Are you sure there is actually a problem? Wiring in a brake controller isn't rocket science. Power, Brake trigger, Ground and Brake are the only wires. I would hook it up and pull the trailer for a while to see if you even have a problem.
I can't tell by what you posted above but the controller won't actually function unless, it senses a trailer load, the brake trigger is on (brake pedal pushed) and the intertia pendelum is swinging.
I have a digital controller in my truck and even when I hit the brakes hard the most I have ever seen is 40. The controller goes to 80.
I don't think gain would affect the lighting. The lights are based on percentage of available power not output voltage. 30% of a max of 11 volts and 30% of a max 14 volts would still show the same light pattern.
This post was edited by Ryan - WI at 15:00:12 02/10/11.
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