Kelly KL-48DCDC-400-5 Series Isolated DC-DC Converter User Manual
- June 10, 2024
- Kelly
Table of Contents
KL-48DCDC-400-5 Series Isolated DC-DC Converter
User Manual 
Kelly Controls, Inc
Kelly DC/DC Converter
User’s Manual
Model:
| KL-48DCDC-400-5 | KL-48DCDC-500-5 | KL-72DCDC-650-5 | KL-96DCDC-800-5 |
|---|---|---|---|
| KL-72DCDC-400-5 | KL-72DCDC-500-5 | KL-96DCDC-650-5 | KL-144DCDC-800-5 |
| KL-96DCDC-500-5 | KL-144DCDC-650-5 | ||
| KL-144DCDC-500-5 |
Rev.1.21
Jan. 2023
Introduction
This manual introduces the Kelly isolated DC-DC Converter’s features,
specifications and installation. Read the manual carefully and thoroughly
before using the converter. If you have any questions, please contact the
support center of Kelly Controls, Inc.
Kelly DC-DC Converter covers wide range of DC input voltages of 40V to 200V,
and outputs DC 13.5V. It is quite efficient and reliable with a compact size.
Feature’
- No arc
- Can be controlled by key switch directly, no need of external relay
- By default, key switch is non-isolated, its input connect to B+. Customer can order isolated key switch which is powered by a separate 12V. (For 500W 650W 800W DC/DC)
- Over temperature protection, shut down at 90°C
- Over current protection
- Low voltage protection: stop working at low battery voltage
- High efficiency with compact size and light case
- Low standby current: ≤5mA
- Isolate between input and output
- The matching connectors and crimp pins will come with each DC/DC converter
- IP66 protection
Specifications
- Nominal input voltage: DC 48V, 60V, 72V, 84V, 96V, 108V, 120V, 144V
- Output voltage: DC 13.5V under 70℃ or DC 12.2V above 70℃
- Operating voltage range: 36V-60V, 45V-90V, 63V-130V, 72V-125V, 90V-180V, 105V-180V
- Output current: 30A, 40A, 50A, 60A
- Output power: 400W, 500W, 650W, 800W
- Operating Temperature Range: -20℃ to 90℃ (case temperature)
- Full – load efficiency: ≥90%
- Ripple coefficient: ≤1%
Model| Input Voltage| Output voltage (at nominal inputvoltage)| Output voltage
(at min input voltage)| Operating Voltage| Output Current| Output Power
---|---|---|---|---|---|---
KL-48DCDC-400-5| 48V| 13.5V| 11.5V| 36V-60V| 30A| 400W
KL-72DCDC-400-5| 60V, 72V| 13.5V| 11.5V| 45V-90V| 30A| 400W
KL-48DCDC-500-5| 48V| 13.5V| 11.5V| 36V-60V| 40A| 500W
KL-72DCDC-500-5| 60V,72V| 13.5V| 11.5V| 45V-90V| 40A| 500W
KL-96DCDC-500-5| 84V, 96V, 108V| 13.5V| 11.5V| 63V-130V| 40A| 500W
KL-144DCDC-500-5| 120V’ 144V,| 13.5V| 11.5V| 90V-180V| 40A| 500W
KL-72DCDC-650-5| 60V,72V| 13.5V| 11.5V| 45V-90V| 50A| 650W
KL-96DCDC-650-5| 84V, 96V, 108V| 13.5V| 11.5V| 63V-130V| 50A| 650W
KL-144DCDC-650-5| 120V, 144V, 156V| 13.5V| 11.5V| 90V-180V| 50A| 650W
11-96DCDC-800-5| 96V| 13.5V| 11.5V| 72V-125V| 60A| 800W
KL-144DCDC-800-5| 144V| 13.5V| 11.5V| 105V-180V| 60A| 800W
Installation
KL-xxDCDC-400-5 Dimensions: 130mm (L)94mm (W)53mm (H)
The case outline and mounting holes’ dimensions are shown below. 
KL-xxDCDC-500-5 Dimensions: 125mm (L)85mm (W)67.5mm (H)
The case outline and mounting holes’ dimensions are shown below.
Figure 4 : Models: KL-xxDCDC-500-5
KL-xxDCDC-650-5 Dimensions: 125mm (L)85mm (W)67.5mm (H)
The case outline and mounting holes’ dimensions are shown below.
Figure 5 : Models: KL-
xxDCDC-650-5 KL-xxDCDC-800-5 (With cooling fan at the bottom)
Characteristics Curves
5.1 Test conditions: Input voltage: 48V, Load resistance: 0.4Ω. The converter
is equipped with an aluminum heat sink. Output voltage, output current and
efficiency are shown in figure 5, 6, and 7.
5.2 Test conditions: Input
voltage: 60V, Load resistance: 0.4Ω. The converter is equipped with an
aluminum heat sink. Output voltage and output current are shown in figure 8
and 9.
Connections
Input:
Red: Input Positive with 15A fuse(2.0mm2 )
Yellow: Key Switch(2.0mm2)
Black: Input Negative(2.0mm2)
Output:
Red: Output Positive(4.0mm2)
Black: Output Negative(4.0mm2)
Contact Us:
Kelly Controls, Inc
Home Page: http://www.kellycontroller.com
E-mail: sales@kelly-controls.com
Phone: (01) 224 637 5092(US)
(+86) 551-64397760(China)
(+86) 139-56008360 (China)
References
- Kelly Controls - Motor Controllers, EV Parts
- Kelly Controls - Motor Controllers, EV Parts
- Kelly Controls - Motor Controllers, EV Parts
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