LEAB PowAirBox A 12 V User manual

www.leab.eu
USER MANUAL
VERSION 5
18/11/2021
POWAIRBOX
12 V, 24 V, 230 V
TYPE A+B
LEAB Automotive GmbH Thorshammer 6 24866 Busdorf

Table of Contents
1 About this Manual................................................................................. 3
2 Safety .................................................................................................... 4
2.1 Intended use ...................................................................................... 5
2.2 Foreseeable misuse ........................................................................... 5
3 About this product................................................................................. 6
3.1 The PowAirBox System ...................................................................... 6
3.2 Supply Unit Structure......................................................................... 7
3.3 Coupling structure ............................................................................. 8
4 Technical specifications ......................................................................... 8
5 Package contents................................................................................... 9
6 Preparation ........................................................................................... 10
6.1 Creating a body cutout ...................................................................... 11
7 Installation ............................................................................................ 12
8 Assembly ............................................................................................... 14
8.1 Mounting the Supply Unit.................................................................. 14
8.2 Connecting the Coupling.................................................................... 14
8.3 Optional: Mounting the Ceiling Bracket ............................................ 15
9 Operation .............................................................................................. 15
9.1 Ejecting the coupling.......................................................................... 17
10 Maintenance ......................................................................................... 17
11 Disposal................................................................................................. 18
12 EU Declaration of Conformity ................................................................ 18
13 Connection Diagram .............................................................................. 19
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
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.
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LEAB Automotive GmbH 1 About this Manual

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.
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 Safety
This manual will help you to handle the unit safely. Use the unit solely in ac-
cordance 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.
WARNING
Danger of cable fire
Using the unit at too high a voltage can cause a cable fire.
1. Only use the unit within the specified voltage limits.
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2 Safety LEAB Automotive GmbH

Notice
Unit defect and faulty ejection due to incorrect connection of
the control modules
Connecting the control modules directly to the unit may result in
faulty ejection of the control modules and unit defect.
1. Do not connect the control modules directly to the unit.
2. Always use an additional relay.
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.
2.1 Intended use
The PowAirBox is a system for supplying electricity and compressed air to
emergency vehicles. With protection class II and protection class IP55, the
PowAirBox is protected against dust and water jets and is therefore suitable
for outdoor use.
2.2 Foreseeable misuse
The supply units and couplings of different voltages (12 V, 24 V, 230 V, 400 V)
each have their own coding and cannot be interchanged. However, with the
same voltage, both types A and B of the PowAirBox are compatible and can be
plugged together to supply a vehicle with power. There is no compressed air
supply, but also no compressed air loss.
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LEAB Automotive GmbH 2 Safety

3 About this product
With the PowAirBox, power is fed in via a special plug-in device. The PowAir-
Box type A combines the supply of electricity and compressed air in a single
line. When the vehicle engine is started, the coupling is automatically discon-
nected from the vehicle and the protective cover closes automatically. The
status display provides reliable information about the current charge status of
the connected battery and the charging process. Two auxiliary contacts in-
stalled in the PowAirBox serve to establish a start locking mechanism.
The supply unit and coupling are supplied with prefabricated connecting
cables. The connection in the vehicle is made via lockable plug-in connectors.
3.1 The PowAirBox System
1 Ceiling bracket 2 Supply unit
When installing the PowAirBox system in the vehicle depot, LEAB recom-
mends direct connection to the electricity and compressed air distribution
with the LEAB PowAirBox ceiling bracket (1). The combination cable (electri-
city and compressed air) leads from the ceiling bracket to the supply unit in-
stalled in the vehicle (2). LEAB also recommends the use of LEAB ABC, LEAB
CPC or LEAB Champ Pro built-in chargers.
For vehicle depots without a complete PowAirBox system, LEAB also offers
supply adapters with different plug connections (e.g. CEE).
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3 About this product LEAB Automotive GmbH

3.2 Supply Unit Structure
1
2
Fig.1: PowAirBox feed front view
1 Protective cover 2 Operating display
1
2
3
45
Fig.2: PowAirBox feed rear view
1 Socket A: Ejection connection 2 Socket B: Connection for the
battery
3 Socket C: Start locking
mechanism
4 Load output connection
5 For type A only: Compressed air
hose connection
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LEAB Automotive GmbH 3 About this product

3.3 Coupling structure
1 2
Fig.3: PowAirBox coupling
1 Combination cable 2 Coupling socket
4 Technical specifications
PowAirBox nominal
voltage
Part number
– 12 V
– 24 V
– 230 V
– Type A: 1549012100
– Type A: 1549024100
– Type A: 1549230100
– Type B: 1549012200
– Type B: 1549024200
– Type B: 1549230200
PowAirBox type B PowAirBox type A
Nominal voltage, supply
unit
12V, 24V, 230V
(depending on variant)
24V or 230V (depending
on variant)
Supply current, max. 16A (AC), 20A (DC) 16A (AC), 20A (DC)
Voltage, vehicle battery 12 V or 24 V (universal) 12 V or 24 V (universal)
Compressed air (type A),
max.
- 13 bar
International Protection
(IP class)
IP55 IP55
Protection class II II
Cable length, supply 4 m 4 m
Auxiliary contacts 2 2
Operating display LED LED
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4 Technical specifications LEAB Automotive GmbH

PowAirBox type B PowAirBox type A
Low voltage alarm LED + acoustic
(interval: 6 s)
LED + acoustic
(interval: 6 s)
Material Polyamide, glass fibre
reinforced (PA6 GF30)
Polyamide, glass fibre
reinforced (PA6 GF30)
Weight 1.2 kg 1.2 kg
Installation depth, supply 121 mm 121 mm
Dimensions (L x W x H) 193 mm x 110 mm
x 145 mm
193 mm x 110 mm
x 145 mm
5 Package contents
Scope of delivery of the supply unit
Total type A Total type B
PowAirBox supply unit x 1 x 1
Connection cable for
connector A, B, C
x 3 x 3
Connection cable for load
output
x 1 x 1
Compressed air hose x 1 -
Connector,
compressed air (IQS)
x 1 -
Mounting frame with seal x 1 x 1
Body seal x 1 x 1
Threaded pin x 6 x 6
M4 screw (Allen 2.5 mm) x 6 x 6
Adhesive tapes for
mounting frame
x 2 x 2
User manual x 1 x 1
Scope of delivery of the coupling
No.
PowAirBox coupling 1x
User manual 1x
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LEAB Automotive GmbH 5 Package contents

6 Preparation
TIP
Requirements for 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.
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6 Preparation LEAB Automotive GmbH

6.1 Creating a body cutout
1. Undo the 6 M4 screws (Allen 2.5 mm) from the power supply.
2. Remove the mounting frame.
3. Place the mounting frame at the assembly site.
4. Mark the inside contour of the frame and the 6 screw holes.
5. Cut out the marked area.
6. Drill the marked holes (Ø 4,5 mm – 5 mm).
7. Screw the 6 threaded pins by hand into the smooth side of the mounting
frame.
8. Glue the 2 adhesive strips to the smooth side of the mounting frame.
9. Check that the threaded pins fit through the holes from the inside.
10.To prevent corrosion, seal the cut surfaces and boreholes.
11.Remove the protective film from the adhesive strips.
12.Glue the mounting frame to the cutout from the inside.
ðThe body cutout is now created. You can connect the supply unit.
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LEAB Automotive GmbH 6 Preparation

7 Installation
WARNING
Warning against loss of pressure in the compressed air tank
A loss of pressure in the compressed air tank during assembly and
installation can lead to serious injuries.
1. Never heat the compressed air hose.
2. Make sure that a non-return valve is installed on the vehicle
side.
Before installing the unit, proceed as follows:
1. Lay the connecting cables supplied and the compressed air hose in the
vehicle.
2. Install suitable fuses for the connection cables A and B (see connection dia-
gram).
3. Attach the connection cables to the vehicle installation.
4. Connect the compressed air hose to the vehicle’s compressed air tank.
NOTE!A detailed connection diagram can be found in the appendix of this
user manual.
Connection socket A: Ejection
NOTE!A detailed overview of the connections can be found in section Sup-
ply Unit Structure [}7].
To connect socket A, proceed as follows:
5. Connect the red positive lead with terminal 50 (starter control) or terminal
15 (switched ignition plus) to socket A (1) for the transmission of the start
signal.
NOTE!The pulse duration of the start signal must be at least 2 s (for the
delayed ejection).
6. Install a fuse in the positive lead (according to ISO 8820-3) as close to the
starter battery as possible: 12 V= 3 A; 24 V= 6 A.
7. Connect the black negative lead to the negative terminal of the starter bat-
tery.
ðSocket A is connected.
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7 Installation 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.
Correct polarity of the connections at the load output:
–2-pin for direct current (12 V and 24 V)
–3-pin for alternating current (230 V).
Connection socket B: Battery
NOTE!A detailed overview of the connections can be found in section Sup-
ply Unit Structure [}7].
To connect socket B, proceed as follows:
8. Connect the red positive lead to the positive terminal of the starter battery
for the supply voltage of the PowAirBox with socket B (2).
9. Install a fuse in the positive lead as close to the starter battery as possible
(according to ISO 8820-3): 12V= 1A; 24V= 1A.
10.Connect the black negative lead to the negative terminal of the starter bat-
tery.
ðSocket B is connected.
11.Optional: Use the two bridged auxiliary contacts at socketC(3) to create a
start locking mechanism.
CAUTION!Max. voltage: 24 V (5 A)
12.Connect the consumers (e.g. charger) to the load output (4).
NOTE!Only use the IQS connector supplied to connect the compressed air
hoses.
13.Connect the enclosed compressed air hose (5) to the compressed air hose
already installed in the vehicle.
ðThe supply unit is installed. You can now mount the supply unit.
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LEAB Automotive GmbH 7 Installation

8 Assembly
8.1 Mounting the Supply Unit.
üAll wires on the back of the PowAirBox are correctly connected.
1. Push the supply unit into the body cutout.
2. Remove the 6 threaded pins.
3. Insert the 6 M4 screws (Allen 2.5 mm) and tighten the screws until the body
seal is flat.
4. To prevent accidental loosening of the screws, apply a threadlocker, e.g
Loctite 243.
ðThe PowAirBox supply unit is mounted and ready to use.
8.2 Connecting the Coupling
TIP
Device defect due to faulty ejection
Incorrect ejection of the coupling due to a tensioned combination
cable can lead to equipment failure.
1. Do not use cable winders or similar in the vehicle depot.
2. When plugging in, make sure that the combination cable
hangs loosely and is not taut.
To connect the coupling, proceed as follows:
NOTE!The auxiliary contacts of the coupling are bridged at the factory in or-
der to establish a start locking mechanism.
1. Connect the connection lines of the combination cable to the power and
compressed air distribution in the vehicle hall. The wires in the combination
cable are numbered accordingly.
2. Connect the connecting leads of the electric cable to the power distribution
in the vehicle depot.
ðThe coupling is connected.
CAUTION!To ensure smooth operation, ensure that the coupling does
not touch the depot floor when unplugged. LEAB recommends a distance of
approx. 70 cm from the depot floor.
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8 Assembly LEAB Automotive GmbH

8.3 Optional: Mounting the Ceiling Bracket
1 Mounting frame 2 Cover
3 Assembled mounting frame and
cover
1. Select a mounting location with a lateral distance of approx. 30 cm from the
vehicle.
2. Install the mounting frame (1) on the depot ceiling.
3. Guide the cover (2) onto the coupling’s combination cable.
4. Insert the combination cable through the bracket opening on the mounting
frame.
NOTE!If necessary, remove individual sealing rings from the bracket open-
ing.
5. Connect the coupling lines with the power and compressed air distribution
at the vehicle depot. (seeconnection diagram).
6. Slide the cover over the mounting frame and fasten it with the screw cap.
ðThe ceiling bracket is mounted.
9 Operation
Notice
Contact erosion when pulling under load
Contact burnout may occur when pulling under load.
1. Do not pull the coupling out of the supply unit when under
load.
2. LEAB recommends using only automatic ejection.
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LEAB Automotive GmbH 9 Operation

Fig.4: PowAirBox
supply unit commis-
sioning
To commission the unit, proceed as follows:
1. Turn the protective cover sideways pointing upwards.
CAUTION!Observe the direction arrow and do not
use the protective cover as a bracket for jackets or sim-
ilar.
NOTE!When plugging in, make sure that the nose of the
coupling is facing to the blue dot on the PowAirBox.
2. 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
status display indicates the status of the PowAirBox
and the connected battery.
1
2
3
4
5
No. Function Battery voltage
12 V battery 24 V battery
1Chaser: Battery is
fully charged.
13.3 V 26.5 V
2Operating dis-
play: Current
voltage of the
battery.
12.6 V… 13.2 V 25.2 V… 26.4 V
3 12.2 V… 12.5 V 24.4 V… 25.1 V
4 12.1 V… 11.6 V 23.1 V… 24.3 V
5Low voltage
alarm
< 11.5 V < 23.0 V
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9 Operation LEAB Automotive GmbH

9.1 Ejecting the coupling
To reject the coupling automatically, proceed as follows:
1. Start the vehicle engine.
ðThe clutch is automatically ejected. The power and compressed air supply is
interrupted.
NOTE!The automatic ejection has a minimal delay to protect the contacts,
but this does not lead to any disturbance of the driving operation.
10 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.
Regular Activities
– Check the unit for external damage each time before you use it.
– Clean the coupling, supply unit and the combination cable regularly.
– Protect the coupling and the combination cable from damp and other li-
quids.
– Protect the coupling and the combination cable from being run over.
– Regularly check the screw connections of the supply unit to the vehicle
body.
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LEAB Automotive GmbH 10 Maintenance

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 LEAB PowAirBox types A and B complies with the re-
quirements of the following 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

13 Connection Diagram
1 PowAirBox supply unit 2 Socket C: Start locking
mechanism
3 Load output connection 4 Socket A: Ejection connection
5 Socket B: Connection for the
battery
6 PowAirBox coupling
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LEAB Automotive GmbH 13 Connection Diagram

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.