Trystan Casey
Testing an electric brake controller can be done in several ways. One common method is to use a circuit tester like the PTW2993, with one pin grounded and the other on the output pin. You can then hit the brake pedal and observe the brake controller's operation. Alternatively, you can test without a trailer by setting your multimeter to DC and checking for voltage readings when the controller is manually activated. If you're experiencing issues with your trailer brakes only working with the manual override lever, the solution often lies in the red wire of the brake controller. Additionally, when testing without a trailer, driving at a slow speed (around 5 MPH) on a dirt road and applying only the trailer brakes can help you examine if each wheel is contributing to the braking effort by observing dirt piles in front of the wheels.
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What You'll Learn
Testing without a trailer
Testing an electric brake controller without a trailer can be done by checking for a slight amperage draw on the output circuit. This can be done using a circuit tester or a multimeter.
If using a circuit tester, sever the blue brake output wire near the brake controller, leaving enough room to reconnect it, and then apply the manual slide. You should get output to the controller side of the wire you severed. If the manual slide activates the trailer brake output wire properly, try the brake pedal. If the brake pedal also activates the brake output, then the problem is likely in the vehicle wiring.
If using a multimeter, set it to DC. You should see no voltage when the controller isn't being manually activated, except for a periodic blip on some models, which is used to verify when a trailer is connected. If you have the voltage turned all the way up, you should see 12+ volts at the pin when the manual override paddle is fully engaged. If you test it by pressing the brake pedal, you'll see a much lower voltage, usually 1.5-4 volts.
For Tow-Pro Elite products, the procedure is slightly different. The Tow-Pro will need to be put into the green User Control mode. With the test light connected between the blue and white wires at the Tow-Pro module, press and hold the brake pedal. The dial colour will change from green to red light, and the test light will illuminate. Rotate the dial from 0 to 10 for a gradual increase in brightness on the globe/test light, confirming correct operation.
It is important to note that a multimeter or LED test light may not be suitable for testing an electric brake system as it may not supply sufficient load to the electric brake circuit. Instead, an incandescent globe or test light can be used to simulate a load like a trailer with electric brakes attached.
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Using a multimeter
Firstly, ensure your multimeter can read amps and ohms, and set it to the ohms setting, represented by the Omega symbol (Ω). You will also need to turn on your car. Next, place the negative probe on one of the brake magnet wires and the positive probe on the other wire. The brake magnet wires have no polarity, so you can place the probes anywhere on the wires. Now, you need to measure the amount of current coming from the connector to the brake wires. If you get any ampere reading, there is an internal short in the brake magnet, and it needs to be replaced. If the reading is below or above the specified resistance range for your brake magnet size, the brake is faulty and needs to be changed.
You can also use the multimeter to check for voltage drops across connections. This will help identify any poor connections, which could be caused by corrosion or damage. Additionally, you can use the multimeter to test the trailer brake wiring between the brake controller and the brake magnet. This will help determine if the controller or wires are faulty.
It is important to note that while a multimeter can help identify some issues, it might not be sufficient for a comprehensive diagnosis of an electric brake system. Further testing may be required, and other tools, such as circuit testers or specialised equipment, might be needed.
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Using a circuit tester
Firstly, it is important to understand that a circuit tester simulates a trailer connection by creating a slight amperage draw on the output circuit. This tricks the brake controller into thinking a trailer is connected, allowing you to test its functionality. Ensure you have a suitable circuit tester, such as the Quickee Tester (Part # 3808) or PTW2993, for this purpose.
Before beginning the test, ensure that the brake controller is properly connected and grounded. Check for any signs of corrosion or dirt on the connector, as this could lead to connection issues. Once you are satisfied with the connections, proceed to the next step.
For the test, you will need to sever the blue brake output wire near the brake controller. Make sure you leave enough room to reconnect it later. Now, with the circuit tester connected, activate the manual slide. You should observe output on the controller side of the severed wire. If the manual slide successfully activates the trailer brake output wire, move on to the next step.
With the circuit tester still connected, press the brake pedal. If the brake pedal successfully activates the brake output, it indicates that the brake controller is functioning correctly. In this case, the issue is likely further back in the vehicle wiring or on the trailer itself.
However, if either the manual slide or the brake pedal fails to activate the respective outputs, further testing is required. You will need to test the wires going into the brake controller. Check if there is power entering the brake controller on the black wire. On the red wire, power should only be present when the brake pedal is pressed. If there is power on the red wire before pressing the brake pedal, it indicates an incorrect connection to the wrong circuit.
In conclusion, using a circuit tester is a straightforward method to troubleshoot issues with an electric brake controller. By following these steps, you can systematically identify whether the issue lies with the brake controller itself or other components in the system. Remember to exercise caution when working with electrical systems and always ensure a safe working environment.
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Testing with a trailer
Testing an electric brake controller with a trailer requires a few simple steps. Firstly, it is important to note that there are different types of brake controllers, such as time-delay and proportional or inertia-based controllers, and different testing methods may be required depending on the type of controller. For example, if you have a proportional mode electric brake controller, you may need to change it to "User-Controlled" mode for the test, as most proportional brake controllers will not apply power to the trailer brakes when the vehicle is stationary.
To test the brake controller, begin by setting up the controller according to the manufacturer's instructions, taking into account the load size, braking sensitivity, and any personal settings. Then, you can manually activate the trailer brakes using the manual activation button, which is a feature of most trailer brake controllers. This allows you to test the brakes without applying the vehicle brakes.
If you suspect an issue with the brake controller or the trailer brakes, there are a few methods you can use to diagnose the problem. One method involves using a multimeter to test the trailer brake wiring between the brake controller and the brake magnet. Connect one probe to the blue wire coming from the connector plug and the other probe to one of the brake magnet wires. With the car powered on, activate the brakes through the pedal or electric control panel. Note that you may need assistance for this step. Check if you are getting the correct amount of current as specified for your brake system. If the current is above or below the recommended specification, it could indicate an issue with the controller or the wires.
Another method to test the trailer brakes is to use a circuit tester. Sever the blue brake output wire near the brake controller, leaving enough room for reconnection, and then apply the manual slide. Using a circuit tester, you should observe output on the controller side of the severed wire. If the manual slide activates the trailer brake output wire, try using the brake pedal. If the brake pedal also activates the brake output properly, the issue may lie in the vehicle wiring or trailer, rather than the brake controller.
By following these steps and methods, you can effectively test an electric brake controller with a trailer and identify any potential issues with the brake controller or the trailer brakes.
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Testing with a test light
When testing an electric brake controller with a test light, it is important to note that a multimeter or LED test light does not supply sufficient load to the electric brake circuit to successfully test the system. Instead, an incandescent globe or test light should be used.
To begin the test, the Tow-Pro remote must be put into the green User Control mode. Then, with the test light connected between the blue and white wires at the Tow-Pro module, press and hold the brake pedal. If the test is successful, the dial colour will change from green to red light, and the test light will illuminate.
Next, rotate the dial from 0 to 10 to observe a gradual increase in brightness on the globe/test light, confirming the correct operation of the Tow-Pro. Once normal operation is confirmed, the unit can be switched back to your preferred mode and adjusted accordingly.
Additionally, with the test light still connected between the blue and white wires, press the override button by depressing the Tow-Pro remote. Again, observe the dial colour change and the illumination of the test light. Rotate the dial from 0 to 10 while depressing the override button to ensure a gradual increase in brightness, confirming the correct operation of the Tow-Pro.
It is important to note that this test procedure may be easier with a second person assisting.
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Frequently asked questions
You can test your brake controller by using a circuit tester like the PTW2993. With one pin grounded and the other on the output pin, hit the brake pedal of your vehicle and the controller should operate normally.
If your brake controller isn't working, it could be an issue with the controller itself, or something in the truck like the connector or trailer. You can test the controller by severing the blue brake output wire and using a circuit tester to check for output to the controller side of the wire.
Drive slowly (around 5mph) down a dirt road with your brake controller set to a strong setting. Apply only the trailer brakes and let the trailer come to a stop. Check each trailer wheel for a small pile of dirt pushed up in front, which indicates that each wheel is contributing to the braking effort.
