LEAB MelfBox User manual

www.leab.eu
USER MANUAL
VERSION 4
14/04/2021
MELFBOX
ELECTRICAL SUPPLY SYSTEM
FOR VERHICLES
LEAB Automotive GmbH Thorshammer 6 24866 Busdorf

Table of Contents
1 About this Manual................................................................................................................ 3
2 General Safety........................................................................................................................ 4
2.1 Intended Use............................................................................................................... 5
2.2 Foreseeable Misuse.................................................................................................. 5
3 About this Product............................................................................................................... 5
4 Technical Specifications.................................................................................................... 7
5 Creating a Body Cutout...................................................................................................... 8
6 Installation.............................................................................................................................. 8
7 Assembly.................................................................................................................................. 10
8 Operation................................................................................................................................. 10
8.1 Operating Status........................................................................................................ 11
9 Cleaning and Maintenance............................................................................................... 11
10 Accessories.............................................................................................................................. 12
11 Disposal.................................................................................................................................... 12
12 EU Declaration of Conformity.......................................................................................... 13
Table of Contents LEAB Automotive GmbH

1 About this Manual
Read this manual carefully and keep it in a safe place. This manual is aimed at
Qualified electricians.
Any modifications to the product or its components are prohibited and do not
conform to its intended use. Only use original LEAB or LEAB-approved ac-
cessories.
Throughout the manual, you will be alerted to warnings and safety notices
about potential hazards associated with handling the device. The colours and
signal words indicate the severity of the hazard:
Notice
Possibility of material damage
The signal word Attention indicates that there is a possibility of
material damage. To avoid material damage, follow the
instruction.
CAUTION
Danger that can lead to minor injuries
A safety instruction with the signal word CAUTION denotes a
hazard with a low degree of risk which, if not avoided, can result
in minor or moderate injury. Read the safety information carefully
and follow the instructions to avoid it.
WARNING
Hazards that can lead to severe injuries or death
A safety instruction with the signal word WARNING indicates a
hazard with a high degree of risk which, if not avoided, will result
in death or severe injury. Read the safety information carefully
and follow the instructions to avoid it.
3LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
LEAB Automotive GmbH 1 About this Manual

DANGER
Danger that will lead to severe injury or death
A safety instruction with the signal word Danger indicates a
hazard with a high degree of risk which, if not avoided, will result
in death or severe injury. Read the safety information carefully
and follow the instructions to avoid it.
You will find notes at some points in the manual. These appear as follows:
NOTE
A note provides useful tips and information about the product.
Read the note carefully and follow the instructions where
applicable.
2 General Safety
This manual will help you to handle the system safely. Use the system solely
in accordance with its intended use. Observe the safety instructions.
WARNING
Danger from short circuits
Open and damaged cables can cause short circuits that can lead
to serious injuries.
1. Before operating, make sure there are no open or damaged
cables.
2. Replace defective parts or damaged cables immediately.
4 LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
2 General Safety LEAB Automotive GmbH

Notice
Reverse polarity can damage the equipment
Errors when connecting the cables can cause equipment damage.
1. Before operating, make sure that all cables are connected
correctly.
Notice
Equipment damage and risk of cable fire
Using the unit at too high a voltage can lead to cable fire and
equipment damage.
1. Only use the device within the specified voltage limits.
2.1 Intended Use
The MelfBox is a vehicle electrical supply system.
The system is designed to operate with a nominal voltage of 230 V (+/- 10%).
The IP55 rating protects it against the ingress of dust in damaging quantities
and against water jets.
2.2 Foreseeable Misuse
Only use the system within the specified voltage limits of 230V (+/- 10%).
Do not point a high-pressure cleaner or other devices directly at the system
when cleaning the vehicle.
3 About this Product
The MelfBox is a vehicle electrical supply system. It has a potential-free
switching contact (normally open contact) to create an immobiliser. An elec-
tronic system prevents contact erosion. The operating display provides in-
formation about the current system status.
5LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
LEAB Automotive GmbH 3 About this Product

1
2
3
Fig.1: MelfBox supply unit
1 Operating display 2 Flap
3 Coupling
1
2
3
4
5
1 Cover 2 Housing with body seal
3 Housing seal 4 Cap
5 Retaining screw
6 LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
3 About this Product LEAB Automotive GmbH

4 Technical Specifications
Part no. 1105002001
Modell MelfBox
Nominal voltage (AC) 230 V (+/-10%)
Current, max. (AC) 16 A
Frequency 50 Hz
International Protection (IP class) IP55
Protection class I
Operating display LED
Switch contact 1 A
Material Polyamide, glass fibre reinforced (PA6
GF30)
Cable cross-section 2.5 mm²
Contacts L1/N/PE
Installation depth 56 mm
Installation diameter 55 mm
Weight 0.12 kg
Dimensions (L x W x H) 62 mm x 67 mm x 67 mm
Package Contents
No. Item
1x Cover
1x Housing
1x Housing seal
1x Body seal
3x Screw 3.5x14
1x Cap
7LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
LEAB Automotive GmbH Package Contents

5 Creating a Body Cutout
NOTE
To ensure perfect operation, observe the following notes on the
assembly site:
1. Choose a vertical surface.
2. Choose a site with minimum dust and which is protected from
jet water.
3. Make sure that there is sufficient space at the assembly site.
Fig.2: MelfBox dimensions
To create the body cutout, proceed as follows:
1 Saw a hole (Ø 55 mm) in the vehicle body.
2 To prevent corrosion, seal the cut surfaces.
ðThe body cutout is now created.
6 Installation
Preparation
Before connecting the unit, perform the following steps:
CAUTION!Install a suitable fuse in the vehicle (up to 16A).
1 Route a connection cable (H07RN-F, 3 x 2.5) in the vehicle.
2 Attach the connection cable to the vehicle installation.
8 LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
6 Installation LEAB Automotive GmbH

3 Optional: Route a cable (H05RN-F, 2 x 0.5) for the immobiliser in the vehicle
and connect it to the specific vehicle installation (control module or sim-
ilar).
ðThe unit is now ready to be connected.
Connecting the Supply Unit
To connect the device, proceed as follows:
4 Pierce the housing seal at the intended location with a
pointed tool.
5 Feed the connection cable (H07RN-F, 3 x 2.5) through
the hole.
6 Connect the wires of the connection cable to the cor-
responding screw terminals.
ðThe device is connected.
Optional: Connecting the Immobiliser
NOTE
The MelfBox has a potential-free switching contact (normally open
contact) to create an immobiliser.
The design of the immobiliser depends on the vehicle. Inquire
from your vehicle manufacturer.
To connect the immobiliser, proceed as follows:
CAUTION!Install a suitable fuse in the vehicle (up to 1A).
7 Insert the immobiliser cable (H05RN-F, 2 x 0.5) through
the second hole of the housing seal.
8 Insert the wires of the immobiliser cable into the push-
in terminals (max. current: 1A).
ðThe immobiliser is connected.
9LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
LEAB Automotive GmbH 6 Installation

7 Assembly
To install the device, proceed as follows:
üThe cables in the MelfBox housing are correctly connected.
üThe body seal is firmly seated on the housing.
1 Place the housing seal in the cap.
2 Attach the cap to the supply unit with the 3 screws (3.5 x 14).
3 Check the tightness of the housing seal.
4 Push the supply unit into the body cutout.
5 Tighten the 3 screws on the front until the supply unit
is firmly seated in the body cutout (maximum
torque:1Nm).
6 Attach the cover.
ðThe device is mounted and ready.
8 Operation
Notice
Inactive immobilisers can cause damage
Note that immobiliser only works when the MelfBox is active
(operating display illuminated).
NOTE
Electronics to prevent contact burnout requires voltage
Contact N is electronically switched and is only open when a 230 V
voltage is applied.
10 LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
8 Operation LEAB Automotive GmbH

To install the device, proceed as follows:
1 Plug the two-pin earthed plug of the connection cable into a 230-V mains
supply.
2 Open the flap of the supply unit.
3 Plug the coupling into the supply unit.
ðThe voltage input is provided at the load output of the supply unit. Connec-
ted consumers are supplied. The operating display shows the operating
status of the device.
8.1 Operating Status
LED Operating status
Blue, flashing The MelfBox is active.
A minimum of 50 W power is removed from the supply unit
(the greater the power, the faster the flashing).
Yellow, steady light The MelfBox is active.
No power is removed.
– Check the connection of the consumers.
– Check the fuse at the outlet of the MelfBox.
NOTE!This operating status only occurs immediately after
inserting the MelfBox coupling. The MelfBox does not
switch back from “blue” to “yellow”.
9 Cleaning and Maintenance
WARNING
Danger from electric shock
Cleaning and maintenance work on a live unit can lead to serious
injury from electric shock.
1. Make sure that the device is de-energised before carrying out
any work.
11LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
LEAB Automotive GmbH 9 Cleaning and Maintenance

Notice
Strong jet water can damage the device
Cleaning with strong jets of water can cause the device to become
damaged.
1. Do not aim pressure washers or other devices directly at the
device.
Regular Activities
– Check the equipment for external damage each time before you use it.
– Clean the supply unit once a month with compressed air.
– Protect the coupling and combination cable from being run over, getting
wet and other liquids.
– Check the tightness of the supply unit in the vehicle body at regular inter-
vals.
10 Accessories
You can order accessories either through your dealer or directly from LEAB.
Just visit our webshop at www.leab.eu or call us on: [phone].
Part number Description
1105001001 Connection cable 2.5 m
1105001002 Connection cable 5 m
1105001003 Connection cable 10 m
11 Disposal
Dispose of the device in accordance with the Waste Elec-
trical and Electronic Equipment Regulations (WEEE).
The system must not be disposed of with household
waste. Take it to a recycling point or return it to your
point of sale.
12 LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
11 Disposal LEAB Automotive GmbH

12 EU Declaration of Conformity
The MelfBox complies with the requirements of the fol-
lowing directives:
– 2014/30/EU: EMV
– 2014/35/EU: NRL
– 2011/65/EU: RoHS
13LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
LEAB Automotive GmbH 12 EU Declaration of Conformity

14 LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
12 EU Declaration of Conformity LEAB Automotive GmbH

15LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
LEAB Automotive GmbH 12 EU Declaration of Conformity

LEAB Automotive GmbH
Thorshammer 6
DE-24866 Busdorf
Tel: [phone]
Fax: [phone]
[email protected]
We make energy
mobile.
It is prohibited to copy, duplicate, translate or otherwise pass on the content of
this guide to third parties without the express written permission of LEAB.