Recently installed 4 new electric brake assemblies and Prodigy P3 controller. Worked great for 800 miles. Plugged the trailer in one morning and got a "Short" error on the controller. Checked all truck/trailer wiring and nothing evident. Next time I plugged in trailer I got an "Overload" error. Prodigy tech support this does not indicate a short to ground but that the system is drawing too much current.This has evolved into a highly intermittent issue with the brakes working about half the time and getting the "Overload" the other half. I have eliminated the truck and controller as being part of the problem.Obviously it has to be wiring in trailer or brake magnets causing the problem. The error will not occur with the truck setting still, but it just doesn't react like a wiring issue, and should show up as a "short" error if it was wiring.Is it possible that the magnets could be breaking down internally under load of breaking??

“intermittent issue with the brakes working about half the time”So half the time you can’t stop? I suggest a pro look at your brakes for MY safety.

dryfly wrote:Recently installed 4 new electric brake assemblies and Prodigy P3 controller. Worked great for 800 miles. Plugged the trailer in one morning and got a "Short" error on the controller. Checked all truck/trailer wiring and nothing evident. Next time I plugged in trailer I got an "Overload" error. Prodigy tech support this does not indicate a short to ground but that the system is drawing too much current.This has evolved into a highly intermittent issue with the brakes working about half the time and getting the "Overload" the other half. I have eliminated the truck and controller as being part of the problem.Obviously it has to be wiring in trailer or brake magnets causing the problem. The error will not occur with the truck setting still, but it just doesn't react like a wiring issue, and should show up as a "short" error if it was wiring.Is it possible that the magnets could be breaking down internally under load of breaking??The magnets should be fine with the miles indicated. Unless the assemblies were installed wrong...Both controller messages are indicative of trailer side wiring issues. First place to start is the cross over wire inside the axle housing. These chafe and the insulation cracks causing both types of error.Short error would be a cross connection on the brake positive and negative wires.Overload could be multiple issues, but most common is brake positive contacting the axle housing.Check any wire nuts and scotch lok wire connectors -they fail but look outwardly fine.

Magnets can fail and have internal shorts. You are going to have to disconnect one magnet at a time to determine which one is at fault.In my trailer, if I ever have to do any brake wiring work, I will homerun every magnet to a common connection in a distribution box so that troubleshooting something like that is easier.Use an ohmeter and measure between the brake terminal and ground of your trailer connector with it unplugged. Since magnets are typically a little over 3 ohms, you should measure slightly below 1 ohm for the 4 of them in parallel.

dryfly wrote:Is it possible that the magnets could be breaking down internally under load of breaking??Were the magnets replaced?

Here's my story: I had a Prodigy controller that was showing an error code. I replaced it with a Prodigy P2. The error code was still displayed. I traced it to a break of the copper inside the jacket of one of my umbilical connections on the truck. I must have tossed up a rock and it was enough to part the copper but not enough to break the jacket. I disassembled the umbilical connector on the truck, stripped back to good wire and reassembled. All is now good.

trailer brake problem | Good Sam Community

westend
Explorer
Oct 14, 2017
Here's my story: I had a Prodigy controller that was showing an error code. I replaced it with a Prodigy P2. The error code was still displayed. I traced it to a break of the copper inside the jacket of one of my umbilical connections on the truck. I must have tossed up a rock and it was enough to part the copper but not enough to break the jacket.
I disassembled the umbilical connector on the truck, stripped back to good wire and reassembled. All is now good.
time2roll
Nomad
Oct 14, 2017
dryfly wrote:
Is it possible that the magnets could be breaking down internally under load of breaking??
Were the magnets replaced?
babock
Explorer
Oct 14, 2017
Magnets can fail and have internal shorts. You are going to have to disconnect one magnet at a time to determine which one is at fault.

In my trailer, if I ever have to do any brake wiring work, I will homerun every magnet to a common connection in a distribution box so that troubleshooting something like that is easier.

Use an ohmeter and measure between the brake terminal and ground of your trailer connector with it unplugged. Since magnets are typically a little over 3 ohms, you should measure slightly below 1 ohm for the 4 of them in parallel.
mapguy
Explorer
Oct 13, 2017
dryfly wrote:
Recently installed 4 new electric brake assemblies and Prodigy P3 controller. Worked great for 800 miles.

Plugged the trailer in one morning and got a "Short" error on the controller. Checked all truck/trailer wiring and nothing evident. Next time I plugged in trailer I got an "Overload" error. Prodigy tech support this does not indicate a short to ground but that the system is drawing too much current.

This has evolved into a highly intermittent issue with the brakes working about half the time and getting the "Overload" the other half. I have eliminated the truck and controller as being part of the problem.

Obviously it has to be wiring in trailer or brake magnets causing the problem. The error will not occur with the truck setting still, but it just doesn't react like a wiring issue, and should show up as a "short" error if it was wiring.

Is it possible that the magnets could be breaking down internally under load of breaking??

The magnets should be fine with the miles indicated. Unless the assemblies were installed wrong...

Both controller messages are indicative of trailer side wiring issues. First place to start is the cross over wire inside the axle housing. These chafe and the insulation cracks causing both types of error.

Short error would be a cross connection on the brake positive and negative wires.

Overload could be multiple issues, but most common is brake positive contacting the axle housing.

Check any wire nuts and scotch lok wire connectors -they fail but look outwardly fine.
Lwiddis
Explorer II
Oct 13, 2017
“intermittent issue with the brakes working about half the time”

So half the time you can’t stop? I suggest a pro look at your brakes for MY safety.

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