Kelly OBC EV Power Unit OBC Plus DC DC Converter User Manual

Kelly OBC EV Power Unit OBC Plus DC DC Converter User Manual

1. 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.

2. 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.
• Powerful microcontroller, extend battery’s life.
• 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

3. Electrical Specifications

3.1. Input Specifications

3.2. Output Specifications

3.3. Protection Specifications

3.4. Environmental Specifications

3.5. Reliability Specifications

3.6. Safety Specifications

3.7. Charging Indicator

4. Naming Regulations & Models

4.1. Naming Regulations

4.2. Models

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

5. Wiring and Installation

5.1. Connections of DC/DC

5.2. Installation Dimensions

5.3. Standard Wiring

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.

6. 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

7. 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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