"I've tested the BrakeSmart trailer brake controller many times with Andrew Lyons of Transwest Truck Trailer RV. Trailer brakes have come a long, way and the BrakeSmart is the leader in improving your safety, your horse's safety and comfort as well as the rest of the population you share the roads with. Trailer brakes are often neglected until there is problem. I've spent too much time with a flashlight in my mouth, sometimes in the rain, working on my trailer brakes, magnets, wiring, and fuses after I discovered my brakes weren't helping any. Heavy loads and shifting animals require that everything works, and surprises can be deadly. You won't find a better product for dependable brake and whole trailer management. BrakeSmart can put your trailer at the same level of technology that your enjoy with your new truck."
- Mr. Truck

About BrakeSmart

No other controller can boast the features of the BrakeSmart. The BrakeSmart controller configures itself automatically to provide the smoothest, fastest response and most proportional truck to trailer brake response possible. Trailers with electric brake systems perform better than with any other brake controller. BrakeSmart reads the actual electrical current required by the trailer brakes. As heat builds in the trailer brakes, the BrakeSmart compensates by increasing the voltage to maintain constant trailer braking force. This feature reduces the common brake fade experienced in electric brake systems using conventional electric brake controllers.

The BrakeSmart controller detects the type of brake system on the trailer. Electric brakes or hydraulic brake systems are controlled optimally by BrakeSmart. Even the gain settings are automatically retained for differences in electric and hydraulic brake systems. And, since the BrakeSmart reads actual truck brake system pressure, annoying gain adjustments for loaded or unloaded trailer conditions are eliminated. Ease of use is one of the remarkable features of BrakeSmart.

The BrakeSmart controller gives you a proportional trailer brake in relation to your tow vehicle. It achieves this by utilizing a pressure sensor mounted at the master cylinder that measures the output pressure of your tow vehicle. The pressure sensor utilized is compatible with all ABS systems used for any tow vehicle. It does not displace any brake fluid and it is the same sensor that many manufactures use in their Vehicle Dynamic Control systems for ABS. This measurement is turned into a signal and sent back to the actuating system on your trailer brakes. This is all accomplished using microprocessors; there are no pendulums or accelerometers in the BrakeSmart. The BrakeSmart controller easily attaches to the dash and is a truly intelligent computer brake controller for both hydraulic and air brake tow vehicles. Just choose the appropriate wiring harness kit for your vehicle and you're ready to go.

BrakeSmart provides a unique approach to trailer brake gain setting. Other brake controllers simply limit the ultimate available brake voltage signal to the trailer brakes as the gain setting is reduced. BrakeSmart changes the rate of application of the trailer brake as compared to the towing vehicle. Unlike other controllers, BrakeSmart is capable of applying full brake voltage to the trailer even when the gain is set to the lowest setting. BrakeSmart also remembers gain settings between electric brake trailers. BrakeSmart eliminates the annoying frequent gain adjustments necessary between loaded and unloaded trailer conditions. Since a full trailer brake is always available at any gain setting, BrakeSmart provides a safety factor no other electronic brake controller possesses.

The graph shows the relationship of the towing vehicle hydraulic brake pressure and the trailer brake signal. At 50% gain setting (the recommended initial gain setting) the trailer brake response is scaled from zero voltage output to full brake output between zero psi truck brake pressure and 1000 psi truck brake pressure. At maximum gain, the scale is from zero to 500 psi truck brake pressure. At minimum gain, the scale is from zero to 1500 psi truck brake pressure. BrakeSmart has 8 gain settings from minimum to the 50% level and 8 gain settings from 50% to the maximum gain setting. With 16 available gain settings, BrakeSmart provides the most proportional truck brake to trailer brake response available.

The BrakeSmart display may be customized to the user's preference. The top line of the BrakeSmart can display a custom message of up to 16 characters that represent a unique personalized message. For instance, "BrakeSmart" can be replaced by a users name or perhaps an organization name. Any message up to 16 characters may be displayed. All entry is accomplished by the keyboard interface.

BrakeSmart Features

Brake Detect - Automatically detects Electric or Electric/Hydraulic brake system connections.
Axle Detect - Automatically detects the number of axles when connected to Electric Brakes.
Brightness Control - Three levels of brightness control for cab usage, non-glare screen.
Custom Display Message - Custom 16 character message set as you like.
Stop Light - Automatically turns on the stop light during operation.
Gain Control - Fine tune Gain Control adjustment for a precise stopping pressure.
Test Mode - Runs a test mode to check brake connection for shorts.
Date, Time & Display - Display the Date, Time and Day in 24 Hour or AM/PM mode

The BrakeSmart is microprocessor controlled, it consistently matches tow vehicle and trailer braking requirements, reads the brake-line fluid pressure for the smoothest and best modulation, has sixteen gain settings for fine adjustment of system current, provides a manual override allowing for finger application of the trailer brakes, and compensates automatically for hot electric brake drag. This feature increases the life and responsiveness of your Electric Brakes.

BrakeSmart - Control Buttons

The four buttons on the left provide the operator access to all adjustments and system information on the BrakeSmart Controller and brake actuator. There is also a manual "thumb brake" on the right side (red button) that can be used anytime to apply trailer brakes.

Why is the BrakeSmart compatible with electric/hydraulic brake actuating systems?

The BrakeSmart was originally designed to be used with electric over hydraulic actuators. The BrakeSmart can handle the fly-back current that these systems produce. The superior, top drawer electronics used in the BrakeSmart gives it capacities that no other controller can match.

The BrakeSmart enhances these systems because we measure the brake pressure of the tow vehicle then give a signal (voltage) that is proportionate to both this pressure reading and what the trailer is asking for. All of this is independent of pedal travel, vehicle or controller attitude.

Resetting the Unit

Press the "M" and the "E" buttons simultaneously to manually reset the BrakeSmart.

Electric Brake Calibration

Note: This procedure is necessary only if your trailer does not have 2 axles. Ensure the tow vehicle and trailer is stopped. Please complete this procedure every time you connect the trailer. This will enable the auto-compensate mode to stop electric brakes from fading during braking operation.

Stop the tow vehicle, connect the trailer, and turn on the motor.
Push and hold the red thumb button all the way down for 2 seconds. The display will update and show the "CALIBRATION DONE" message.

Unique BrakeSmart Features

The BrakeSmart is a truly "set it and forget it" trailer brake controller. The ability to measure the tow vehicle output brake pressure and then turn that data into an appropriate signal for the application, makes this controller second to none! Every 2 minutes the BrakeSmart performs a total system diagnostic test. Its microprocessors perform over 2000 computations per second! As the BrakeSmart is executing an instruction, it is acquiring a command. It's a pretty busy guy. But this is only scratching the surface. The BrakeSmart's microprocessors have the ability to perform 4 million computations per second! That's power for the future!

Trailer Compatibility

The BrakeSmart is compatible with any trailer that has electric brakes. In addition, it is one of the only controllers that will work with electric/hydraulic brake actuators. It will work with any trailer out there, from one axle to four and even more with reprogramming. Travel trailers, Horse and Livestock trailers, 5th Wheel RV and Gooseneck RV trailers, Equipment and Cargo trailers, Car Haulers, Boat and Transport trailers. Intensity adjustments: When the display is in the default mode, simply adjust the arrow keys up or down to adjust the brightness.

Amps & Volts Mode

In this mode the BrakeSmart displays the measured amperage and voltage under load. If a problem is detected in either, a visual and audible alarm will be present. A reading of 10 volts or less will kick in a warning. The BrakeSmart automatically detects the number of axles on your trailer.

With optimum wiring and connections for an electric brake trailer, you should show amperage readings accordingly:

1 axle trailer - 5.8 - 6 amps
2 axle trailer - 10.8 - 12 amps
3 axle trailer - 15.5 - 18 amps

General rule of thumb is 6 amps per axle, 3 amps per wheel/magnet.

The BrakeSmart Command Menu

Adjust The Brake Controllers Gain

Use this feature to set gain mode. BrakeSmart has 8 gain settings from minimum to the 50% level and 8 gain settings from 50% to the maximum gain setting. With 16 available gain settings, BrakeSmart provides the most proportional truck brake to trailer brake response available. There is an optimum setting for any truck to trailer combination. The BrakeSmart is programmed with a gain setting of 50% from the factory. Most people find that there is no need to adjust from this point.

Set Initial Brake Constant

The default setting for the "Initial brake constant" is 26 without a trailer attached. If your trailer has electric brakes and when you attach it, the value should be right around 20. This feature allows you to adjust the initial voltage that is sent back to your trailer brakes as soon as you have a brake action. The "Initial brake constant" is a voltage figure being assigned a value. The value being assigned is in brake pressure. For instance, if you tap on your brakes just enough for the brake lights to come on with the "IBC" at 26, the first PSI reading on the BrakeSmart display should read right about 51 psi. What is being "said" is that with a setting at 26, voltage is being sent to your trailer brakes that is equal to 51 psi. You can increase or decrease the "IBC" with the result being a harder or lighter initial brake action as soon as your stop light circuit is activated, your initial brake action. This feature is helpful in "balancing" the truck and trailer brake action especially with bumper pull type trailers.

Set Time of Day

This feature allows you to set the time of day.

Set Today's Date

This feature allows you to set the Month, Day, and Year.

Enter Your Own Custom Message

You can enter a personal message of up to 16 characters. Your custom message will be displayed along with the Day, Date, and Time when the BrakeSmart is in the default screen mode. You can choose from a variety of symbols, both upper and lower case letters, and numbers. Simply "arrow up or down" to scroll through letters, numbers, & symbols until you find the one you want. Then press "E" which will move the cursor to the right one space. Repeat until you have up to 16 characters or blank spaces.

Set Power Off Delay

You may adjust the time allowed before the display screen goes blank when there has been no activity such as a brake application. The BrakeSmart is programmed with a power management system that automatically shuts down power to the display after a period of time. The power off delay time is adjustable through the menu from 30 minutes to 5 hours in thirty minute increments. This reduces the battery drain from less than one ampere to a few thousands of an ampere. Any activity will bring the display back on.

Press Enter for Power Save Mode:

You may instantly turn off the display with this feature. This does not disable the controller. Your trailer brakes will continue to function if applied. This function is most commonly utilized during long stretches of night driving. After adjusting the intensity level you may still find the display too bright. The display will come back on as soon as there is any activity such as a brake application.

Set Pressure Sensor

The BrakeSmart can be used with both hydraulic and air brake tow vehicles. There are two types of pressure sensors, hydraulic & air, each of which are included in the appropriate wire harness kit. For hydraulic brake tow vehicles choose 2000. For air brake tow vehicles choose 150. There was an earlier version of the pressure sensor that was scaled to 1500 psi. All current kits are using the 2000 psi sensor. The BrakeSmart controller will now recognize the appropriate sensor.

Fuse Test Mode

This design feature will alert you if the 15A fuse in the back of the BrakeSmart has blown. This fuse is on the Brake Light Circuit only. Your BrakeSmart controller will continue to work if this fuse is blown. This is to alert you that the circuit is being overloaded possibly by other lights.
Note: If you have LED lights on the Brake Light Circuit, turn this function to Off. LED lights may flash when the BrakeSmart is running it's system check every 2 minutes.

Set Beeper Mode

Allows you to turn on or off the audible alarm. If an error is detected, an initial visual and audible alarm will commence. The audible alarm will then go into a cycle mode. You may find that it will be some time before you can investigate. This feature allows you to turn off the audible alarm which may become distracting. The visual alarm will remain.

Set Pump Mode

This is to be set to "On" only if you have an Ausco brand trailer brake actuator on your trailer. There is a value of 1.0. This can be scaled between .1 and 2.0. This feature immediately applies full brake for the corresponding time in seconds when you have a brake application. This allows the Ausco unit to "wake up" and thus decrease the lag time between brake action and application. A value of 2.0 is the maximum setting recommended.

Set Power Factor

Think of this as a very fine tuned gain adjustment, a voltage tuning mechanism. The unit is programmed from the factory at 1.0. This scale can be adjusted in increments from .5 to 1.5. Most users will never need to adjust this setting. Always adjust the Brake Controller Gain first. What this function does is limit or increase the amount of maximum brake you can achieve. Roll it down past 1.0 and essentially maximum brake availability will not be achieved. Raise this up past 1.0 and you will achieve maximum brake at a lower brake pressure, essentially achieving maximum brake faster.

Manual Button Gain Percentage

You can actually adjust the gain setting for the manual thumb control from 30% to 90% in increments of 5. Remember that the manual control is separate from the pressure sensor at the master cylinder. The brake achieved by the manual control is only proportionate to how far you depress the manual control.

Set EGT Cutoff Temperature

An EGT and Turbo boost module is in the works and will be available soon. This function will allow the user to set the maximum temperature at which the exhaust gas will reach before an alarm is set off.

After a short absence, the BRAKESMART is back and better than ever! The BrakeSmart is truly an "install it and forget it" brake controller.