BM PRO TrailSafe Series User manual

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OWNER’S MANUAL
TrailSafe Series
TrailSafe+
TrailSafe
MODELS

POWERING YOUR ADVENTURES
With over 50 years’ experience in power
solutions combined with manufacturing
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.
4

5

Designed by BMPRO, one of Australia’s leading power solution experts, the BMPRO product
range is proudly designed and manufactured in Melbourne, Australia, 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.
Copyright © 2023
MANUAL PART 038983
REV 5.0
CONTENTS
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . 4
ABOUT THE TRAILSAFE . . . . . . . . . . . . . . . . . . . . . . 8
KEY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . 8
VEHICLE STANDARDS . . . . . . . . . . . . . . . . . . . . . . 8
INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . 9
TRAILSAFE WIRING INSTRUCTIONS . . . . . . . . . . . . . . . . 10
TRAILSAFE WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . 11
TRAILSAFE+ WITH SWAYCONTROL WIRING INSTRUCTIONS . . . . . . 13
TRAILSAFE+ WITH SWAYCONTROL WIRING DIAGRAM . . . . . . . . . 15
USING THE TRAILSAFE . . . . . . . . . . . . . . . . . . . . . 17
INITIAL SELF-TEST . . . . . . . . . . . . . . . . . . . . . . . 17
IN-CAR MONITOR . . . . . . . . . . . . . . . . . . . . . . . . 17
LED STATUS INDICATORS . . . . . . . . . . . . . . . . . . . . 18
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
TRAILSAFE OPERATIONAL USE WITHOUT SWAYCONTROL . . . . . . . 19
TRAILSAFE+ OPERATIONAL USE WITH SWAYCONTROL . . . . . . . . . 20
SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . 22
FAQS AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 22
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 24
WARRANTY TERMS AND CONDITIONS . . . . . . . . . . . . . . . 26
6

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.
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.
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
2000kg.
8

INSTALLATION INSTRUCTIONS
It is recommended that installation of the TrailSafe or TrailSafe+ is carried out by
a trained auto electrician.
Using the supplied mounting screw, mount the unit on the right-hand side of the
trailer’s drawbar, about 300mm from the tow ball hitch.
The TrailSafe needs to be secured tightly to prevent it from vibrating loose.
Tighten the mounting screw to between 10-25Nm.
WARNING
Do not tighten the mounting screw to a torque higher than 30Nm.
The unit must be mounted horizontally on top or the side of the drawbar, with the
wires pointing towards the rear of the trailer (away from the tow vehicle) and the
pull pin facing the tow vehicle.
Only one mounting point is required for the unit to swivel in an emergency.
Attach the other end of the pull pin cord to the towing vehicle using a D-shackle
or similar.
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.
TRAILSAFE WIRING INSTRUCTIONS
NOTE: This section applies to the TrailSafe without the use of a SwayControl. If
you are using the TrailSafe+ with the SwayControl, refer to the TrailSafe+ with
SwayControl Wiring Instructions section.
The TrailSafe has multiple coloured 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.
Wire the TrailSafe to the house battery, trailer brakes and brake lights. Refer to
the TrailSafe Wiring Diagram.
WIRE CONNECTION
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: 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.
WARNING
Failure to install the fuse may result in permanent and serious failure or damage to
the TrailSafe and/or the wiring.
10

TRAILSAFE WIRING DIAGRAM
*Refer to your display monitor’s manual for connection instructions.
11

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 and the battery to protect against wiring faults and issues.
WARNING
If you have a BatteryPlus35/J35 installed, all negatives must pass through the
BatteryPlus35/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.
12

TRAILSAFE+ WITH SWAYCONTROL WIRING
INSTRUCTIONS
NOTE: This section applies to the TrailSafe+ when also using a SwayControl. If
you are using the TrailSafe without a SwayControl, refer to the TrailSafe Wiring
Instructions section.
The TrailSafe+ has 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.
Wire the TrailSafe+ to the house battery, trailer brakes and brake lights. Refer to
the TrailSafe+ With SwayControl Wiring Diagram.
WIRE CONNECTION
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.
13

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.
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.
WARNING
Failure to install the fuse may result in permanent and serious failure or damage to
the TrailSafe and/or the wiring.
14

TRAILSAFE+ WITH SWAYCONTROL WIRING DIAGRAM
*Refer to your display monitor’s manual for connection instructions.
15

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
the 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.
WARNING
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
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.
16

USING THE TRAILSAFE
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 completed, 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.
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.
If you are using BMPRO’s TrailCheck, refer to the Wireless Monitor TrailCheck
manual for more details.
17

CALIBRATION
STATE STATUS CONDITION SOLUTION
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.
LED STATUS INDICATORS Continuous Flash
Blink Every Few Secs
Solid Colour
No Light
LED STATUS KEY
18

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+ Operational Use With SwayControl section of this manual.
STATE STATUS CONDITION SOLUTION
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:
910.5V for lead-acid
batteries
911.5V for Lithium batteries
If necessary, check the
TrailSafe by depressing the
brake.
COLOUR CONDITION
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.
19

TRAILSAFE+ OPERATIONAL USE WITH SWAYCONTROL
The LED on the TrailSafe+ displays different indicators if used with BMPRO’s
SwayControl.
NOTE: If you are using the TrailSafe+ without BMPRO’s SwayControl, refer to the
TrailSafe Operational Use Without SwayControl section of this manual.
STATE STATUS CONDITION SOLUTION
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
10s
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
over-voltage
/ under-
voltage
There is a house battery
overvoltage(> 20V) or
undervoltage (< 3V) on the
SwayControl.
Check the power source
voltage. The required voltage
is 12-15V
20