LEAB MelfBox User manual

www.leab.eu
USER MANUAL
VERSION 2
06/01/2022
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 ......................................................................... 6
5 Creating a Body Cutout.......................................................................... 7
6 Installation ............................................................................................ 8
7 Assembly ............................................................................................... 9
8 Operation .............................................................................................. 10
8.1 Operating Status ................................................................................ 11
9 Cleaning and Maintenance .................................................................... 11
10 Accessories............................................................................................ 12
11 Disposal................................................................................................. 12
12 EU Declaration of Conformity ................................................................ 12
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 accessories.
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
Safety instructions with the signal word CAUTION indicate a hazard
which, if not avoided, can result in minor or moderate injury. Read
the safety instructions carefully and follow them to avoid the hazard.
WARNING
Hazards that can lead to severe injuries or death
Safety instructions with the signal word WARNING indicate a hazard
which, if not avoided, can result in death or severe injury. Read the
safety instructions carefully and follow them to avoid the hazard.
DANGER
Danger that will lead to severe injury or death
Safety instructions with the signal word Danger indicate a hazard
which, if not avoided, will result in death or severe injury. Read the
safety instructions carefully and follow them to avoid the hazard.
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LEAB Automotive GmbH 1 About this Manual

You will find useful tips and tricks in certain parts of the manual. These appear as
follows:
TIP
Tips provides additional, useful information.
Read the tip 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.
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 cor-
rectly.
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.
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2 General Safety LEAB Automotive GmbH

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 electronic system
prevents contact erosion. The operating display provides information about the
current system status.
1
2
3
Fig.1: MelfBox supply unit
1 Operating display 2 Flap
3 Coupling
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LEAB Automotive GmbH 3 About this Product

1
2
3
4
5
1 Cover 2 Housing with body seal
3 Housing seal 4 Cap
5 Retaining screw
4 Technical Specifications
Part no. 1105002002
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
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4 Technical Specifications LEAB Automotive GmbH

Package Contents
No. Item
1x Cover
1x Housing
1x Housing seal
1x Body seal
3x Screw 3.5x14
1x Cap
5 Creating a Body Cutout
TIP
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.
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LEAB Automotive GmbH 5 Creating a Body Cutout

6 Installation
Preparation
Before connecting the unit, proceed as follows:
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.
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 similar).
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 corres-
ponding screw terminals.
ðThe device is connected.
Optional: Connecting the Immobiliser
TIP
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.
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6 Installation LEAB Automotive GmbH

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. cur-
rent: 1 A).
ðThe immobiliser is connected.
TIP
To protect the contacts of the immobiliser, their cable is connected to
the MelfBox via a Phoenix plug.
1. Before disassembling the MelfBox, disconnect the Phoenix plug
of the immobiliser cable above the connection terminals.
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.
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LEAB Automotive GmbH 7 Assembly

8 Operation
Notice
Inactive immobilisers can cause damage
Note that immobiliser only works when the MelfBox is active
(operating display illuminated).
TIP
Electronics to prevent contact burnout requires voltage
Contact N is electronically switched and is only open when a 230 V
voltage is applied.
To install the device, proceed as follows:
1. Plug the two-pin earthed plug of the connection cable into a 230-V mains sup-
ply.
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. Connected
consumers are supplied. The operating display shows the operating status of
the device.
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8 Operation LEAB Automotive GmbH

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.
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.
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LEAB Automotive GmbH 9 Cleaning and Maintenance

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 intervals.
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 EU Declaration of Conformity
The MelfBox complies with the requirements of the follow-
ing directives:
– 2014/30/EU: EMV
– 2014/35/EU: NRL
– 2011/65/EU: RoHS
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12 EU Declaration of Conformity LEAB Automotive GmbH

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LEAB Automotive GmbH 12 EU Declaration of Conformity

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12 EU Declaration of Conformity LEAB Automotive GmbH

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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.