Kelly KL-48DCDC-400-5 Series Isolated DC-DC Converter User Manual

KL-48DCDC-400-5 Series Isolated DC-DC Converter
User Manual

Kelly Controls, Inc

Kelly DC/DC Converter

User’s Manual
Model:

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: [email protected]
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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