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Electric Brake Controllers for Camper Trailers
everything
you want to know about brake controllers by were afraid to ask
INTRODUCTION
This article is intended as a guide to what an electric brake controller
is, what it does & what is available on the market for camper trailers
weighing between 750kg to 2 tonne. It does not cover drawbar mounted
Break-Away brake controller systems which are required on all
trailers over 2 tonne Gross Trailer Mass. Break-away controllers are designed to
apply the trailers braking system if it becomes detached from the tow
vehicle. The break-away switch module requires an onboard battery which is
trickle charged and a check facility to ensure that the trailers safety
system is operational at all times.
THE LAW
In December 1998
an agreement was reached by all State Ministers of Transport to
implement national towing regulations throughout Australia.
The uniform law states all trailers
with an Aggregate Trailer Mass (including the load) over 750 kg must be
fitted with brakes to comply with the national road regulations.
According to the Australian Design Rules, all trailers over 750kgs GTM, irrespective of the towing capacity or unladen mass of the tow vehicle,
must have an effective brake system fitted. All brakes must be operable
from the drivers seat of the tow vehicle except for over-ride brakes.
The minimum braking system required for a trailer or caravan depends on
its type and weight, as well as the weight of the tow vehicle.....
• Up to 750kgs GTM: No brakes are required.
• 751 to 2,000kgs GTM: There must be a braking system on the wheels of at least one axle and
over-ride brakes are
permitted. However, for caravans exceeding 1000kgs, independent brakes
(electric brakes are the most common
form) are strongly recommended.
• Over 2,000kgs GTM: A brake
system operating on all wheels is required. The system must be capable
of automatically activating should the trailer become detached from the
tow vehicle. Under these circumstances the brakes must remain applied
for at least 15 minutes. These 'break away' systems are compulsory on
all trailers over 2,000kgs GTM.
WHAT IS AN ELECTRIC BRAKE
CONTROLLER
An electric
trailer brake controller is a device that supplies power from a vehicle
to a trailers electric brakes when the vehicles brakes are applied.
Any trailer with electric brakes
needs a brake controller to activate the operation of the brakes.
Power is fed from the vehicles stoplights into the controller,
activating the
trailers brakes via a separate heavy duty circuit fed through
the trailers connecting
plug and socket. This allows
the trailers brakes to come on automatically when you apply the vehicles
brakes,
at a rate set by the controller.
When the controller is
adjusted
correctly, the driver will be able to slow the tow vehicle and trailer
combination just as smoothly as if the tow vehicle was by itself.
It is important the
wiring is heavy enough for the power to run through to the trailer with
a good earth return, not just earthed to the body. Of course proper
maintenance of the brakes with regular adjustment of the shoes & care of
the magnets goes without saying.
Most electric brake controllers are of a slimline contoured design
allowing under dash placement easily within the drivers reach.
From the drivers seat you can control the rate of brake application from
soft to aggressive my simply moving the control forward or backward.
Most controllers also have a manual over-ride device which allows the user to
apply the trailers brakes independently of the vehicles brakes.
There are two
types of electric brake controllers - motion sensing or pendulum
style
and time delay activated or solid state. Although the controllers
methods are different, both types of controllers are very similar. Both
allow the user to adjust output or braking power & both have a pressure
sensitive manual over-ride trigger that can be used to apply the trailer
brakes independent of the vehicles brakes & as well as having the same wiring
configuration.
MOTION SENSING or
pendulum style controllers are enabled by the brake pedal switch and
activated by a pendulum circuit that senses the vehicles stopping
motion and applies a proportional voltage to the trailers brakes. When
properly adjusted the trailer will decelerate at the same speed as the
tow vehicle. This increases braking efficiency and reduces brake wear. A
big advantage of the pendulum style controller that it will operate well under adverse
braking conditions and have a smooth braking action. Although most
pendulum style controllers are bulky, more
expensive and must be mounted and calibrated level, there are
exceptions such as the new generation controllers like Tekonsha Prodigy.
TIME DELAY controllers operate the trailers brakes at a
pre-determined braking rate. These controllers are designed to activate
the brakes at a set delay from when the stoplights are activated. In
some instances the rate of brake application is no different for a
gradual stop to that of an attempted emergency stop. It is important to
note that while time delay controllers provide some braking, it does
not provide the most efficient balanced braking for the combination of
car and trailer. Time delayed controllers are
inexpensive, have a low profile, and can be mounted on any angle.
MOTION SENSING CONTROLLERS
The Prodigy is a
technologically advanced controller. Even with its pendulum
based output it requires no levelling and is equipped with a
self-adjusting sensing device to compensate for varying terrain. Its
digital display illustrates the voltage level delivered to the trailers
brakes whilst driving and also reports any electrical fault conditions
such as power loss, short circuits. It has a plug in wiring
harness for easy removal and a unique pocket mounting for flexible
options. This unit has a variable power level that is further
complimented by a boost feature for incremental power.
Tekonsha
Voyager
The
Voyager unit is a pendulum based controller with an indicator
light to confirm that the trailer is connected and the circuit is
complete. The indicator light also changes colour as an indication of
the amount of power going to the trailers brakes. The Voyager controller
has a manual-braking slide lever and variable gain
control. It provides smooth braking but can be a bit fiddly to
adjust.
Tekonsha
Primus
The Primus has a totally proportional electric trailer brake control
applying power to the trailer brakes in proportion to vehicles
deceleration . It utilizes the primary sensor technology from Prodigy
and features a one step set up system allowing the driver maximum
flexibility when determining how the trailer should respond to a braking
event. Snap in dash mounting clip and removable electrical connector
allow unit to be quickly stored when not in use. It shows a digital
readout depicting a secure electrical connection and the amount of
voltage delivery to the trailer brakes.
Tekonsha
Sentinel
The Sentinel is the product of extensive consumer research by Tekonsha.
It is inertia activated using integrated circuitry for safe, smooth
stops. The ergonomic design allows contour installation on dash for
maximum visibility with comfortable access to the manual override slide
lever. The LED power delivery display shows the amount of current
delivery to the trailer brakes and glows green when a complete
connection is made to the trailer.
Tekonsha
Envoy
The Envoy is built with simplicity and reliability in mind. It's easy to
install and easier to set and use & easily adjustable to accommodate
different trailer weights. Envoy is equipped with a inertia activated
sensor that detects the tow vehicles rate of deceleration and applies
proportional braking to the trailer. It has a pivot mount & is ideal
for installation in newer model tow vehicles.
AccuPower
AccuTrac
The AccuTrac is an inertia activated brake controller.
The AccuTrac is especially suited for constantly changing load
conditions as. The dual action slide
controls allow customized stopping power both in town and on the
highway. It features dual brake action setting controls, solid state
electronics, easy to set up and adjust, positive LED indicator confirms
brake connection.
AccuPower DigiTrac II
The AccuPower DigiTrac II is a good choice for your constantly changing
heavy load conditions. It is able to detect the difference between a
gradual deceleration like slowing to a traffic light and the stopping
power required when braking for an unexpected event. It's advanced
electronics and patented Inertia Sensing System are designed for
consistent and predictable stopping power. The Inertia Sensing System
uses two separate power delivery controls - one for the "around town"
gradual stopping and one for the urgent sudden stops.
Hayes Lemmerz
Energize III
The Energize III unit is a simple to use pendulum based
controller. It has a manual pendulum level which is highly visible and
easy to set. A roller gain wheel allows easy tuning of braking quantity
and the manual braking slide overrides gain settings for full emergency
braking. An LED indicator light intensifies as braking power increases,
which is a useful control feature. It is simple, reliable and provides
smooth brakes.
Hayes Lemmerz Endeavor
The Endeavour is an advanced Energize III. It has a manual pendulum
level but the digital readout guarantees a precise set. An
increase/decrease button sets braking levels and a digital display
indicates the amount of power being sent to the caravan brakes. The
digital display also provides visual warning of several fault
conditions, including current limit and short or open circuit. The easy
to use manual override slide operates independently of the power setting
to allow full braking output when desired.
AccuPower Pilot
The AccuPower Pilot mounting options are very flexible as you are
able to mount it in any direction even upside down. It has a large
digital two-digit display making it easy to read the the voltage output to brakes (vs. a percentage output)
as well as connection to the trailer.
Features include
microprocessor allowing control to be mounted upside down and still have
a readable display, protection against short circuit and loss of ground
& with an optional ball mount available.
AccuPower POD
The POD (Power On Demand) can
be mounted in any direction, even upside down. It features solid state
electronics, power on LED for a positive tow vehicle to trailer
connection & manual over-ride controls.
Hayman Reese
 The Hayman Reese
controller features simple operation, slim design and unlimited mounting
positions. Not being a pendulum based
controller its power level is varied by adjusting the Sync and Output
controls on the unit. The sync relates to the timing of the brakes,
(advanced or delayed) and the output level control adjusts
the power. Because there is no internal pendulum sensor the Hayman Reese
controller will deliver the same braking performance every time you
apply the vehicle brakes which limits its ability to deliver smooth and
effective braking in all stopping scenarios. The unit also has a manual control that allows
variable independent application of the trailers brakes.
Redarc
The
Redarc is a miniature solid state controller which provides a smooth and
progressive brake application when the vehicle brakes are applied.
Adjustable braking force is by a finger tip rotary control, while a
manual switch provides manual override to operate the trailer brakes and
brake lights without applying vehicle brakes. The intensity of the
braking depends on the position of the sensitivity adjustment. An LED
indicator advises operating mode by changing from green to red as
braking force is increased.
ATS 
All
Trailer Spares in Brisbane have their own electronic in house brand
brake controller which is suitable for mounting in the vehicle.
GLS Electronics have their XLE12 which is a compact sized electronic
brake controller, suited to be mounted in any position. Operation is
reliable even on the roughest of roads. Brake pressure is adjusted via a
control knob.
A FEW
DEFINITIONS
ATM (Aggregate Trailer Mass)
The total laden weight of a trailer, which includes the tow ball
mass and whatever you add as payload (eg. water, gas, luggage). The ATM
is specified by the trailer manufacturer and must not be exceeded.
GCM (Gross Combination Mass)
The maximum laden mass of a motor vehicle plus the maximum laden
weight of any trailer it can tow. The GCM is specified by the vehicle
manufacturer.
GTM (Gross Trailer Mass)
The total permissible mass which includes whatever you add as
payload (eg. water, gas and luggage) that can be supported by the wheels
of a trailer. This does not include the mass supported by the tow ball.
The GTM is specified by the manufacturer and must not be exceeded.
Tare Mass
The unladen weight of the trailer.
Tow Ball Mass
The weight imposed on the rear of the tow vehicle's tow ball from
the coupling of a trailer or caravan.
Payload
Payload is specified by the manufacturer. It must not be exceeded
under any circumstances. Safety, insurance & warranty may be affected if
the specified payload is exceeded.
Info by Rob
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