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: [email protected]
Phone: (01) 224 637 5092(US)
(+86) 551-64397760(China)
(+86) 139-56008360 (China)
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