Datasheet BWR-5-900-D12A, BWR-5-700-D5A, BWR-5-700-D48A, BWR-15-330-D48A, BWR-15-330-D12A Datasheet (DATEL)

Features

Dual Output

A-Series, BWR Models

INNOVATION and EX C ELL E N C

E

®

®

It’s hard to beat the combination of low cost, small size (standard 2" x 1" x 0.375"
package) proven reliability and outstanding electrical performance offered by the
7-10W, dual-output models of DATEL’s new A-Series DC/DC converters. These highly
effi cient, 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 qualifi cation program that includes HALT (Highly Accelerated Life Testing).

The wide input voltage ranges of these A-Series duals (4.7-7.25V for "D5A"
models, 9-18V for "D12A" models and 18-72V for "D48A" models) make them excel­lent candidates for battery-powered systems or for distributed power architectures.
Their ±5, ±12 or ±15 Volt outputs cover virtually all standard applications.

These popular power converters are fully isolated (1500Vdc guaranteed) and
display excellent line and load regulation (±0.3% max. for line and ±1% max. for load).
They are completely I/O protected (input overvoltage shutdown and reverse-polarity
protection, output current limiting and overvoltage protection) and contain input (pi
type) and output fi ltering to reduce noise. They require no external components and
offer true "plug-and-play" convenience.

These extremely reliable, cost-effective power converters carry industry-standard
pinouts making them ideal replacements for other more costly, less reliable power
converters in computer, telecom/datacom, instrumentation and ATE applications.
They are an excellent choice for both new design-ins and upgrading older systems.

Figure 1. Simplifi ed Schematic

High-Reliability, 2" x 1"

7-10 Watt, DC/DC Converters

+

V

IN

–

V

IN

+V

OUT

–V

OUT

COMMO

N

PWM

CONTROLLER

OPTO

ISOLATION

REFERENCE &

ERROR AMP

■

■

■

■

■

■

■

■

■

■

■

■

■

Low cost! Highly reliable!

Proven SMT-on-pcb construction

Qual tested; HALT tested; EMC tested

Designed to meet UL1950 and

EN60950 (basic insulation)

Output voltages: ±5, ±12 or ±15 Volts

Wide input voltage ranges:

4.7-7.25V, 9-18V or 18-72V

Small packages, 2" x 1" x 0.375"

Industry-standard pinouts

Fully isolated, 1500Vdc guaranteed

Guaranteed effi ciencies to 82%

–40 to +100°C operating temperature

Modifi cations and customs for OEM’s

DATEL, Inc., Mansfi eld, MA 02048 (USA) · Tel: [phone] Fax: [phone] · Email: [e-mail] · Internet: www.datel.com

A- SERIES

A Series

7-10W, DUAL OUTPUT DC/DC CONVERTERS

BWR-5/700-D5A ±5 ±700 50 75 ±0.3% ±1.0% 5 4.7-7.25 25/1772 76% 79% C2, P12

BWR-5/900-D12A* ±5 ±900 75 100 ±0.3% ±1.0% 12 9-18 25/930 81% 82% C2, P12

BWR-5/700-D48A* ±5 ±700 50 100 ±0.3% ±1.0% 48 18-72 15/180 79% 81% C2, P12

BWR-12/335-D5A ±12 ±335 75 120 ±0.3% ±1.0% 5 4.7-7.25 40/1846 76% 78% C2, P12

BWR-12/415-D12A* ±12 ±415 100 120 ±0.3% ±1.0% 12 9-18 20/986 83% 84% C2, P12

BWR-12/415-D48A* ±12 ±415 75 120 ±0.3% ±1.0% 48 18-72 15/249 80.5% 84% C2, P12

BWR-15/275-D5A ±15 ±275 75 120 ±0.3% ±1.0% 5 4.7-7.25 40/2089 75% 79% C2, P12

BWR-15/330-D12A* ±15 ±330 75 120 ±0.3% ±1.0% 12 9-18 25/980 83% 84% C2, P12

BWR-15/330-D48A* ±15 ±330 75 120 ±0.3% ±1.0% 48 18-72 15/247 81.5% 84% C2, P12

0.10

(2.54)

0.800

(20.32)

0.60

(15.24)

0.100
(2.54)

1.00

(25.40)

0.400

(10.16)

BOTTOM VIEW

1

2

3
4

5

0.800

(20.32)

METAL CASE

INSULATED BASE

0.040 ±0.002 DIA.
(1.016 ±0.051)

0.20 MIN
(5.08)

0.200
(5.08)

2.00

(50.80)

0.375
(9.53)

2

Case C2

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 (+V

IN).

Performance Specifi cations and Ordering Guide

Output

Input

➀

➀ Typical 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.

Input Voltage Range:
D5 = 4.7-7.25 Volts (5V nominal)
D12 = 9-18 Volts (12V nominal)
D48 = 18-72 Volts (48V nominal)

Nominal Output Voltages:

±5, ±12 or ±15 Volts

Maximum Output Current

in mA from each output

Wide Range Input

Output Confi guration:
B = Bipolar

A-Series

High Reliability

15B WR 330 D12 A-

/

-

Output Power (Watts)

Ambient Temperature (°C

)

10

9

8

7

6

5

4

3

2

1

0

BWR-5/700-D5A E
BWR-5/900-D12A C
BWR-5/700-D48A F
BWR-12/335-D5A D
BWR-12/415-D12A A
BWR-12/415-D48A A
BWR-15/275-D5A D
BWR-15/330-D12A A
BWR-15/330-D48A B

D

D, E

E, F

–40 0 40 45 50 55 6 0 6 5 7 0 75 8 0 85 9 0 9 5 1 00

A, B

C

B

C

F

A

R/N (mVp-p) ➁ Regulation (Max.) Effi ciency

Packag e

VOUT IOUT VIN Nom. Range IIN ➃ (Case,
Model (Volts) (Amps) Typ. Max. Line Load ➂ (Volts) (Volts) (mA) Min. Typ. Pinout)

PART NUMBER STRUCTURE

TEMPERATURE DERATING

MECHANICAL SPECIFICATIONS

I/O Connections

Pin Function P12

1 +Input

2 –Input

3 +Output

4 Common

5 –Output

* Magnetic feedback.

TECHNICAL NOTES

BWR Models

7-10W, DUAL OUTPUT DC/DC CONVERTERS

Floating Outputs

Since these are isolated DC/DC converters, their outputs are "fl oating." Any

BWR model may be confi gured 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 3 and 5), with either output grounded.

The Common pin (pin 4) should be left open. Minimum 20% loading is

recommended under these conditions.

Filtering and Noise Reduction

All A-Series BWR 7-10 Watt DC/DC Converters achieve their rated ripple and

noise specifi cations 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 low-ESR

tantalum or electrolytic capacitors across the output terminals. Output capac-

itors should be connected between their respective output pin (pin 3 or 5) and

Common (pin 4) 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, 10V

"D12A" Models 20µF, 35V

"D48A" Models 10µF, 100V

To Reduce Output Ripple

±5V Output 47µF, 10V, Low ESR

±12/15V Outputs 22µF, 20V, Low ESR

In critical, space-sensitive applications, DATEL may be able to tailor the

internal input/output fi ltering of these units to meet your specifi c require-

ments. Contact our Applications Engineering Group for additional details.

3

➀ These power converters require a minimum 20% loading on each output to maintain

specifi ed regulation. Operation under no-load conditions will not damage these devices;
however they may not meet all listed specifi cations.

➁ Application-specifi c internal input/output fi ltering can be recommended or perhaps added

internally upon request. Contact DATEL Applications Engineering for details.

➂ Devices can be screened or modifi ed for higher guaranteed isolation voltages.

Contact DATEL Applications Engineering for details.

➃ D5A Models: Zener/transorb only

Performance/Functional Specifi cations

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

Input

Input Voltage Range:

D5A Models 4.7-7.25 Volts (5V nominal)

D12A Models 9-18 Volts (12V nominal)

D48A Models 18-72 Volts (48V nominal)

Input Current See Ordering Guide

Input Filter Type

➁ Pi

Reverse-Polarity Protection Yes (Instantaneous, 6A maximum)

Output

VOUT Accuracy (50% load):

±5V Outputs ±1.5%, maximum

±12/15V Outputs ±1%, maximum

Temperature Coeffi cient ±0.02% per °C

Ripple/Noise (20MHz BW)

➁ See Ordering Guide

Line/Load Regulation See Ordering Guide

Effi ciency See Ordering Guide

Isolation Voltage

➂ 1500Vdc, minimum

Isolation Capacitance 200pF

Current Limiting Auto-recovery

Overvoltage Protection ➃ Zener/transorb clamps, magnetic feedback

Dynamic Characteristics

Transient Response (50% load step) 200µsec max. to ±1.5% of fi nal value

Switching Frequency 165kHz (±15kHz)

Environmental

Operating Temperature (ambient):

Without Derating –40 to +65/70°C (Model dependent)

With Derating to +100°C (See Derating Curves)

Storage Temperature –40 to +105°C

Physical

Dimensions 2" x 1" x 0.375" (51 x 25 x 9.5mm)

Shielding 5-sided

Case Connection:

D5A and D12A Models Pin 2 (–V

IN)

D48A Models Pin 1 (+V

IN)

Case Material Corrosion resistant steel with

non-conductive, epoxy-based black

enamel fi nish and palstic baseplate

Pin Material Brass, solder coated

Weight 1.3 ounces (37 grams)

Input Voltage:

D5 Models 10 Volts
D12 Models 20 Volts
D48 Models 80Volts

Input Reverse-Polarity Protection Current must be <6A. Brief
duration only. Fusing recommended.

Output Overvoltage Protection

±5V Outputs 13 Volts, limited duration
±12V Outputs 28 Volts, limited duration
±15V Outputs 36 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 Specifi cations Table is not implied.

Absolute Maximum Ratings

If you’re designing with EMC in mind, please note that all of DATEL’s BWR

7-10 Watt A-Series DC/DC Converters have been characterized for radiated

and conducted emissions in our new EMI/EMC laboratory. Testing is con-

ducted 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 specifi cations can

be supplied upon request. Radiated emissions plots to FCC and CISPR 22

for model BWR-15/330-D48A appear below. Published EMC test reports are

available for each model number. Contact DATEL’s Applications Engineering

Department for more details.

Figure 2. Using External Capacitors to Reduce

Input/Output Ripple/Noise

1

2

3

5

4

C

IN

C

OUT

C

OUT

+

+

+

–OUTPUT

+INPUT

–INPUT

+OUTPUT

COMMON

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 7-10 Watt DC/DC Converters, you should use slow-blow type fuses with

values no greater than the following:

V

IN Range Fuse Value

"D5A" 3A

"D12A" 2A

"D48A" 1A

4

80

70

60

50

40

30

20

10

0

–10

–20

Frequency (MHz

)

100

1000

FCC Class B Limit

BWR-15/330-D48A Radiated Emissions

FCC Part 15 Class B, 3 Meters

Converter Output = ±15Vdc @ ±300mA

Radiated Emissions (dBµV/M)

Radiated Emissions

BWR-15/330-D48A Radiated Emissions

EN 55022 Class B, 10 Meters

Converter Output = ±15Vdc @ ±300mA

80

70

60

50

40

30

20

10

0

–10

–20

Frequency (MHz)

100

1000

Radiated Emissions

EN 55022 Class B Limit

Radiated Emissions (dBµV/M)

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 capa-

bility; 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 converters 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, railway, aerospace and industrial

applications. We may already have the converter you need.

Contact us. Our goal is to provide you the highest-quality, most cost-effective

power converters available.

A Series

7-10W, DUAL OUTPUT DC/DC CONVERTERS

CUSTOM CAPABILITIES

EMI RADIATED EMISSIONS

BWR Models

7-10W, DUAL OUTPUT DC/DC CONVERTERS

DS-0322 02/01

5

Quality and Reliability

The A-Series are the fi rst DC/DC Converters to emerge from DATEL’s new,

company-wide approach to designing and manufacturing the most reliable

power converters available. The fi ve-pronged program draws our Quality

Assurance function into all aspects of new-product design, development,

characterization, qualifi cation and manufacturing.

Design for Reliability

Design for Reliability is woven throughout our multi-phased, new-product-

development 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 qualifi cation 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 Acceler-

ated Life Testing) repeatedly during the design and early manufacturing

phases to detect potential electrical and mechanical design weaknesses

that could result in possible future fi eld 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-specifi c stresses (such

as dc voltage variation) and combined environments. The stresses are not

meant to simulate fi eld 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 profi le (shown above) consists of thermal

cycling (–55 to +125°C, 30°C/minute) and simultaneous, gradually increas-

ing, 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.

Qualifi cation

For each new product, electrical performance is verifi ed via a comprehensive

characterization process and long-term reliability is confi rmed via a rigorous

qualifi cation 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 fi ne 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 fi nal-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. When-

ever 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 refi ne our assembly operation to

yield one of the lowest product defect rates in the industry.

Typical HALT Profi le

Qualifi cation 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 specifi cation

Qualifi cation Testing

* Interim electrical test at 200 hours.

10 20 30 40 50 60 70 80 90

40

20

0

Random Vibration

(

G's

)

Temperature (°C)

Test Time (minutes)

100

80

60

40

20

0

–20

–40

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. Specifi cations are subject to change without notice. The DATEL logo is a registered DATEL, Inc. trademark.

DATEL (UK) LTD. Tadley, England Tel: [phone]
DATEL S.A.R.L. Montigny Le Bretonneux, France Tel: [phone]
DATEL GmbH München, Germany Tel: [phone]
DATEL KK Tokyo, Japan Tel: [phone], Osaka Tel: [phone]

DATEL, Inc. 11 Cabot Boulevard, Mansfi eld, MA 02048-1151
Tel: [phone] [phone] Fax: [phone]
Internet: www.datel.com Email: [e-mail]

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INNOVATION and EX C ELL E N C

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