Electric Brake Controller Selection
Roanoke, Va
Last
updated: Oct 25, 2009
When someone asks 'What is the best brake controller?', there are several things to consider. This page will provide information that should assist you in making the right decision based on your towing needs.
Factors to consider:
- How long you intend to keep your truck and/or RV
- Who will do the Installation (yourself of someone else)
- How complicated is setup and adjustment
- Anticipated driving condition (dry, flat, mountains, snow, ice, rain, traffic, etc)
- Frequency of towing
- Your tow vehicle and RV weight
- How you value your investment
- Cost of the brake controller, installation and connector
Importance:
- Simple economics - long term or short term investment
- Usually when someone does their own work they better understand how things work. It is easier to trouble-shoot when you know how it was installed and wired. Some controllers require tapping into the Master Brake Cylinder
- You will eventually need to setup the device and make adjustments
- Some controllers may work better in different terrains
- Frequent towing may justify the investment of a better controller
- TV and RV weight should be considered more importantly with regards to axles count. Not all controllers support 6/8 brakes
- You are protecting your TV, RV but more importantly your family and others on the highway
- Cost is always a factor. Consider only the difference between the worst and best. Thats the real consideration
Once you can answer these questions, the choice should be easier. Whatever you should decide, be sure you understand the operation and how to properly setup and adjust your controller. You will eventually need to do this. Your family, tow vehicle, trailer and others are all at risk if something should happen to go wrong.
Definitions:
Proportion - according to Merriam-Websters:
1:
harmonious
relation of parts to each other or to the whole: balance, symmetry
2 a: proper
or equal
share <each did her proportion of the work>
b: quota, percentage
b: quota, percentage
3: the
relation of
one part to another or to the whole with respect to magnitude,
quantity, or degree: ratio
4: size,
dimension
5:
a statement of equality between two ratios in which the first of the
four terms divided by the second equals the third divided by the fourth
(as in 4/2=10/5) — compare extreme 1b, mean 1c — in proportion:
proportional
To apply 'proportional' to braking suggests that you can map the brake pedal actions from the driver (input) to braking power voltage (output) to electric brakes of the RV. No braking = 0VDC output, Full braking = 12VDC output with all intermediate voltage values corresponding respectively to the TV braking.
For the purpose of this document, the term 'Proportional Braking' will be used to describe any brake controller that provides varying output to the RV brakes based on varying input from the TV or driver including interia operated devices.
The table below describes the 5 methods I am aware of for detecting braking demands.
| Sensing Method | Accuracy | Proportional | Description | Pros/Cons |
| Brake fluid pressure | High | Yes | Pressure transducer converts brake fluid pressure to 0-12VDC output | Pros:
Direct relationship to TV braking Cons: More difficult to install |
| Cable | High | Yes | Cable attaches to the brake pedal arm and the brake controller | Pros:
Directly related to brake pedal action Cons: Cable can slip and housing wear out, more difficult to install |
| Accelerometer | High | Yes | Change in motion of tow vehicle (inertia) | Pros:
Improved technology over pendulum, easy to install Cons: Relies on TV deceleration |
| Pendulum | Medium | Yes | Change in motion of tow vehicle (inertia) | Pros:
Inexpensive Cons: Limited mounting angle affected by hills. Relies on TV deceleration |
| Full Electronic | Low | No | Time delay Ramp up output | Pros:
Inexpensive, easy to install, position insensitive Cons: Jerky stops, constant need for adjustment to conditions |
The table below identifies the manufacturer and model, the maximum number of brakes the controller will operate, whether the controller supports electric over hydraulic, sensing method and estimated cost from online stores.
The pricing is was found on the internet using the normal search features and known online discount stores. You may be able to find a better deal.
All brake controllers are activated by some method related to touching the brake pedal; either by the brake light switch or the device itself.
| Manufacturer/Model |
No. of Brakes | Elec/Hyd | Activation (Turn-on) |
Sensing Method | Estimated
cost approx Jan 2009 |
| BrakeSmart |
8 | Yes | Brake
Sw |
Brake Fluid Pressure | $435.00 |
| MaxBrake | 8 | Yes | Pressure |
Brake Fluid Pressure | $350.00 |
| Jordan Ultima 2020 | 6 | Unk | Cable |
Cable attached to Brake Pedal | No longer be available |
| Tekonsha P3 | 8 | Yes | Brake Sw | Single Axis Accelerometer | $122.00 |
| Tekonsha Prodigy | 8 | Yes |
Brake Sw | Single Axis Accelerometer | $90.00 |
| Tekonsha PrimusIQ | 6 | Unk |
Brake Sw | Single Axis Accelerometer | $100.00 |
| Tekonsha Primus | 6 | Unk | Brake Sw | Pendelum | $86.98 |
| Tekonsha
Voyager |
6 | Unk | Brake Sw | Pendelum | $69.97 |
| Tekonsha Setinel | 8 |
Unk | Brake Sw | Pendelum | |
| Tekonsha
Envoy |
4 |
Unk | Brake Sw | Pendelum | $53.09 |
| Telonsha Pilot | 6 | Unk | Brake Sw | Electronic Time Delay | $69.99 |
| Tekonsha POD | 4 | Unk | Brake Sw | Electronic Time Delay | $44.95 |
| Tekonsha AccuTrak | 4 | Unk | Brake Sw | Electronic & 2 Pendelum | $55.99 |
| Tekonsha DigiTrac II | 8 | Unk | Brake Sw | Electronic & 2 Pendelum | $77.50 |
| Hayes Genesis | 8 |
Unk | Brake Sw | 2 Axis Accelerometer | $119.95 |
| Hayes G2 | 8 |
Unk | Brake Sw | 3
Axis Accelerometer |
$117.00 |
| Hayes Energizer III | 4 |
Yes |
Brake Sw | Pendulem | $74.05 |
| Hayes Syncronizer | 4 |
Unk | Brake Sw | Electronic | $59.95 |
| Hayes
Endeavor |
8 |
Yes |
Brake Sw | Pendelum |
$89.95 |
| Valley Odyessy | 8 | Unk | Brake Sw | Dual Axis Accelerometer | $99.95 |
| Valley Odyessy II | 8 | Unk | Brake Sw | Dual Axis Accelerometer | $130.00 |
| Valley Journey | 8 | Unk | Brake Sw | Electronic Time Delay | $63.00 |
| Reese
Brakeman, Drawtite, Activtor II U haul (sold under various names) |
4 | Unk | Brake Sw | Electronic Time Delay | $60.00 |
| Activator
III |
8 |
Unk | Brake Sw | Electronic
Time Delay |
$85.00 |
Display:
Most controllers have a digital display used during setup and configuration. This display is also used to provide feedback to the driver such as boost, trailer not connected indicator, shorted indicator, missing or open ground and other diagnostics. Some are offering various color panels for the display area.
Some activate the brake lights when the manual operator is used. These are features you need to determine if they are important to you.
Connector harness:
Most controllers have a wiring harness available with a connector at each end - plug on one end matching the TV receptacle and the plug on the other end matching the brake controller. This is the most simple installation. You will need to check each model for availability and usually ordered separately based on the vehicle make/model and brake controller mfg.
Sensing methods:
I believe most agree the most important element of a brake controller is the sensing method used to detect the braking demands of the driver. Each mfg may be different.
Electric over hydraulic capable:
Electric over hydraulic brake systems are relatively new compared to conventional electric brakes and controllers. Many of the modern electric brake controllers are presently (10/2009) being tested by the hydraulic actuator mfgs for use with the Electric over Hydraulic actuators.
I was not able to verify whether each controller was able to handle Electric over Hydraulic brakes and it is so noted below by Unk (unknown) in the above table. Contact the mfg of the E/H actuator and/or brake controller with specific questions.
Integrated brake controllers:
American auto makers (Ford, GM and Dodge) trucks are now offering integrated brake controllers as an option with the Tow Packages. Each of those manufacturers are using the Brake Fluid Pressure method for sensing of braking demands.
Electric over Hydraulic Brake Systems
The difference between standard electrically operated brakes and Electric over Hydraulic is the brake controller provides power to the brake solenoids for standard brakes. When applied to E/H the brake controller is feeding an electric motor. The motor drives a hydraulic pump which feeds the hydraulic brakes. These are mfgs I am aware of - there may be more.
Dexter:
http://www.dexteraxle.com/home
http://www.dexteraxle.com/inc/sdetail/1126
http://dexteraxle.com/brake_controller___actuators
Carlisle HydraStar:
http://carlislebrake.com/pdfs/Controller List 9-12-07.pdf
http://www.carlislebrake.com/trailer_brake_actuators.php
Kodiak:
Kodiak Trailer
http://www.kodiaktrailer.com/
http://www.youtube.com/southwestwheel
Alko:
http://www.al-kousa.com/
Also see this awesome sketch:
Electric and Electric over Hydraulic Brakes sketch
For reference - Air and Vacuum Over Hydraulic brakes:
http://www.tpub.com/content/engine/14081/css/14081_89.htm
http://www.tpub.com/content/engine/14081/css/14081_91.htm
BrakeSmart: $435.00 - Complete w/harness, fittings and instructions
http://www.drperformance.com/brakesmart.html
MaxBrake: $350.00 - Complete w/harness, fittings and instructions
http://www.maxbrake.com/brake-controller.php
MaxBrake installation video:
http://www.maxbrake.com/brake-controller.php
Jordan: $130.00 - Order harness separate if available
Jordan is no longer available - this information is provided for those who own or need information.
http://www.bestbrakecontroller.com/
Tekonsha Primus IQ:
Tekonsha Primus
Valley Odessy:
Valley Odessy
Kelsey-Hayes:
Kelsey-hayes
Hayes G2:
http://www.brakecontroller.com/g2.htm << good table of features
Several different brands:
Various Brand - General Information
Other information and links to online stores:
http://members.cox.net/bruce.wittmeier/technical/LinksRelatedRVing.html
Bruce A. Wittmeier