Zeliox ZEL16-1,2-EU Guide
User & Installation
Manual
Zeliox Compact
ENGLISH
2
Table of contents
1. Operation 7
2. Main menu 9
3. Engine run signal 11
4. Settings Menu 13
5. Operating conditions 15
6. 12V charger 17
7. Battery 18
8. Sensors 21
9. Potective devices 22
10. Safety 23
11. Trouble shooting 24
1. Installation 26
2. Rear connections 27
3. Engine run signal 30
4. APPENDIX II - MSDS - (Material Safety Data Sheet) 32
5. Glossary and abbreviations 39
6. Technical Information 40
7. Error Zeliox Compact 42
User Manual
Installation Manual
Information contained in this document may be changed without prior notice.
3
Introduction
This manual includes both a user and installation guide
Denition
Welcome to the world of Excessive Power: Zeliox Compact.
The Zeliox Compact is a battery powered mobile power converter designed for
use in vehicles, vessels, tiny houses etc. The inverter supplies different output
voltages, 5V, 12V and 230V. The Zeliox Compact functions are highly reliable and
quiet, without the emission of harmful substances.
Zeliox Compact types:
This user manual is for the Zeliox Compact:
Zeliox Compact
ZEL16-1,20-EU 1600Watt – 1.2kWh - shore power
Dimensions and weight
Dimensions 420 x 190 x 370 mm (l x h x d)
Weight ZEL16-1,20-EU 23 Kg
ZEL16-1.20-EV 22 Kg
Product identication
Zeliox Compact - lithium-ion battery powered inverter
Product Identication Number (PIN)
Unique serial number on the side, in the format: ZC-XX-XXXX
(for example , “ZC-20-0001”)
Initial supplier identier
Zeliox BV
Spaarpot 13,
5667 KV, Geldrop
www.zeliox.com
Telephone number
0031 40 3400 383 General / Sales
0031 40 3400 384 Service
Copyright
Zeliox Compact User manual © 2021 Zeliox Compact. All rights reserved.
Nothing in this document may be reproduced in any way whatsoever or
shared with third parties without the written permission of Zeliox BV.
4
Warnings
WARNING:
• Do not use the Zeliox Compact without fully reading this user manual.
WARNING:
• This is a category C2 UPS product.
• In an inhabited area, this product can cause radio interference, in
which case the user should take additional measures.
• This is a Class I product. Only connect a 230V from a source that is
grounded, including any extension cords.
• This is a Class 9 (hazardous materials UN3481) electrical device,
this means that it is a power source with high energy density and
hazardous materials in a sealed metal housing.
• Make sure that the installation of the Zeliox Compact meets the
IP20 requirements, the lowest degree of protection of the Zeliox
Compact is IP20.
WARNING:
• Check that the Zeliox Compact is not damaged during transport.
If damaged, contact the supplier.
• Disable the Zeliox Compact completely (on/off switch) and check for
dangerous voltages before changing a connection.
• Make sure that the Zeliox Compact is connected correctly and
according to the instructions for use.
• The installation must be done according to the national guidelines.
• The installation must be carried out by professional installers only.
• When installing, national security regulations must be strictly
housing, installation, spacing, clearance, markings and separation.
• Heavy inductive loads can cause damage to the Zeliox Compact.
Additional optional measures are needed for this type of high loads.
For more safety information, see Appendix II – MSDS (Material Safety
Data Sheet pag. 32-40).
5
Notes
Please note
• Do not submerse in water.
• Do not short-circuit.
• Do not open the Zeliox Compact.
• Do not discharge the Zeliox Compact before fully charging it.
• Charge only within the indicated limits.
• Keep the Zeliox Compact turned off during movement and
installation.
• Do not place the Zeliox Compact upside down or on its back.
• Do not switch the Zeliox Compact in series or in parallel.
•
• Do not cover or block the fan air intake/outlet.
• Do not plug into its own socket.
Risks in case of re:
• Risk of explosion.
• Combustion gases that are highly irritating to the eyes and respiratory organs.
General measures to be taken by the driver when these risks occur:
• Turn off the engine.
• Place a warning signal on the road to warn others.
• Inform others of the risk and make sure you stay out of the wind.
lithium batteries (UN3481) on board.
In case of re:
• Ventilate.
• If possible, immerse the Zeliox Compact completely in water.
oxide are formed.
• Possibly extinguishing with a carbon dioxide extinguisher.
NON SPILLABLE
LI-ION BATTERY
6
User
Manual
Zeliox Compact
ENGLISH
7
1. Operation
1.1 Operation Zeliox Compact
To operate the Zeliox Compact push the on/off switch with LED (1) and the
TFT screen (2).
1. On/off switch
2. Socket outlet
3. Control screen
1.1.1 On/off switch
With a push of the on/off switch, the Zeliox can be switched on and off.
The button contains a LED that can display various statuses* of the Zeliox
Compact.
An optional dashboard connector has the same function one to one.
* LED statuses:
• Constantly on: the Zeliox Compact is on.
warning to the end user that the Zeliox is connected to the mains and that
driving away is not possible. If necessary, the Zeliox Compact can
be connected to the start interrupter of the vehicle. Ask for the
possibilities at your supplier.
mode and needs to be charged.
5
6
1
34 2
4. Light sensor
5. USB type A 5V 2A
6. Fan air
8
1.1.2 TFT control panel
The Zeliox Compact can be fully operated via the TFT control panel.
The control panel is a resistive touch screen for better robustness.
1.1.3 USB type A
No data exchange takes place over this output, only a voltage of 5V is
offered. The maximum current that the Zeliox Compact can deliver is 2A
distributed between the two connectors.
Type Connector: USB type A.
1.1.4 230V outlet
This standard socket (Schuko) allows you to connect your electrical
devices.
Use a extension cord if multiple devices need to be used at the same
time. Make sure that the total power does not exceed the Zeliox Compact
Do not use a extension cord connected to the Zeliox Compact outside the
harness (vehicle/vessel) if the Zeliox is not connected to the mains.
The voltage on this connector is around 230V/50Hz and is purely
sinusoidal, which results in less electromagnetic radiation.
The maximum output power is 1600W.
1.1.5 Light sensor
The light sensor is located at the front next to the USB, it is used for
ambient dimming.
1.1.6 Fan air
Do not block or cover the intake or outlet.
9
2. Main menu
Using the various icons, the Zeliox Compact can be operated and the
statuses can be viewed.
2.1 Status information on the main menu
2.1.1 The following statuses are displayed on the main menu:
1. Vehicle charging status – Indicates whether the Zeliox is charging via
the vehicle.
2. 230V in status – Indicates whether Zeliox Compact is connected to
shore power.
3. Status information – Displays the various voltages in the Zeliox Compact.
4. Isolation monitor status – Indicates the status of the isolation monitor.
5. Zeliox settings statuses – Indicates which settings are active.
6. Various operational statuses.
7. Settings menu – Only accessible by the experts of Zeliox® (installation
manual).
8. 230V out-Indicates whether the 230V output is active (operable).
9. 12V out-Indicates whether the 12V output is active (operable).
10. Current indication–Indicates whether there is power running to the
various outputs.
11. Main battery status – Displays the current capacity of the main battery.
D B F
ISO:
Status:
1
2
3
4
5 6
7
8
9
1011
10
2.1.2 Control options from main menu
The following can be operated via the main menu:
• 230V output
• 12V output
• Status page
• Settings menu
2.1.3 Various Operational statuses
This trio of spheres displays the following statuses:
D
– Lights up green when DC/DC converter (vehicle charging) is active
B
– Lights up green when backup battery is charging
F
– Lights up green if Main battery is full
2.1.4 Isolation guard status
These three colored spheres display the status of the insulator watchman:
– Green: 230V in available
– Yellow: Isolation monitor active
– Red: Isolation error detected
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3. Engine run signal
3.1 Setting engine running signal
3.1.1 Introduction
The engine running signal is used by the Zeliox Compact to detect whether
the alternator produces voltage. If this signal is not adjusted properly, there
is a chance that the Zeliox Compact will not be charged or that the battery
of the vehicle will be drained by the Zeliox Compact.
The engine running signal of the Zeliox Compact can be set via the main
screen of the Zeliox Compact (software-wise), this in contrast to the D +
boxes which must be adjusted with a set potentiometer.
3.1.2 Required materials
The following materials are needed to set the engine running signal:
• Vehicle
• (Digital) Voltmeter
• Pin code
3.1.3 Procedure
Follow the following procedure:
1. Measure the voltage on the battery when the engine is idling, note this
value as V battery.
2. Measure the voltage on the battery with idling motor, note this value
as V idle.
3. Start the Zeliox Compact.
4. Go to the settings menu:
Note:
A PIN code is required
for this menu.
5. Enter the PIN code (0000).
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6. Press the option: Engine Runs hyst.
7. First, the upper voltage limit is requested, this is the value at which the
Zeliox Compact begins to charge. The value to be entered is V idle - 0.2.
For example, V idle = 14.4V then the value to be entered is 144 (period
is added automatically). Type the value and exit with enter.
8. Then the lower voltage limit is requested, this is the value at which
the Zeliox Compact stops charging again. The value to be entered is
V battery + 0.5. For example if V battery = 12.7V then the value to be
entered is 127 (period is added automatically). Enter the value and exit
with enter. The lower limit MUST be lower than the upper limit, if not,
the procedure starts again.
9. Now press the arrow to the left twice (bottom left), The Zeliox Compact
now asks if the changes should be rejected (discard changes),
press NO.
10. Changes are now saved and the engine running function can be tested.
13
4. Settings Menu
4.1 Display settings
A number of Zeliox Compact settings can be adjusted via this menu.
The settings menu contains the following options:
4.1.1 Code
To change the settings enter the code 0000
4.1.2 Display xed dimming
If the touch screen is not touched, the display will dim slowly. When the
display is touched, it will light up at full strength. This reduces the own
power consumption of the Zeliox Compact.
4.1.3 Display ambient dimming
The backlight adapts to the ambient brightness, the power consumption
4.1.4 Set time and date
The Zeliox is set at the right time from the factory. The date has the
following format: DD/MM/20YY
4.1.5 Mute
The buzzer of the Zeliox Compact can be switched off via settings. The
Zeliox Compact will only generate sound in case of errors. If mute is set,
this way, this way you get feedback when touching the touchscreen.
4.1.6 Undervoltage beep
When the Zeliox Compact is in undervoltage, a beep will be generated in
(of by default).
4.1.7 Language setting
You can set the language of the Zeliox Compact. The language is displayed
at the top right.
• Dutch (NL)
• English (EN)
• German (DE)
• French (FR)
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4.1.8 12V at start
The 12V output is active when this option is set (off by default).
4.1.9 230V at start
The 230V output is active when this option is set (on by default).
4.1.10 Marquee status
With this setting the marquee can be switched on/of, in the area above
the Zeliox logo, additional information can be shown:
• Fan 1 and 2 speed
• Battery temperature
• Battery voltage
• Auxiliary voltage
• Air pressure
15
5. Operating conditions
5.1 Operating the Zeliox Compact
5.1.1 Introduction
This chapter describes the various Zeliox Compact modes and how to get
into these modes.
5.1.2 Zeliox off
In this mode, the Zeliox is completely off:
• Led in power switch off
• Display off
• No voltages on the outlets
In this position the main battery is continuously monitored to detect
undervoltage. Undervoltage will eventually damage batteries beyond repair.
In case of damage, they will have to be replaced by a Zeliox expert.
5.1.3 Zeliox Compact operating condition “on”
In this state the Zeliox Compact is not connected to the mains, and
the 230V inverter is switched on. 230V will be applied to both front
immediately available, but can be switched via the 230V-out icon on the
touch screen.
• USB 5V/2A is not switchable and always available, unless the Zeliox
Compact is switched off.
• The 12V output is available and can be turned on via the 12V icon on the
touch screen.
• The white LED in the on/off switch lights up constantly as an indication
that the Zeliox Compact is on.
5.1.4 Enable “on” operating state
The Zeliox Compact can be switched on by the on/off switch. There are
more ways to turn the Zeliox Compact on: via the mains or incoming power
via 12V. For more information, see the following chapters.
16
5.1.5 Operating status “interactive charging via shore power”
In this state, the Zeliox Compact is connected to the mains and the charger
will be active. 230V will be applied to both front (schuko socket) and the
can be switched via the 230V-out icon on the touch screen.
• USB 5V/2A is not switchable and always available, unless the Zeliox
Compact is switched off.
• The 12V output is available and can be turned on via the 12V icon on the
touch screen.
•
charging is active.
5.1.6 Operating condition “automatic charging via shore power”
This mode can be used when the Zeliox Compact is connected to a timer.
This also prevents the inverter from being left on unnecessarily when the
voltage drops.
The following voltages appear directly on the respective outputs:
• 230V at the front and rear
• 5V front USB
On the display, the 230V-in icon will light up and the LED in the switch will
manually via the main menu.
5.1.7 Operating status “Autonomous charging via shore power”
switch on and off (long term storage)
started. Connect the Zeliox Compact to the shore power, this will now
start to charge. Press the on/off switch, a warning will be shown that the
Zeliox Compact is charging. Press the on/off switch again and the Zeliox
Compact will turn off.
The Zeliox Compact will now turn on when the battery comes into
undervoltage and will charge. After the batteries are fully charged, the
Zeliox Compact will automatically switch off again.
17
6. 12V charger
6.1 Installations with a 12V charger
6.1.1 Operating status “on, with recharging from alternator”
The Zeliox Compact connected to the alternator in this state and it is
charging. The “vehicle “charger of the Zeliox Compact is now active.
Because the Zeliox Compact is switched on via the on/off switch, the 230V
inverter will be active. 230V will be applied to both front (Schuko socket)
available, but can be switched via the 230V-out icon on the touch screen.
USB 5V/2A is not switchable and always available, unless the Zeliox
Compact is switched off.
The 12V output is available and can be turned on via the 12V off icon on
indicate that charging is active.
6.1.2 Operating status “on, with charging from alternator” switch on and off
First switch on the Zeliox Compact via on/off switch, then start the engine,
the Zeliox Compact is now recharged and the outputs are available. Turn
off the engine to stop the top-up. Use the on/off switch to turn off the
system.
6.1.3 Operating status “autonomous charging alternator”
Charge while driving. The Zeliox Compact will automatically start up as
soon as the alternator starts charging. During this mode it is not possible
to operate the touchscreen, only a status is visible. USB 5V output is still
available in this mode.
6.1.4 Operating status “autonomous charging alternator” switch on and off
The Zeliox Compact must be off. As soon as the alternator starts charging,
the Zeliox Compact will wake up and start charging. The Zeliox Compact
will go out again as soon as the alternator stops charging.
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7. Battery
7.1 Battery Mode
7.1.1 Introduction
The main battery of the Zeliox has a voltage range of 10 to 14.4 Volts. This
voltage determines in which condition the Zeliox Compact operates. The
following operating conditions are:
• Discharge mode
• Battery protection mode
• Power safety mode
• Charging mode
7.1.2 Discharge mode
In this mode, the Zeliox Compact is not charged via shore power or
vehicle charging and the required energy is extracted from the internal
main battery. The following conditions determine how long the end user
can use this mode:
• Charge level of the internal main battery
• Load capacity connected to the Zeliox Compact
• To a lesser extent the ambient temperature of the Zeliox Compact
• The age of the Internal main battery
The voltage of the internal battery in this mode is between 10.2 and
14.4 volt, when reaching a voltage of 10.2 volts, the Zeliox Compact will
switch to battery protection mode.
7.1.3 Battery Protection Mode
Do not fully discharge the internal battery, this is not good for the service
life. To extend the life of the main battery, the voltages on the outputs
are switched off (except for the USB output as it is limited to max 1A).
The voltages on the outputs come back when the main battery reaches a
voltage of 12V or when the Zeliox Compact is connected to the mains.
In this mode, the Zeliox Compact will indicate on the display that the main
battery needs to be charged.
Since the Zeliox Compact itself also uses energy, the main battery voltage
will slowly decrease further to a level of 9.8V. When this voltage is reached,
the Zeliox Compact will switch to Power safety mode to further protect the
main battery.
19
7.1.4 Power safety mode
The power safety mode starts when the main battery reaches a voltage
below 9.8 volts. The Zeliox Compact will go completely off.
The Zeliox Compact control unit will operate entirely on a back-up battery.
Power consumption is minimized and the Zeliox Compact will give a
warning for about 7 days via the LED in the on/off switch. This LED will
The Zeliox Compact can be restarted by the following actions:
• Connecting to the mains
• Turn on contact (vehicle/vessel)
The main battery will be recharged after the Zeliox Compact is connected
to the mains or the contact is turned on. The Zeliox Compact will switch
off again after 10 seconds if the ignition is turned on, but the alternator
does not charge.
If the backup battery runs out, please contact Zeliox.
7.1.5 Charging mode
The Zeliox Compact is connected to the mains or charged by the alternator.
Charging will remain active until the battery has reached a voltage of 14.4
Volts. The charger places a higher voltage on the main battery due to the
alternator. The battery level indicator will not indicate the nominal voltage
of the main battery but will be based on the charging voltage.
7.2 Battery behaviour
7.2.1 Introduction
This chapter describes the behaviour of a LiFePO4 battery that is of
interest to the end user.
7.2.2 Battery characteristics
The main battery in the Zeliox Compact is of the type LiFePO4. This
lightweight battery has some good features such as high energy density.
A theoretical ideal voltage source has a number of characteristics:
• Constant voltage
• Internal resistance of 0 ohms
• Unlimited power
• Temperature independent
20
7.2.3 Lithium battery
A Lithium battery is unfortunately not ideal, the end user will have to take
this into account.
The internal resistance of a Lithium battery is sub milli (one thousandth)
ohm. At high currents, the voltage of the battery will therefore drop. After
removing a high current, the voltage of the battery will recover. The cables
to which the battery is connected also give a loss.
7.2.4 Voltage
The voltage that the battery delivers depends on the current charge. If the
charge of the battery decreases due to consumption, the voltage of the
battery will also decrease.
7.2.5 Chemical process
A chemical process takes place in the battery in which charge moves.
The mobility of this charge determines the amount of energy that can be
delivered over a certain period of time.
It is therefore possible that at high load, the battery cannot supply the
requested energy. This does not mean that the battery is empty, but it will
recover afterwards.
7.2.6 Battery protection
The ambient temperature affects the behaviour of the battery. A Lithium
battery should not be charged below 5°C to prevent damage to the battery.
The charging circuit of the Zeliox Compact is therefore switched off below
5°C and the discharge of the battery is switched off at 0°C. (a winter
package is optionally available).
The end user should be aware of the battery limitations above as they
7.2.7 Battery behaviour
It is possible that the stresses of the individual cells differ when the main
battery comes in undervoltage. This is normal behaviour and not a cause
Due to a number of protective measures in the Zeliox Compact, the life of
the battery will be extended.
eventually needs to be replaced.
Table of contents
