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Last Changed 12/10/2009
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We originally purchased a Prodigy brake controller as it had a very
good rating. A friend who has a Volvo 610 to pull his trailer was
using a Prodigy controller. He did not feel he was getting good
braking action from the Prodigy. He then tried a Genesis controller
feeling that perhaps it would work better with his Electric over
Hydraulic brakes. Again, he feel he was not getting good braking
action.
A lot of analysis decided that the mass of the Volvo in a braking
situation did not generate enough deceleration movement to cause the
Prodigy or the Genesis controller to function as expected.
My friend tried a Hayes Air Brake Controller that has a servo that
moves with the application of braking applying trailer braking in
proportion to the pressure of the truck brakes rather than the
deceleration of the truck. My friend now felt he was getting
adequate braking.
Acting on my friends experience, we originally choose the
BrakeSmart controller. The BrakeSmart controller sensing braking
air pressure electronically rather than using a mechanical servo and
applies a proportional braking voltage to the trailer. I felt the
extra cost of the BrakeSmart controller was justified by the more
technical approach to trailer brake control.
The source for the BrakeSmart controller was
Dr Performance. It seems that the supply of
BrakeSmart controllers is sketchy. The current site is pretty lean on information but I have seen a preview of the new site and
it will be highly informative. Another source for BrakeSmart controllers is
Trans-West, ask to speak with Joe or Todd in the parts department.
Note - It seems like BrakeSmart is no longer available. |
MaxBrake |
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MaxBrake is a new player in the brake controller marketplace. The MaxBrake
works a lot like the BrakeSmart unit sensing air or hydraulic pressure of brake application to send braking voltage to the trailer brakes.
We had the occasion to buy a MaxBrake controller also. The installation of the MaxBrake follows the BrakeSmart installation. |
MaxBrake Controller Installation |
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We mounted the MaxBrake sensor using the same tee we had placed in the Volvo brake light switch air line. In the Volvo, the is a 1/4"
OD air line.
We ordered a 1/4" OD x 1/4" OD x 1/4" ID Branch Tee with push-in connectors for the 1/4" OD brake hose line. |
click on images to enlarge |
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I used a bracket that had held the VORAD head unit as a mount for the MaxBrake controller on the top edge of the dash. Since the
MaxBrake brake is designed for installation under a dash, I had to add a piece of 3/4" square tubing as a spacer so he Manual Override
Knob was accessible under the controller. |
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It is close enough to operate the brakes manually and the view of the controller is good. |
click on images to enlarge |
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Another view of the controller placement |
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The setup of the MaxBrake is a lot simpler than the BrakeSmart.
The only concern we have with the MaxBrake is the brightness of the display. It is almost impossible to see in the daylight when
located on top the dash.. The photo above showing the display was with a blackout panel blocking the sunlight, This doesn't affect
how the MaxBrake works, it is just would be an advantage to have the visual indication of the brake controller is operational. |
click on images to enlarge |
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We decided to place a cover over the MaxBrake controller for two
reasons.
One was to cut the glare from the aluminum colored case on the LCD
monitor behind the controller. |
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The other reason for the cover over the MaxBrake was to cut glare on the LCD display.
The cover is tilted upwards to cut the glare that comes from the driver's shirt and arms. |
click on images to enlarge |
BrakeSmart Controller Installation |
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Behind the instrument cluster on a Volvo you will find two air lines with switches on the end. The orange house senses the parking
brake. The black hose is the stop light sensor.
The advantage of using this hose for the BrakeSmart sensor is that it is inside the firewall so the harness does not need to be fed
through the firewall. |
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I ordered a 1/4" OD x 1/4" OD x 1/4" ID Branch Tee with push-in connectors for the 1/4" OD brake hose line. I
originally intended to just replace the 1/4" OD x 1/4" OD Connector that is on the end of the black hose with the Brake Light
Switch plugged into the other end.
The brake light switch did not seat well in the Branch Tee so I inserted the Branch Tee in the line before the Brake Light Switch. |
click on images to enlarge |
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I used a bracket that had held the VORAD head unit as a mount for the BrakeSmart controller on the top edge of the dash. |
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It is close enough to operate the brakes manually and the view of
the controller is good. |
click on images to enlarge |
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This is the BrakeSmart controller in normal idle mode. |
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Here I applied the brakes to show how the BrakeSmart indicates the amount of braking pressure it is sensing to apply the trailer brakes
voltage. |
click on images to enlarge |
