Caution: Busta 4.2 is Not Plug and Play

When using Busta 4.2 for your trailer connection, it’s crucial to be aware of the following warnings to ensure the safe and proper operation of your vehicle and trailer.

1. Ignition Precautions

• Turn Off Vehicle Ignition: Before connecting or disconnecting the Busta 4.2 to your trailer, ensure that your vehicle’s ignition is turned off. Failure to do so may result in improper signal transmission.

2. Trailer Recognition

• Initial Trailer Connection: Upon connecting the trailer and switching on the ignition, your vehicle’s Body Computer will recognize the trailer. This recognition is essential and, in some jurisdictions, a legal requirement. It activates the Trailer Tell Tale, which operates in tandem with turn signals.

3. Vehicle Computer Communication

• Communication to Vehicle Computers: The Body Computer communicates the trailer’s presence to other vehicle computers, affecting various functions:
  • Anti-Lock Brakes, Stability Control, Traction Control, Autonomous Emergency Braking, Smart Cruise Control, Blind Spot Detection, and Lane Change Assist are adjusted to enhance safety during motion.
  • Powertrain control may adapt engine fuelling, throttle response, and transmission shift points.
  • Suspension adjustments at highway speeds reduce directional instability during lane changes and cornering.
  • Rear lighting changes to disable rear fog and reversing lights to prevent glare from the trailer.
  • Trailer lighting modifications ensure proper signaling and lighting.
  • Parking sensors are disabled to prevent interference.

Please note that not all vehicle makes and models have all of these features.

4. Ignition During Disconnect

• Turn Ignition Off When Disconnecting: Failing to turn off the ignition when disconnecting the Busta 4.2 from the trailer can cause the vehicle to believe the trailer is still connected. This confusion can lead to a ‘limp home mode’ and error logging in vehicle computers.

5. Electric Brake Compatibility

• European Vehicles and Electric Brakes: European vehicles without an electric brake controller require a wiring modification to tow a trailer with electric brakes.

6. Trailer Brake Activation

• Load Resistors: Avoid connecting a Busta 4.2 to a trailer with load resistors, as they may draw more current than the Busta 4.2 can supply (maximum 4 amps). Disconnect load resistors before connecting the Busta 4.2 and remember to reconnect them after towing.
• Horse Floats: Some horse float manufacturers use non-LED internal lights connected to the park light circuit. Ensure these lights are LED or modify the wiring to supply an alternate power source to avoid overloading the Busta 4.2 (maximum 4 amps) and voiding its warranty.

7. Trailer Brake LEDs

• Pulsing Brake LEDs: Certain electric brake controllers emit pulses to the trailer’s electric brake solenoids to ensure connectivity and issue warnings. These pulses may persist after ignition is turned off, draining the battery. To address this:
  • Run a separate wire from the brake controller to the trailer connector.
  • Install an ON/OFF switch or relay in the power supply circuit to disable the brake controller when not in use.

If trailer manufacturers have installed a diode causing brake LEDs to flash with the pulses, contact the manufacturer to disconnect the diode.

Safety First: Following these warnings and precautions ensures the safe and efficient use of Busta 4.2 for your trailer connections. Always prioritise safety and compliance with local regulations.

Lamp check systems in vehicle and trailer lighting have come a long way, and understanding their history and challenges is crucial. Originally, these systems used very low voltage to monitor the lamps, and they did so by monitoring the current passing through them. This approach worked well for incandescent lamps, as the low voltage didn’t cause them to light up. However, when LED lamps were introduced, a new problem emerged.

LEDs have higher resistance compared to incandescent lamps, and the existing low voltage systems couldn’t provide enough current to prevent “lamp failure” warnings. Over time, these systems started triggering false warnings, especially as vehicle and trailer connections aged or became contaminated.

To address this issue, the concept of pulsed cold lamp checks was introduced. This innovative solution significantly reduced the occurrence of false “lamp failure” warnings. However, as vehicle owners and drivers started replacing incandescent lamps with LEDs and connecting trailers with LED arrays instead of incandescent lamps, new challenges surfaced.

In the pulsed cold lamp check process, the lamp check units send short pulses of near battery voltage to various lamps within the vehicle’s external lighting system and the trailer lighting connector. It’s essential to note that these lamp check units remain active while the vehicle is in operation, and they may continue emitting pulses even after the vehicle has been turned off.

The key difference lies in how incandescent lamps and LEDs respond to these pulses. Incandescent lamps have low “off” resistance and take some time (between 120 and 250 milliseconds) to emit light when voltage is applied. In contrast, LEDs and LED arrays have high “off” resistance and illuminate almost instantly in response to short lamp check pulses.

Understanding these nuances is crucial for vehicle owners and drivers, especially when considering lamp replacements or connecting trailers with LED lighting systems. The evolution of lamp check systems demonstrates the ongoing efforts to enhance safety and reliability in vehicle lighting.

The warning for a trailer lamp failure may show up in your vehicle when you use the park and stop lights. This warning appears because most vehicles’ lamp check modules can’t check the LED circuits of a trailer’s park and stop lights. To address this issue, load resistors have been added to both the Busta 4.2 and Euro units. These resistors generate heat and waste power, but they are often unnecessary, so they are left unconnected.

If you receive a trailer lamp failure warning, you’ll need to follow these steps:

1. Undo the cable gland tail and remove the rubber seal at the trailer end of the unit by removing the two screws on that end.
2. Inside the unit, you’ll find three wires. If you’re unsure about performing these operations, seek assistance from someone who can help.
3. On the trailer end, use a thin spanner to grip the 19mm (3/4in) body nut of the cable gland to prevent it from rotating and breaking the silicone sealant seal. Loosen the tail with another 19mm (3/4in) spanner and then remove it by hand, sliding it away from the body.
4. Remove the black silicone sealant from the two screw holes in the trailer end plate using a hobby knife or a similar tool. Ensure the O-ring seals under the screw heads are still intact. To access the rubber seal, gently move the end plate along the cable a short distance, then move it back against the unit’s case, and slide the seal along the cable away from the body. Check the sealing gasket on the end plate for any damage.
5. Retrieve the three insulated wires with pre-stripped ends from inside the unit. The White wire has an end cap, while the Red and Black wires have plastic sleeves over the bare wire ends.
6. The White wire serves as the earth wire.
7. The Black wire is for the park circuit load resistor(s) – one resistor for the Mk4 and two resistors for the Euro.
8. The Red wire is for the stop circuit load resistors – two resistors for all units.
9. Depending on the warning you receive:
   • If the lamp failure warning is only for the trailer park circuit, connect the Black wire to the White wire.
   • If the warning is only for the trailer stop circuit, connect the Red wire to the White wire.
   • If the warning is for both the trailer’s park and stop circuits, connect all three wires together.
10. Unscrew the end cap from the White wire and remove the sleeve from the Red and/or Black wires. Straighten the bared wire ends, twist the required wires together, and screw the end cap from the White wire over them to terminate the twisted wires. If only two wires are terminated, leave the sleeve over the remaining unused wire. If all three wires are terminated, the plastic sleeves are no longer needed. Dispose of them thoughtfully.
11. Apply a small amount of neutral cure silicone sealant around the end plate gasket’s surface and reattach the end plate using the original screws (ensure the O-rings under the screw heads are still in place). Apply a small amount of black neutral cure silicone sealant to cover the screw heads, as originally sealed. Slide the rubber seal along the cable and into the cable gland. Hand-tighten the tail onto the cable gland. Use two 19mm (3/4in) spanners, one thin one on the nut, to tighten the tail onto the gland without breaking the silicone sealant seal between the cable gland nut and end plate.

Required Tools and Materials:

To work with the Busta 4.2, you will need the following tools and materials:

1. Busta 4.2
2. Various hand and power tools
3. Test light
4. Soldering iron
5. Solder

Fixings for Installation:

You’ll require the following fixings to mount the Busta 4.2 and attach the cable to the trailer:

• Self-tapping screws
• Screws
• Nuts & washers
• ‘Pop’ rivets
• ‘P’ clips, etc.

Electrical Insulation and Waterproofing:

For electrical insulation and waterproofing, make sure to have the following materials on hand:

• Electrical insulating tape
• Waterproofing materials such as silicone sealant, heat shrink tubing, self-amalgamating tape, and liquid electrical tape, etc.

Warranty Information:

The Busta 4.2 comes with a two-year warranty against defects in parts and manufacture from the date of purchase. Each unit is manufactured with care and sealed to an IP-68 rating. However, please note that this warranty does not cover internal or external corrosion, or any damage caused by liquid or dust ingress once it’s operational.

Maintenance Recommendations:

It’s highly recommended that you regularly inspect the assembly for potential entry points for liquids and dust (such as nicks, cuts, or abrasions) and seal any openings with silicone sealant. This prevents the ingress of liquids or dust, which can corrode the wires and electronics over time. If you encounter damage, please return the Busta 4.2 to LAB Electronics for assessment and repair, as there are no user-serviceable parts inside.

Regulatory Compliance:

The Busta 4.2 does not comply with E/ECE/324 – E/ECE/TRANS/505 regulations, as it does not monitor the trailer’s turn signal LEDs. Therefore, it cannot inform the driver of any faults by turning off the trailer telltale in the instrument cluster. It is the driver’s responsibility to ensure that all vehicle and trailer lighting is functioning correctly.

The Busta 4.2 is designed for use with all 12-volt negative earth towing vehicles adhering to European lighting regulations. It’s specifically tailored for trailers with a single tail/license plate lighting circuit that doesn’t require monitoring of the trailer’s turn signal LEDs. This guide will help you install the Busta 4.2 to enable trailer recognition and control over the trailer’s park, brake, and turn signal LEDs when needed.

Compatibility:

• Busta 4.2 can be used with any towing vehicle, not limited to those following European lighting regulations.

Important Precautions:

• Do not install the Busta 4.2 on a towing vehicle, as it will always register the presence of a trailer.

Getting Started:

1. Carefully read the entire set of instructions before proceeding.
2. If you’re unsure about any step, seek assistance from someone with experience.
3. Refer to the ‘You Will Need’ list further down in this guide and gather all the necessary tools and materials for the installation.

Cable Specifications:

• Busta 4.2 includes a 600mm (2ft) 7-core cable, with each wire rated at 10 amps.
• The cable consists of Yellow (left turn), Green (right turn), Red (brake light), Brown (park/license plate light), and White (earth) wires.
• Each LED driver circuit can handle up to 4 amps of LED current.
• Do not connect any light bulbs to the LED driver circuits on the trailer.

Wiring Preparation:

• Print the plug and socket wiring page provided at the end of this guide.
• Identify and note down the uses and colors of the wires on your trailer.

Ensure you have these tools and materials ready before you start the installation process to streamline the procedure and ensure a successful setup.

Connection Method:

• You have the flexibility to choose your preferred connection method:
  • Solder the individual wires together.
  • Fit them into terminal blocks.
  • Crimp insulated terminals to the wires.
  • Crimp un-insulated terminals to the wires and fit them into plugs and sockets.

Mounting Location:

• Busta 4.2 can become very hot during operation. Ensure proper ventilation.
• Select a location for mounting with adequate ventilation, such as a spacious area under a bench seat, in the trailer’s electrical box, or a similar uncluttered space.

You Will Need:

1. Soldering iron and solder (if you choose to solder the connections).
2. Terminal blocks (if you prefer this connection method).
3. Insulated terminals (for crimping to wires).
4. Un-insulated terminals (for crimping to wires).
5. Plugs and sockets (for alternative connection options).
6. Adequate ventilation space in your chosen mounting location.
7. Wire cutters/strippers.
8. Electrical tape or heat-shrink tubing (for insulating soldered connections).
9. Screwdrivers (if required for securing terminal blocks or plugs).
10. Printed plug and socket wiring page (provided at the end of this guide).
11. A suitable space to mount the Busta 4.2 (e.g., under a bench seat or in the trailer’s electrical box).

Installation Steps:

1. Disconnect the trailer from the vehicle and isolate any power sources in the trailer.
2. Trailer LEDs:
   • Position the Busta 4.2 in your chosen location.
   • Connect the earth wire in the trailer cable to the White wire from the Busta 4.2 and solder them together.
   • Connect the left turn signal wire in the trailer cable to the Yellow output wire from the Busta 4.2 and solder them together.
   • Connect the right turn signal wire in the trailer cable to the Green output wire from the Busta 4.2 and solder them together.
   • Connect the brake light wire in the trailer cable to the Red output wire from the Busta 4.2 and solder them together.
   • Connect the tail/license plate wire from the trailer to the Brown output wire from the Busta 4.2 and solder them together.
3. Vehicle End of Busta 4.2:
   • Connect the lighting cable going to the vehicle plug end of the cable.
   • Connect the earth wire in the trailer cable to the White wire to the Busta 4.2 and solder them together.
   • Connect the left turn signal wire in the trailer cable to the Yellow input wire to the Busta 4.2 and solder them together.
   • Connect the right turn signal wire in the trailer cable to the Green input wire to the Busta 4.2 and solder them together.
   • Connect the brake light wire in the trailer cable to the Red input wire to the Busta 4.2 and solder them together.
   • Connect the tail/license plate wire from the trailer to the Brown input wire to the Busta 4.2 and solder them together.
4. Unused Wires:
   • You may have two unconnected wires, Black and Blue, which pass through the Busta 4.2.
   • If these wires are unnecessary, you can cut them back and leave them disconnected. Otherwise, connect them to the remaining wires in your trailer cable for any additional uses.

Follow these steps carefully to ensure a successful installation of the Busta 4.2 for enhanced trailer functionality.

The Busta 4.2 is designed for 12-volt negative earth towing vehicles adhering to European lighting regulations. It provides trailer recognition and control over the tail/license plate lighting circuit, park lights, brake lights, and turn signal LEDs. This guide will help you install the Busta 4.2 to your trailer effectively.

Compatibility:

• Busta 4.2 is compatible with all 12-volt negative earth towing vehicles adhering to European lighting regulations.
• It can be installed on any vehicle, not limited to those following European regulations.

Important Note:

• Do not install Busta 4.2 on the towing vehicle, as it will always falsely recognize a trailer connection.
• Please read these instructions thoroughly. Seek assistance if needed.
• Refer to the “You will need” list further down this guide to gather tools and materials before installation.

Cabling Information:

• Busta 4.2 comes with a 600mm (2ft) 7-core cable, each wire rated at 10 amps.
• The cable includes Yellow (left turn), Green (right turn), Red (brake light), Brown (park/license plate light), and White (earth) wires.
• Each LED driver circuit can handle up to 4 amps of LED current.
• Do not connect any light bulbs to the LED driver circuits on the trailer.

You Will Need:

1. Busta 4.2 trailer lighting control unit
2. Soldering iron and solder
3. Heat shrink tubing or electrical tape
4. Wire strippers/cutters
5. Trailer plug (if adding a new cable)
6. Screwdriver or appropriate fasteners for mounting
7. Location for mounting with proper ventilation (preferably high and dry)
8. Multimeter (for testing connections, if available)
9. Safety gear, including safety glasses and gloves
10. User manual or wiring diagram for your specific trailer (if available)

Gathering these tools and materials will ensure a smooth and efficient installation of the Busta 4.2 for your trailer.

Installation Steps:

1. Busta 4.2 can get very hot during operation. Ensure proper ventilation, and avoid mounting on heat-sensitive materials.
2. Select a mounting location with adequate ventilation, preferably high and dry. It should be within reach of the trailer’s existing lighting wiring. You may redirect the trailer lighting cable to this location and add a new cable from Busta 4.2 to the vehicle.
3. At the connection points, remove the minimum amount of outer sheath necessary to make the wiring connections. For a cleaner finish, stagger cut the wires and remove only the minimum insulation needed for solder connections.
4. Disconnect the trailer from the vehicle and isolate any power sources in the trailer.

Connecting to Trailer LEDs:

• Fit Busta 4.2 in the selected location.
• Position the trailer’s existing lighting cable up to the trailer end of Busta 4.2.
• Connect as follows:
  • Solder the earth wire in the trailer cable to the White wire from Busta 4.2.
  • Solder the left turn signal wire in the trailer cable to the Yellow output wire from Busta 4.2.
  • Solder the right turn signal wire in the trailer cable to the Green output wire from Busta 4.2.
  • Solder the brake light wire in the trailer cable to the Red output wire from Busta 4.2.
  • Solder the tail/license plate wire from the trailer to the Brown output wire from Busta 4.2.

Connecting to the Vehicle End:

• If adding a new cable, fit a trailer plug to the vehicle end of the new cable.
• Connect as follows:
  • Solder the earth wire in the trailer cable to the White wire from Busta 4.2.
  • Solder the left turn signal wire in the trailer cable to the Yellow input wire to Busta 4.2.
  • Solder the right turn signal wire in the trailer cable to the Green input wire to Busta 4.2.
  • Solder the brake light wire in the trailer cable to the Red input wire to Busta 4.2.
  • Solder the tail/license plate wire from the trailer to the Brown input wire to Busta 4.2.

Unused Wires:

• Two unconnected wires pass through Busta 4.2: Black and Blue.
• If not needed, you can cut and leave them disconnected.
• Otherwise, connect them to the remaining wires in your trailer cable for their intended uses.

By following these instructions, you can successfully install Busta 4.2 for optimal performance in towing your trailer.

Testing Your Trailer’s LED Lights:

1. To ensure the proper functioning of your trailer’s LEDs, first, make sure that all exposed soldered connections are positioned apart and away from contact with each other or any metal parts of the trailer.
2. Reconnect all power sources within the trailer.
3. With the vehicle’s ignition and lights switched off, connect the trailer to your vehicle.
4. Turn the ignition on and verify that any previously blinking trailer LEDs have stopped. Ensure that the trailer’s indicator lights now work with the turn signals and hazard signals of your vehicle.
5. Start the vehicle’s engine, switch on the park lights, and use the foot brake to confirm the operation of the LEDs. Ensure that there are no warnings indicating lamp failures. Refer to the last page if there are any issues.
6. Once all trailer LEDs are functioning correctly, turn everything off and insulate the exposed soldered connections separately.

Insulating and Sealing Connections:

To prevent the entry of liquid and dust into cable ends, follow these steps:

1. Apply a small amount of silicone sealant to seal all open ends of the cable outer sheaths. Use a small screwdriver or a similar tool to push the sealant around the wires.
2. For complete sealing, consider using self-amalgamating tape and/or heat shrink tape over the connections. Ensure that the cable is securely attached to the trailer where required.

Operational Note:

Always connect and disconnect the trailer with your vehicle’s ignition and lights switched off. Connecting or disconnecting the trailer with the vehicle’s ignition and/or lights switched on can lead to malfunctions or unintended operation of some vehicle computer systems.