LEAB PowAirBox II 230 V Supply Unit Kit User Manual

POWAIRBOX II
230 V, TYP A + B
PowAirBox II User Manual

VERSION 3
17.11.2023
www.leab.eu
LEAB Automotive GmbH
Thorshammer 6
24866 Busdorf

About this user manual

Read this user manual carefully and keep it in a safe place. This user manual is intended for Users with previous knowledge in the field of automotive electrics.
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.
Within this user manual, you will be notified of potential hazards involved in handling the device through warnings and safety instructions. The colours and signal words indicate the severity of the hazard:

Notice
Possibility of material damage
The signal word Notice 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.

You will find useful tips and tricks in some parts of the user manual. These appear as follows:

TIP
Tips provides additional, useful information.
Read the tip carefully and follow the instructions where applicable.

Safety

This user manual is designed to help you handle the unit safely. Use the unit solely in accordance with its intended use. Observe the safety instructions.

DANGER
Electric shock due to disconnection of the coupling
Driving off with the coupling plugged in can cause the coupling to tear off and open cables.

1. When plugging in, make sure that the combination line hangs loosely and is not taut.
2. Do not use cable winders or similar for the combination line.
3. Do not hang any objects or items of clothing on the coupling or combination line.
4. Make sure that there is always enough space to eject the coupling.
5. LEAB recommends setting up a start prevention system using the auxiliary contacts of the PowAirBox II.

WARNING
Risk of injury 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
Risk of injury due to cable fire
Using the unit at too high a voltage or current can cause a cable fire.

1. Only use the unit within the specified voltage and current limits.

WARNING
Risk of injury due to damaged, protruding parts
Damaged, protruding parts can catch people when driving past.

1. Always ensure that the protective cover of the PowAirBox II is undamaged and not bent.
2. Regularly check the housing of the PowAirBox II for sharpedged damage and scratches.

CAUTION
Risk of injury due to bursting
Excessive pressure in the compressed air system can cause components to burst and result in injuries.

1. Observe the maximum pressure limit of 13 bar.

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 and unit damage.

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 II is a system for feeding current (230 V, 16 A) and compressed air (max. 13 bar) into emergency vehicles. All live components of the PowAirBox II are insulated against contact in accordance with protection class II.
In addition, the PowAirBox II is protected against dust and water jets in accordance with IP55 rating and is therefore suitable for outdoor use.
The system components of the PowAirBox II may only be installed by qualified electricians. The unit is used and applied by non-specialists.

2.2 Foreseeable misuse
The feeds and couplings of the PowAirBox II system are mechanically coded according to the respective supply voltage and cannot be interchanged. However, the couplings of PowAirBox types A and B (with and without compressed air) can be plugged in mixed  with the same supply voltage. When a type B clutch is plugged into a type A PowAirBox, the vehicle is supplied with the correct voltage, but not with compressed air.

About this product

The PowAirBox II type A allows current and compressed air combined to be supplied combined in a single line via a special plug-in device. The type B variant is identical in construction, but does not contain a compressed air feed. When the vehicle engine is started, the inserted coupling is automatically disconnected from the vehicle or it can be manually ejected by operating the touch sensor. The protective cover closes automatically. The operating display provides reliable information on the current charge status of the connected battery and the charging process. Two auxiliary contacts installed in the PowAirBox II serve to establish a start locking mechanism.

The supply unit and coupling are supplied with prefabricated connection cables. The connection in the vehicle is made via lockable plug-in connectors.

3.1 The PowAirBox II System

1. Ceiling bracket
2. Supply unit

When installing the PowAirBox system in the vehicle depot, LEAB recommends direct connection to the electricity and compressed air distribution with the LEAB PowAirBox ceiling bracket (1). The combination cable (electricity and compressed air) leads from the ceiling bracket to the supply unit installed in the vehicle (2). LEAB also recommends the use of built-in chargers such as the ABC, CPC or Champ Pro series.
For vehicle depots without a complete PowAirBox II system, LEAB also offers supply adapters with different plug connections (e.g. CEE).

3.2 Supply Unit Structure

Fig. 1: PowAirBox II front view

Fig. 2: PowAirBox II connection side

1. Socket D: Connection for CAN and auxiliary contact 3
2. Socket C: Connection for auxiliary contacts 1 and 2
3. Socket A/B: Connection for battery and ejection signal
4. Connection for 230 V output
5. Connection for the compressed air hose (type A only)

Technical specifications

| PowAirBox II, type A| PowAirBox II, type B
---|---|---
Part number| 1101002001| 1101002002
Compressed air (type A), max.| 13 bar| –
Installation depth, supply| 75 mm| 75 mm
Supply current, max.| 16 A (AC)| 16 A (AC)
IP rating| IP55| IP55
Protection class| II| II
Auxiliary contacts| 2| 2
Nominal voltage, supply unit| 230 V| 230 V
Voltage, vehicle battery| 12 V or 24 V (universal)| 12 V or 24 V (universal)
Low voltage alarm| LED + acoustic| LED + acoustic
Cable length, supply| 4 m| 4 m
Material| Polyamide, glass fibre reinforced (PA6 GF30)| Polyamide, glass fibre reinforced (PA6 GF30)
Operating display| LED| LED
Dimensions (L x W x H)| 192 mm × 109 mm × 100.5 mm| 192 mm × 109 mm × 100.5 mm
Weight| 1.2 kg| 1.2 kg

Package contents

Assembly

For installation and assembly of the PowAirBox II components, please refer to the installation instructions enclosed separately.

Operation

DANGER
Risk of electric shock due to water ingress
An open, damaged or torn protective cover can lead to water penetration.

1. When opening the protective cover, make sure that it is undamaged.
2. Before plugging in the coupling, check that there is no water in the supply unit.

WARNING
Risk of injury from using an incorrectly coded coupling
Feeding in the wrong voltage can lead to damage or fire of connected devices.

1. Only use a coupling that is coded according to the appropriate supply voltage.
2. Never remove one or more coding pins from the plug connection.
3. Do not attempt to insert the coupling into the supply unit by force.

CAUTION
Risk of injury from over-tightening the protective cover
Turning the protective cover beyond the upper engagement point (maintenance position) can cause cuts or crushing injuries to the hands.

1. Turn the protective cover only as far as necessary to plug in the coupling.

Notice
Caution when opening the protective cover
Improper opening can damage or tear off the protective cover.

1. To open the protective cover, turn it only in the direction of the directional arrow on it.
2. Do not pull on the protective cover to open it.
3. Do not turn the protective cover beyond the engagement point (maintenance position).
4. If the protective cover is damaged or missing, contact LEAB Service as soon as possible.

To commission the unit, proceed as follows:
The PowAirBox II is ready for operation as soon as all associated components have been properly assembled and installed. The level of on-board power supply (12 V or 24 V) is automatically detected. If the coupling is connected to the PowAirBox II, power and compressed air are fed in automatically. When the coupling is plugged in, the status display lights up permanently.

7.1 Plugging in the coupling
To plug in the coupling, proceed as follows:
CAUTION! Do not use the protective cover as a bracket for jackets or similar.
CAUTION!  Observe the direction arrow on the protective cover.

1. Turn the protective cover sideways upwards until the insertion opening is completely exposed.
2. Plug the coupling into the PowAirBox II supply unit.
3. If you have turned the protective cover up to the maintenance position and it has engaged there, turn it back again until it rests against the plugged-in coupling.

⇒ The coupling is plugged in, connected consumers are supplied with power and compressed air. The status display indicates the status of the PowAirBox II and the connected battery.

7.2 Ejecting the coupling

Notice
Contact erosion when the coupling is pulled out manually during operation
Contact erosion leads to increased wear and malfunction of the plug connection.

1. Do not pull the coupling by hand to disconnect it from the PowAirBox II.
2. LEAB recommends using only the automatic ejection by starting the vehicle engine or operating the touch sensor on the PowAirBox II.

To automatically eject the coupling, do one of the following:
NOTE! The automatic ejection has a minimal delay to protect the contacts, but this does not lead to any disturbance of the driving operation.

1. Start the vehicle engine or
2. Operate the touch sensor on the PowAirBox II for 2 seconds.

⇒ The coupling is automatically ejected. The power and compressed air supply is interrupted.

7.3 Operating status
If the vehicle is not connected to the supply unit, the status display is switched off. To check the state of charge, proceed as follows:

1. Press the touch sensor for 1 second.
   ⇒ The current state of charge of the starter battery is displayed for 5 seconds.

… 26.4 V
3| Yellow: Battery charge status is below 40%| 11.8 V … 12.1 V| 23.6 V … 24.2 V
4| Red: Battery charge status is below 20%| 11.5 V … 11.8 V| 23.0 V … 23.6 V
5| Red (flashing) + acoustic signal:
Low-voltage alarm, battery charge level is below 10%| < 11.5 V| < 23.0 V
No.| LED status display (supply unit)| Meaning
---|---|---
1| Blue (flashing)| 230 V applied
2| Red| Error, no 230 V supply
3| Red (flashing) after plugging in the coupling| Current draw below 5 W
– Check the fuse of the vehicle
4| White| Touch sensor pressed or the ejection signal of the vehicle applied

Maintenance

DANGER
Electric shock due to missing PE protective conductor contact
A sheared or torn out PE protective conductor contact can lead to electric shock with serious or fatal injuries.

1. Protect the supply line with a residual current device (RCD).
2. Regularly ensure that the condition of the PE contact in the PowAirBox II supply unit is perfect. This is slightly longer than the other contact pins.

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.

TIP
Maintenance position of the protective cover
To provide better access for maintenance work, the protective cover locks into the upper position.

1. Turn the protective cover upwards until it engages and the supply unit does not close again automatically.
2. After completing maintenance, turn the protective cover back manually.

Regular Tasks

• 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 liquids.
• Protect the coupling and the combination cable from being run over.
• Regularly check the screw connections of the supply unit to the vehicle body.

Disposal

Dispose of the device in accordance with the Waste Electrical 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.

EU Declaration of Conformity

The PowAirBox II complies with the requirements of the following directives:

• 2014/30/EU: EMV
• 2014/35/EU: NRL
• 2011/65/EU: RoHS

We make electricity mobile.
LEAB Automotive GmbH
Thor’s Hammer 6
24866 Busdorf
Tel: +49 (0) 4621 9 78 60-0
Fax: +49 (0) 4621 9 78 60-260
info@leab.eu

References

• Spezialist für mobile Stromversorgung // LEAB // mobile energy

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