philippi EM-box 3 User manual

Manual EM-box 3
Hardware 3.1 - REV 3B - JAN 20 Page 1
Energy Management Box
12V or 24V
The EM-box fulfils the task of an intelligent main current distributor, which distributes charging currents from various
charging sources to the connected battery banks with low loss. The engine (alternator and starter), the starter, the
service and the optional bow battery are connected to it.
Other charging sources such as battery charger, solar cells, wind generator, hydrogen generator, etc. are also
connected. The connected high-current and continuous current loads are protected on their positive lines by bolt fuses
type SHB.
The EM-box reduces the complex high current installation to a minimum and creates a clear and traceable installation.
No further elements are required in the basic installation, as the EM-box replaces all otherwise necessary individual
parts such as negative busbar, measuring shunts, main switch, deep discharge protection, charging current
distributor, fuse holder...
Cable cross sections and tubular cable lugs up to 70 mm2 / hole 8 mm can be connected to the connection bolts.

Manual EM-box 3
Hardware 3.1 - REV 3B - JAN 20 Page 2
Content
1. Safety ................................................................................................................................................................3
2. EM-box Introduction and configuration ...........................................................................................................4
2.1 Connection with one engine, one starter battery and one house battery...................................................5
2.2 Connection with one engine, one starter battery, house and bow battery.................................................5
2.3 Connection of two alternators......................................................................................................................6
2.4 Connection with two engines, one starter battery and one house and one bow battery ...........................7
2.5 Connection with two engines, two starter battery and one house battery (Power boat/Katamaran)........8
2.6 Charging sources...........................................................................................................................................8
2.7 Battery charger .............................................................................................................................................8
2.8 Combi-Inverter..............................................................................................................................................8
2.9 Loads .............................................................................................................................................................9
2.10 Engine with 2- or 3- wire connection......................................................................................................9
3. Installation ......................................................................................................................................................10
3.1 Safety before installation............................................................................................................................10
3.2 High current connection at the EM-box (bolt 1-8)......................................................................................10
3.3 Auxiliary connection....................................................................................................................................12
3.3.1 AUX-Charging in (Wind, Solar..) (X1)...................................................................................................13
3.3.2 Control lines Main switch (X2)............................................................................................................13
3.3.3 Temperature probe für Batteries und alternator (X3)........................................................................14
3.3.4 Alive out Service / Start (X4) ...............................................................................................................14
3.4 Battery disconnect switch...........................................................................................................................15
3.5 Control LEDs................................................................................................................................................16
4. First start of EM-box .......................................................................................................................................16
4.1 Setup Batteries............................................................................................................................................16
4.1.1 3rd battery bank (Bow-Battery)..........................................................................................................16
4.2 Setup Energy ...............................................................................................................................................17
4.3 Setup battery switch...................................................................................................................................17
4.4 Setup special function.................................................................................................................................17
5. Operation EM-box...........................................................................................................................................18
5.1 Charge division............................................................................................................................................18
5.2 Voltage and current measurement.............................................................................................................18
5.3 Battery disconnect switchs .........................................................................................................................18
5.3.1 Emergency start ..................................................................................................................................18
5.3.2 Manual switching of the battery disconnect switch...........................................................................18
5.3.3 Control of the battery disconnect switch ...........................................................................................18
5.4 Fuse monitoring ..........................................................................................................................................19
5.5 Own consumption EM-box .........................................................................................................................19
5.6 Overload / Overtemperature / Übervoltage...............................................................................................19
5.7 Deep discharge disconnect .........................................................................................................................19
6. Anhang ............................................................................................................................................................20
6.1 Dimensions EM-box ....................................................................................................................................20
6.2 Order No. for optional accessories .............................................................................................................20
6.3 Technical data .............................................................................................................................................20

Manual EM-box 3
Hardware 3.1 - REV 3B - JAN 20 Page 3
1. Safety
o No changes may be made to the device, otherwise the CE mark will be removed.
o The EM-box may only be connected by qualified electricians.
o Before connecting the EM-box, the battery leads must be disconnected. Ensure that the polarity of the batteries is
correct!
These installation and operating instructions are part of the component delivery. It must be kept in a safe place -
important for later maintenance work - and passed on to any subsequent owners of the EM-box.
Exclusion of liability
philippi elektrische systeme cannot monitor compliance with the operating instructions or the conditions and methods
of installation, operation, use and maintenance of the EM-box. Therefore, we do not assume any responsibility and
liability for loss, damage or costs resulting from incorrect installation and improper operation.
Warranty
We provide a warranty for the delivered equipment based on our "General Terms and Conditions - Section 7". These
terms and conditions are the basis of all sales and delivery offers, they are printed in our catalogues and attached to
all offers and order confirmations.
CE mark
This device meets the requirements of the EU directives: 2014/30/EC "Electromagnetic compatibility" The conformity
of the device with the above directives is confirmed by the CE mark.
Intended use
The EM-box serves as a high current distributor for battery systems with a nominal DC voltage of 12V or 24V and
must be installed in dry locations.
Scope of delivery
- EM-box 12V or 24V
- Operating instructions
- 2x pluggable terminals MC1,5/13-STF-3,81 for control and measuring lines
- Plug-in terminal MSTB2.5/4-STF-5.08 for continuous positive
- Plug-in terminal PC5/4-STF-5.08 for charging inputs
- Pipe socket wrench SW13 (M8)
Key to the symbols
Battery Charger Alternator Battery Starter Panel Charger/Inverter
Bow thruster Bilge pump Engine-Ventilator Monitor PSM Solar Windgenerator Hydro-Generator

Manual EM-box 3
Hardware 3.1 - REV 3B - JAN 20 Page 4
2. EM-box Introduction and configuration
The following diagram shows the basic internal structure of the EM box. The EM-box offers the following basic
connection options, which can be deviated from in individual cases or which can be extended by additional
configurations. The EM-box is available as 12V or 24V version.
Plus-Seite (Hochstromanschlüsse) Front-Side
(1) INPUT battery-charger max.150 A Life OUT Starter-Battery max. 8 A
(2) INPUT alternator (engine) max.150 A Life OUT House-Battery max. 8 A
(3) Starter battery Charge IN Solar max. 40 A from Solar regulator
(4) OUPUT starter (Engine) Charge IN Wind max. 40 A from regulator
(5) House battery
(6) OUPUT 1 (distribution panel)
(7) OUPUT 2 (Inverter/combi),
(8) OUPUT L (Charging out for Bow-Battery)
Minus-Side:
All terminals on the negative side are connected to each other by an internal busbar. The negative terminals of the
continuous current terminals (continuous current/ solar, wind) are also internally connected to the busbar.

Manual EM-box 3
Hardware 3.1 - REV 3B - JAN 20 Page 5
2.1 Connection with one engine, one starter battery and one house battery
Figure 2.1 shows the installation for yachts with one engine and two battery groups. The positive charging cable
between the alternator and the starter motor is already removed, so that a three-wire motor connection to the EM-box
is possible. There is no need for a separate starter motor minus cable because the starter motor is connected to the
minus via the engine block.
Figure 2.1: Connection with one engine, one starter battery and one house battery
2.2 Connection with one engine, one starter battery, house and bow battery
Figure 2.22: Connection with one engine, one starter battery one house and bow battery

Manual EM-box 3
Hardware 3.1 - REV 3B - JAN 20 Page 6
From the EM-box the charging cable to the bow battery is connected to connector (8). If the state of charge of the bow
battery is to be recorded, a shunt SHC 612 is required in the negative line directly at the bow battery.
The charging line from the EM-box to the bow battery must be protected with an additional high-current fuse on the
bow battery, as well as the bow thruster and/or the anchor winch.
The battery disconnector consists of
a manual main switch (e.g. BH 400, BH 500) or
for load currents up to 260A use a main switch FBC 265 remotely controllable via the system monitor PSM2
or
for load currents above 260 A (e.g. for bow thrusters) from a remotely controllable main switch FBR 500 and a
control interface TSC, which is controlled via the system monitor PSM2.
2.3 Connection of two alternators
Figure 2.3: connection of two alternators
a) If the total current of the two alternators is less than 250 A, the two alternators can be connected to terminals
(-1/+1) and (-2/+2) (left figure).
b) If the charging current of one alternator is greater than 150 A, the two alternator inputs (-1/+1) and (-2/+2) can
be connected in parallel (right figure).

Manual EM-box 3
Hardware 3.1 - REV 3B - JAN 20 Page 7
2.4 Connection with two engines, one starter battery and one house and one bow battery
Figure 2.4: Anschluss mit zwei Motoren und 1 Starter–Batterie, LM-Strom < 250A
Figure 2.4 shows the installation for yachts with two engines and one starter battery. If the total charging capacity of
the two alternators is less than 250 A, it is possible to work according to chapter 2.3a with parallel connected
connections (-1/+1) and (-2/+2) for the alternators and starters (-4/+4). If the total alternator output is greater than 250
A, proceed according to Figure 2.3b. The installation of the EM-box eliminates the need for a second starter battery
while maintaining the same starting reliability.

Manual EM-box 3
Hardware 3.1 - REV 3B - JAN 20 Page 8
2.5 Connection with two engines, two starter battery and one house battery (Power boat/Katamaran)
Figure 2.5 shows the installation for catamarans with two engines and two starter batteries.
The minus of the STB engine is connected to (-1). The STB starter (+) is connected to the charge output (+8) of the
EM-box via an additional remote controlled main switch FBC 265 to switch the starter on and off. The charging output
(B+) of the STB alternator is connected directly to (+1) of the EM-box.
Figure 2.5: Connection with two engines, two starter battery and one house battery (Power boat/Katamaran)
2.6 Charging sources
Charging always takes place even when the main switch is switched off and the EM-box is always active when
charging current is available. This applies to all charging devices connected to the charging terminals (+1, +2) and
AUX1, AUX2 (for solar / wind / hydrogen generator).
2.7 Battery charger
The charging output of the battery charger is connected directly to terminals (+1) and (-1) and can thus be identified in
the PSM's energy monitor as a charging source with its own charging current display.
2.8 Combi-Inverter
Comb inverters with outputs of up to 2 kW continuous output at 12 V are connected to the terminal (+7, -7), see also
the previous connection diagrams. When the combi inverter is in charge mode, the service battery and automatically
the starter and bow batteries are also charged by the EM-box.

Manual EM-box 3
Hardware 3.1 - REV 3B - JAN 20 Page 9
2.9 Loads
If more than 2 high current consumers are to be connected directly to the EM-box, an external bolt fuse distributor
(e.g. BlueSea 5196) is connected to the connection (+6). The positive connection (+6) is thus extended for additional
loads. On the minus side, a negative busbar can be used to simplify the installation.
Note: Only the total current can be displayed for the loads at a common connection
2.10 Engine with 2- or 3- wire connection
To connect the engine to the EM-box, the internal positive connection cable between the alternator and the starter
motor should be removed, so that the starter cable (+) can be connected separately from the alternator output (+). In
this case the connection is made according to the left picture, as in all the connection diagrams already shown. If the
separation of the internal positive connection line between the alternator and the starter motor is not possible, the
motor is connected according to the "2 wire" configuration, as shown in the right picture.
„3 wire“-configuration „2 wire“-configuration

Manual EM-box 3
Hardware 3.1 - REV 3B - JAN 20 Page 10
3. Installation
The following parts are required to install the EM-box:
a) Fuses for the consumer outputs (pin fuse type SHB, not included in delivery)
Connection 6 (vehicle electrical system): (bolt fuse SHB 30, 50, 75, 125, 200 A)
Connection 7 (Combination Inverter) (bolt fuse SHB 125, 200 A)
Connection 8 (bow battery) (bolt fuse SHB 50, 75, 125 A)
b) If cable lengths from EM-box to battery > 1m are used, an additional main fuse (fuse holder SHD plus STS 200 A or
stud fuse holder SHB, suitable for the cable cross-section) must be installed at the positive pole of the service battery.
c) Temperature sensor TEMP-BT for recording the battery temperatures (optional)
d) PSM system monitor for configuration and display of all operating parameters of the EM-box
e) M12 P-BUS cable for data connection to the system monitor
3.1 Safety before installation
- Important: The EM-box should generally be mounted outside the engine compartment in an "easily accessible"
location to allow "safe manual operation" from the remote battery disconnectors.
- Install the EM-box in a dry and ventilated place. Do not mount the EM-box upside down to prevent liquids from
entering the EM-box via terminals X1-4.
- Important: Disconnect the pole terminals on the batteries during installation to protect against short circuits during
installation!
- Observe the polarity of the batteries and consumer lines. Batteries and consumers connected with reversed polarity
cannot be detected by the EM-box and can lead to the destruction of the EM-box and consumers or to dangerous
short-circuit currents!
- Before connecting the first battery to the EM-box, check the correct polarity and nominal voltage 12V or 24V on the
connecting leads.
- To facilitate installation, the nuts on the connecting bolts are not tightened on delivery.
- All nuts on the high current connections must be tightened firmly with a pipe socket wrench SW13!
- If the connections are not used, the nuts must also be tightened firmly.
3.2 High current connection at the EM-box (bolt 1-8)
Important: On the left side all minus cables are connected, on the right
side are all plus cables. Mixing up the plus and minus connections of the
batteries will destroy the internal protection diodes against overvoltage
and may subsequently lead to the failure of the EM-box functionality!
The bolt fuses type SHB at the connections +6, +7, +8 are mounted
according to figure 3.1.
First the bolt fuse is inserted and then the cable lugs are attached. Up to
2 cable lugs can be fitted as shown.
Abbildung 3.1: installation of bolt fuse

Manual EM-box 3
Hardware 3.1 - REV 3B - JAN 20 Page 11
Important: For all unused outputs, the nut must be tightened so that no error
message is displayed by the control LEDs (6a-8a) or the PSM system monitor
due to a supposed fuse failure.
If two different cable cross-sections are clamped to one bolt, a branch bolt
holder ABH1 with fuse as shown in Figure 3.2 must be used in addition, to fuse
the smaller cross-section according to its cable cross-section.
(1) IN Battery charger (max. 150A)
The required cable cross section must be dimensioned according to the maximum charging current of the
battery charger.
(2) IN alternator (max. 150A)
No fuse protection required for alternator connection,
required cable cross section (according to ISO 10133):
Alternators up to 60 A: min. 16 mm²,
Alternators up to 90 A: min. 25 mm²,
Alternators up to 120 A: min. 35 mm²,
Alternators up to 150 A: min. 50 mm²,
For cable lengths greater than 2 m, the next higher cross-section must be selected.
(3) IN Starter-Battery
The required cable cross section must be dimensioned according to the motor manufacturer's specifications.
For correct dimensioning the total length of the cable from starter battery to EM-box and from EM-box to starter
motor must be taken into account.
(4) OUT Starter-Engine
The required cable cross section must be dimensioned according to the motor manufacturer's specifications.
For correct dimensioning the total length of the cable from starter battery to EM-box and from EM-box to starter
motor must be taken into account.
(5) IN house battery (to be fused at battery positive pole!)
The required cable cross section and the fuse at the positive pole of the service battery(ies) depends on the
maximum charging current of the charging sources (generator, charger...) and on the sum of the consumer
currents. The larger value in each case is to be used for dimensioning.
Max. Charging/consumer currents up to 60 A: min. 16 mm²,
Max. Charge/consumer currents up to 120 A: min. 35 mm²,
Max. Charge/consumer currents up to 200 A: min. 50 mm²,
Max. Charge/consumer currents up to 250 A: min. 70 mm² (or 2 x 50 mm²),
on the battery max. charging/consuming currents up to 250 A: min. 70 mm² (or 2 x 50 mm²),
No more than the maximum continuous current of 250 A should be carried via the EM box.
(6) OUT 1 (distribution panel), (fuse with bolt fuse SHB)
The required cable cross section and the fuse value depend on the maximum current of the connected loads.
Continuous load max. 150 A.
(7) OUT 2 (Inverter), (fuse with bolt fuse SHB)
The required cable cross section and the fuse value depend on the maximum current of the connected loads.
Continuous load max. 150 A.
(8) OUT Bow-Battery, (fuse with bolt fuse SHB)
The required cable cross section and fuse rating depends on the maximum charging current of the connected
alternator (1), min. 50 mm² and max. 150 A.
Figure 3.2: installation of double bolt
fuse

Manual EM-box 3
Hardware 3.1 - REV 3B - JAN 20 Page 12
3.3 Auxiliary connection
At the front of the EM-box are the connections for the control and measuring lines and the PBUS.

Manual EM-box 3
Hardware 3.1 - REV 3B - JAN 20 Page 13
3.3.1 AUX-Charging in (Wind, Solar..) (X1)
The EM-box offers 2 additional charging inputs for charging currents up to 40 A each (sum of both connections max.
60 A) for alternative energy sources like solar, wind or hydrogen generators.
To increase the current carrying capacity both inputs can be connected in parallel. When the overload is removed, the
fuses automatically reset themselves. The current measurement per input enables the charging current and its energy
yield to be displayed on the PSM system monitor.
Note:
The alternative energy sources such as solar, wind or hydrogen generators are simply connected to the EM-
box with their controllers. Unregulated charging sources with unacceptably high voltages for the EM-box
could destroy the EM-box.
3.3.2 Control lines Main switch (X2)
The battery main switches can be controlled remotely and are usually switched and displayed via the PSM system
monitor. In parallel, push-button switches can be used alternatively in any number for control. To display the switching
status of the main switches, an LED indicator light can be connected to the corresponding "LED" connector (see
connector X2).
The connection has an internal current limitation to 12-15 mA and allows the direct connection of a light emitting
diode with and without series resistor. We recommend the panel STC3 for this
purpose.
An additional push-button switch can be installed on the control column for an
emergency start from the cockpit to initiate an emergency start from the service
battery.
The switches are redundant to the CAN bus.
3.3.2.1 Control lines Sense (X2)
In order to use the full potential of the EM-box the alternator must have a sense input so that the EM-box can control
the alternator. This adapts the charging voltage to the battery requirements and extends it to an IUoU characteristic.
Two sense connections (LM1, 2) are available.
LM_Sense_1: Connection Sense of alternator 1 (regulator)
LM_Sense_2: Connection Sense of alternator 2 (regulator)
The sense connection of the alternator regulator is internally connected to the B+ output of the alternator on most
older LMs. This connection must be disconnected and separately led outside and connected to the sense connection
of the EM-box.
- VolvoPenta, Nanni and Bukh engines with a 50A / 60A Valeo-LM (up to approx. 2006) have a yellow sense
cable already ex works.
- VolvoPenta engines with a 115 A Mitsubishi-LM (from approx. 2004) have a sense connection already ex
works.
- Yanmar engines with a 120 A Valeo-LM (from approx. 2015) have a sense connection ex works.
- Modified alternators with Mastervolt alpha3 regulator (in preparation)
Alternators can usually be retrofitted, please contact us or ask your service company.

Manual EM-box 3
Hardware 3.1 - REV 3B - JAN 20 Page 14
3.3.2.2 Wind generator Stop (X2)
To stop a wind generator when the battery is fully charged, a control relay can be connected to this terminal, which
triggers the stop at the wind generator. This is implemented differently depending on the wind generator and can be
found in the wind generator manual. The current carrying capacity of the output is 0.3 A. Internally the line is
electronically fused with 250 mA.
Figure 3.3: connection Wind generator Stop
3.3.3 Temperature probe für Batteries und alternator (X3)
A temperature sensor connection is provided for each battery group. The temperature sensor is attached to the
outside of the battery or to the pole. The temperature can be read in the battery display of the PSM. If the temperature
is outside the permissible range, an alarm message is issued. If the alternator is controlled via the sense output of the
EM-box, the battery temperature is included in the control of the charging characteristic.
3.3.3.1 P-BUS (X3)
An M12 T-adapter cable must be connected to the four connections to establish the connection to the P-Bus.
All components connected to the P-Bus are connected to each other by P-Bus network cables. See the operating
instructions for the philippi system monitor.
3.3.3.2 Ignition cable (X3)
If an externally excited alternator is installed on the EM-box at connection 1 (alternator), the ignition plus cable
"terminal 15" is connected to connection "+ ignition" so that the EM-box can switch an excitation voltage to the
alternator output.
To start chargers which only start with reverse voltage, the battery voltage can be switched on via a relay (e.g.
detection of the AC mains voltage) to start the charger.
3.3.4 Alive out Service / Start (X4)
The consumers are connected to this connection which must always be in operation independently of the main
switches. The output is electronically fused internally at the positive pole (10A) and only requires an external fuse if
the conductor cross-section for this line is less than 1.5 mm², and if necessary for the respective negative line.
The currents on the continuous positive lines are detected by the battery management of the service/starter battery.

Manual EM-box 3
Hardware 3.1 - REV 3B - JAN 20 Page 15
3.4 Battery disconnect switch
Disconnect switch Starter-Battery (A)
The main switch of the starter battery disconnects or closes the connection of the
starter battery to output +2 (starter motor). Electrical operation is via the system
monitor or a pushbutton (see 3.3.2 Main switch control lines). The associated status
LED indicates the switching status.
In emergencies, the main switch can be switched on and off mechanically at the two
upper buttons. The left key switches the main switch off mechanically and the
right key switches the main switch on mechanically.
Disconnect switch emergency start (B)
The main switch "emergency start" disconnects or closes the connection of the
service battery to output +2 (starter motor). Electrical operation is via the system
monitor or a pushbutton (see 3.3.2 Main switch control line). The corresponding
status LED indicates the switching status.
During electrical actuation, the starter output is switched from the starter battery to
the consumer battery.
In emergencies, the main switch can be switched on and off mechanically at the two
middle buttons. The right button mechanically switches the emergency start off,
and the left button switches the emergency start on
Disconnect switch House-Battery (C)
The main switch of the service battery disconnects or closes the connection of the
service battery to the outputs +6, +7 (consumer). Electrical operation is via the
system monitor or a button (see 3.3.2 Main switch control line). The corresponding
status LED indicates the switching status.
In emergencies, the main switch can be switched on and off mechanically at the two
lower buttons. The left key switches the main switch off mechanically and the
right key switches the main switch on mechanically.
In "normal operation" the main switches (A) and (C) are switched ON (indicator light is on) and the main switch (B)
"emergency start" is switched OFF (indicator light is off).
In "emergency operation" i.e. for an emergency start of the machine with empty or defective starter battery with the aid
of the service batteries, the main switch (A) is switched OFF (indicator light is off) and the main switch (B) "emergency
start" is switched ON (indicator light is on). This means that the engine is supplied by the service battery. After the
engine has been switched off, it is possible to switch back to normal operation. The batteries are always charged by
the alternator regardless of the switch position!
Attention:
Manual operation of the button is not indicated by the status LED. Therefore the actual switching state deviates from
the display.
After manually switching on the main switches, electrical operation via the system monitor or external push buttons
must be carried out subsequently in order to synchronise the display and ensure 100% contact with the relay before
high continuous currents (> 50 A) flow. A short-term high current (5 sec.) is however possible.

Manual EM-box 3
Hardware 3.1 - REV 3B - JAN 20 Page 16
3.5 Control LEDs
The EM-box has in total 7 LEDs to indicate the operating states.
Important: In energy saving mode (no charge and load current less than 0.2A) all LEDs flash briefly only every 10
seconds to reduce current consumption.
Operating status EM-box (green LED)
flashing: EM box ready for operation (in energy-saving mode)
permanently lit: EM box detects current flow greater than 0.2 A (charging or discharging current)
Error indication at the outputs (red LEDs)
permanently lit: failure of the bolt safety device SHB at output (6)
permanently lit: failure of the bolt safety device SHB at output (7)
permanently lit: failure of the bolt safety device SHB at output (8)
flashing: like permanently lit, but energy-saving
Switching status main switch relay (yellow LEDs)
permanently lit: starter battery disconnect switch on (A)
permanently lit: emergency start device on (B)
permanently lit: Service Battery disconnect switch on (C)
flashing: like permanently lit, but energy-saving
4. First start of EM-box
After connecting the service battery group the EM-box goes into operation. This is indicated by the green LED located
above the "Energy Management Box" label.
slowly flashing = device ready for operation
permanently lit = batteries are charged or discharged
If the battery disconnect or emergency start switches are switched on, this is indicated by the yellow LEDs.
The defect of a main fuse is indicated by the red LEDs.
All functions of the EM-box can be set from the PSM. All relevant data is displayed on the PSM and the main switches
are operated via touchscreen. Please refer to the operating instructions of the System Monitor.
After initial commissioning, the EM-box must be registered on the PSM and the following configurations must be set
via the philippi system monitor:
4.1 Setup Batteries
- Nominal capacity (Ah)
- Battery type (GEL, AGM, lead acid)
The entries must be made separately for the starter, service and bow battery. Then the batteries must be fully
charged so that the capacity calculation can synchronize with the battery status. See also the explanations of the
philippi system monitor, chapter Battery management.
4.1.1 3rd battery bank (Bow-Battery)
a) No 3rd battery group
If no third battery group is connected, it will be hidden from the display in the battery monitor and will not be charged.
The following settings must be made:
- Nominal capacity: 0 Ah and battery name: "not active".
b) 3rd battery group connected
The output (+8) is used to charge a 3rd battery group. To activate the charging function, the bow battery must be set
to nominal capacity greater than 0 Ah (factory setting). As the load currents of the bow battery are not recorded, no
battery management is possible. Only the voltage of the bow battery is therefore displayed on the philippi system
monitor. If a capacity display is also to be available for the bow battery, an additional battery management shunt SHC
612 must be installed directly on the bow battery.

Manual EM-box 3
Hardware 3.1 - REV 3B - JAN 20 Page 17
On this external shunt, the battery name must be configured to "EM-box-Bug" in order to be recognized as such by the
EM-box. The EM-box then detects this shunt and takes over the current, voltage and temperature values for the
battery management. The configuration of the battery capacity of the bug battery and all other parameters is then
done through the settings of the EM-box bug battery.
4.2 Setup Energy
In the Energy setup, the symbols for the individual shunts (current measurement) can be configured individually in
order to obtain a correct representation for the existing system. The factory setting is:
Shunt (+1): charging source Charger
Shunt (+2): charging source alternator
Shunt (+4): not active (possible: engine (starter) or alternator)
Shunt (+6): load1: Vehicle electrical system
Shunt (+7): load2: Inverter
Shunt (+8): not active (possible: charging current of the bow battery or with external shunt also the separate load
current of the bow battery)
Shunt (Aux1): Solar charging source
Shunt (Aux2): charging source wind / hydrogen generator
4.3 Setup battery switch
A PIN for switching the main switches can be activated in Setup. Further settings are not necessary.
4.4 Setup special function
Firmware Update EM-box
This function can be used to update the firmware of the EM-box. For this purpose a file named "mnc_vxyy" must be
created. (firmware version x.yy) to a micro SD card and inserted into the SD card holder of the PSM2.
Reset EM-box
Performs a warm start of the EM-box. Not normally required.
Solartrigger
If solar charge controllers (MPPT) are connected to the EM-box which only start with battery back voltage, the solar
trigger must be activated to start the solar charge. Thereby a voltage is cyclically applied to the inputs AUX1 and
AUX2 to activate the solar charge. As the solar trigger requires energy for the function, which is drawn from the
service battery (average 2 mA), this function should only be activated if necessary. The solar trigger period is preset to
300 s and the pulse duration to 15 s and can be adjusted if necessary. Various trigger modes are available for this
purpose:
1) Automatic
An attempt is made to start the solar controller with the internal supply voltage; if this voltage drops sharply due to the
load on the controller, the battery is switched on. The cycle time and the trigger time are adjustable.
2) Trigger high power
An attempt is made to start the controller by connecting the battery. The cycle time and the trigger time are adjustable.
3) Permanent low power
The solar input is continuously supplied with the internal supply voltage. This increases the power consumption of the
EM-box
4) Permanent high power
The solar input is continuously supplied with the battery voltage. This increases the power consumption of the EM-
box.
Charging Starter-Batterie (function not available)
During charging, the starter battery can be disconnected from the charge to prevent overcharging. In some engine
control systems this will result in an error message that the alternator has failed. To prevent this, this function can be
activated. This ensures that the starter battery is always charged.

Manual EM-box 3
Hardware 3.1 - REV 3B - JAN 20 Page 18
5. Operation EM-box
5.1 Charge division
The EM-box controls the charging voltage of the alternator via its voltage sensor connection, the so-called sense
input. If this is not available, it should be retrofitted by a specialist company in order to obtain optimum charge control
if possible.
The three-step charge control takes into account:
- Battery type (wet, gel, AGM, lithium)
- Battery temperatures (in the range of -20°C...+50°C to determine the gassing voltage with 14.4 V at 20°C or 28.8 V
and its correction with 18...36 mV/°C or 36...72 mV/°C)
- Battery charging currents 0.5%C...2%C (to determine the switchover time to trickle charge)
- Time of the battery charging phases (2h...16h, for safety shutdown or according to the specifications of the battery
manufacturer for charging)
- The EM-box distributes the charging current (max. 250 A) low-loss to the three independent battery groups and
regulates the offered voltage according to the respective state of charge of the battery group.
The charge current distribution is sequential. This means that the battery groups to be charged are switched on for
charging depending on their state of charge and disconnected also from the charging process again in order to enable
the batteries to be fully charged via the alternator with a sufficiently long alternator running time and to prevent
overcharging. While the individual battery groups are being charged, the charging current can be temporarily
suspended by the charging program in order to charge the other battery groups optimally according to the set battery
type.
5.2 Voltage and current measurement
At all 8 positive power bolts and the charge inputs AUX1/2, the current is measured individually and made available to
the PSM system monitor for display. The voltage measurement is performed for the starter, service and bow battery.
The current and voltage values are used to calculate the capacity for the 2 nd starter and service battery groups.
When the battery disconnector are switched off the EM-box goes into a power saving mode, the current and voltage
measurement and the resulting capacity calculation remains active.
5.3 Battery disconnect switchs
A battery disconnect switch is available for the starter battery and the service battery. These can be switched via the
control lines and via the P bus (CAN bus). Manual operation of the main switches directly on the EM-box is also
possible in emergencies,
A third main switch can be activated for EMERGENCY START of the engine via the service battery, which is switched
via the control lines or via the philippi P-Bus.
5.3.1 Emergency start
If the starter battery is empty, the engine cannot be started. In this case, the engine (starter motor) can be supplied via
the consumer battery by activating the emergency start function. For this purpose, the starter connection is switched
internally from the starter battery to the consumer battery. The charging functionality is not affected by this.
5.3.2 Manual switching of the battery disconnect switch
In the event of a failure of the electronics of the EM-box or in a emergency case the main switches can be operated
directly on the EM-box.
Important: Manual operation of the button is not indicated by the status LED. After a manual operation of the
main switch an electrical operation must be carried out as soon as possible.
5.3.3 Control of the battery disconnect switch
In order to enable control via the system monitor even when the main switches are switched off, its power supply must
be connected to the continuous positive output of the EM-box.
In principle, the battery main switches must be controlled via the control lines on terminal X2, in order to be able to
switch the main switches in an emergency (e.g. in case of CAN bus failure).

Manual EM-box 3
Hardware 3.1 - REV 3B - JAN 20 Page 19
5.4 Fuse monitoring
SHB bolt fuses are used for the main protection of the consumer connections. The bolt fuses are electronically
monitored by the EM-box at the respective connections. For each connection a red LED indicates the failure of the
corresponding fuse (error message).
If the nut of an unused consumer connection is not tightened or is loosely tightened, this can also lead to an error
message.
5.5 Own consumption EM-box
The EM-box has an own power consumption of < 10 mA in idle mode. This corresponds to a maximum daily
capacity loss of 0.25 Ah/day. Even if the main switch is switched off, this can lead to a complete discharge of the
connected batteries if recharging is not possible.
Therefore, the connection cable from the service battery to the EM-box must be removed if it is not used for a
longer period of time (> 1-2 months, depending on battery capacity) to prevent a deep discharge of the batteries.
Alternatively, a small solar panel (> 20 W) can be used to cover the EM-box's own consumption and to provide an
additional buffer for the batteries.
The EM-box goes into active mode as soon as
a) the discharge current is greater than 1 A or
b) a charging current via the connections 6.7 (combined inverter) is greater than 200mA
c) a charge current across terminals 4 (starter) is greater than 200mA
d) the voltage at terminals 1, 2 (alternator, charger) is greater than 0,5 V of the lowest battery voltage.
e) a voltage is present at the ignition lock signal input on X3
5.6 Overload / Overtemperature / Übervoltage
The EM-box can carry currents up to 250 A (short time). The maximum load capacity also depends on the ambient
temperature. If the currents exceed the maximum load capacity of the EM-box during operation or if the temperatures
measured in the EM-box are too high, the EM-box tries to protect itself. The first step is to display a message on the
PSM monitor indicating that the EM-box is in overload. The second step is to reduce the current. This is only possible
if the EM-box has influence on the charging source. The last step is to interrupt the charge or switch off the main
switch relay to protect the EM-box from destruction.
5.7 Deep discharge disconnect
The EM-box is equipped with a deep discharge protection. This protects the connected batteries from a dangerous
deep discharge. If the battery voltage drops below 9-11 V during discharge, the corresponding main switch is switched
off. A corresponding warning message "Battery X is empty!" appears additionally on the system monitor. If the battery
is to be used in an emergency, a further discharge can be activated by switching on the corresponding main switch
again for 5 minutes. The new disconnection is triggered repeatedly after 5 minutes as long as the (charging) battery
voltage does not exceed 12.0 V for a 12V battery.

Manual EM-box 3
Hardware 3.1 - REV 3B - JAN 20 Page 20
6. Appendix
6.1 Dimensions EM-box
EM-box V3 -12V 0 7100 1000
EM-box V3 -24V 0 7100 1001
6.2 Order No. for optional accessories
Bolt fuse SHB 30 A 6 0892 5301
Bolt fuse SHB 50 A 6 0892 5501
Bolt fuse SHB 75 A 6 0892 5751
Bolt fuse SHB 125 A 6 0892 6121
Bolt fuse SHB 200 A 6 0892 6201
Bolt fuse holder ABH 1 7 0010 5191
ANL fuse holder SHD 1 6 3400 1102
ANL fuse STS 125 A 6 5701 6121
ANL fuse STS 160 A 6 5701 6161
ANL fuse STS 200 A 6 5701 6201
ANL fuse STS 250 A 6 5701 6251
Temperature probe TEMP-BT 0 5900 3000
Remote switch panel STC 3 0 7100 0103
Systemmonitor PSM 2 0 7100 2235
M12 P-BUS- cable 0,5m 5 0411 1158
M12 P-BUS- cable 1m 5 0411 1152
M12 P-BUS- cable 2m 5 0411 1153
M12 P-BUS- cable 5m 5 0411 1154
M12 P-BUS- cable 10m 5 0411 1157
Batterie-Management Shunt SHC 612 0 7100 0612
Remoteable battery disconnect FBC 265 0 8301 2750
6.3 Technical data
Operating voltage 8-16 Volt DC
Current consumption max. 500 mA in charging mode, < 10 mA in idle mode (at 12V operation).
Connection bolt M8
Weight 4 kg
Dimensions H x W x D 332 x 240 x 75 mm
Temperature range - 15°C / + 50 °C
Protection class IP 21
Battery disconnect switch (for cabling with 70 mm2 or higher)
Continuous current 200 A @25°C (sum of all consumer or battery currents)
Overload 250 A @25°C (20min)
Peak load 1500 A @25°C (0.5s)
alternator regulator, charging current distributor
Charging characteristic IUoU adjustable to battery type (GEL, AGM, acid)
Max. charging current 160 A
Recommended alternator 35 -150 A
current measurement, state of charge determination
Permanent load 150 A per shunt, thereby sum of all shunt currents max. 300 A
Overload 1500 A 0.5 s; 500 A 1 minute
Resolution 10 mA
Accuracy 1 %
load circuits 2, max. 200 A, protection via M8 pin fuses, type SHBxx
Total current of outputs 1+2 max. 200 A, (continuous load)
Increased protection for short-term loads is at your own risk