user manual - trailerpartsnz · 2017. 11. 9. · once brake commander is installed, fittedwith a...

USER MANUALR2-04-0

MultiVolt 12-24V

Contents4 Overview4 Brake Commander

5 Wireless Remote

6 Using Brake Commander6 Powering Up Brake Commander

6 The Wireless Remote

7 Disengaging the Park Brake

7 Powering Down Brake Commander

8 Brake Commander Installation8 Choosing the Mounting Location

9 Mounting to the Trailer

10 Attaching a Master Cylinder

11 Electrical Overview

11 ElectricalSpecifications

12 Electrical Connections

13 Auxiliary Circuit Test

13 Tail Light Circuit Test

13 Brake Light Circuit Test

14 Connecting a Break-Away Switch

14 Break-Away Circuit Test

15 Wireless Remote15 Charging the Wireless Remote

15 Turning the Wireless Remote ON and OFF

16 Connecting a Wireless Remote

17 Status Icons

18 Settings Menu

21 Functions

22 LED’sandWarnings22 BrakeCommanderLED’s

23 Wireless Remote Warnings

Overview

Brake Commander

Wireless Remote

Using Brake CommanderOnceBrakeCommanderisinstalled,fittedwithamastercylinderandtheWirelessRemoteis plugged into a USB power source, Brake Commander is ready to be used.

The Wireless Remote features Instant ON technology, thus it only needs to be pre-charged if it is intended to be used in situations that do not permit connection to a USB power source.

Powering Up Brake CommanderPower-upBrakeCommander by connecting your trailer’s electrical connector to the towvehicle.Turnyourvehicle’sParker’sorHeadLightsON.Ittakesapproximately2minutestofullychargetheBrakeCommander.IfyourtowvehicleisfittedwithanAuxiliarycircuit,youdon’tneedtoturnonyourlights.Tocheckpowerisbeingsupplied,thePowerLEDontheBrake Commander should be ON.

During the power-up, Brake Commander establishes a wireless network and performs a series of system checks. If the Brake Commander was previously left with the Park Brake On or the Break-Away active, the system checks will be performed once the condition is cleared.

The system checks may take up to 60 seconds to complete. If they are interrupted by a braking event (pressing the brake pedal in your tow vehicle or the OveRide button on the Wireless Remote), the start-up routine restarts once the interrupting condition is removed.NOTE If during the power-up, the system checks detect any issues, the Wireless Remote will display a status icon and warning message. Refer to page 17 for status icon details and pages 23 through 25 for warning messages.

NOTE A Low Power warning will be active for the first few minutes after powering up Brake Commander - this is normal and will clear once the Capacitor Banks have been sufficiently charged for 1 minute.

The Wireless RemoteConnecting the Wireless Remote to a USB power source will turn it ON, it will then begin periodically searching for a Brake Commander. The Wireless Remote will automatically join thefirstBrakeCommanderitfinds.TheBrakeCommanderwillnotpermitadditionalremote’sto join simultaneously.

TheWirelessRemote’sscreendisplaysBrakeCommander’sstatusasaniconaswellasany warning messages that may prevent Brake Commander from operating correctly.

When connected to a Brake Commander the Wireless Remote will enter “sleep” mode after 20 seconds of inactivity.

The Wireless Remote can be woken from sleep, by pressing either the “+” (plus), “-” (minus) or “Override” buttons. Additionally the Wireless Remote will wake from sleep when the brakes are used or a warning is activated.

The Wireless Remote can only be turned OFF when it its no longer connected to a Brake Commander. To turn off press and hold the “-” (minus) button until the screen goes black.

Brake Commander OperationWiththeBrakeCommanderpoweredbytheHeadlightsandtheWirelessRemoteconnectedto the Brake Commander. The system will provide proportional brake response in relation to

the rate of deceleration.

When stationary, if the bakes are operated. Brake Commander will only provide a minimal brake response as there is no deceleration.

The Sensitivity or “Gain” can be adjusted independently in both the forward and reversing directions. The Sensitivity allows the brake response to be tuned to suit the weight of the trailer and/or the drivers personnel preferance. Ideally the sensitivity should be set so as the tow vehicle and trail feel to brake equally. To achieve this:

• While driving slowly in a safe area

• Set the forward sensitivity to an initial value, 40% is a good starting point.

• Brake lightly at a constant rate, check if the trailer brakes can be felt.

• Repeat the test until the trailer brakes are just felt to be braking harder than the tow vehicles.

• Then reduce the forward Sensitivity by approximately 5%.

All settings are stored in the Brake Commander device, if a new or different remote is connected, it will access the values stored in the device.

If the Wireless Remote is lost or damaged the braking system will continue to provide braking, howevertheminimumbrakeresponsewillbesignificantlyhighersoastoactasawarningtothe driver that a remote is not present. Operating in this condition is not recommended and should be resolved as soon as possible.

If the driver forgets to turn the lights ON or there is an electrical fault preventing the normal power supply, Brake Commander will be charged every time the driver usesthebrakes,oncesufficientlycharged,thebrakingsystemwillprovidebraking,howevertheminimumbrakeresponsewillbesignificantlyhighersoastoactasawarning to the driver of the condition. Operating in this condition is not recommended and should be resolved immediately.

Brake Commander provides a Park Brake function that can be used in temporary conditions only. The park brake function can applied by double clicking the “+” (plus) button and released by double clicking the ”-” (minus) button. The function canbeappliedorreleasedwheneverthedeviceissufficientlycharged.Additionallyoperating the Brakes will release the Park function automatically.

Brake Commander InstallationBrake Commander is an Electro-Mechanical trailer brake controller. Brake Commander is bolted to the trailers frame and a hydraulic master cylinder is attached. Brake Commander iswiredintothetrailerswiring,thereforenospecificwiringisrequiredforthetowvehicle.

Once installed Brake Commander uses built-in sensors and electronics to provide proportional line pressure to the trailers brakes.

Choosing the Mounting LocationBrakeCommanderisintendedtobemountedonthetrailer’sdrawbarareaandonalevelsurface such as the TOP FACE of a draw bar or cross member.

Brake Commander can be mounted at any angle relative to the direction of travel when viewed from above.

If considering mounting Brake Commander inside the boot of a caravan or a tool box etc, it is recommended to check the wireless signal strength before mounting.

Brake Commander is weather resistant, however DO NOT mount the device in a position that will allow Brake Commander to be submerged in water.

Mounting to the Trailer4x mounting holes have been provided for attaching Brake Commander to the trailer. The drawing below indicates the size and location of the mounting holes.

Brake Commander can be secured to the trailer by directly bolting it to the trailer frame. Alternately Brake Commander can be bolted to a sub plate that is in turn secured to the trailer by means of welding or bolting. DO NOT weld Brake Commander directly to the frame of the trailer.

Attaching a Master CylinderBrakeCommanderoperatesthemastercylinderbypushingdirectlyonthemastercylinder’spiston. To install the master cylinder, remove any rubber boots and linkages, ensure the clip that retains themastercylinder’spistonfitscomfortablyoverBrakeCommander’spiston.Measure the available stroke of the master cylinder, then bolt the master cylinder to the mounting boss. A gasket compound may be used to seal this connection.

NOTE The available stroke of master cylinder is required for the stroke parameter in the Wireless Remote’s Setup menu.

When Brake Commander is powered up, the start up routine will automatically locate the master cylinders piston and calibrate the Start Point. Once the start up routine is complete, theSTATUSLEDwill beON.Refer to theWirelessRemote’sFunctions on page21 fordetails on how to re-run the start up routine if required. Connect hydraulic lines and braking system as required. For assistance in bleeding the brakes refer to the Functions on page 21.

Electrical OverviewBrake Commander is connected to the Earth, Tail Lights, Auxiliary, and Brake Light Circuit of thetrailer’swiring.ForBreak-AwayfunctionalityaBreak-Awayswitchmayalsobeconnected.

Brake Commander supports 2 sources of power supply, Auxiliary and Tail Lights. When towed by vehicles with an active Auxiliary pin, Brake Commander will draw its power from the Auxiliary Circuit. If power is not available on the Auxiliary Circuit, Brake Commander can bepoweredbyswitchingthevehicle’slightstoParker’sorHeadLightstoprovidepoweronthe Tail Light Circuit.

NOTE When initially charging the Brake Commander 12-24v units, the charge rate will begin at a reduced amount (< 0.5amps). Once the Capacitor Bank reaches a preset value the current draw will increase to the full charge rate. During this stage the remote will indicate “Low Power”.

ElectricalSpecifications

System VoltageNominal 12.0 - 24.0 VMaximum 32.0 VMinimum 9.0 V

Current RatingsEarth Max 6.5AAuxiliary Max 6.5AHeadLights Max 6.5ABrake Lights Max 6.5ABreak-Away <100mA at 12.0V

Wiring ColoursEarth WhiteTail Lights BrownAuxiliary GreenBrake Lights RedBreak-Away Yellow

Electrical Connections

Wire in the Earth, Auxiliary, Tail Lights and Brake Lights ensuring that each wire is connected to the corresponding circuit on the trailer.

NOTE If wires are not connected correctly, Brake Commander may be irreversibly damaged when powered up.

NOTE Brake Commander recommends using a 12V power source such as a small motorbike battery and test leads to test the wiring connection’s. Alternatively if you are confident that the electrical connections are correct, you may use the tow vehicles standard connection as the source for the 12V power.

NOTE If Break-Away is not required, leave the Break-Away (yellow) wire unattached; DO NOT connect to earth or any other electrical circuit.

The Wireless Remote is required for functionality during the testing procedures. Refer to page 15 for details about charging the Wireless Remote and turning it on.

A master cylinder should be attached prior to conducting the following tests.

Auxiliary Circuit TestOncesatisfiedall4wiresareconnectedcorrectly,usinga12Vpowersource;1. Connect“NEG”tothetrailer’sEarthCircuit.

2. Connect“POS”totheAuxiliaryCircuit.BrakeCommander’sPOWERLEDshouldimmediatelyturnON indicating the Auxiliary Circuit is operating correctly.

3. The POWER LED will turn OFF immediately when the 12V power source is removed.

NOTE At this stage Do Not leave the power source attached for longer than 10-20 seconds, this prevents the start-up routine running and various warnings from being generated. If the power source is left on, the start-up routine will run and warnings such as No Power Supply will be generated when the power source is removed. Any warnings will not be cleared until the condition has been rectified.

NOTE The important test at this point is that the POWER LED is turning ON when 12V is connected to the Auxiliary Circuit. If the POWER LED does not turn on, check the wiring for any problems.

Tail Light Circuit TestAspertheAuxiliaryCircuitTestabove,usinga12Vpowersource;1. Connect“NEG”tothetrailer’sEarthCircuit.

2. Connect“POS”totheTailLightCircuit.BrakeCommander’sPOWERLEDshouldimmediatelyturnON indicating the Tail Light Circuit is operating correctly.

3. The POWER LED will turn OFF immediately when the 12V power source is removed.

NOTE At this stage Do Not leave the power source attached for longer than 10-20 seconds, this prevents the start-up routine running.

NOTE The important test at this point is that the POWER LED is turning ON when 12V is connected to the Tail Light Circuit. If the POWER LED does not turn on, check the wiring for any problems.

Brake Light Circuit TestTo test the Brake Light Circuit, connect the 12V power source to the Tail Light Circuit as per the Tail Light Circuit Test, however this time leave the 12V power source connected. 1. Allow Brake Commander to charge for 2 minutes. During this time a connection with the Wireless

Remote will be established (if a connection is not automatically established within 2 minutes refer to page 16 for details on connecting a Wireless Remote).

2. As soon as a connection with the Wireless Remote is established and the Capacitor Bank is sufficientlycharged,astart-upprocedurewillrun.Waitforthestart-upproceduretocomplete.

3. Connect the 12V power sources “POS” to the Brake Light Circuit. You should immediately hear Brake Commander start as it attempts to apply line pressure to the brake system. Brake Commander will stop when minimum line pressure is reached or the stroke limit is reached.

4. Remove the 12V power source “POS” from the Brake Light Circuit and Brake Commander will retract to the home position.

NOTE If you repeatedly place the 12V “POS” on and off the Brake Light Circuit, Brake Commander will move in and out accordingly.

Connecting a Break-Away SwitchWhen connecting a Break-Away Switch no external batteries are required. Use this Brake Commander Manual for the connection instructions and DO NOT install the Break-Away Switch with alternate instructions.

Make sure the Break-Away Switch is a normally open (N.O.) configuration.Connect oneleadfromtheswitchtoBrakeCommander’sYellowlead,connectthesecondleadfromtheswitch to Earth. Check and ensure continuity between the switches second lead and Brake Commander’sEarth.

Break-Away Circuit TestTo test the Break-Away Circuit, connect the 12V power source to the Tail Light Circuit as per the Tail Light Circuit Test, however this time leave the 12V power source connected.

1. Allow Brake Commander to charge for 2 minutes. During this time a connection with the Wireless Remote will be established (if a connection is not automatically established within 2 minutes refer to page 16 for details on connecting a Wireless Remote).

2. As soon as a connection with the Wireless Remote is established and the Capacitor Bankissufficientlycharged,astart-uproutinewillrun.Waitforthestart-upprocedureto complete.

3. Operate the Break-Away switch manually. You should immediately hear Brake Commander start as it attempts to apply line pressure to the brake system. Brake Commander will stop when required line pressure is reached or the stroke limit is reached.

4. Reset the Break-Away switch and Brake Commander will retract to the home position.

Wireless RemoteAll Brake Commanders are supplied with a Wireless Remote. Although Brake Commander handles all critical brake control operations internally, the Wireless Remote provides constant feedback to the driver as well as independent trailer brake control via the OverRide button.

NOTE a Wireless Remote must be connected to the Brake Commander when towing.

Charging the Wireless RemoteThe Wireless Remote has a USB compliant charging port allowing the Wireless Remote to be charged by computers with USB ports, wall socket USB charges or 12V style USB chargers.

When charging, a battery indicator on the screen will indicate the battery is charging. When the battery is fully charged the indictor will change to show the battery level.

Note If the battery indicator is RED while charging, the Wireless Remote is preconditioning the battery and will automatically switch off if removed from the USB power source.

Turning the Wireless Remote ON and OFFConnecting the Wireless Remote to a USB power source will turn it ON and it will begin searching for a Brake Commander.

Pressing the “ + “ (plus), “ - “ (minus) or OverRide button will wake the Wireless Remote from Sleep. The Wireless Remote will turn ON and begin searching for a Brake Commander.

To turn the Wireless Remote OFF, wait for the screen to display NO DEVICE FOUND, then hold down the “ - “ (minus) button for 2 seconds.

Note The Wireless Remote can only be turned OFF when it is not connected to a Brake Commander. While connected, the Wireless Remote will sleep if no buttons are pressed for 20 seconds. The Wireless Remote will wake to display any changes to device status (including normal brake usage) or warnings.

Connecting a Wireless RemoteForaWirelessRemotetooperatewithaBrakeCommanderitmustfirstbeconnectedtoit.

TheWirelessRemotewillautomaticallyconnecttothefirstavailableBrakeCommander;

Toachievethebestpossibleresults;

• Ensure the Brake Commander you are connecting to has been turned ON for 2 minutes or more.

• Ensure the Brake Commander is not already connected to another Wireless Remote, if so, move the other Wireless Remote out of radio range.

• Turn the Wireless Remote ON by connecting it to a USB power source or wake it from sleep with the . “+” (plus) button, “-”(minus) button, or Override Button

• The STATUS LED on the Brake Commander will blink rapidly whenever Brake Commander is resetting the wireless network, the wireless network is reset whenever there is no communication for a period of 20 seconds. Short delays in establishing an automatic connection may occur if the network is being reset while the Wireless Remote is searching.

Once connected, the Wireless Remote will display the current status of the Brake Commander. The buttons can now be used to perform various functions as outlined.

If a Wireless Remote has been charged and is sitting in the tow vehicle sleeping, Brake Commander will wake it up and establish an automatic connection. This connection method can take a while (2-3 minutes), manually waking the Wireless Remote will establish the connection quicker.

Status IconsTheiconsdisplayedbytheWirelessRemoteprovidefeedbackaboutBrakeCommander’sstatus. Refer to page 23 through 25 for warning icons and descriptions.

System Ready

Also implies the brakes are not currently in use

Brakes are ON or OverRide is ON

Park Brake is active

Break-Away is active

Searching

The Wireless Remote is searching for a Brake Commander

No Device Connected

The Wireless Remote is not connected to a Brake Commander. Make sure Brake Commander is turned on, in radio range and the Wireless Remote is linked with the Brake Commander

Please Link

The Wireless Remote has established communication withaBrakeCommanderandiswaitingforconfirmation

Settings MenuWith the Wireless Remote connected to the Brake Commander, press the Setup button to entertheSettingsmenu.Thefirstparameterisdisplayed.Tomovetothenextparameterwithin the menu, press the Setup button again. The Settings menu will automatically exit if no buttons have been pressed for more then 10 seconds.

Brake Response Forward

To tune the brake response for the forward direction, enter the Settings menu (by pressing the Setup button) and locate the Brake Response Forward parameter. Use the “ + ” (plus) or “ - “ (minus) buttons to adjust the value.

Allowable range is from 0% to 200%. The default value is 100%.

Brake Response Reverse

To tune the brake response for the reverse direction, enter the Settings menu (by pressing the Setup button) and locate the Brake Response Reverse parameter. Use the “ + ” (plus) or “ - “ (minus) button to adjust the value.

Allowable range is from 0% to 100%. The default value is 20%

Settings menu when Locked

Settings



Settings menu when Unlocked

Settings



Serial Numbers

Installation Angle

Stroke

Start Point

Device 1.1.1000000000000

Remote 1.1.1000000000000

Brake Commander model designator

Brake Commander serial number

Wireless Remote model designator

Wireless Remote serial number

Serial Numbers

Maximum Output

Settings menu when Locked

Settings



Settings menu when Unlocked

Settings



Serial Numbers

Installation Angle

Stroke

Start Point

Device 1.1.1000000000000

Remote 1.1.1000000000000





Serial Numbers

Maximum Output

Stroke

AfterBrakeCommanderisinstalled,themastercylinder’sstrokemustbeenteredintothesystem. To set the stroke, enter the Settings menu (by pressing the Setup button) and locate the Stroke parameter. Use the “ + ” (plus) or “ - “ (minus) button to adjust the value.

Allowable range is from 10.0mm to 45.0mm. The default value is 25.4mm.

Installation Angle

After Brake Commander is installed, the installation angle relative to the direction of travel must be entered into the system. To set the angle, enter the Settings menu (by pressing the Setup button) and locate the Installation Angle parameter. Use the “ + ” (plus) or “ - “ (minus) button to adjust the value. Refer to the diagram below for assistance in setting the angle.

Allowable range is from -180 degrees to 180 degrees. The default value is 0 degrees.

NOTE When the device is not mounted on “Normal” angles, the mounting angle will need to be determined accurately.

Maximum Output

BrakeCommander’soutputcanbeadjustedsoitdoesnotoverloadhydrauliccomponents.To set the maximum output, enter the Settings menu (by pressing the Setup button) and locate the Maximum Output parameter. Use the “ + ” (plus) or “ - “ (minus) button to adjust the value. Refer to the table below for indicative 3/4” and 7/8” master cylinder outputs.

Allowable range is from 20% to 100%. The default value is 80%.

Maximum Output % 3/4” Master Cylinder - PSI 7/8” Master Cylinder - PSI100% 1400psi 1050psi90% 1260psi 945psi80% 1120psi 840psi70% 980psi 735psi60% 840psi 630psi50% 700psi 525psi40% 560psi 420psi30% 420psi 315psi20% 280psi 210psi

NOTE All values are indicative only and will vary due to manufacturing tolerances and environmental conditions.

Start Point

The start point refers to the position in which Brake Commanders piston returns to when the brakes are released. The start point can be adjusted using the “ + ” (plus) or “ - “ (minus) button. The Brake Commander piston will jog in the desired direction accordingly. Use this function to set the start point so as Brake Commanders piston is close (within 1mm) of the MasterCylinderspistonbutnottouchingit.ItisadvisabletosetthisvaluepriortofixingtheMaster Cylinder to the Brake Commander. When bringing the Master Cylinder to mounting position by hand, no preload should be felt.

Allowable range is from 0.0mm to 45.0mm. The default value is 6.0mm. The default value suits typical Master Cylinders used.

Serial Numbers

Serial Numbers and model designators for both the Brake Commander and the Wireless Remote are displayed as shown below.

Device 1.1.1000000000000

Remote 1.1.1000000000000





FunctionsOverRide Button

With the Wireless Remote connected to a Brake Commander, pressing the OverRide button will activate the trailer’sbrakes independentlyof the towvehicle’sbrakes.TheOverRidebutton is pressure sensitive, so the harder it is pressed the harder the trailer brakes will be applied.Releasingthebuttonreleasesthetrailer’sbrakes.

Park Brake Engage / Disengage

With the Wireless Remote connected to a Brake Commander, double-clicking the “ + “ (plus) button will engage the Park Brake. Double-clicking the “ - “ (minus) button will disengage the Park Brake.

WARNING: Hydraulic Park Brakes lose line pressure over time. If parking your trailer on inclines or for extended periods DO NOT rely solely on the Park Brake, secure the trailer with wheel chocks or similar.

NOTE When Brake Commander starts with the Park Brake engaged it cannot complete the start-up routine until the Park Brake is disengaged either by using the Wireless Remote (as described above) or by the Automatic Park Brake release.

NOTE When bleeding brakes on your trailer, the Park Brake can be engaged and disengaged to pump the brakes. Make sure Brake Commander has been turned on for 2 minutes or more.

Automatic Park Brake Release

WiththeParkBrakeengaged,operatingthevehicle’sbrakeswilltriggeranautomaticreleaseof the Electronic Park Brake.

Unlock Settings Menu

ToUnlockSettingsmenu;

• Make sure the Wireless Remote is communicating with the Brake Commander.

• Take the Wireless remote to the Brake Commander.

• HoldWirelessRemoteclosetothedevice,within5cm,thecloserthebetter.

• The Settings menu will now be unlocked and the remote may be moved away from the Brake Commander device.

• The settings menu will remain unlocked until no buttons have been pressed for more than 5 minutes.

Re-Run Startup Routine

With the Wireless Remote connected to a Brake Commander and the System Ready status displayed, press and hold Setup button until you hear Brake Commander start. This will re-runthestart-uproutinesandre-calibratethemastercylinder’sstartpoint.

LED’sandWarningsBrake Commander LEDs

The POWER LED indicates whether or not Brake Commander is receiving power from an external source (Tail Lights or Auxiliary circuit).

ON Brake Commander is receiving power

OFF Brake Commander is not receiving power. Check all electrical connections before use

TheSTATUSLEDindicatesBrakesCommander’sstatus.

ON Brake Commander is ON and there are no warnings or active functions. Brake Commander is ready for use

Quick blink, long pause The Park Brake is ActiveBlink, pause Brake Commander is starting up, or running Startup routines3 Quick blinks, long pause Brake Commander requires attention. Check the Wireless

Remote for warning detailsRapid blinking, no pause The Wireless Network is being reset

Pat. PendingModel: BC32X1-W

Check STATUS is ON before towing

Check POWER is ON before towing

REFE

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MANU

AL BE

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GREFER TO MANUAL BEFORE OPERATING

Wireless Remote WarningsWhen a warning is triggered an audible alert will sound and warning icon will appear in additiontothecurrentstatusicon.Thewarning’sdescriptionisshownbelowthestatusicon.

Example of warning icon when status is System Ready

Refer to the following warning details for more information

Example of warning icon when status is Brake ON or OverRide ON


Example of warning icon when status is Park Brake active


Example of warning icon when status is Break-Away active


Master Cylinder Limit Reached

The Master Cylinder Limit Reached warning is displayed if Brake Commander has reached themastercylinder’sstrokelimit.

• Check the brake system for leaks, worn master cylinder seals, and air in the brake system.

• Ensure the master cylinder is correctly sized for the braking system.NOTE This warning will persist for a short time even after the warning condition is cleared, allowing the driver time to see the warning.

Limit Reached

The Limit Reached warning is displayed if Brake Commander has reached its own stroke limit.

• Mountthemastercylindersothatthemastercylinder’spistonsitsclosertotheBrakeCommander.

• OrreducethedistanceBrakeCommander’spistonneedstomovebeforecontactingthemastercylinder’spiston.

NOTE This warning will persist for a short time even after the warning condition is cleared, allowing the driver time to see the warning.

No Master Cylinder Found

TheNoMasterCylinderFoundwarning is displayed ifBrakeCommander did not findamaster cylinder when starting up.

• If a master cylinder is attached, this warning indicates the spring return of the master cylinderisinsufficient.

NOTE This warning will persist until the startup routine is re-run and a master cylinder is found.

No Start Point Found

TheNoStartPointFoundwarningisdisplayedifBrakeCommanderwasunabletofindavalidStartPoint - thepointatwhichBrakeCommander’spistonfirst touches themastercylinder’spiston.

• BrakeCommander looks for a consistent contact point.Check themaster cylinder’ssealsarenotcausingit’spistontostick.

NOTE This warning will persist until the startup routine is re-run and a Start Point is found

Turn Lights On

The Turn Lights ON warning is displayed when Brake Commander determines the trailer is in Motion but a power source is not present.

• Check all wiring connections.

• CheckthepowersourcemeetstheElectricalSpecificationsonpage11.NOTE This warning will persist for a short time even after the warning condition is cleared, allowing the driver time to see the warning.

No Power Source

The No Power Source warning is displayed if Brake Commander is not receiving the minimum power requirements.


• CheckthepowersourcemeetstheElectricalSpecificationsonpage11.NOTE This warning will persist for a short time even after the warning condition is cleared, allowing the driver time to see the warning.

Low Power

The Low Power warning is displayed if Brake Commander’s internal Capacitor Bank isrunning low on power. While this warning is displayed, please drive safely while it is being charged.


• Check that Brake Commander is receiving the required power. Refer to the Electrical Specificationsonpage11.

• If this message is displayed frequently without excessive brake usage, re-run the start-up routine (refer to page 21) to ensure Brake Commander is operating correctly.

NOTE This warning will persist for a short time even after the warning condition is cleared, allowing the driver time to see the warning.

Low System Voltage

TheLowSystemVoltagewarningisdisplayedifBrakeCommander’spowersupplyisunderthe minimum voltage when starting up.

• Check that Brake Commander is receiving the required voltage. Refer to the Electrical Specificationsonpage11.

NOTE Brake Commander will not operate when this warning is triggered. If the voltage increases to an acceptable level, the warning will be cleared and normal operation will resume.

Motor Shutdown

TheMotorShutdownwarningisdisplayedifBrakeCommander’smotorhasbeenshutdownto prevent damage to the Motor and Electronics.

• Ensurethemastercylinderisnotstuckandthemastercylinder’sstrokehasbeensetcorrectly

NOTE In the shutdown condition brake output will be maintained at the level prior to the shutdown. The motor will be released from the shutdown after 5 seconds.

Motor Sensor Error

TheMotorSensorErrorwarningindicatesafaultwithinBrakeCommander’smotorsensor.

• Contact Brake Commander for further assistance.NOTE Brake Commander will not operate with this warning.

Load Sensor Error

TheLoadSensorErrorwarningindicatesafaultwithinBrakeCommander’sLoadSensor.


Cap Bank Error

TheCapBankErrorwarningindicatesafaultwithinBrakeCommander’sinternalCapacitorBank.


P.O. BOX 2107 Phone: 1300 94 97 98Bowral NSW 2576 Australia Web: www.brakecommander.com

Brake Commander S/N

Wireless Remote S/N

user manual - trailerpartsnz · 2017. 11. 9. · once brake commander is installed, fittedwith a...

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