Kelly Controls Inc Kelly EV Power Unit OBC + DC/DC Converter User Manual

Kelly EV Power Unit
OBC + DC/DC Converter
User’s Manual

Introduction

This manual introduces the Kelly EV Power Unit, which integrates a high- efficient on-board charger and a DC/DC converter. It saves space, weight, and cabling, thereby minimizing the cost of inventory, installation, and service. It is quite efficient and reliable with a compact size. Kelly EV Power Unit is designed for electric vehicles, such as electric sedan, electric van, electric golf, electric light truck etc. Read the manual carefully and thoroughly before using the Power Unit. If you have any questions, please contact the support center of Kelly Controls, Inc.

Features

2.1. Features of On-Board Charger

• High efficiency, light weight and quiet operation
• Automatic operation for ALL Lead Acid Batteries Flooded, AGM or Gel Cell, and Lithium Batteries.
• With powerful microcontroller, can more intelligently manage and maintain each cell, improve battery utilization, prevent battery overcharge and discharge, pro-long battery life, and monitor battery status.
• With cooling fan, good heat dissipation
• LED indicator light, all aluminum shell, beautiful and reliable
• Input/output protections
• Intelligent charging: stop work after charging completed; auto recharge when the battery voltage is lower than the set value.
• IP66 enclosure
• Safety Standard: 1(iec364-4-41)

2.2. Features of DC/DC Converter

• No arc
• Can be controlled by key switch directly, no need of external relay
• Input/output protections
• Low standby current: 1mA
• Isolate between input and output
• IP66 enclosure

Electrical Specifications

3.1. Input Specifications

Item

| Specifications
---|---

OBC

Input Voltage| 220VAC±15%
Input Current| ≤8A
Input Frequency| 50Hz±10%
Leak Current| <0.75mA at full load, meet to Class II
AC Power Factor| ≥0.98

DC/DC

Input Voltage| DC 48V-156V

3.2 Output Specifications

Item

|

Specifications

---|---

OBC

Output Voltage| DC 48V-156V
Output Current| 9.5A-30A
Output Power| 1200W-1500W
Efficiency| ≥93%

DC/DC

Output Voltage| DC 12.2V
Rated Output Voltage| DC 13.5V
Output Current| 40A, 50A
Output Power| 480W, 600W
Max Efficiency| 93%
Ripple coefficient| ≤1%

3.3. Protection Specifications

Under voltage protection: shut down, auto-recovery
Output Protection| Over voltage protection: shut down, auto-recovery
Under voltage protection: shut down, auto-recovery
Over temperature protection: reduced current output at 70℃, shut down at 85℃, auto-recovery
Short circuit protection: shut down, auto-recovery
No-load protection: no output when unconnected with battery
Auto-stop protection: stop the vehicle at charging

3.4. Environmental Specifications

3.5. Reliability Specifications

Item|

Description

---|---
MTBF| Average operting life≥3000H (25℃, full load)
Vibration Test| Passed test: 5mm/50Hz/600s

3.6. Safety Specifications

Item

|

Specifications

---|---
Insulation Resistance| Input to output| DC500V   50MΩ   min   (25 ℃ , Humidity≤70%)
Input to case| DC500V   50MΩ   min   (25 ℃ , Humidity≤70%)
Output to case| DC500V   50MΩ   min   (25 ℃ , Humidity≤70%)
Hi-Pot| Input to output| 1500Vac 50Hz 1minute ≤10mA
Input to case| 1500Vac 50Hz 1minute ≤10mA
Output to case| 1500Vac 50Hz 1minute ≤10mA

3.7. Charging Indicator

LED Indicator

|

Battery level

---|---
Green| 100%
Red| <80%
Yellow| >80%

Naming Regulations & Models

4.1. Naming Regulations

4.2. Models

Models

| OBC Power| OBC Output Current|

DC/DC Output Power

---|---|---|---
KCG4812D| 1200W| 24A| 480W
KCG4815DX| 1500W| 30A| 600W
KCG6012D| 1200W| 19A| 480W
KCG6015DX| 1500W| 24A| 600W
KCG7212D| 1200W| 16A| 480W
KCG7215DX| 1500W| 21A| 600W
KCG8415DX| 1500W| 17A| 600W
KCG9615DX| 1500W| 15A| 600W
KCG10815DX| 1500W| 13A| 600W
KCG12015DX| 1500W| 12A| 600W
KCG14415DX| 1500W| 10A| 600W
KCG15615DX| 1500W| 9.5A| 600W

KCG7215DX means: 2 in 1unit which integrates a 72V/1.5KW charger and a 600W DC/DC converter.

Wiring and Installation

5.1. Connections of DC/DC

Description

|

Wires

---|---
Input| Red: B+ Black: B- Pink: Key switch of DC/DC
Controllable Output| Red: + (controlled by a key switch) Black: GND Yellow: Driving disable signal

5.2. Installation Dimensions

5.3. Standard Wiring

Wiring Instruction: I Input: Red wire with ring terminal: Positive of battery pack: Black wire with ring terminal: Negative of battery pack: Pink thinner wire: Key switch input wire of DCDC converter,
2. Output: (Controllable output) Red wire on 2pin connector: Output positive of DCDC: Black wire on 2pin connector: Output negative of DCDC.This output is enabled or disabled by the key switch input wire which is Pink thinner wire on DJ702IA-2.8-21
3,Output disable signal: Yellow thinner wire:Output a 12V volt into high level brake switch input port of controller when input of charger(220VAC EU Type Plug) is connected to state grid. I2-15V relative to B-
AC vs. Battery vs. DC Output, three way isolation

| | | | | | Airing  Diagram| KELLY CONTROLS, LLC
---|---|---|---|---|---|---|---
| | | | |
| | | | | | |
KCG
Mark| | Subarea| Signatory| | Date| ii/2022|
Design| Fany| | StandardizeFany| | | modification| Number| Droportior
Assessor| Dan| | | |
| | | V2 3E
Technics| Qijie H| | Authorize| Steven|
Sum|

Figure 3: Kelly EV Power Unit Standard Wirin g
5.4. Important Safety Precautions
Hazardous conditions may result if the Unite is not installed or operated correctly. Please read the following instructions to prevent personal injury or damage to the charger.

• Remove metal items like rings, bracelets and watches when working with batteries.
• The Unit must not be operated in damp, wet environment, or near heat sources.
• High voltage inside the case, may cause harm to the human body. If the Unit fails, please contact us. DO NOT disassemble the Unit.
• The Unit should be used where clean and well ventilated. Don’t sheltered inlet or outlet during charging, and make sure that both inlet and outlet have air space of at least 10cm.
• The Unit should be used to prevent children closer and touch.
• Prohibit using or storing near flammable, explosive goods.
• Do not wash with water, we recommend using a clean rag dipped a small amount of alcohol.
• Before charging, please connect the DC terminal to battery first, and then connect the AC terminal.
• No charging or after charging complete, be sure to unplug the DC terminal and AC terminal.

Warning:

1. Disconnect the AC input power before changing the setting of the charger.
2. Charger output voltage must be same with the nominal voltage of battery pack.
3. Batteries generate explosive Hydrogen and Oxygen gases during normal operation. Be sure to be installed in a well ventilated location.

Characteristics

6.1. Charging Curve
Kelly charger adopts Intelligent charging modes, which can achieve rapid charging and extend battery life. Charging curve is given below.

Pulse charging can eliminate polarization and deepen chemical reaction.
It increases the capacitance of the battery, saves energy, brings convenience to use.

6.2. Indicator LEDs

Note: The red LED will flash repeatedly when in fault.
6.3. Output Power Curve of DC/DC

6.4. Efficiency Values of DC/DC under Different Loads

Warranty

There are no user-serviceable parts inside the Unit. Do not attempt to open it as this will void your warranty. However, periodic, exterior cleaning of the Unit should be carried out.
The Unit is a high powered device. When working with any battery powered vehicle, proper safety precautions should be taken that include, but are not limited to, proper training, wearing eye protection, avoidance of loose clothing, hair and jewelry. Always use insulated tools.

1. One year limited warranty

2. There are no warranty for defects or damages caused by the following reasons, including but not limited to:
   a. Caused by faulty installation
   b. Abuse or misuse including exposure to excessive heat or humid environment
   c. Caused by disassembling or repair without authorization
   d. Caused by natural disasters and force majeure
   e. Caused by abnormal external forces

3. There shall be no responsibility or liability whatsoever on the part of the Warrantor or its employees and representatives for injury to any persons, or damage to property, or loss of income or profit, or any other consequential or resulting damage which may be claimed to have been incurred through the use or sale of the equipment, including any possible failure of malfunction of the equipment, or part thereof. The Warrantor assumes no liability for incidental or consequential damages of any kind.

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)
http://www.kellycontroller.com
(+86) 139-56008360 (China)

References

• Kelly Controls - Motor Controllers, EV Parts
• Kelly Controls - Motor Controllers, EV Parts

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