Datasheet BWR-15-670-D48A, BWR-15-670-D12A, BWR-15-500-D5A, BWR-5-1700-D48A, BWR-5-1700-D12A Datasheet (DATEL)

...

Download

Page 1

–V

OUT

–V

OUT

COMMON

PWM

CONTROLLER

REFERENCE &

ERROR AMP

ON/OFF

CONTROL

TRIM

OPTO

ISOLATION

DATEL, Inc., Mansfield, MA 02048 (USA) • Tel: (508)339-3000, (800)233-2765 Fax: (508)339-6356 • Email: sales@datel.com • Internet: www.datel.com

Figure 1. Simplified Schematic

Features

Dual Output

A-Series, BWR Models

High-Reliability, 2" x 2"

15-20 Watt, DC/DC Conver ters

For your mid-range pow er requirements, it’ s hard to beat the combination of low cost, proven reliability and outstanding electrical performance offered by the 15-20W, dual-output models of D A TEL’s new A-Series DC/DC converters. These highly efficient, rugged converters combine straightforward circuit topologies, the newest components, proven SMT-on-pcb construction methods, and highly repeatable automatic-assembly techniques. Their superior durability is substantiated by a rigorous in-house qualification program that includes HAL T (Highly Accelerated Lif e Testing).

The ultra-wide input voltage ranges of the A-Series duals (4.7-7.5V for "D5A" models, 9-36V for "D12A" models and 18-75V for "D48A" models) make them excellent candidates for battery-powered systems or for distributed power architectures . Their ±5, ±12 or ±15 V olt outputs cov er virtually all standard applications.

These popular power converters are fully isolated (1500Vdc guaranteed) and display excellent line and load regulation (with specs as low as ±0.3% max. for line and ±0.5% max. f or load). They are completely I/O protected (input ov ervoltage shutdown and reverse-polarity protection, output current limiting and overvoltage protection) and contain input (pi type) and output filtering to reduce noise. They require no external components and offer true "plug-and-play" convenience.

These extremely reliable, cost-effective power converters are housed in standard 2" x 2" x 0.45" metal packages coated with electrically non-conductive materials. The y offer industry-standard pinouts and are ideally suited for high-volume computer , telecom/datacom, instrumentation and A TE applications.

INNOVATION and EX C ELL E N C E

A- SERIES

■

■■

■

■■

■

■■

■

■■

■

■■

■

■■

■

■■

■

■■

■

■■

■

■■

■

■■

■

■■

■

Low cost! Highly reliable! Proven SMT-on-pcb construction Qual tested; HAL T tested; EMC tested Designed to meet UL1950 and

EN60950 (basic insulation)

mark available (75V -input models) Output voltages: ±5, ±12 or ±15 Volts Ultra-wide input voltage ranges:

4.7-7.5V , 9-36V or 18-75V Small packages, 2" x 2" x 0.45" Industry-standard pinouts Fully isolated, 1500Vdc guaranteed Guaranteed efficiencies to 82% –40 to +100°C operating temperature Modifications and customs for OEM’ s

Page 2

15-20W, DUAL OUTPUT DC/DC CONVERTERS

A Series

1 2 3 4 5 6 7 8

Notes:

For "D5A" and "D12A" models, the case is connected to pin 2 (–V

IN).

For "D48A" models, the case is connected to pin 1 (+VIN).

I/O Connections

BOTTOM VIEW

1.800

(45.72)

0.10

(2.54)

2.00

(50.80)

0.40

(10.16)

0.200 (5.08)

0.400

(10.16)

0.100 (2.54)

1 2

METAL CASE

INSULATED BASE

0.040 ±0.002 DIA. (1.016 ±0.051)

2.00

(50.80)

0.20 MIN (5.08)

0.45

(11.43)

1.200

(30.48)

3 EQ. SP. @

0.400 (10.16)

Case C4

➀

T ypical at TA = +25°C under nominal line voltage and full-load conditions unless otherwise noted.

➁

Ripple/Noise (R/N) measured over a 20MHz bandwidth.

➂

Balanced loads, 20% to 100% load.

➃

Nominal line voltage, no-load/full-load conditions.

Function P7

+Input –Input No Pin

On/Off Control

+Output

Common

–Output

Trim

Nominal Output Voltages:

±5, ±12 or ±15 Volts

Maximum Output Current

in mA from each output

Input Volta ge Range:

D5 = 4.7-7.5 Volts (5V nominal) D12 = 9-36 Volts (24V nominal) D48 = 18-75 Volts (48V nominal)

Wide Range Input

Output Configuration:

B = Bipolar

12B WR 830 D48 A-/ -

A-Series

High Reliability

Performance Specifications and Ordering Guide

➀

IOUT

(mA)

R/N (mVp-p)

➁

Load

➂

VOUT

(Volts)

Output

Package

(Case,

Pinout)

Efficiency

Regulation (Max.)

Line

VIN Nom.

(Volts)

Range

(Volts)

Model

Input

IIN ➃

(mA)

Max.

Typ.

Min.

BWR-5/1500-D5A ±5 ±1500 50 100 ±0.5% ±1.0% 5 4.7-7.5 75/3750 79% 80% C4, P7 BWR-5/1700-D12A ±5 ±1700 75 100 ±0.3% ±0.5% 24 9-36 15/753 80.5% 83% C4, P7 BWR-5/1700-D48A ±5 ±1700 75 100 ±0.3% ±0.5% 48 18-75 15/377 81% 83% C4, P7 BWR-12/625-D5A ±12 ±625 75 120 ±0.5% ±1.0% 5 4.7-7.5 75/3750 79% 81% C4, P7 BWR-12/830-D12A ±12 ±830 75 100 ±0.3% ±0.5% 24 9-36 30/1000 81.5% 83% C4, P7 BWR-12/830-D48A ±12 ±830 75 100 ±0.4% ±0.5% 48 18-75 15/510 81% 83% C4, P7 BWR-15/500-D5A ±15 ±500 75 150 ±0.5% ±1.0% 5 4.7-7.5 75/3659 80% 82% C4, P7 BWR-15/670-D12A ±15 ±670 75 100 ±0.3% ±0.5% 24 9-36 30/979 82% 83% C4, P7 BWR-15/670-D48A ±15 ±670 75 100 ±0.3% ±0.5% 48 18-75 15/484 82% 84% C4, P7

Output Power (Watts)

Ambient Temperature (°C

)

20 19 18 17 16 15 14 13 12 11 10

9 8 7 6 5 4 3 2 1 0

BWR-5/1500-D5A C BWR-5/1700-D12A B BWR-5/1700-D48A B BWR-12/625-D5A C BWR-12/830-D12A A BWR-12/830-D48A A BWR-15/500-D5A C BWR-15/670-D12A A BWR-15/670-D48A A

–40 0 40 4 5 5 0 5 5 60 65 70 75 80 85 9 0 9 5 1 0 0

PART NUMBER STRUCTURE

MECHANICAL SPECIFICATIONS

TEMPERATURE DERATING

Page 3

15-20W, DUAL OUTPUT DC/DC CONVERTERS

BWR Models

Floating Outputs

Since these are isolated DC/DC converters, their outputs are "floating." Any BWR model may be configured to produce an output of 10V, 24V or 30V (for

±5V, ±12V or ±15V models, respectively) by applying the load across the

+Output and –Output pins (pins 5 and 7), with either output grounded. The Common pin (pin 6) should be left open. Minimum 20% loading is recommended under these conditions. The total output voltage span may be externally trimmed as described below.

Filtering and Noise Reduction

All A-Series BWR 15-20 Watt DC/DC Converters achieve their rated ripple and noise specifications without the use of external input/output capacitors. In critical applications, input/output ripple and noise may be further reduced by installing electrolytic capacitors across the input terminals and/or lowESR tantalum or electrolytic capacitors across the output terminals. Output capacitors should be connected between their respective output pin (pin 5 or

7) and Common (pin 6) as shown in Figure 2. The caps should be located as close to the power converters as possible. Typical values are listed in the tables below. In many applications, using values greater than those listed will yield better results.

To Reduce Input Ripple

"D5A" Models 47µF, 16V "D12A" Models 20µF, 50V "D48A" Models 20µF, 100V

To Reduce Output Ripple

±5V Outputs 47µF, 10V, Low ESR ±9/12/15V Outputs 22µF, 20V, Low ESR

In critical, space-sensitive applications, DATEL may be able to tailor the internal input/output filtering of these units to meet your specific requirements. Contact our Applications Engineering Group for additional details.

Performance/Functional Specifications

T ypical @ TA = +25°C under nominal line voltage and full-load conditions, unless noted.

➀

These converters require a minimum 20% loading on each output to maintain specified regulation.Operation under no-load conditions will not damage these devices; howeve r they may not meet all listed specifications.

➁

Application-specific internal input/output filtering can be recommended and perhaps added internally upon request. Contact DATEL Applications Engineering for details.

➂

Applying a voltage to the Control pin when no input power is applied to the conve rter can cause permanent damage to the converter.

➃

Devices can be screened or modified for higher guaranteed isolation v oltages. Contact DATEL Applications Engineering for details.

Input

Input Voltage Range:

"D5A" Models 4.7-7.5 Volts (5V nominal) "D12A" Models 9-36 Volts (24V nominal) "D48A" Models 18-75 Volts (48V nominal)

Input Current See Ordering Guide Input Filter Type

➁

Overvoltage Shutdown:

"D5A" Models 10 Volts "D12A" Models 40 Volts "D48A" Models 80 Volts

Reverse-Polarity Protection Yes (Instantaneous, 10A maximum) On/Off (Sync.) Control (Pin 4)

➂

TTL high = off, low (or open) = on

Output

VOUT Accuracy (50% load):

±5V Outputs ±1.5%, maximum ±9/12/15V Outputs ±1%, maximum

Temperature Coefficient ±0.02% per °C Ripple/Noise (20MHz BW)

➁

See Ordering Guide

Line/Load Regulation See Ordering Guide Efficiency See Ordering Guide Isolation Voltage

➃

1500Vdc, minimum

Isolation Capacitance 550pF Current Limiting Auto-recovery Overvoltage Protection Zener/transorb clamps, magnetic feedback

Dynamic Characteristics

Transient Response (50% load step) 200µsec max. to ±1.5% of final value Switching Frequency 165kHz (±15kHz)

Environmental

Operating Temperature (ambient):

Without Derating –40 to +50/55/60°C (Model dependent) With Derating to +100°C (See Derating Curves)

Storage Temperature –40 to +105°C

Physical

Dimensions 2" x 2" x 0.45" (51 x 51 x 11.4mm) Shielding 5-sided Case Connection:

"D5A" and "D12A" Models Pin 2 (–V

IN)

"D48A" Models Pin 1 (+VIN)

Case Material Corrosion resistant steel with

non-conductive, epoxy-based, black enamel finish and plastic baseplate

Pin Material Brass, solder coated Weight 2.7 ounces (75.6 grams)

Input Volta ge:

"D5A" Models 12 Volts "D12" Models 44 Volts "D48" Models 88 Volts

Input Reverse-Polarity Protection Current must be <10A. Brief

duration only. Fusing recommended.

Output Overvoltage Protection

±5V Outputs 6.8 Volts, limited duration ±12V Outputs 15 Volts, limited duration ±15V Outputs 18 Volts, limited duration

Output Current Current limited. Max. current and

short-circuit duration are model dependent.

Storage Temperature –40 to +105°C Lead Temperature (soldering, 10 sec.) +300°C

These are stress ratings. Exposure of devices to any of these conditions may adversely affect long-term reliability. Proper operation under conditions other than those listed in the Performance/Functional Specifications Table is not implied.

Absolute Maximum Ratings

TECHNICAL NOTES

Page 4

15-20W, DUAL OUTPUT DC/DC CONVERTERS

A Series

Figure 3a. Trim Connections Using a Trimpot

Figure 2. Using External Capacitors to Reduce

Input/Output Ripple/Noise

20k

Ω

5-10 Turns

LOAD

+INPUT

–INPUT

TRIM

COMMON

–OUTPUT

+OUTPUT

+INPUT

–INPUT

+OUTPUT

TRIM

LOAD

COMMON

–OUTPUT

Figure 3b. Fixed-Value Trim Down Resistor

+INPUT

–INPUT

+OUTPUT

TRIM

LOAD

COMMON

–OUTPUT

Figure 3c. Fixed-Value Trim Up Resistor

–OUTPUT

+INPUT

–INPUT

+OUTPUT

COMMON

OUT

Input Fusing

Certain applications and/or safety agencies may require the installation of fuses at the inputs of power conversion components. For DATEL A-Series BWR 15-20 Watt DC/DC Converters, you should use slow-blow type fuses with values no greater than the following:

VIN Range Fuse Value

"D5A" 6A "D12A" 4A "D48A" 2A

On/Off Control

The On/Off Control pin (pin 4) may be used for remote on/off operation. A TTL logic high (+2 to +5 Volts, 250µA max.) applied to pin 4 disables the converter. A TTL logic low (0 to +0.8 Volts, 70µA max.), or no connection, enables the converter. Control voltages should be referenced to pin 2 (–Input). Applying a voltage to the Control pin when no input power is applied to the converter can cause permanent damage to the converter.

Synchronization

In critical applications employing multiple switching DC/DC conver ters, it may be desirable to intentionally synchronize the switching of selected converters (so the system noise can be reduced with notch filtering) or to purposely desynchronize the converters (to lessen the current-carrying requirements on intermediate dc buses). For multiple A-Series Converters, an external clock can be applied to pin 4 (Control) of each device. It should be a square wave with a maximum 1µsec "high" duration and an amplitude between +2V and +5V (see On/Off Control) referenced to pin 2 (–Input). The frequency of the synchronizing clock should be higher than that of any individual conver ter. Therefore, it should be 185kHz ±5kHz.

Output T rimming

The total output voltage span, from +Output (pin 5) to –Output (pin 7) may be trimmed ±5% via a single external trimpot or fixed resistor. The trimpot should be connected as shown in Figure 3a with its wiper connected to pin 8 (Trim). A trimpot can be used to determine the value of a single fixed resistor which should be connected as shown in Figures 3b and 3c. Connect the resistor between pin 8 (Trim) and pin 5 (+Output) to trim "down" the output voltages. Connect the resistor between pins 8 and 7 (–Output) to trim "up" the output voltages. Fixed resistors should be metal-film types with absolute TCR’s less than 100ppm/°C to ensure stability.

Page 5

15-20W, DUAL OUTPUT DC/DC CONVERTERS

BWR Models

If you’re designing with EMC in mind, please note that all of D ATEL ’ s BWR 1520 Watt A-Series DC/DC Converters have been characterized for radiated and conducted emissions in our new EMI/EMC laboratory . Testing is conducted in an EMCO 5305 GTEM test cell utilizing EMCO automated EMC test software. Radiated emissions are tested to the limits of FCC Part 15, Class B and CISPR 22 (EN 55022), Class B. Correlation to other specifications can be supplied upon request. Radiated emissions plots to FCC and CISPR 22 for model BWR-5/1700-D48A appear below . Published EMC test reports are available f or each model number. Contact D A TEL’s Applications Engineering Department for more details.

BWR-5/1700-D48A Radiated Emissions

EN 55022 Class B, 10 Meters

Converter Output = ±5Vdc @ ±1.6A

–10

–20

Frequency (MHz)

100

1000

Radiated Emissions

EN 55022 Class B Limit

Radiated Emissions (dBµV/M)

–10

–20

Frequency (MHz)

100

1000

FCC Class B Limit

BWR-5/1700-D48A Radiated Emissions

FCC Part 15 Class B, 3 Meters

Converter Output = ±5Vdc @ ±1.6A

Radiated Emissions (dBµV/M)

Radiated Emissions

DATEL’s world-class design, development and manufacturing team stands ready to work with you to deliver the exact power converter you need for your demanding, large volume, OEM applications. And ... we’ll do it on time and within budget!

Our experienced applications and design staffs; quick-turn prototype capability; highly automated, SMT assembly facilities; and in-line SPC quality-control techniques combine to give us the unique ability to design and deliver any quantity of power conv erters to the highest standards of quality and reliability .

We have compiled a large library of DC/DC designs that are currently used in a variety of telecom, medical, computer, r ailway , aerospace and industrial applications. We may already have the converter you need.

CUSTOM CAPABILITIES

EMI RADIATED EMISSIONS

Page 6

DS-0323 10/98

DATEL makes no representation that the use of its products in the circuits described herein, or the use of other technical information contained herein, will not infringe upon existing or future patent rights. The descriptions contained herein do not imply the granting of licenses to make, use, or sell equipment constructed in accordance therewith. Specifications are subject to change without notice. The DATEL logo is a registered DATEL, Inc. trademark.

Quality and Reliability

The A-Series are the first DC/DC Converters to emerge from DATEL’s new, company-wide approach to designing and manufacturing the most reliable power converters available. The five-pronged program draws our Quality Assurance function into all aspects of new-product design, development, characterization, qualification and manufacturing.

Design for Reliability

Design for Reliability is woven throughout our multi-phased, new-productdevelopment process. Design-for-reliability practices are fully documented and begin early in the new-product development cycle with the following goals:

1. To work from an approved components/vendors list ensuring the use of reliable components and the rigorous qualification of new components.

2. To design with safety margins by adhering to a strict set of derating guidelines and performing theoretical worst-case analyses.

3. To locate potential design weaknesses early in the product-development cycle by using extensive HALT (Highly Accelerated Life Testing).

4. To prove that early design improvements are effective by employing a thorough FRACA (Failure Reporting Analysis and Corrective Action) system.

HALT Testing

The goal of the accelerated-stress techniques used by DATEL is to force device maturity, in a short period of time, by exposing devices to excessive levels of "every stimulus of potential value." We use HALT (Highly Accelerated Life Testing) repeatedly during the design and ear ly manufacturing phases to detect potential electrical and mechanical design weaknesses that could result in possible future field failures.

During HALT, prototype and pre-production DC/DC converters are subjected to progressively higher stress levels induced by thermal cycling, rate of temperature change, vibration, power cycling, product-specific stresses (such as dc voltage variation) and combined environments. The stresses are not meant to simulate field environments but to expose any weaknesses in a product’s electro/mechanical design and/or assembly processes. The goal of HALT is to make products fail so that device weaknesses can be analyzed and strengthened as appropriate. Applied stresses are continually stepped up until products eventually fail. After corrective actions and/or design

changes, stresses are stepped up again and the cycle is repeated until the "fundamental limit of the technology" is determined.

DATEL has invested in a Qualmark OVS-1 HALT tester capable of applying voltage and temperature extremes as well as 6-axis, linear and rotational, random vibration. A typical HALT profile (shown above) consists of thermal cycling (–55 to +125°C, 30°C/minute) and simultaneous, gradually increasing, random longitudinal and rotational vibration up to 20G’s with load cycling and applied-voltage extremes added as desired. Many devices in DATEL’s new A-Series could not be made to fail prior to reaching either the limits of the HALT chamber or some previously known physical limit of the device. We also use the HALT chamber and its ability to rapidly cool devices to verify their "cold-start" capabilities.

Qualification

For each new product, electrical performance is verified via a comprehensive characterization process and long-term reliability is confirmed via a rigorous qualification procedure. The qual procedure includes such strenuous tests as thermal shock and 500 hour life. Qual testing is summarized below.

In-Line Process Controls and Screening

A combination of statistical sampling and 100% inspection techniques keeps our assembly line under constant control. Parameters such as solder-paste thickness, component placement, cleanliness, etc. are statistically sampled, charted and fine tuned as necessary. Visual inspections are performed by trained operators after pick-and-place, soldering and cleaning operations. Units are 100% electrically tested prior to potting. All devices are temperature cycled, burned-in, hi-pot tested and final-electrical tested prior to external visual examination, packing and shipping.

Rapid Response to Problems

DATEL employs an outstanding corrective-action system to immediately address any detected shortcomings in either products or processes. Whenever our assembly, quality or engineering personnel spot a product/ process problem, or if a product is returned with a potential defect, we immediately perform a detailed failure analysis and, if necessary, undertake corrective actions. Over time, this system has helped refine our assembly operation to yield one of the lowest product defect rates in the industry.

Typical HALT Profile

Qualification Test Method/Comments

HALT DATEL in-house procedure High Temperature Storage Max. rated temp ., 1,000 hours Thermal Shock 10 cycles, –55 to +125°C Temperature/Humidity +85°C, 85% humidity, 48 hours Lead Integrity DATEL in-house procedure Life Test +70°C, 500 hours* Marking Permanency DATEL in-house procedure End Point Electrical Tests Per product specification

Qualification Testing

* Interim electrical test at 200 hours.

10 20 30 40 50 60 70 80 90

Random Vibration (G's)

Temperature (°C)

Test Time (minutes)

100

–20

–40

DATEL (UK) LTD. T adle y, England Tel: (01256)-880444 DATEL S.A.R.L. Montign y Le Bretonneux, France Tel: 01-34-60-01-01 DATEL GmbH München, Germany Tel: 89-544334-0 DATEL KK Tokyo , J apan T el: 3-3779-1031, Osaka Tel: 6-354-2025

DATEL, Inc. 11 Cabot Boulevard, Mansfield, MA 02048-1151 Tel: (508) 339-3000 (800) 233-2765 Fax: (508) 339-6356 Internet: www.datel.com Email: sales@datel.com Data Sheet Fax Back:(508) 261-2857

INNOVATION and EX C ELL E N C

ISO 9001

SO 9001

REGISTERED

15-20W, DUAL OUTPUT DC/DC CONVERTERS

A Series