Brake
Controller Overview
This
information is provided to assist in understanding various brake
controllers.
I am not attempting to show preference or
bias.
This
list is in no particular order other than
the order which I learned
about these brake controllers.
General:
Trailer brakes operate on 0-12VDC provided by the tow vehicle
(TV).
It is assumed that with an output of 0VDC there is no braking and at
12VDC
maximum braking and any value between 0-12VDC being proportional to the
braking of the tow vehicle.
Trailer brakes typically draw 2.5-3.5 amps per brake solenoid. If
your trailer has 2 wheels/2 brakes (tandem axle) per side, your nominal
current level
will be
10-14 amps at maximum output voltage of 12VDC.
Not all trailer brakes will lock
even with full 12VDC applied. It does not mean your brakes are
defective. Its is simply the characteristics of electric brakes,
traction and trailer weights.
All brake controllers utilize electronics and most have some form
of mechanical process for sensing the braking demands from the driver.
Brake controllers take information from their their sensing method
(input) and convert to 0-12VDC (output) to the trailer brakes.
You might say this is a 'black box' with the input being the driver
actions and the output is 0-12VDC. Each controller provides
information to the driver via a LED digital display. This display
is also used during setup and adjustment.
The major difference between brake controllers is how they obtain
information from the driver to determine the level of output required
for the braking conditions.
Most installation instructions focus on vehicles equipped with a 'Tow
Package'. The Tow Package usually provides a connector under the
dash to connect the brake controller and a 4 and/or 7 pin wire harness
and plug installed at the rear bumper. Vehicles without the 'Tow
Package' may still use any of these brake controllers. However,
the installer wil be responsible for making the necessary connections
without the aid of the plug under the dash for the controller and the
wire harness and plugs at the rear bumper.
Factory Tow Packages usually include relays and fuses which must be
installed prior using a brake controller. The relays and fuses
are usually included with the Tow Package bundled in a plastic bag with
installation diagrams.
Most controllers (when bought new) include the necessary hardware and most
wiring for complete installations. Connectors are available for
most vehicle manufacturers and brake controllers. Most connectors
can be found on the internet and at RV dealers. If not, some
soldering and/or wirenuts and splicers may be required for connecting
the brake controller. Specify the controller and vehicle when
purchasing a prefit connector. The wiring kit harnesses are sold
separately for each vehicle and controller manufacturer and model -
approx. $8-15.00.
Setup and testing will vary between each manufacturer and model.
Regardless of who does the installation, it is important to fully
understand the operation of your brake controller. It will aid
you when adjusting and tuning the controller to your RV and driving
conditions.
An estimated cost of each controller is provided only because this is
always a question when considering the various brake controllers.
It may take some searching on the internet or dealers to find the best
prices as they will always
be changing.
This is not a complete list of available controllers but those which
seem most popular. For further details about any specific brake
controller please visit their website.
Setting
up an inertia controller may be a little more difficult. You
cannot simulate the inertia therefore must have your rig connected and
space to test your setup.
Reese
Brakeman and DrawTite Activator II:
Reese
Brakeman
DrawTite
Activator II
Reese Brakeman or DrawTite Activator II (known also by other names and
sold by
U-Haul, etc)
This controller is a fully electronic device. It has no moving
parts and can be mounted literally in any position.
This controller has 2 adjustment settings:
Output level - the maximum preset
output
(0-12VDC) seen by the RV brakes
Time/Gain - how long it takes (seconds, I believe) to reach the maximum
preset output level.
Each time this controller is energized or initiated by driver depressing
the brake pedal, the controller output starts the ramp up. This
output
starts
at 0VDC and continues to increase toward the preset maximum
output. If
the brake pedal is released before the preset output level is reached,
it simply resets to 0 and is ready for use again. If the brake is
held
on the output will continue to increase at a linear rate toward
the preset maximum output level. Once the
time/gain has expired, the maximum output level is reached and the
controller will continue to provide the preset level output as long as
the
driver holds their foot on brake pedal.
The output may or may not be 12VDC depending on what the driver has set
the maximum voltage output. If the output is too low, simply turn
the
dial on the face of the brake controller to increase the output
level. This can be done at any time. If reaching the
maximum voltage
output seems to take too long, simply adjust the dial on the side of
the unit to a
lower (less time) level. The unit will return the display to the
voltage output as
soon as the brakes are applied.
Reese Brakeman and DrawTite Activator II are very simple to install -
just connect 4 wires per
instructions provided.
The controller provides a continuous display of the voltage output
except when adjusting the maximum voltage output and Time/gain setting.
Tekonsha
Voyager:
Tekonsha Voyager
The
Tekonsha Voyager is
an inertia device. A pendulum is used to sense change in
motion. The Voyager uses the difference in initial installation
angle, and current angle of "pendulum" to determine amount of braking
needed at the time the brakes are applied.
The Voyager displays voltage provided to the trailer brake
solenoids.
The Voyager is easy to install - just connect 4 wires and mount within
the angle range per instructions.
Inertia as defined by Merriam Websters is:
1 a : a property of matter by which it remains at rest or in uniform
motion in the same straight line unless acted upon by some extern
al
force b : an analogous property of other physical quantities (as
electricity)
2 : indisposition to motion, exertion, or change
Tekonsha Prodigy is an inertia device. This unit implements
a bending bar in a capacitive field (accelerometer)
technology for sensing
change in motion. Prodigy uses difference in angle before brakes
were depressed, and
angle of "pendulum" after brakes are depressed, to determine amount of
braking. This provides compensation for pendelum action in hilly terrains.
Prodigy provides a 15% and 30% boost presets
which deliver increased voltage at the time the brakes are applied.
The Prodigy displays voltage provided to the trailer brake
solenoids.
The Prodigy provides an led indicating the trailer is connected.
The Prodigy is easy to install - just connect 4 wires and mount within
the angle range (approx 0-70 degrees) per instructions.
Jordan
Ultima 2020
Jordan Ultima 2020
The Jordan uses a cable
connected to the brake pedal arm to sense braking. The cable
housing is attached to the controller and usually to a cross member at
the dashboard. The cable itself is connected to the brake
controller,
run through the cable housing and connected to the brake pedal arm with
a spring loaded connector. When the brake pedal is depressed the
movement sent to the Jordan controller by this cable.
The Jordan Ultima 2020 provides an led indicating the trailer is
connected.
The Jordan Ultima 2020 displays amperage drawn by the brake
solenoids. This provides information that can identify that
1 or more solenoids are not working. If a solenoid fails or a
wire breaks, you cannot obtain the highest level of current draw
expected for your brakes and it will be reflected in the LED display.
The Jordan installation requires connection of 4 wires, mounting a
small single
screw cable clamp at lower dashboard area for the cable housing and
attaching the bracket to the brake pedal arm.
BrakeSmart:
BrakeSmart
The BrakeSmart taps into the Master Brake Cylinder and senses
brake fluid pressure, processes the information through a pressure
transducer to provide a 0-12VDC output. The Brakesmart will
respond directly proportonally to the brake pedal pressure.
Installation requires installing a fitting into the master brake
cylinder and wiring the input/output to the controller.
The BrakeSmart displays voltage provided to the trailer brake solenoids.
BrakeSmart additional informaton:
BrakeSmartFAQs
TowCommand
Module
The Ford TowCommand Module is a factory
installed option on new vehicles from Ford Motor Company. This
controller taps into the Master Brake Cylinder and senses brake fluid
pressure, processes the information through a pressure
transducer to provide a 0-12VDC output. The Ford TowCommand
Module will respond directly proportonal to the brake pedal pressure.
The TowCommand Module is integrated
with the vehicles PCM; therefore,
it is the first trailer brake controller
to adapt its output based on the state of the tow vehicle's ABS.
The Ford TowCommand Module displays voltage provided to the trailer
brake solenoids.
Note:
Ford Motor Company does
not recommend this controller for after
market applications but can be added as an Original Equipment accessory
for Ford 2005-2006 models.
See here:
Ford
TowCommand Module Accessory