BM PRO TrailSafe Series User manual

TEAMBMPRO.COM
OWNER’S MANUAL
TrailSafe SERIES
TrailSafe+
TrailSafe
MODELS

TEAM
BMPRO
.COM
POWERING YOUR ADVENTURES
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and design facilities in Melbourne,
Australia, BMPRO are the leading
experts in RV power management.
Inspired by the great outdoors, we
have created a range of rugged, smart
and reliable products to power your
adventures.
Our range of battery, power and RV
management and control systems gives
you peace of mind when you are on the
road, so that you can relax in even the
most far-flung destinations, knowing
you have control over your power
needs.
To learn more about the BMPRO range
of products, please visit our website
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SAFETY PRECAUTIONS
Please read the Safety Precautions before installing or using the TrailSafe or
TrailSafe+. Be sure to observe all precautions without fail. Failure to observe these
instructions properly may result in property damage or personal injury which,
depending on the circumstances, may be serious and cause loss of life.
After completing installation of the TrailSafe or TrailSafe+, conduct a trial operation
to check for faults. Refer to the Inital Self-Test section of this manual for information
on how to check for faults.
WARNING
Correct installation is the most critical factor in ensuring the safe use of the TrailSafe
If every consideration of these instructions has been satisfied, the TrailSafe will be
safe to operate.
Before wiring / servicing TrailSafe, disconnect it from all power sources.
The pull pin should be tested before use to confirm the switch function and battery
status.
The TrailSafe is a high precision electronic product. It contains no user-serviceable
parts inside. Do not try to dismantle, modify or repair it yourself. Disassembly,
service or repair by an unauthorised person will void the warranty.
It is essential the house battery is well maintained and must have at least 50% of
nominal capacity available.
It is essential all wiring is protected by fusing close to any power source.
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5

Copyright © 2021
MANUAL PART 036002
REV 2.0
Designed by BMPRO, one of Australia’s leading power solution experts, the BMPRO range
of products are proudly Australian-Made in Melbourne, Victoria and represent a high-
quality product that will provide years of service.
DISCLAIMER: BMPRO accepts no liability for any loss or damage which may occur from
the improper or unsafe use of its products. Warranty is only valid if the unit has not been
modified or misused by the customer.
CONTENTS
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . 4
ABOUT THE TRAILSAFE . . . . . . . . . . . . . . . . . . . . . . . 8
KEY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 9
MOUNTING LOCATION . . . . . . . . . . . . . . . . . . . . . . . 9
MOUNTING METHOD . . . . . . . . . . . . . . . . . . . . . . . 9
MOUNTING ORIENTATION . . . . . . . . . . . . . . . . . . . . . 9
WIRING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . 10
TRAILSAFE WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . 12
TRAILSAFE+ WITH SWAYCONTROL WIRING DIAGRAM . . . . . . . . . . 13
INITIAL SELF-TEST . . . . . . . . . . . . . . . . . . . . . . . . 15
LED STATUS INDICATORS . . . . . . . . . . . . . . . . . . . . . . 16
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . 16
TRAILSAFE OPERATIONAL USE WITHOUT SWAYCONTROL . . . . . . . . 17
TRAILSAFE+ OPERATIONAL USE WITH SWAYCONTROL. . . . . . . . . . 18
IN-CAR MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . 20
SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
FAQS + TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . 20
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 22
WARRANTY TERMS AND CONDITIONS . . . . . . . . . . . . . . . . . 23
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7

ABOUT THE TRAILSAFE
The TrailSafe is a system designed to activate the electric brakes of a trailer or
caravan (or similar) in the event of a disconnection from the towing vehicle. It utilises
the house battery located on the trailer to activate the electric brake system and
brake lights on the trailer in an emergency breakaway situation.
The TrailSafe also provides an indication of the charge status of the house battery
and checks the condition of the pull pin and effective activation of the brakes. This
information is displayed via a multi-coloured LED on the TrailSafe unit. This can also
be displayed on the Bluetooth TrailCheck available for in-car monitoring if installed.
The mechanical pull pin is forcibly detached if the towing vehicle becomes separated
from the trailer. Upon disconnection, the brakes and brake lights are activated as
long as charge remains in the trailer battery or until the pin is replaced.
There are two available models in the TrailSafe series: the TrailSafe and TrailSafe+.
The TrailSafe+ includes an extra cable to integrate it with BMPRO’s SwayControl.
KEY FEATURES
9Bluetooth and wired connectivity options for in-vehicle monitors
9Works off house battery – no additional battery required
9LED status indicators for full system safety check at trailer tongue
9Tests pull pin functionality as well as battery health
9Activates brake lights as well as electric brakes in the event of a breakaway
9When wired to BMPRO’s proactive electronic stability control SwayControl and
used with the wireless in-car monitor, provides comprehensive data on the RV
safety system (only available with TrailSafe+)
9Meets Australian regulations for break away systems on trailers over 2000kgs
VEHICLE STANDARDS
Australian Design Rule 38/05 mandates that for all trailers having a Gross Trailer
Mass over 2000 kg, an emergency braking system is required on all wheels and must
be capable of automatically activating should the trailer become detached from the
tow vehicle. In such a situation the brakes must remain active for a minimum of 15
minutes.
8

INSTALLATION INSTRUCTIONS
MOUNTING LOCATION
Secure the TrailSafe or TrailSafe+ to the right hand side draw bar of the trailer (the
driver’s side) approximately 300mm from the tow ball hitch. Mount horizontally on
top or side of the draw bar.
MOUNTING METHOD
Mount on the arm of the trailer using the supplied mounting screw or similar. Only
one mounting point is required so that the unit can swivel in an emergency. Ensure
that it is secured tightly so that it does not vibrate loose.
MOUNTING ORIENTATION
The wires should be pointing towards the rear (away from the tow vehicle) so that
the pull pin is facing towards the tow vehicle. The pull pin will then be pulled out
freely should the vehicle and trailer separate. The other end of the pull pin cord is
attached to the towing vehicle by a D-shackle or similar.
Figure 1: TrailSafe mounting diagram
9

NOTE: Larger wire sizes may be used. The minimum is shown.
For the black/red wire, a 30A automotive-grade fuse must be located as close to the
trailer battery as possible, but not before the battery charging source feed.
WIRING INSTRUCTIONS
The TrailSafe and TrailSafe+ have multiple colored wires coming from the rear side
which require connection to ensure correct functionality. As this is a safety critical
system, all wiring should be done by a suitably qualified Auto Electrician.
If you are using the TrailSafe, wire it to the house battery, trailer brakes and brake
lights. Refer to TrailSafe Wiring Diagram.
If you are using the TrailSafe+ along with BMPRO’s SwayControl, wire the TrailSafe+
to the house battery, trailer brakes and brake lights. Refer to TrailSafe+ with
SwayControl Wiring Diagram.
TRAILSAFE
RED (14AWG / 2.5mm2) Connect to the positive of the brake lights.
BLUE (12 AWG/ 4mm2) Connect to the positive of the brakes.
PURPLE (14 AWG/ 2.5mm2) Connect to a remote voltage monitor.
WHITE (14 AWG/ 2.5mm2) Connect to the negative of the house battery.
BLACK/RED (12AWG / 4mm2) Connect to the positive of the house battery (30A fuse
required).
GREEN (20AWG / 0.5mm2)
If using LiFePO4 Unconnected: connect to the positive
terminal of the house battery.
If using Lead Acid: connect to the negative terminal of the
house battery.
WARNING
The green wire must be connected to a battery positive terminal when a LiFePO4
battery is used. Failure to do so may result in false battery capacity information.
Failure to install the fuse may result in permanent and serious
failure or damage to the TrailSafe and/or the wiring.
WARNING
10

WARNING
The green wire must be connected to a battery positive terminal when a LiFePO4
battery is used. Failure to do so may result in false battery capacity information.
Failure to install the fuse may result in permanent and serious
failure or damage to the TrailSafe and/or the wiring.
WARNING
TRAILSAFE+
RED (14AWG / 2.5mm2) Connect to the positive of the brake lights.
BLUE (12 AWG/ 4 mm2) Connect to the positive of the brakes.
PURPLE (14 AWG/ 2.5 mm2) Connect to a remote voltage monitor.
WHITE (14 AWG/ 2.5 mm2) Connect to the negative of the house battery.
BLACK/RED (12AWG / 4mm2) Connect to the positive of the house battery (30A fuse
required).
GREEN (20AWG / 0.5mm2)
If using LiFePO4 Unconnected: connect to the positive
terminal of the house battery.
If using Lead Acid: connect to the negative terminal of the
house battery.
YELLOW (20AWG / 0.5mm2)
If SwayControl is being used, connect to the YELLOW
cable of SwayControl via connector.
If SwayControl is not being used, leave unconnected.
THIN RED (20AWG / 0.5mm2)
If SwayControl is being used, to the RED cable of
SwayControl via connector.
If SwayControl is not being used, leave unconnected.
NOTE: Larger wire sizes may be used. The minimum is shown.
For the black/red wire, a 30A automotive-grade fuse must be located as close to the
trailer battery as possible, but not before the battery charging source feed.
11

Pin 6: Brake Light
Pin 3/10: 0V
Pin 5: Brake
3rd Party Monitor
TRAILSAFE WIRING DIAGRAM
Tow Vehicle
Blue
Purple
Brakes
+
–
Brake Lights
+
–
Chemistry
Selection
TrailSafe Trailer
Red / Black
White
Red
Green
LEGEND
30A Fuse
House
Battery
*Refer to your display monitor’s manual for connection instructions.
1
6
5
3
2
7
4
12
11
10
9
8
*
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1
6
5
3
2
7
4
12
11
10
9
8
TRAILSAFE+ WITH SWAYCONTROL WIRING DIAGRAM
Tow Vehicle
Blue
Purple
TrailSafe+
Trailer
Red / Black
White
Red
Green
SwayControl
LED
Left Brake
Right Brake
Pink
Purple
LEGEND
30A Fuse
Black
Blue
LED
White
Brake Lights
+
–
House
Battery
Chemistry
Selection
TrailSafe+ LED Connector
SwayControl LED Connector
Pin 6: Brake Light
Pin 3/10: 0V
Pin 5: Brake
3rd Party Monitor
*Refer to your display monitor’s manual for connection instructions.
*
13

Do not connect the TrailSafe+ blue wire directly to trailer brakes if the SwayControl
is also installed. Failure to do so disables the unit’s ability to control sway.
WARNING
The return (negative) wires of the brakes and brake lights from trailer must be wired
directly to:
9One of the negative output connections on BatteryPlus35 or J35 if fitted
9To the non-battery side of a negative side shunt such as the BC300
9Directly to the battery negative in all other cases
Ensure the house battery has a suitable charging source such as a BatteryPlus35,
J35 or other charging means and is functioning correctly. Refer to manufacturer’s
instructions for these products as required. A basic charging means such as diode
from the Auxiliary to the house battery may be employed in simple systems.
An external automotive-grade fuse is required to be fitted (30A maximum) between
the TrailSafe / TrailSafe+ and the battery to protect against wiring faults and issues.
If you have a BP35/J35 installed, all negatives must pass through the BP35/J35
before connecting to the house battery.
WARNING
If you have a BC300 installed, all negatives must pass through the BP35/J35, and
then the BC300 before connecting to the house battery.
WARNING
14

INITIAL SELF-TEST
1. Before starting, ensure the TrailSafe or TrailSafe+ pull pin is in place.
2. Power up the TrailSafe or TrailSafe+ from your 12V battery as per the wiring
instructions. The LED will display a continuous flashing PURPLE, indicating the
first stage of calibration is in progress. This will last for up to 5 minutes.
3. When the first stage is completed, the LED will display a solid PURPLE. When
this happens, pull the safety pin out. The LED will display a continuous flashing
PURPLE again, indicating the second stage of calibration is in progress. This will
last for up to 1 minute.
4. If the LED indicates an alternating PURPLE/RED, the wiring Voltage Drop in the
black/red wire (+v) and/or the white wire (-v) is exceeding 10% of the nominal
voltage. Check the wiring connections and consider increasing the black/red and/
or the white wire size.
5. Once completeted, LED will display a solid PURPLE again. At this stage, put the
pull pin back in. The LED will then display a status indicator. For details, refer to
the LED Status Indicators section of this manual.
15

LED STATUS INDICATORS
BLINK EVERY FEW SECS
SOLID COLOUR
CONTINUOUS FLASH
NO LIGHT
LED STATUS KEY
CALIBRATION
Initialisation
pin in
The TrailSafe is in calibration.
Wait about 5 minutes until
the LED displays a solid
PURPLE.
Completed 1st calibration stage. Remove the pin.
Initialisation
pin out
The pull pin is out when calibration
starts.
Put the pull pin back in and
wait for 1 minute, or power
cycle the unit to restart
calibration.
The TrailSafe is in calibration.
Wait about 1 minute until
the LED displays a solid
PURPLE.
Completed 2nd calibration stage. Put the pin back in.
The wiring voltage drop is
exceeding 10% of the nominal
voltage. The LED will flash both
purple and red.
Check wiring and
connections and consider
increasing the wire size.
The pull pin was removed
before the calibration stage was
completed. The LED will flash both
purple and orange.
Put the pull pin back in to
restart.
Initialisation
complete
The TrailSafe has finished
calibrating, and is calculating
battery capacity.
Wait for the LED to move to
standby mode. The LED may
stay orange for some time,
or may move to standby
mode very quickly.
CONDITION
STATUS SOLUTIONSTATE
16

TRAILSAFE OPERATIONAL USE WITHOUT SWAYCONTROL
Once the TrailSafe has finished calibrating and is ready for operational use, the
colour of the LED will change depending on the charge state of the battery.
NOTE: If you are using the TrailSafe+ alongside BMPRO’s SwayControl, refer to the
TrailSafe with SwayControl section of this manual.
Standby
mode
The TrailSafe is in standby as no brake activity has been detected
for 1 minute. The colour will change depending on the charge state
of the battery.
Brake pedal
depressed For 1
minute
The colour will change depending on the charge state of the
battery.
Pin out
A trailer breakaway has occured. The colour will change
depending on the charge state of the battery.
There is a TrailSafe breakaway
switch fault. The LED will flash
both orange and red.
Do not use unit. Replace the
unit.
Battery flat Always
on
The battery is flat. Charge or replace the house
battery.
Other
The TrailSafe is in standby, or there
is no power, or the voltage is less
than:
10.5V for Lead Acid batteries
11.5V for Lithium batteries
If necessary, check the
TrailSafe by depressing the
brake.
CONDITION
STATUS SOLUTIONSTATE
The house battery capacity is sufficient for 15 minutes of emergency braking
operation.
The house battery may have insufficient capacity for 15 minutes of emergency
braking operation.
Check the battery to ensure at least 10Ah of house battery capacity is available.
The house battery is not detected or there is insufficient capacity for 15 minutes of
emergency braking operation.
Charge or replace the house battery.
CONDITIONCOLOUR
17

TRAILSAFE+ OPERATIONAL USE WITH SWAYCONTROL
The LED on the TrailSafe+ displays different indicators if used with BMPRO’s
SwayControl.
NOTE: If you are not using the TrailSafe+ with BMPRO’s SwayControl, refer to the
Operational Use section of this manual.
Battery flat
Always
on
The battery is flat.
Warning: this state will
override other LED indicators.
Refer to the Battery Flat
section for more information.
Charge or replace the house
battery.
Normal
operation,
battery
sufficient
Sway event
active
Standby
mode
The TrailSafe is in standby as no brake activity has been detected
for 1 minute, and the SwayControl is in “sleep” mode
Battery
insufficient
The house battery may have
insufficient capacity for
15 minutes of emergency
braking operation.
Check the battery to ensure
at least 10Ah of house battery
capacity is available.
SwayControl
not detected
The SwayControl is not
detected by the TrailSafe+.
Check if the SwayControl is
connected.
No power
No power to SwayControl
after a “wake-up” signal from
the brake controller.
Check the quality of power,
ground and brake controller
wire connections. Check for any
blown fuses on the tow vehicle
and trailer.
Battery
overvoltage/
undervoltage
There is a house battery
overvoltage(> 20V) or
undervoltage (< 3V) on the
SwayControl.
Check the power source voltage.
The required voltage is 12-15V.
CONDITIONSTATUS SOLUTIONSTATE
10s
18

Battery Flat
If the battery is flat, the LED will show a constant RED even if other LED indication
states are also active at the same time. The only indication states that will not be
overridden are the fault indicators.
Fault Indicators
Off-road
mode
The SwayControl is disabled momentarily. The unit will return to
normal operation when not on rough terrain. The LED will flash
both green and red.
Other
The three following
conditions are met:
• The SwayControl is in
“sleep” mode.
• The TrailSafe+ is in
standby.
• The house battery
capacity is sufficient for
15 minutes of emergency
braking operation.
If necessary, check the TrailSafe
by depressing the brake.
There is no power.
CONDITIONSTATUS SOLUTIONSTATE
BLINK ONCE EVERY FEW SECS
SOLID COLOUR
CONTINUOUS FLASH
NO LIGHT
LED STATUS KEY
BLINK TWICE EVERY FEW SECS
BLINK 3 TIMES EVERY FEW SECS BLINK 4 TIMES EVERY FEW SECS
System
malfunction
The SwayControl has suffered
a system malfunction.
A service centre repair is
required.
The SwayControl has no
control of the trailer.
A service centre repair is
required.
Left brake
short
There is a wiring short in the
left-side brake. Repair the wiring short.
Right brake
short
There is a wiring short in the
right-side brake. Repair the wiring short.
CONDITIONSTATUS SOLUTIONSTATE
10s
BLINK ONCE EVERY 10 SECS
19

IN-CAR MONITOR
If an in-car monitor is used, it needs to be located in a position where it is visible to
the driver.
Refer to the Wireless Monitor TrailCheck manual for more details.
SERVICING
Do not attempt to service the TrailSafe or TrailSafe+ yourself, or dismantle, modify
or repair the TrailSafe or TrailSafe+ yourself, as this will void your warranty. If your
TrailSafe product requires servicing, please consult your BMPRO dealer or visit
teambmpro.com for assistance.
FAQS AND TROUBLESHOOTING
Need more help troubleshooting your TrailSafe or TrailSafe+?
Contact our customer service team online at teambmpro.com/technical-support.
When I pull the pin, the TrailSafe indicator does not illuminate?
1. Check the supplied fuse on the black/red wire.
2. Check the wiring matches the diagram.
3. Ensure TrailSafe or TrailSafe+ pin slot is clean of dirt.
4. Ensure the house battery is charged.
Why should I test TrailSafe before hitching it to the tow vehicle?
Testing the TrailSafe or TrailSafe+ ensures that the house battery has sufficient
capacity to operate the brakes for at least 15 minutes should the need arise.
What is the difference between a solid green, orange and red status indicators on
the TrailSafe?
GREEN confirms that the battery has been detected, has been determined to have
sufficient charge and no fault in the wiring to the brakes has been detected. Good to
go!
ORANGE indicates there is a need for a secondary check as the battery maybe too
low.
RED indicates that battery not detected or not having enough capacity for 15 minutes
emergency brake operation.
20