Optronics introduces OEM-integrated trailer charging system
Optronics International has introduced the Co27 DC-DC Battery Charger, a patent-pending intelligent charging system designed to address chronic battery failures in commercial trailers caused by undercharging through traditional 7-pin wiring connections.
Commercial trailers equipped with electric-over-hydraulic power packs, powered landing gear, and liftgates frequently experience premature battery failure, with standard diode-and-fuse connections through the 7-pin connector creating voltage drop, which prevents batteries from charging beyond roughly 50% to 60% capacity. In colder temperatures, that reduced state of charge can render a lead-acid battery effectively unusable.
The Co27 is engineered to eliminate that cycle. Installed within the trailer and connected through the existing 7-pin plug, the unit activates when it detects 13.2 volts or higher from the towing vehicle’s alternator. A software-driven algorithm delivers a three-stage charging process for lead-acid batteries—bulk, absorption, and float—to restore and maintain full capacity. Lithium-iron-phosphate batteries receive an optimized two-stage cycle. Battery chemistry is selected during installation through a simple wiring configuration, allowing fleets and OEMs to standardize on one unit across battery types.
“The cost of not having this product is significantly higher than the cost of having it,” said Mathew Jenkins, president and CEO of Optronics International. “One bad experience, a failed dump cycle, a stalled liftgate, or a battery replacement that pulls an operator off the road can easily exceed $1,000 when you factor in the battery, the service call, and lost productivity. The Co27 is equivalent to the cost of just one battery.”
The Co27 also features adaptive current management. Upon activation, it measures circuit resistance between the trailer and towing vehicle. If high resistance is detected due to corroded connectors, aging wiring, or undersized conductors, the unit reduces current draw to protect upstream wiring and fuses. When conditions permit, it charges at its full 10-amp capacity.
To prevent parasitic drain, the charger draws zero standby current when the towing vehicle is not running, helping parked trailers retain charge between jobs.
Chronic undercharging affects more than battery replacement costs. Reduced voltage can slow dump cycles, strain hydraulic motors, and increase wear on components more expensive than the battery itself. In severe cases, operators may be unable to complete deliveries, delaying payment and impacting revenue.
The Co27 is being released alongside a new Dump Trailer Wiring Harness Kit from the Optronics USA Harness division, engineered to minimize voltage drop and optimize charging performance. The combined offering provides trailer manufacturers with an integrated electrical solution that includes charging, modular wiring harnesses, and lighting systems.
Housed in a sealed anodized aluminum enclosure with stainless steel fasteners, the Co27 carries an IP67 rating for dust and water resistance and has been proven in the Australian commercial vehicle market for more than 15 years under extreme operating conditions.
The charger supports 12-volt towing vehicles charging 12- and 24-volt lead-acid batteries as well as 12-volt lithium-iron-phosphate systems and is backed by a two-year limited warranty. The Co27 is currently available in limited stock.
The company will showcase the Co27 at NTEA Work Truck Week 2026, March 10–13, at the Indiana Convention Center in Indianapolis.