BMPRO TrailSafe Series TrailSafe+ Emergency Trail Break Owner’s Manual

: June 6, 2024
: BMPRO

TrailSafe SERIES
MODELS
TrailSafe TrailSafe+
OWNER’S MANUAL

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 teambmpro.com

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.

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 highquality 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.

ABOUT THE TRAIL SAFE

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

Bluetooth and wired connectivity options for in-vehicle monitors
Works off house battery no additional battery required
LED status indicators for full system safety check at trailer tongue
Tests pull pin functionality as well as battery health
Activates brake lights as well as electric brakes in the event of a breakaway
When 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+)
Meets 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.

INSTALLATION INSTRUCTIONS

MOUNTING LOCATION

Secure the TrailSafe or TrailSafe+ to the right-hand side drawbar of the trailer (the driver’s side) approximately 300mm from the tow ball hitch. Mount horizontally on top or side of the drawbar.

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

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.
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 trail safe and/or the wiring.

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 (I 2AWG / 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.
Y ELLOW (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.

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 trail safe and/or the wiring.

TRAILSAFE WIRING DIAGRAM

*Refer to your display monitor’s manual for connection instructions.

TRAILSAFE+ WITH SWAY CONTROL WIRING DIAGRAM

*Refer to your display monitor’s manual for connection instructions.

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.
The return (negative) wires of the brakes and brake lights from trailer must be wired directly to:

One of the negative output connections on BatteryPlus35 or J35 if fitted
To the non-battery side of a negative side shunt such as the BC300
Directly 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.

INITIAL SELF-TEST

Before starting, ensure the TrailSafe or TrailSafe+ pull pin is in place.
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.
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.
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.
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.

LED STATUS INDICATORS

LED STATUS KEY

BLINK EVERY FEW SECS| SOLID COLOUR
CONTINUOUS FLASH| NO LIGHT

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.

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.

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.
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:
10.5V for Lead Acid batteries
11.5V for Lithium batteries| If necessary, check the TrailSafe by depressing the brake.

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.

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| | 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.
LED STATUS KEY

CONTINUOUS FLASH
BLINK ONCE EVERY 10 SECS
BLINK ONCE EVERY FEW SECS
BLINK 3 TIMES EVERY FEW SECS| SOLID COLOUR
NO LIGHT
BLINK TWICE EVERY FEW SECS
BLINK 4 TIMES EVERY FEW SECS
STATE| STATUS| CONDITION| SOLUTION
---|---|---|---
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 mergency braking operation.| If necessary, check the TrailSafe by depressing the brake.
There is no power.

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

STATE	STATUS	CONDITION	SOLUTION

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?

Check the supplied fuse on the black/red wire.
Check the wiring matches the diagram.
Ensure TrailSafe or TrailSafe+ pin slot is clean of dirt.
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 may be too low.

RED indicates that the battery is not detected or does not have enough capacity for 15 minutes emergency brake operation.
It is possible that with dual axles brakes, heavy brake light loads, warm batteries, a large load on the trailer etc, that the battery is sufficient but failing to give a clear pass.
It is necessary that there is at least 10Ah of useful battery capacity remaining, which may require 20% of aged 100Ah-rated battery for this load. If any loads (e.g. lights, 12V fridges) are on in the trailer, turn these off if possible. If your trailer or caravan has a display showing remaining battery capacity this should be able to provide a useful indication that there is enough battery capacity remaining for the emergency braking function.
Refer to the LED Status Indicators section of this manual for information.
Can I use a wired in-car monitor?
A wired 12VDC battery voltage indicator can be used with the TrailSafe or TrailSafe+ if desired.
When I pull the pin, the LED display is flashing RED and ORANGE?
The pull pin is faulty, which may cause the brakes to not operate correctly or for as long as desired. Refer to the LED Status Indicators section of this manual for information.
I have charged my house battery, but the TrailSafe shows a RED LED.
If a large load is applied to the house battery, such as a fridge, the house battery terminal voltage may drop below the minimum TrailSafe threshold, due to the internal resistance of the house battery.

Switch off any loads and re-test.

Refer to the LED Status Indicators section of this manual for information.
I thought it was not a good idea to remove the pin?
This is a key feature of the device. By removing the pin to test the unit, it checks to ensure that the switch is functioning. It also checks the battery is ready to function should an emergency happen.
The LED is indicating a solid RED all the time?
The battery voltage is very low and is considered flat. Charge or replace the battery.
Refer to the LED Status Indicators section of this manual for information.

SPECIFICATIONS

TRAIL SAFE/TRAILSAFE+ SPECIFICATIONS

WARRANTY TERMS AND CONDITIONS

Registering your BMPRO product is an important step to ensure that you receive all the benefits you are entitled to. Please visit teambmpro.com to complete the online registration form for your new product today.

BMPRO goods come with guarantees that cannot be excluded under Australian Consumer
Law. You are entitled to a replacement or refund for major failure and for compensation for any reasonably foreseeable loss or damage. You are entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure. The benefits under this Warranty are in addition to your other rights and remedies under a law in relation to the goods to which this Warranty relates (the Australian Consumer Law).
BMPRO warrants products against defects for a period of two years, commencing from the original date of purchase. Proof of purchase is required before you can make a claim under this warranty.
HOW TO PROTECT YOUR RIGHTS UNDER THIS WARRANTY
The TrailCheck is designed to be installed by a suitably qualified installer. You or your installer should carefully inspect the products before installation for any visible manufacturing defects. We accept no responsibility in addition to our consumer guarantee obligations where a product has been installed incorrectly.
This warranty does not extend to product failures or defects caused by, or associated with, but not limited to: failure to install or maintain correctly, unsuitable physical or operating environment, accident, acts of God, hazard, misuse, unauthorised repair, modification or alteration, natural disaster, corrosive environment, insect or vermin infestation and failure to comply with any additional instructions supplied with the product.
BMPRO may seek reimbursement of any costs incurred by BMPRO when a product is found to be in proper working order or damaged as a result of any of the warranty exclusions mentioned in point 4 of this statement
To enquire or make a claim under this warranty, please follow these steps:
A. Prior to returning a BMPRO product, please email [email protected] to obtain a Return Material Authorisation (RMA) number B. Package and send the product to:
BMPRO Warranty Department
19 Henderson Road
Knoxfield, VIC 3180
Please mark RMA details on the outside of the packaging. C. Please ensure the package also includes: a copy of the proof of purchase, a detailed description of the fault and your contact details including phone number and return address.
BMPRO will not be liable for any costs, charges or expenses incurred in the process of returning a product in order to initiate a warranty claim.