Powairbox manual Eng
Contents
1. and before initial use and always follow the respective instructions Please keep this manual near the device for future reference so that operators can use it to find out about the device s functions Contents Important noteonusingthedevice u ne oo see sense ce ee ee ee ee ees i 2 3 Eo R l m a 10 Technical data a hos zu bu a wb ae a Ben he WE en an ae 11 CE Declaration ofConformity 2 222 ce ee seen nenne nennen SCODE OF SUDONY nc au un 0 Bene we an ae AEAEE EEES an 26 Se oe So ae ee Performance characteristics and operating functions Installations and assembly Installation Spot u 262s nto 000 00 au 00 a eR Seow ew na le ran ar Installation Connection of power and compressed dir 2 ec ee ee Completion Installation of the ceiling device optional 0 0 00 ee en COUDIING CONNGCHON ssas za a de os Ba A Bn ed ae A es Se ae oe hn de DDELALON 554 66 oa ak oe oe krer inou ee a ee Be he Hos Gh 58 oh oh oe Oe Troubleshooting 4 44 4 ox wees wd ae au Sn be be es ed Se we Maintenance and service 0 oo ce ee ee nennen een en ee as Warranty conditions ce ce ce ee ce ee en een nenn Spare parts accessories ke ee nennen ee te ee en nen Dimensional drawing o ae 22 cc ce nee nen ernennen ee te ee e vn DAN DA ANH NN LA WH KH Wh A WH WH W Ln mB Ww N H 9 O 1 Scope of supply With the LEAB PowAirBox 12V 24V 230V y2. device with or without charger Combined cable 230V amp compressed air Power distributor 230V Compressed air Compressor 8 10 bar Energy distribution at the station y power amp compressed air PowAirBox supply 3 Installation and assembly When selecting the installation location the installation process itself and electrical connection to the on board power supply observe the specifications in the vehicle body manufacturer s manual and general technical regulations Electrical work on cables and consumers and the connection set up should only be carried out by appropriately authorised electrical specialists Installation spot The PowAirBox must be installed on a vertical surface to guarantee perfect function Ideal installation locations are near the driver door or on the rear of the vehicle Make sure there is sufficient installation space available This particularly applies to the necessary installation depth of 121 mm The PowAirBox cover can be opened to the left or right space requirements must be checked here too Installation The PowAirBox is delivered with the mounting frame already mounted this serves as an installation template at the same time Loosen the 6 black screws hexagon socket 2 5 mm and remove the mounting frame Place the mounting frame in the installation position on the surface of the vehicle and mark the inner contour of the frame and the 6 screw holes The rubber sea
3. ordered from LEAB Service at bestellung leab eu or in the LEAB shop at http shop leab eu under specification of the article number Ceiling device Supply adapter Mounting frame Installation seal Champ 1230 Pro Champ 2420 Pro CPC 1230 CPC 2430 CTS CTS 10 Description PowAirBox ceiling device with stainless steel holder PowAirBox adapter Schuko gt PowAirBox 5 0 m PowAirBox mounting frame VA PowAirBox seal for installation Battery charger Champ 1230 Pro Battery charger Champ 2420 Pro Battery charger CPC 1230 J117C Battery charger CPC 2430 J114C Combined sensor cable voltage temperature for CPC battery chargers 5 0m Combined sensor cable voltage temperature for CPC battery chargers 10 0 m Article number 1549000000 1549230022 9970360000 9970250002 0101043890 0101043891 0101036930 0101036931 1601035598 1601035595 Inquiries for spare parts can be made by calling 49 4621 9780 110 or sending an email to bestellung leab eu 13 9 Dimensional drawing 121 5 163 110 DETAIL B 1 1 Alle Angaben in mm 14 10 Technical data Supply voltage Rated current Compressedair Contacts standard Display On board voltage Lifting magnet Material Dimensions Weight charging station Type of protection Weight coupling Choice of 12 V 24 V or 230 V 20A Max 13 bar 5 pole of which 2 are auxiliary contacts Battery state of
4. PowAirBox 12V 24V 230V Supply system for power and compressed air with automatic ejection PowAlrBox 230 V 20A LEAB User Manual Vio www leab eu Important information about this documentation The technical data information and illustrations have been put together carefullyand correspond to the production status atthetime the documentation was prepared However the manufacturer retains the right to improve or modify the products specifications and documentation without notice at any time according to technical requirements and the latest development status The descriptions have been prepared in detail and with great care Nevertheless errors can never be ruled out entirely No liability will be accepted for errors of damage which could originate from these or from faulty interpretations The contents of this documentation may not be copied reproduced translated or forwarded to third parties in any other way without the express permission of LEAB Automotive GmbH Caution Safety note non observance can lead to personal injury or material damage as well as impair the device function Caution Hazard through electric voltage Safety note non observance can lead to injuries and death as well as damage or destroy the device Note Supplementary information on how to handle the device Important note on using the device To avoid operational errors you should read this manual carefully before installation
5. central terminal B first to make installa tion easier Once all the cables and compressed air pipe if appropriate have been connected to the charging station push the PowAirBox into the cut out Carefully insert the 6 hexagon socket screws and tighten them evenly until the rubber seal is flush cleanly all the Do not use an electric or way round pneumatic screwdriver to Use medium strength threadlocker tighten the M4 screws to avoid unintentional loosening at a later date Installation of the ceiling device optional We recommend the optional ceiling device see accessories Chapter 8 for trouble free operation Ceiling device with multi cable Stainless steel mounting frame PA cover Mount the mounting frame on the ceiling at a distance of about 30 cm away from the side ofthe vehicle If the distance is not large enough the cable will swing back after ejection and could get caught in the vehicle body If the distance is too large the cable could swing too far from the vehicle and could touch the vehicle parked next to it The length of the cable must be dimensioned in such a way that the coupling does not touch the floor A distance of 60 to 80 cm is usually ideal This avoids mechanical damage to the coupling and contact with the wet depot floor Coupling connection When connecting the cable to the coupling assign the wires as follows Function Combined cable power compressed air Electric cable H07 BQ
6. charge charge control undervoltage alarm Universal 12 and 24 VDC Universal 12 and 24 VDC Glass fibre reinforced polyamide See drawing 1 2 kg without cable P55 1 14 kg with 4 m multi cable Length of connection cable charging station and coupling 4 m standard other lengths on request Warranty 36 months 11 CE Declaration of Conformity The product LEAB PowAirBox 12V 24V 230V with without compressed air supply complies with the requirements of the directives 2011 65 EU of the European Parliament and Council dated 8th June 2011 restricting the use of certain hazardous substances in electrical and electronic devices The following EU directives were applied 2006 95 EC 2004 104 EC and Low Voltage Directive 72 245 EEC Busdorf 31 01 2014 5 N U 7 L Bart Westerkamp Managing Director 15 LEAB www leab eu LEAB Automotive GmbH Thorshammer 6 24886 Busdorf Germany T 49 0 46 2197 860 110 F 49 0 46 2197 860 260 powairbox leab eu O N 4 N Q 5001 isO vg emen 09 fs QA IS A le
7. green yellow green yellow 1 brown 2 blue Auxiliary contact 1 5 black 4 Auxiliary contact 2 grey Both auxiliary contacts are bridged in the coupling to show the message mains connected to the vehicle If you want to use the auxiliary contacts for transmitting data to or from the vehicle the auxiliary contacts in the coupling must be connected according to the table above The PowAirBox cable must not be used together with balancers cable winders or similar These systems might lead to the coupling in the PowAirBox becoming jammed and not being ejected and consequently to a lapse of warranty 4 Operation The battery display on the charging box indicates the current state of the battery connected Insertthe PowAirBox coupling into the PowAirBox charging box To do this use your thumb to turn the box cover up to the side the cover will pivot away and reveal the plug contacts Insert the coupling into the charging box until you can feel and hear it click in place The coupling is actually held in place bya particularly strong magnet The vehicle s batteries are now charged which is signalised by a circulating and flashing display Start the vehicle engine to eject the coupling automatically and interrupt the power and compressed air supply 5 Troubleshooting If your PowAirBox is not working as it should please try to localise the fault using the following procedure first Has the starter been p
8. he specifications of the vehicle body manufacturer s manual when connecting the air line If you connect permanent voltage to terminal B the current battery voltage will always be displayed Completion Once all the cables have been routed properly in the vehicle and connected correctly connect the plugs to the respective terminals on the PowAirBox charging Station When inserting the plugs turn them slightly to the left and right until the guide engages and then tighten the sealing cap by hand Terminal B 2 wired cable to permanent voltage Battery indicator brown blue Terminal A 2 wired cable to starter clamp 50 brown blue Do not connect sees e eee e e permanent voltage Terminal C Connection to 2 auxiliary e o contacts contacts are bridged in the coupling and be used for indication or start prevention Compressed air hose ee Hose 6 mm is mounted only with type PowAirBox A Output 12 24 or 230V Depending on the type 2 or 3 pin connector 2 pol 12 24 V plus pin 1 minus pin 2 to battery 2x 4mm 3 pol 230 V 3 wires to 230 V cabinet 3x 2 5 mm LEAB charger can come with appropriate plug ready to run plug amp go Do not use any tools when screwing the plugs into the terminals in order to avoid damage to the plugs or thread Assign plugs and terminals correctly and do not mix them up in order to guarantee correct function We recommend occupying the
9. l is already glued to the back of the mounting frame Do not remove the protective film from the adhesive tape yet e o Cut or nick the marked inner area out and drill the marked holes using a drill size 4 5 to5 mm Br RN N o Wm N SS L aM O o UNE The mounting frame is made of stainless steel and has 6 press in nuts Screw the 6 x 4 mm threaded pins provided into the nuts by hand from the smooth side Check whether the mounting frame fits the cut out from the inside and whether the threaded pins fit easily m al through the drilled holes Sealthe cut surfaces and drilled holes with zinc primer or similar to avoid corrosion later Once you have made sure that everything fits pull the protective film offthe rubber seal and glue the frame into the cut out from the inside The threaded pins can now be removed they are no longer required Connection of power and compressed air We recommend routing the connection cables provided and the compressed air hose in the vehicle and connecting this to the on board voltage and the 230V on board installation before final installation of the PowAirBox charging station Then connection to the PowAirBox should be made via the cable screw connections Terminal A The start signal for the ejector magnet should ideally be provided via terminal 50 starter control Do not connect permanent plus This could destroy the ejector magnet Note t
10. ou have purchased a high quality power and compressed air supply system for emergency vehicles Please check before use whether the following items are included in the scope of supply e PowAirBox charging station type A with compressed air supply or B without compressed air supply e PowAirBox coupling with 4 m cable Connection cable A for charging station plug amp play length 4 m Connection cable B for charging station plug amp play length 4 m Connection cable C for charging station plug amp play length 4 m e Connection cable output 12 24V 2 wire or 230V 3 wire for charging station plug amp play length4 m Connection hose for compressed air length 4 m only for version A for compressed air Mounting frame for PowAirBox charging station Attachment screws hexagon socket A2 black M4x25 6 pcs English manual this document optional further cable lengths on request If the scope of supply does not correspond to these items or the PowAirBox coupling or connection cable are damaged please contact your dealer or LEAB directly If you should require an additional manual you can download this in PDF format from www leab eu free of charge or access our product page directly by smartphone If you should require spare parts or accessories for your LEAB PowAirBox please see section 8 of this manual and send your order by email to powairbox leab eu 2 Performance characteristics and ope
11. ovide more information Clean the coupling and charging box cable regularly to guarantee perfect function and detect any damage immediately Protect the coupling and cable from being driven over by vehicles other mechanical damage and wet conditions Protect the cable from damage by sharp edged vehicle or building parts Do not use the pivoted cover of the PowAirBox to hang cables or jackets on Check regularly that the screws are tight Have regular checks done in accordance with accident prevention regulation BGV A3 Do not used a damaged PowAirBox or parts of one again Replace faulty parts or damaged cables without delay Only use the PowAirBox for the voltages given Always have any necessary repairs done exclusively by LEAB Always make sure the device is voltage free before starting work Spare parts can be purchased from your specialist dealer or from LEAB directly 11 7 Warranty conditions Providing installation has been carried out professionally and the devices are used according to their intended purpose LEAB offers mandatory warranty overa period of 36 months after the date of purchase If any defects of faulty functions should occur during this period under normal conditions of use LEAB will either repair the device free of charge or replace it at their own discretion New or repaired parts of equal value can be used for replacement A warranty claim cannot be recognised under the following ci
12. rating functions The LEAB PowAirBox is asystem which supplies both electrical power and compressed air to emergency vehicles by using a special coupling and multi cable The coupling is automatically disconnected from the vehicle when the vehicle engine is started the protective cover closes automatically The battery indicator standard feature provides reliable information about the current state of charge of the vehicle battery as well as the charging process Two auxiliary contacts in the PowAirBox can be freely assigned and used either for signal transmission or to establish start prevention as required There are two systems available e PowAirBox type A for supplying power and compressed air at the same time PowAirBox type B for supplying power Each of these systems is available either for 12 24 or for 230V supply Coded pins prevent plugs and couplings of different voltages being mixed up Systems with and without compressed air are 100 compatible and can also be inserted mixed alternately In this case there is no air supply but no loss of air either PowAirBox charging station and coupling are delivered with 4m connection cable each in the standard version Other lengths are available on request Connection in the vehicle is by means of lockable IP68 plug contacts We recommend the use of the PowAirBox in connection with the built in battery chargers of the series LEAB ABC LEAB CPC and LEAB Champ Ceiling
13. rcumstances The device was not used in accordance with the recommendations given in this manual The device was used for purposes other than general automotive solar industrial or maritime applications without prior agreement with LEAB The device was repaired or modified without express permission from LEAB The device shows signs of damage caused by overload penetration of humidity water oil acid mechanical force excess or insufficient voltage or any other non intended use Pre conditions for warranty payments Warranty claims can be made to your specialist dealer or LEAB directly The following documents are required Invoice or delivery note Model description or type Serial number Detailed description of the fault and installation if appropriate Procedure If the device cannot be put back into operation perfectly according to the instructions in this manual or if the fault persists contact your dealer s Service department or LEAB directly If this is no help either please request a processing form and processing number RMA number as well as a free UPS pick up sticker free UPS pick up service unfortunately only possible in Germany by calling 49 0 4621 97860 120 or sending a mail to service leab eu You can send the defective device to us together with these documents free of charge We will then examine it and repair it if necessary 12 8 Spare parts accessories The following accessories can be
14. ressed Press the starter Coupling is not ejected Power at terminal 50 Measure the voltage at terminal 50 Coupling jammed Has acable winder been used Battery display not shown Battery connected Check terminal B connection Check Flor LS in the depot Charger not charging 230V voltage at the coupling Check the supply cable Check Fl or LS in the vehicle If this is not successful please contact your specialist dealer or LEAB Have the serial number and date of purchase on hand as well as an accurate description of the fault so that we can help you as quickly as possible 10 6 Maintenance and service Regular tests Check the PowAirBox regularly before every use as follows e Supply cable and coupling undamaged e Charging station undamaged e Supply cable fixed securely to the ceiling e Have the coupling and cables been in contact with water oil or other fluids When used commercially the LEAB PowAirBox is part of an electrical installation in the sense of the German accident prevention regulation BGV A3 This employers liability association regulation prescribes the regular testing of devices for electrical safety usually once a year Please clarify with your employers liability association whether you are affected by this or any comparable regulation and take the measures necessary for the safety of your employees Your employers liability association or work accident insurance company will be able to pr
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