash Module is removed or disconnected while the trailer is in use.
2. Do not mount or activate RF generating items (such as two-way radios) near (less than 12 into the Dash Module or Power Module).
3. The PRODIGY iD employs an internal sensor. It senses deceleration and generates an output that is based on deceleration, thus the term “Proportional Braking”.
4. The PRODIGY iD will “HOLD” your trailer with 25% of the power setting while you are at a standstill with the brake pedal applied for longer than 5-7 seconds.
5. The PRODIGY iD will brake proportionally in reverse. It will apply the appropriate brake voltage based on deceleration.
6. WARNING The Gross Combined Weight Rating (GCWR) must never exceed the vehicle manufacturers’ recommendation.
7. WARNING Follow all installation and mounting instructions to allow the inertial sensor to operate properly.
8. For Technical Assistance and Warranty Information call: 1-800-632-3290 or www.tekonsha.com
9. Tekonsha EDGE™ App is not required for use, but adds additional features.

Components of PRODIGY iD

A. Power Module
B. Dash Module
C. Manual Knob
D. LED Display
E. Knob Base
F. Mounting Collar
G. Red Cap
H. Universal Wire Harness
I. Hardware Kit
J. Drill Template

Installation Instructions

**WARNING** If you need additional assistance or do not have the tools required for the installation, stop the installation and contact a professional installer.

Tools Required

A. Drill motor
B. Drill bit: 7/32”
C. Hole saw: 1”
D. Center punch
E. Allen/hex wrench: 1.5mm
F. Wire cutters
G. Crimp tool
H. Voltage Tester
I. Panel removal tools

Determine Mounting Location

Dash Module and Display Assembly
WARNING The Prodigy iD Dash Module and Display must be securely mounted to the vehicle. Failure to install the Dash Module and Display within the specified constraints may cause impaired performance.
WARNING To prevent SERIOUS INJURY, DEATH, or DAMAGE to the vehicle, make sure the area behind the dash panel is clear before drilling. The minimum required space for installation is approximately 2.32in (59mm) tall, 2.17in (55mm) wide, and 2.68in (68mm) deep.
WARNING Correct orientation and mounting of the Dash Control and Display is required for proper operation. The Dash Control and Display must be securely mounted to a solid surface.
CAUTION Do not remove the red cap until after the Dash Module has been mounted.
NOTE: The Dash Module connects to the Power Module with the included harness. Consider the location of both modules relative to each other and verify harness routing before drilling any holes.

Dash Module Mounting Orientation Considerations

The Prodigy iD must be parallel to the direction
of travel (±20 degrees), see below.| The front of the Prodigy iD must be horizontal (±20 degrees), see below.| The Prodigy iD can be mounted from 0 to 360 degrees, in the direction of travel, see below.
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Automatic Leveling of the Sensor
The Prodigy iD will automatically acquire the proper level setting. It will also automatically adjust as you travel up or downhills. Determine a suitable mounting location for the Dash Module. The Dash Module can mount in vehicle panels up to 0.17in (5.0mm) thick. It must be within a maximum angle relative to the forward direction of vehicle travel for the inertia sensor to work correctly and for the driver to access the Manual Override and Dash Module (manual braking). For ease of installation, temporarily remove the panel for drilling and mounting. Place Drill Template on a panel at desired Dash Module mounting location and mark each drill point with the center punch.
CAUTION To ensure alignment of the display, confirm horizontal centerline alignment, then drill holes sized as indicated, and in the alphabetical order shown. The drill template may optionally be removed from the panel prior to drilling if holes are marked properly. A scale copy of the Drill Template is included in this booklet as a backup and for reference.

Dash Module Assembly
IMPORTANT Using Mounting Collar assembly, ensure fit and clearance with drilled panel holes. Trim as necessary to ensure the perimeter of the Mounting Collar can sit flush to the mounting panel before continuing. Verify that Mounting Collar has its aluminum “Clamp Wings” locked in the inward position and insert into the drilled hole with Indicator Arrow on the outside point up to the “12 o’clock position”

With Mounting Collar inserted in the panel, free the Clamp Wings by loosening (counter-clockwise) screws one-half turn with the 1.5mm hex key. Once free, clamp the Mounting Collar to the panel by hand tightening screws clockwise. This will clamp the Mounting Collar to the panel. Ensure the assembly is secured to the panel and that both Clamp Wings are hand tight.
**WARNING Do not overtighten. Failure to properly tighten the Mounting Collar screws could cause improper/reduced performance, excessive road noise, and even damage to the device.
****CAUTION Do not remove the red cap until after Dash Module is firmly secured to the panel.
WARNING** Verify assembly orientation. Snap Rear Switch Assembly into Mounting Collar.

Insert and tighten Screws to secure the Dash Module to the Mounting Collar. Verify that screw heads are flush and the entire assembly is secured to the dashboard.
**WARNING Hand tightens only. Verify assembly is firmly secured to the panel and in the final mounting location.
Align Knob Base as shown with Indicator Arrow pointing up in the “12 o’clock” position and press straight inward until all three snap fits engage. When properly assembled, Knob Base should be able to turn evenly with a spring return. Remove the red anti-static cap.
CAUTION DOES NOT TOUCH THE ELECTRICAL CONTACTS.
CAUTION After removal of the Red Dust Cap, DO NOT TOUCH THE ELECTRICAL CONTACTS. THIS MAY DAMAGE THE DEVICE. Align Display Assembly as shown with logo lettering oriented upwards. Press inward until both snaps are engaged.
Align large snaps on Manual Knob with notches on Knob Base. Push on until snaps are fully engaged. Remove lens protector.
Power Module Mounting
CAUTION The Power Module must be mounted in a suitable location.
The Power Module can be mounted to any suitable surface with Tie-Wraps or screws. Do Not mount to, or underneath the carpeting which will not allow for proper module cooling.
Select a Location**
Use (2) 14in Tie Wraps to mount the Power Module to a suitable surface. Secure the excess wiring with 8in Tie-Wraps (provided).

Vehicle Wiring

**WARNING** Inadequate grounding may cause intermittent braking or lack of sufficient voltage to trailer brakes and may result in accidents.

1. The WHITE wire must be connected to a suitable ground location. The negative terminal of the battery is a suitable ground location in the absence of a Trailer Tow Package connection.

2. Connect BLACK (+) wire through an automatic reset circuit breaker 20 amp for 1-2axles, 30 amp for 3-4 axles to the POSITIVE (+) terminal of the battery. The BLACK  wire is the power supply line to the brake control.

3. The RED (stoplight) wire must be connected to the vehicle braking circuit.
   WARNING Do not disrupt the vehicle braking circuit. If you are unsure of which wire to use, contact a local vehicle dealer, Tekonsha dealer or technical support.

4. The BLUE (brake output) wire must be connected to the trailer connector’s brake wire.

5. Connect the 4-Pin Universal Wire Harness to the Power Module.

6. Turn on the Vehicle’s Ignition Switch.

7. 7. Rotate the Manual Override to verify that the Dash Module and  Display are illuminated. The display will Flash if the trailer is not connected, or when the trailer is connected.

Typical Wiring Diagram

Power Module Wiring

OPTION 1: Universal Wire Harness Installation
WARNING Reversing BLACK and WHITE wires, or improper wiring will damage or destroy the brake control. Be sure to solidly connect all four wires or the brake control will not function properly. Use of proper gauge wire when installing the brake control is
CRITICAL; smaller gauge wire may result in less than efficient braking.
Minimum wire gauges are as follows:

• 1-2 axle applications – 14 AWG.
• 3-4 axle applications – 12 AWG.

1. The brake control must be installed with a 12-volt negative ground system.
2. Soldering is recommended or crimp-on butt connectors are a suitable substitution.
3. Route all wires as far from the radio antenna as possible to reduce AM interference.
4. Collection of water inside the trailer connector mounted on the tow vehicle will reduce the life of the connector.
5. Use the Universal Harness and splice the wires into the function wires as shown on the Wiring Diagram.
   Wiring Legend
   BLACK Wire (Positive Battery, 12VDC)
   WHITE Wire (Negative Battery, Chassis Ground)
   RED Wire (cold side of stoplight switch)
   BLUE Wire (brake output to the trailer)

OPTION 2: Plug & Play Wire Harness (Sold Separately) If your vehicle comes equipped with a factory tow package, brake control function wires with a connector may exist under the vehicle dash. Consult the vehicle manual or call for the location of the harness. A vehicle-specific Plug & Play harness may be purchased separately. For easy installation simply plug the vehicle-specific connector into the factory tow package harness and plug the other end directly into the Plug & Play Harness on the brake control.

Tekonsha Edge™ Mobile App

WARNING DO NOT USE THE TEKONSHA EDGE™ APP WHILE DRIVING.
ONCE YOUR PRODUCT IS INSTALLED:

| DOWNLOAD TEKONSHA EDGE APP
---|---
CREATE AN ACCOUNT
 GET IN RANGE OF BRAKE CONTROL
FOLLOW DIRECTIONS ON THE APP SCREEN

Operating Instructions

Manual Override
The Manual Override is the rotary control knob. It allows the user to apply the trailer brakes to the maximum power set by the user with the Power Output setting.
When the Manual Override is rotated clockwise, the Brake Output Voltage will override the proportional value. The Brake Output Voltage will increase, starting at and going to the Maximum value as set by the Power Control set.

Menu Button

The Menu Button is used to enter the Programming Menu and confirm settings. When the Menu Button is held for longer than 5 seconds, the display will change to the  Programming Menu. Rotating the Manual Override is used to change Menu selections and settings.
Display Readings after Connecting the PRODIGY iD
Once the PRODIGY iD Dash Module and Display Assembly have been installed correctly and power is applied, the display will indicate connectivity.

• Initial Power to the Power Module with the trailer connected. Once the units and trailer are connected, the display will indicate a connection, .

NOTE: The center dot is for power ON. The 2nd dot is for Boost ON. This convention is used throughout these instructions.

• If flashing or for 15 seconds, then changes to (dot), check all connections to the trailer (see Troubleshooting Chart).

• Manual Override activated (with trailer), denotes a hypothetical power output.
  The Power Output value is set by rotating the Manual Power Knob. The range is a % from 0.0 to 10, or 100%. This is an indication of the Brake Output Voltage being supplied to the brakes.

Power Saving Mode

• With no motion or braking activity for at least 15 minutes, the Prodigy iD will enter Power Saving Mode, the display will automatically return to normal operation with any activity.

Programming Menu/Sub Menu Display Setting Options

M
a
i
n
M
e
n
u| | Power Output|
---|---|---|---
Boost Setting
Brake Controller Type
Display Brightness
Electric / Hydraulic
Reverse Mode.
Passcode

How to Navigate the Programming Menu

1. Long press (5 Sec) on the Menu Button to enter the Menu.
2. Rotate the Manual Control to change the Menu selection.
3. Short press (1 Sec) on the Menu Button to enter Sub Menu.
4. Rotate the Manual Control to change the values.
5. A short press on the Menu Button to confirm the value.
6. The value selected will be shown on the display.
7. Long press on the Menu Button to exit Menu or wait 2 seconds for selection to update and go back to Main Menu.

Programming Menu Navigation

Power Output

The Power Output setting menu allows the user to configure the maximum output power that can be delivered to the trailer’s brakes. The maximum brake output is limited by the Power Output setting. The Power Output setting range will be from 0.0 to 10 (100%), in the increment of 0.5. Refer to How to Navigate the Programing Menu or Edge™
App to change.

Adjusting Power Output
Once you have properly mounted the PRODIGY iD and connected the Power Module’s electrical wiring harness to the vehicle, connect the trailer’s electrical connector to the tow vehicle. The following illustration should be on the display.

1. Set the Power Output to.**60**

2. With the engine running, fully rotate the Manual Override and verify that the display is **60. **

3. NOTE: Always warm trailer brakes before setting the Power Output. To warm trailer brakes, drive a short distance of ¼ mile (0.4 km) at about 45 mph (70 kph) applying the Manual Override at a low setting to allow the trailer brakes to engage at a low level.

4. Drive tow vehicle and trailer on a dry level paved surface at 25 mph (40 kph) and fully apply the Manual Override.
   • If trailer brakes lock up:
   • Decrease Power Output
   • If braking was not sufficient:
   • Increase Power Output

5. Repeat Step 4 until power has been set to a point just below wheel lock-up or at a force sufficient to achieve maximum braking power.

6. Using the brake pedal, make a few low-speed stops to check the power setting. Trailer braking is initiated and terminated via a signal from the stoplights``

Boost

WARNING To prevent SERIOUS INJURY or DEATH:

• NEVER use the Boost feature to compensate for a potential problem with your trailer brakes. Have your trailer brakes adjusted or repaired immediately.
• ALWAYS select your Boost setting based on your towing situation, driving preference, and condition of your trailer brakes.
• DO NOT use Boost during icy road conditions.
• Boost is disabled in Timer mode.

Boost may be adjusted for individual drivers’ preferences or changing road conditions. The Boost control is located in the menu as .
The Boost setting is designed to allow a more aggressive setting for your trailer brakes and has four (4) levels: and. Each Boost setting level increases the sensitivity of the Brake Control Unit’s inertial sensor, enhancing the participation of the trailer brakes during a braking event.

Boost Menu
The Boost setting menu allows the user to configure the boost level that will provide an increased deceleration. The Boost levels are Boost “OFF” , Level-1 , Level-2 and Level-3 .

Refer to How to Navigate the Programing Menu or Edge™ App to change.

Typical Boost Settings For Optimal Performance
(with properly adjusted trailer brakes*)

*Increased Boost setting may be needed if trailer brakes are worn, see Appendix A or a dealer for brake adjustment or repair.

NOTE:

1. Always warm the trailer’s brakes before setting the power. Warm trailer brakes tend to be more responsive than cold brakes. To warm trailer brakes, drive a short distance (1/4 mile) at 45 MPH with a manual lever engaged enough to cause trailer braking at a low level.
2. WARNING The power should never be set high enough to cause trailer brakes to lock up. Skidding trailer wheels can cause loss of directional stability of trailer and tow vehicle. 3. The power may need to be adjusted for different load weights and road conditions.
3. Not all trailer brakes will lock up due to various conditions. However, the inability to lock up the brakes generally indicates the need for an inspection to determine the cause.
4.  When the power is set correctly you should feel unified braking between the trailer and tow vehicle.

Brake Controller Type

Controller type may be set for individual drivers’ preferences. The brake control type is located in the menu as .

Proportional Braking
provides for a Brake Output Voltage that is proportional to the deceleration rate of the tow vehicle and trailer.

Timer mode
provides for a Brake Output voltage that increases voltage over time. The ramp time starts when the brake pedal is depressed. Ramp time varies from 1-4 seconds, and maximum power output will vary with the Power Output setting. Boost is disabled in Timer mode.

Refer to How to Navigate the Programing Menu or Edge™ App to change.

Display Brightness

The display brightness setting menu allows the user to control the brightness of the LED display. The display brightness is located in the menu as .
The brightness can be controlled in 3 Levels to . The dis- play brightness levels are ( =Dim), ( =Normal) and ( =High Brightness).

Refer to How to Navigate the Programing Menu or Edge™ App to change.

Electric or Hydraulic Mode

The Electric/Hydraulic mode setting allows the user to select the electric (E) or hydraulic (E/H) mode of operation for the trailer that is being used. The mode setting is located in the menu as .

NOTE: This refers to the specific type of brakes that are installed on the trailer that is being used. Electric Brakes are the most common, but some larger trailers use Hydraulic disks or drum brakes that are controlled by an Electric Motor and Hydraulic Pump. This type of braking system is referred to as an Electric over Hydraulic brake system.

When in E/H Mode the display will indicate which mode the controller is in by the size of the connectivity display. A full height indicates E/H mode.

Display of Connection E/H Mode

Disconnect Notification E/H Mode

Refer to How to Navigate the Programing Menu or EDGE™ App to change.

Reverse Mode

The user has the option to temporarily cancel the effects of Boost. This might be useful during parking, especially when backing up the trailer. The reverse mode setting is located in the menu as .

To Set or Clear the Reverse Mode Setting
Refer to How to Navigate the Programing Menu or EDGE™ App to change.
Reverse Mode will last for a period of 3 minutes, or until the user selects the Reverse Clear option from the Menu.
The user is notified that Reverse Mode is in effect by the Idle Mode display showing or .

Passcode Clear

This code is set through the EDGE™ App for secured Bluetooth communication between the App and the PRODIGY iD. The Passcode setting is located in the menu as P . R.

To clear the Passcode
The user has the option to clear the 6-digit passcode stored in the brake controller module.

• Exit the Edge™ App for either Android or iPhone.
• Follow the Menu navigation to Passcode Menu **PR.**
• With the Manual Override, select either **P.5** to Set, (no Action Needed) or **P.C** to Clear.
• When the passcode clear option is selected, the Display will rapidly flash **P.C**for 4 seconds.
• If the passcode was successfully cleared, the display will show for 2 seconds then change to. **P.R**
• To enter new passcode, start the Edge™ App and follow the instructions to connect.
• If the passcode did not clear, the display will flash **P.3** for 2 seconds. Ensure the Edge™ App is closed and repeat steps.

Refer to Edge™ App for Additional Features

• Refer to page 18en for Tekonsha Edge™ Mobile App.

Troubleshooting Chart

21en).
• Loss of connection between Power Module and Dash Module.
• Loss of power to Power Module.
• Loss of ground to Power Module.
• Vehicle battery input exceeds 17.0V.| • Depress brake pedal or manual override.
• Verify connection from power module to dash module.
• Verify connection to Power Module &  vehicle.
• Verify battery voltage on black wire (12-14 volts).
• Verify ground on white wire.
Trailer Disconnected Flashes for 15 sec. With trailer connected| • Trailer is disconnected from the tow vehicle.
• Trailer connector is dirty, corroded, or bent/misaligned terminals.
• Trailer or tow vehicle connector not wired correctly.
• Open on electric brake wire (broken or disconnected wire).
• Loss of ground to brake magnets (broken or disconnected wire).| • Connect trailer.
• Check, clean, and/or repair trailer connectors as needed.
• Correct trailer or tow vehicle connector wiring.
• Repair/replace electric brake wire as needed.
• Repair ground to brake magnets as needed.
Power ON, Boost OFF, Trailer Disconnected| Normal Operation: Power to Prodigy iD, Boost is OFF
and no trailer connected.| No action is required.
Open Ground Flashes 2 times per sec.| Power Module loses connection to vehicle battery ground while Trailer is connected.| Check connection to ground on white wire of power module.
Electrical Overload Flashes 2 times per sec.| • Defective Brake Magnet.
• Intermittent short on electric brake wire or bare wire.
• Total Brake Current exceeds 4-Axle Load.
• Thermal Overload – Reduced Braking Power.| • Locate and replace defective Brake Magnet.
• Locate and repair faulty brake wire.
• Decrease electrical load.
• Thermal Overload – Reduced Braking Power.
Short Circuit Flashes 2 times per sec.| • Power Module detects brake wire short to ground.
• Use of some test lights or non-Tekonsha testers can cause this.
• Short in 7-way between Brake Output and other terminals.
• Electric brake wire on tow vehicle or trailer is shorted out.| • Use Tekonsha-approved test light or tester.
• Inspect and repair trailer connector, if needed.
• Inspect and repair/replace electric brake wire.
Power interruption while the brake pedal is depressed. Flashes for 15 sec.| • Manual Override or brake pedal applied while connecting to power.
• Manual Override or Brake Pedal activation within 5 seconds of initial Power applied to Power Module.
• Poor connection to battery power.
• Red and Black wires reversed.| • Unplug power module from the vehicle. Verify manual override or brake pedal not applied for 10 seconds after reconnecting
to power.
• Verify connection to battery power.
• Verify that red and black wires are connected correctly
---|---|---
No Braking, Flashes continuously| Power Control set to zero.| Increase Power Setting.
Passcode Cleared Flashes for 4 sec.| Normal Operation:
• P.C Flashes during successful clear operation.| No action is required.
Communication Error between Power Module
and Dash Module. Flashes for 15 sec.| • Communication Failure between Power Module and Dash Module.
• Controller type has defaulted to Timer.
• Display may be blank.
• Partial or complete loss of Manual Override braking.| Check Dash Module harness for
connection and/or damage.
Passcode Error Flashes for 5 sec.| • Failed to clear 6 digit Passcode.
• EDGE™ App was not closed prior to Passcode Clear.| Close EDGE™ App before passcode clear.
Internal Error (SPI Bus Corruption) Flashes
continuously| Internal Error with the Prodigy iD.| Contact Technical Support.
Internal Error (Manual Override) Flashes continuously| Internal Error with the Prodigy iD.| Contact Technical Support.

Appendix A: Trailer Brake Adjustment

To achieve maximum performance, Trailer Brakes must be adjusted after the first 200 miles, (320 km) of operation. And, when the brake shoes and drums have “seated” at 3,000 miles (4,800 km) intervals, or as use and performance required. The brakes should be adjusted in the following manner:

1.  Jack up the trailer and secure on adequate capacity jack stands. Follow trailer manufacturer recommendations for lifting and supporting the unit. Check that the wheel and drum rotate freely.
   WARNING NEVER lift or support your trailer on any part of the axle or the suspension system.

2. Remove the adjusting hole cover from the adjusting slot on the bottom of the brake backing plate.

3. With a screwdriver or standard adjusting tool, rotate the star wheel of the adjuster assembly to expand the brake shoes. Adjust the brake shoes out until the pressure of the linings against the drum makes the wheel very difficult to turn.
   NOTE: With drop spindle axles, a modified adjusting tool with about an 80-degree angle should be used.

4. Then rotate the star wheel in the opposite direction until the wheel turns freely with a slight lining drag.

5. Replace the adjusting hole cover and lower the wheel to the ground.

6. Repeat the above procedure on all brakes.

WARNING To prevent SERIOUS INJURY or DEATH:

• BEFORE getting under the trailer, ALWAYS block the trailer tires and use jack stands that are properly placed on firm ground and have sufficient capacity for your trailer. DO NOT lift or place supports on any part of the suspension system.
• ALWAYS follow your trailer manufacturer’s recommendations for lifting and supporting the unit.

Technical Support and Patent Information
Questions?: 1-800-632-3290
CONTAINS FCC ID: T9JRN4020
PATENT INFO: CEQPAT.COM

References

• Tekonsha

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