Manual High-Power Battery Charger ACE 12/90

The ACE 12/90 high-power battery charger charges up to three battery banks with a total of 90 A. The manual explains installation, cabling, selecting the charging curve with DIP switches, parallel operation and the LED indicators.

Manual edition: The PDF manual gives no date or version number. It applies to the ACE 12/90, 24/45, 24/60, 24/80 and 24/100; this page contains the content for the ACE 12/90. Manual as PDF (English) · Go to product: ACE 12/90 high-power battery charger

Contents

Scope of delivery

  • Battery charger
  • one AC input connector
  • one DC output connector
  • one TEMP-AL temperature sensor
  • the operating manual

Safety and installation location

The unit meets class I according to EN 60335-2-29. Installation and initial commissioning should be left to an electrician or professional installer, and on pleasure craft in accordance with ISO 13297. Before maintenance work the AC mains is disconnected; never work on the unit while it is live.

  • The PE terminal must be connected to the earth conductor of the installation and connected before all other terminals. The charger may only be energised when closed. The installation must have a double-pole residual current circuit breaker with 30 mA sensitivity.
  • The charger is mounted vertically, with the connections pointing downwards. Other positions can reduce the available power and impair the IP protection.
  • Leave a clear area of 150 mm around the unit for ventilation and for opening. Do not place anything on the charger.
  • Mounting with 4 × M6 round-head screws (head diameter under 10 mm). Housing 270 × 360 × 130 mm; the drilling spacings are shown in the dimensional drawing.
  • The housing may only be operated closed. The power section may only be opened with permission from philippi, otherwise the warranty is void.

Dimensional drawing of the ACE 12/90 high-power battery charger with housing 270 × 360 × 130 mm and drilling spacings

Wiring diagram and cabling

Typical installation of the ACE 12/90 high-power battery charger with residual current circuit breaker, fuses at the batteries and temperature sensor

A typical installation needs a residual current circuit breaker with overcurrent protection (RCB), suitable fuses at the batteries and a temperature sensor in the battery compartment. Appendix 4 of the PDF manual shows further cabling variants, for example with one engine battery, with engine plus house batteries or with three house batteries.

The main cable entry runs through a cable gland, and the battery cables run through cable grommets. When connecting or disconnecting a cable, the power supply is switched off and the batteries are disconnected from the charger.

AC side: The unit works automatically on single-phase mains from 90 to 265 V AC and 47 to 65 Hz. Minimum cross-section of the AC cables for the ACE 12/90: 3 × 4 mm² at 115 V and 3 × 2.5 mm² at 230 V. Where the mains can be 115 V or 230 V, the cross-section for 115 V always applies. Use cable ferrules without insulating collar; the upstream circuit breakers must match the unit. The charger runs as soon as it is live and stops when it is disconnected from the mains or via the circuit breaker.

When using a generator, first check compatibility (power, voltage, overvoltage, frequency). The manual strongly recommends disconnecting the charger from the AC mains when the generator is started. Damage caused by voltage surges is excluded from the warranty.

Battery side: Disconnect the batteries before connecting. Check polarity and voltage with a calibrated voltmeter; voltage, current and setting must match the battery type. The connections are M6 threaded studs.

Terminal Connection
-BAT Negative of the batteries
+BAT E Positive, starter battery (engine)
+BAT 1 Positive, house battery 1
+BAT 2 Positive, house battery 2

For battery cables up to 3 m in length, the minimum cross-section for the ACE 12/90 is 35 mm², and the diameter of the connection hole is 6 mm. If you have fewer than three batteries, leave the unused terminals unconnected.

Avoiding interference: Keep at least 2 m away from sensitive devices, earth shielded cables at both ends (recommendation), keep power and battery cables separate and separate power cables from control cables by at least 200 mm.

Settings with DIP switches

The charger is set to the battery type and application with DIP switches. Settings are made with the AC input and DC output disconnected. There are three switch groups:

  • SW1200 (A, B, C, D): battery type
  • SW1201 (E, F): E switches boost, F switches refresh
  • SW1202 (1 to 4): ID of the charger on the CAN bus or LIN bus

Battery type (A to D), values for the 12 V model. The manual gives the values for 24 V; for 12 V batteries they are halved.

A B C D Battery type Maintenance (U1) Charging (U2) max. boost max. absorption
0 0 0 0 Lead-acid, flooded 13.4 V 14.1 V 2 h 4 h
1 0 0 0 (factory) Lead-acid, sealed 13.8 V 14.4 V 2 h 4 h
0 1 0 0 Gel 13.8 V 14.4 V 2 h 4 h
1 1 0 0 AGM (refresh not recommended for all AGM types) 13.6 V 14.4 V 2 h 4 h
0 0 1 0 Spiral cell 13.6 V 14.4 V 2 h 4 h
1 0 1 0 Lead-calcium-tin 14.4 V 15.1 V 2 h 4 h
0 1 1 0 Winter storage/standby, sealed battery 13.4 V 13.4 V 0 h 0 h
1 1 1 0 Power supply mode 12.0 V 12.0 V 0 h 0 h
0 0 0 1 SPE1 (flooded battery) 13.2 V 14.8 V 2 h 4 h
1 0 0 1 LiFePO4 with BMS (with protection relay) 13.8 V 14.4 V 6 h 1 h
0 1 0 1 Stormline 13.7 V 14.5 V 2 h 6 h
0 1 1 1 reserved for CAN bus
1 1 1 1 reserved for the HPO-DISPLAY-R remote display

The voltages apply at +BAT 1, +BAT 2 and +BAT E at 10 % of the rated current (tolerance ±1 %). Some specific settings are possible; please ask us.

Boost and refresh: Boost charges faster, is time-controlled and ends automatically when the battery current falls below 20 % of the rated current. Switch E switches boost off. Refresh periodically applies a voltage step to maintain the battery, promote its equalisation and prevent sulfation; switch F activates the function.

ID (SW1202): When using the CAN bus or LIN bus, a unique ID from 0 to 15 must be selected. In parallel operation via the LIN bus, ID 5 is the master, and IDs 13, 14 and 15 are slave 1, 2 and 3.

Factory setting: lead-acid sealed, boost on, refresh off. This compromise charges classic lead-acid, gel, AGM, spiral cell and LiFePO4 batteries with BMS satisfactorily. The installer sets the unit depending on the battery type, application and the cross-section and length of the output cables, and decides whether boost is needed. For special batteries, the battery manufacturer's specifications apply. philippi elektrische systeme GmbH is not liable for battery damage or inefficient charging.

Temperature sensor, P-BUS, parallel operation and remote display

  • Temperature compensation: The temperature sensor adjusts the absorption and floating voltage to the temperature of the battery compartment, at -18 mV/°C for the 12 V model. No compensation is applied for winter storage/standby, stabilised DC supply and LiFePO4 with BMS.
  • P-BUS: The unit has two sockets for 6-pin Molex Microfit 3.0 connectors (reference 43025-0600). The HPO-T cable special accessory is plugged into one of them to integrate the unit into the P-BUS (in the shop: ACE-T-KABEL HPO). The manual names the P-BUS system monitors PSL and PSM as remote display, for example P-BUS System Monitor PSL.
  • Parallel operation: With the KIT-HPO-LINK parallel connection kit, up to 4 chargers can be connected in parallel, with balancing and charge control via the LIN bus (connector X1200).
  • Remote display: The HPO-DISPLAY-R touchscreen remote display is connected to the LIN bus (X1200).
  • Connections: J1201/J1202 CAN bus, X1200 LIN bus or remote display, X1201 temperature sensor.

Charging curve and thermal derating

With boost on, the unit delivers a five-stage IUoU curve with automatic weekly recycling: boost, absorption, floating, refresh, reboost.

  • Boost (bulk charge): starts at switch-on when the battery is empty; the current is at its maximum.
  • Absorption (full charge): begins when the boost voltage is reached; the current falls. Both phases together last at most T Boost plus T Abs.
  • Floating (float charge): begins after T Boost or at a current below 20 % of the rated current; the voltage drops to the floating value.
  • Refresh: automatic weekly cycle; regardless of the position of the boost switch, a safe, time-limited voltage step occurs every 7 days.
  • Reboost: new charging cycle with boost when constant DC loads are detected.

With boost off, the unit delivers a single-stage IU curve with constant voltage; charging then takes longer.

The manual also shows a thermal derating curve as a function of ambient temperature and AC input voltage (230 V, 115 V, below 95 V). Rated charging applies from -20 °C to +50 °C; above that the power is reduced, and above 60 °C the unit switches off and restarts automatically as the temperature falls.

LED indicators and troubleshooting

LED State Meaning
green LED "On" on Charger is switched on
green LED "On" off No or poor-quality AC power, input fuse blown or internal malfunction
orange LED "Boost" flashing Boost phase (switch E = 1)
orange LED "Absorption" on Absorption phase (switch E = 1)
green LED "Floating" on Floating phase
green LED "Refresh" flashing Refresh phase (switch F = 1)
orange LED "Com" flashing Communication in progress (LIN bus or CAN bus)
red LED "Fault" on Abnormal operation: output short circuit; charging voltage (upstream of the distribution) below 11 V ± 5 % for longer than 10 seconds on the 12 V model (only active in the floating phase); battery temperature sensor below -10 °C or above 50 °C; fan failure

When replacing fuses, use only the type and size recommended in the manual. The technical data give 4 × 30 A/32 V in the negative pole, and Appendix 1 gives the designations F700, F701 and F702 for the ACE 12/90. The input fuses (F1/F2) are 2 × 20 A/250 V.

Maintenance and repair

  • Before maintenance and repair, disconnect the charger from the AC mains and from the batteries.
  • In dusty environments, vacuum regularly, because dust impairs heat dissipation.
  • Check the condition of the battery regularly and tighten nuts and screws once a year.
  • For repairs, contact philippi or your dealer. Repairs without prior consent from philippi void the warranty.

According to the manual, the warranty is 36 months. More on this: Warranty and repair.

Technical data ACE 12/90

Feature Value
Part number HPO12-90
Model / rated current / rated power 12 V / 90 A (±7 %) / 1282 W
Recommended battery bank 700 to 1200 Ah
Input 90 to 265 V AC single-phase, 47 to 65 Hz, automatic
Current consumption 230 / 115 V AC 6.0 / 16.0 A
Recommended generator power 1600 W
Power factor / efficiency 1 / typically 87 %
Input fuses 2 × 20 A/250 V (6.3 × 32), F1/F2
Outputs 3 (+BAT E, +BAT 1, +BAT 2) and 1 × -BAT, integrated MOSFET splitter, each output individually usable at rated current
Connection M6 threaded studs
Factory configuration boost / floating 14.4 V / 13.8 V for sealed lead
Regulation accuracy / ripple below 1 % at rated conditions
Output fuses in the negative pole 4 × 30 A/32 V
Cooling / noise level Electric fan, temperature- and current-controlled / below 50 dBA at 1 m
Operating temperature at 230 V AC Rated charging from -20 °C to +50 °C, power derating above 50 °C, shutdown above 60 °C with automatic restart
Storage temperature / humidity -20 °C to +70 °C / up to 96 % non-condensing
Material painted aluminium
Dimensions (L × H × D) / weight 270 × 360 × 130 mm / 6.8 kg
Mounting 4 × M6 round-head screws
Protection rating IP23
Standards EN 61204-3 (EMC), EN 60335-2-29 (safety)
Protective functions Input overvoltage protection by VDR (not covered by the warranty), reverse polarity protection by fuse tripping, short-circuit and overload protection, overheating protection
Accessories Temperature sensor (-18 mV/°C), parallel operation up to 4 units, HPO-DISPLAY-R touchscreen remote display; isolated CAN bus interface integrated as standard

Frequently asked questions

How many batteries does the ACE 12/90 charge at the same time?

The ACE 12/90 has three outputs: +BAT E for the starter battery and +BAT 1 and +BAT 2 for house batteries, plus a common negative pole. Each output can deliver the rated current of 90 A. If you have fewer than three batteries, leave the unused terminals unconnected.

How do I set the battery type?

The battery type is selected with DIP switches A to D (SW1200), with the AC input and DC output disconnected. From the factory the charger is set to sealed lead, boost on, refresh off. Switch E switches boost, switch F refresh. For special batteries, ask the battery manufacturer and an installer.

Can I operate several chargers in parallel?

With the KIT-HPO-LINK parallel connection kit, up to 4 battery chargers can be connected in parallel. Control runs via the LIN bus. Each unit receives a unique ID via DIP switch SW1202; one unit works as master, the others as slave 1 to 3.

What does the red Fault LED mean?

The red Fault LED lights up in abnormal operation: with an output short circuit, with a charging voltage below 11 V (12 V models) for longer than 10 seconds in the floating phase, with a battery temperature sensor below -10 °C or above 50 °C, and with fan failure. Check these points, otherwise get in touch.

Matching products and further pages

Questions about selection or installation? Get in touch.