diversion controller

[(unknown)]

I purchased a commercial diversion controller for $129. I must have had to much current on the diversion load and the controller stopped working. I soaked the box in petrol to disolve the tar and this is what I found. . 1 bosch 50 amp relay $4.75. 1 zenner diode 25 cents. 1 reed relay $3.80. 2 x 220 uf capacitors 25 v $0.25 each. 1 printed circuit board wouldn't cost more then 2 dollars to make. 1 plastic container 1 dollar or less a bit of tar also cheap. The whole unit wouldn't cost more the $15 dollars to make and the Zenner diode can be sellected to suit the type of batteries you are charging. see up loaded photo for simple circuit diagram.  Not sure if copy right but I drew the circuit based on the hardware I had in front of me. This controller can be used to drive a high amp relay so that the 50 amp relay doesn't get burnt out as happened in my case.

129 for 15 dollars of parts seems a bit rich.

Fixed the picture link

[spinningmagnets]

Jesse, I think you posted this story twice. If a diversion controller is the same as what Ive read about here, I think its called a dump load controller (yes?).

If so, I believe Ghurd has published the plans for a robust, reliable, and cheap dump load controller. If you Google this site, perhaps you can compare the two?

[(unknown)]

Sorry about it being posted twice I forgot to insert a picture of the circuit diagram the first time. I wanted to remove the first posting but I think the site administrator has to do that.

Yes it is called a dump load controller but my point in posting this circuit and story was to show how easy it is to make a dump load controller for under 20 dollars and there are ruthless compannies out there selling products worth 15 dollars for 129 dollars. I have mannaged to get a printout of the Ghurd circuit diagram thanks and will consider using it. Thanks

[ghurd]

Not a very good design.

Sea50?

G-

[s4w2099]

What controller did you buy?

For $129 you could have bought a nice PWM dumpload controller?

That is not nearly as simple as what you have stated. It is expensive to build a 3 stage controller.

Ruthless? I doubt it

[ghurd]

From the removed post, you could pick my brain about the circuit!

G-

[scottsAI]

Jesse,

Ever bought car repair parts from a dealer?

Mark up is 10-20x from OEM cost.

Example: Mass Air Flow sensor. Try to buy one for less than $300.

OEM cost $14 to $20!!! Parts, package cost to supplier is $4, complex manufacturing/engineering cost brings their total cost to $11, lucky to get 20% mark up when they sell to OEM. They are not allowed to sell that part to anybody else. OEM must protect dealers!

Free market places the burden of a good deal on the buyer.

When you bought the controller you must have though it was a good deal.

Not until it broke did you think otherwise.

Buyer beware!

In decent quantities your cost above are 3-4x high.

Large quantities 5x high.

Have fun,

Scott.

[(unknown)]

It is called a #sea-50 Diversion load controller for $129.95.  It can be purchased from survival unlimited or hydroappliances.

[(unknown)]

You guessed right

[(unknown)]

Yes I know a bit about parts.  Dad went to get a radiator pipe, toyota wanted 130 bucks for it.  I suggested to him that we go to a muffler place they had us up and running for $20 bucks. The pipe was 1" diameter by 1 foot long with two bends in it it took all of 5 min for the muffler place to put the bends in.