DATEL BWR-5-6-3.3-7-D48s, BWR-5-6-3.3-7-D24s, BWR-5-6-3.3-7-D12s Datasheet

5V and 3.3V, 2" x 2"

33 Watt, DC/DC Converters

Dual Output

Mixed Voltage, BWR Models

Features

Figure 1. Simplifi ed Schematic

INNOVATION and EX C ELL E N C

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Regulated 3.3V and 5V outputs

5V @ 6Amps/3.3V @ 7 Amps capability

33 Watts total output power

No-load operation

Available input voltage ranges:
10-18V, 18-36V or 36-75V

Small 2" x 2" x 0.45" package

UL1950 and EN60950 safety approvals

mark available (75V-input models)

Continuous short-circuit protection

Fully isolated, 1500Vdc guaranteed

–40 to +100°C operating temperature

Input under and overvoltage shutdown

Output overvoltage protection

Thermal shutdown

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

+INPUT

–INPUT

SWITCH

CONTROL

+5V OUTPUT

+3.3V OUTPUT

OUTPUT
RETURN

TRIM

PWM

CONTROLLER

REFERENCE &

ERROR AMP

OPTO

ISOLATION

ON/OFF

CONTROL

(SYNC)

UV & OV

COMPARATORS

ACTIVE

BLEEDER

THERMAL

SHUTDOWN

For applications requiring 33 Watts of power from 5V and 3.3V, DATEL offers a
new power sharing DC/DC converter capable of meeting your output current require­ments. The BWR-5/6-3.3/7-D48 (36-75V input), BWR-5/6-3.3/7-D24 (18-36V input)
and BWR-5/6-3.3/7-D12 (10-18V input) are fully isolated DC/DC converters capable
of delivering any combination of 5V and 3.3V loading up to a combined total of 33
Watts of output power.

Housed in a standard 2" x 2" x 0.45" metal package coated with electrically non­conductive fi nish, these conv erters utilize a shared control-loop system to assure load
regulation of ±1% for 3.3V output and ±1.5% for 5V output. All models include input
Pi fi ltering, input overvoltage and undervoltage shutdown circuitry, output overvoltage
protection, output short-circuit and current limiting protection, and thermal shutdown.
Each design also provides trim capability, on/off control function, or an optional sync
control. Fully synchronous output rectifi cation renders high effi ciency and no-load
operation.

BWR power sharing modules offer low ripple and noise performance, high
effi ciency (88%), 1500Vdc of isolation voltage, and are fully specifi ed for –40
to +100°C operation. These devices meet IEC950, UL1950 and EN6950 safety
standards, including BASIC insulation requirements for "D48" models. CB reports
are available on request. "D48" models are CE marked (meet LVD requirements).

33W, DUAL OUTPUT, MIXED-VOLTAGE DC/DC CONVERTERS

XWR Series

Performance Specifi cations and Ordering Guide

➀

PART NUMBER STRUCTURE

V1 Nominal Output Voltage:
5 Volts

5

BWR

6-

/

D48-

Input Voltage Range:
D12 = 10-18 Volts (12V nominal)
D24 = 18-36 Volts (24V nominal)
D48 = 36-75 Volts (48V nominal)

I

1 Maximum Output Current:

6 Amps

Dual Output/
Mixed-Voltage Series

3.3 7

/

-

S

V2 Nominal Output Voltage:

3.3 Volts

I2 Maximum Output Current:

7 Amps

Add "S" suffi x as desired

Part Number Suffi xes

BWR 33 Watt DC/DC's are designed so an On/Off Control function

with positive polarity (no suffi x) or a Sync function ("S" suffi x) can be

added in the pin 4 position.

No Suffi x On/Off Control function (positive polarity) on pin 4

S Suffi x Sync function on pin 4

BWR-5/6-3.3/7-D12

5 6 40 100 ±1% ±1.5% ±2.5%

12 10-18 70/3308 83% 86% C4, P33

3.3 7 95 140 ±0.5% ±1% ±1.5%

BWR-5/6-3.3/7-D24

5 6 40 100 ±1% ±1.5% ±2.5%

24 18-36 50/1615 85% 88% C4, P33

3.3 7 95 140 ±0.5% ±1% ±1.5%

BWR-5/6-3.3/7-D48

5 6 40 100 ±1% ±1.5% ±2.5%

48 36-75 25/780 85% 88% C4, P33

3.3 7 95 140 ±0.5% ±1% ±1.5%

➀ Typical at TA = +25°C under nominal line voltage and balanced "full-load" conditions (5V @ 3.3A/3.3V @ 5A).
➁ Any combination of 5V/3.3V rated I

OUT current, not to exceed 33 Watts of output power. (See derating graphs.)

➂ Ripple/Noise (R/N) measured over a 20MHz bandwidth. All models are specifi ed with 1µF ceramic

output capacitors.

Output

Input

➃ Tested from 10% load to 100% load (other output at 10% load).
➄ Nominal line voltage, no load/balanced full-power condition.
➅ Tested from no-load to 100% load (other output at no-load).
➆ Output trim may impact 5V load regulation.

R/N (mVp-p) ➂ Regulation (Max.)

➆

Effi ciency

Packag e

V

OUT IOUT ➁ VIN Nom. Range IIN ➄ (Case,

Model (Volts) (Amps) Typ. Max. Line Load ➃ No Load ➅ (Volts) (Volts) (mA) Min. Typ. Pinout)

MEC ANICAL SPECIFI CATIONS

2

BOTTOM VIEW

1.800

(45.72)

0.10

(2.54)

2.00

(50.80)

8

5

6

7

0.40

(10.16)

0.200
(5.08)

0.400

(10.16)

0.100
(2.54)

1
2

4

METAL CASE

INSULATED BAS

E

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)

I/O Connections

Pin Function P33

1 +Input

2 –Input

3 No Pin

4 On/Off Control

5 +5V Output

6 Output Return

7 +3.3V Output

8 Trim

Notes:

For "D12" and "D24" models
the case is connected to
pin 2 (–Input).

For "D48" models, the case
is connected to pin 1 (+Input).

Case C4

BWR Models

33W, DUAL OUTPUT, MIXED-VOLTAGE DC/DC CONVERTERS

Performance/Functional Specifi cations

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

Input

Input Voltage Range:

D12 Models 10-18 Volts (12V nominal)

D24 Models 18-36 Volts (24V nominal)

D48 Models 36-75 Volts (48V nominal)

Overvoltage Shutdown:

➁

D12 Models 19-23 Volts (21V nominal)

D24 Models 37-42 Volts (40V nominal)

D48 Models 77-81 Volts (79V nominal)

Start-Up Threshold:

➁

D12 Models 9-10 Volts (9.3V nominal)

D24 Models 16.5-18 Volts (17V nominal)

D48 Models 34-36 Volts (35V nominal)

Undervoltage Shutdown:

➁

D12 Models 8.5-9.6 Volts (9.3V nominal)

D24 Models 16-17 Volts (16.5V nominal)

D48 Models 32.5-35 Volts (34V nominal)

Input Current:

Normal Operating Conditions See Ordering Guide

Standby Mode:

Off, OV, UV, Thermal Shutdown 10mA typical

Input Refl ected Ripple Current:

Source Impedance <0.1Ω, no external input fi ltering

D12 Models 200mAp-p (150mAp-p typical)

D24/D48 Models 250mAp-p (225mAp-p typical)

Internal Input Filter Type Pi (0.022µF - 4.7µH - 2.46µF)

Reverse-Polarity Protection:

➁

D12 Models 1 minute duration, 6A maximum

D24 Models 1 minute duration, 4A maximum

D48 Models 1 minute duration, 2A maximum

On/Off Control (Pin 4):

➁ ➂ ➃ ➅

D12, D24 & D48 Models On = open or 13V - +V

IN, IIN = 50µA max.

Off = 0-0.8V, I

IN = 1mA max.

Sync (Option, Pin 4): ➁ ➂ ➃

Input Threshold (Rising Edge Active) 1-2.7 Volts

Input Voltage Low 0-0.9 Volts

Input Voltage High 2.8-5 Volts

Input Resistance 35kΩ minimum

Output High Voltage (100µA load) 3.5-4.8 Volts

Output Drive Current 35mA

Input/Output Pulse Width 160-360nsec

Output

VOUT Accuracy

5V Output ±3% maximum

3.3V Output ±1.5% maximum

Minimum Loading Per Specifi cation No load, see Performance Specifi cations

Ripple/Noise (20MHz BW)

➁ ➄ See Ordering Guide

Line/Load Regulation

➁ See Ordering Guide

Effi ciency See Ordering Guide / Effi ciency Cur ves

Cross Regulation:

➁

5V Output (5V@0.6A, 3.3V@0.7-7A) ±6% maximum

3.3V Output (3.3V@0.7A, 5V@0.6-6A) ±0.5% maximum

Trim Range

➁ ±5%

Isolation Voltage:

Input-to-Output 1500Vdc minimum

Isolation Capacitance 470pF

Isolation Resistance 100MΩ

Temperature Coeffi cient ±0.02%/per°C

Output (continued)

Current Limit Inception: ➁

5V @ 95% VOUT (3.3V @ 0A) 7.6 -9.0 Amps

3.3V @ 98.5% V

OUT (5V @ 0A) 11.3 -12.7 Amps

Short Circuit Current:

➁

5V Output 5 Amps average, continuous

3.3V Output 6 Amps average, continuous

Overvoltage Protection:

➁ Magnetic feedback

5V Output 6.8 volts

3.3V Output 4.5Volts

Maximum Capacitive Loading

D12 Models 3.3V 1000µF

5V 470µF

D24, D48 Models 3.3V 2000µF

5V 1000µF

Dynamic Characteristics

Dynamic Load Response: ➁

5V (50-100% load step to 4% V

OUT) 300µsec maximum

3.3V (50-100% load step to 2.5% V

OUT) 300µsec maximum

Start-Up Time: ➁

V

IN to VOUT 20msec maximum

On/Off to V

OUT 15msec maximum

Switching Frequency 285kHz (±15kHz)

Environmental

MTBF ➆ Bellcore, ground fi xed, full power, +25°C

operating ambient temperature

D12 Models 1.3 million hours

D24/D48 Models 1.67 million hours

Operating Temperature (Ambient):

➁

Without Derating:

D12 Models –40 to +50°C

D24 Models –40 to +60°C

D48 Models –40 to +68°C

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

Case Temperature:

Maximum Operational +100°C

For Thermal Shutdown

➁ +110°C minimum, +117°C maximum

Storage Temperature –40 to +120°C

Physical

Dimensions 2" x 2" x 0.45" (50.8 x 50.8 x 11.43mm)

Internal Case Connection:

D12/D24 Models –Input (Pin 2)

D48 Models +Input (Pin 1)

Case Material Corrosion resistant steel with

non-conductive, epoxy-based, black

enamel fi nish and plastic baseplate

Pin Material Brass, solder coated

Weight: 2.7 ounces (76.5 grams)

Primary to Secondary Insulation Level

D12/D24 Models Operational

D48 Models Basic

➀ Balanced "full-load" is 5V @ 3.3A/3.3V @ 5A. All models are specifi ed with external

1µF ceramic output capacitors.

➁ See Technical Notes/Graphs for details.
➂ Devices may be ordered with On/Off Control function or a Sync function.

See Part Number Suffi xes and Technical Notes for details.

➃ Applying a voltage to On/Off Control (pin 4) when no input power is applied to the

converter may cause permanent damage.

➄ Output noise may be further reduced with the installation of additional external output

capacitors. See Technical Notes.

➅ On/Off control is designed to be driven with open collector or by appropriate voltage

levels. Voltages must be referenced to the input return pin (–Input).

➆ Demonstrated MTBF available on request.

3

33W, DUAL OUTPUT, MIXED-VOLTAGE DC/DC CONVERTERS

XWR Series

4

Absolute Maximum Ratings

Input Voltage:

Continuous: "D12" Models 23 Volts
"D24" Models 42 Volts
"D48" Models 81 Volts
Transient (100msec): "D12" Models 25 Volts
"D24" Models 50 Volts
"D48" Models 100 Volts

Input Reverse-Polarity Protection

➁ Input Current must be limited. 1 minute

duration. Fusing recommended.
"D12" Models 6 Amps
"D24" Models 4 Amps
"D48" Models 2 Amps

Output Current

➁ Current limited. Devices can withstand

an indefi nite output short circuit.

On/Off Control (Pin 4) Max. Voltages
Referenced to –Input (pin 2)
No Suffi x +V

IN

"S" Suffi x +5.7 Volts

Storage Temperature –40 to +120°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, nor recommended.

TECHNICAL NOTES

5V & 3.3V Regulation

The BWR 33 Watt Series converters are designed such that both the 5V and

3.3V outputs share a common regulation feedback control loop. Though the

feedback loop is infl uenced by both outputs, the 3.3 Volt output is dominant.

As a result, the 3.3 Volt regulation (1%) is superior to the 5 Volt regulation (4%).

The converters are specifi ed for load regulation of 10% to 100% loading and

for no-load to 100% loading. Operation below 10% of full load mandates

an increase in the regulation tolerance of ±0.5% for 3.3 Volt output and an

increase of ±1% for the 5 Volt output. A slight increase in switching noise

may also be observed for operation below 10% loading.

Operation with a full load on 3.3 Volt output and light to no load on 5 Volt

output is the most demanding for +5V regulation. Under such conditions the

internal "bleeder" circuit is activated to provide an internal load thereby keep-

ing regulation within the published specifi cations. The bleeder is activated

gradually so as not to cause any erratic behavior on the converters outputs. A

slight degradation in effi ciency will occur while this internal load is activated.

Filtering and Noise Reduction

The BWR 33 Watt Series Converters achieve their rated ripple and noise

specifi cations with the use of 1µF output capacitors. In critical applications,

input/output noise may be further reduced by installing additional external

I/O capacitors. Input capacitors should be selected for bulk capacitance,

low ESR and high rms-ripple-current ratings. Output capacitors should be

selected for low ESR and appropriate frequency response. All caps should

have appropriate voltage ratings and be located as close to the converter

as possible.

Start-Up Time

The V

IN to VOUT start-up time is the interval of time where the input voltage

crosses the turn-on threshold point, and the fully loaded output voltage enters

and remains within its specifi ed accuracy band. Actual measured times will

vary with input source impedance, external input/output capacitance, and the

slew rate of the input voltages. The BWR-5/6-3.3/7 Series implements a

soft start circuit that limits the duty cycle of the PWM controller at power up,

thereby limiting the Input Inrush current.

The On/Off Control to V

OUT start-up time assumes the converter has its

nominal input voltage applied but is turned off via the On/Off Control pin.

The specifi cation defi nes the interval between the time at which the converter

is turned on and the fully loaded output voltage enters and remains within

its specifi ed accuracy band. Similar to the V

IN to VOUT start-up, the On/Off

Control to V

OUT start-up time is also governed by the internal soft start

circuitry and external load capacitance.

Input Overvoltage/Undervoltage Shutdown and Start-Up Threshold

Under normal start-up conditions, devices will not begin to regulate until

the ramping-up input voltage exceeds the Start-Up Threshold Voltage (35V

for "D48" models). Once operating, devices will not turn off until the input

voltage drops below the Undervoltage Shutdown limit (34V for "D48" models).

Subsequent re-start will not occur until the input is brought back up to the

Start-Up Threshold. This built in hysteresis prevents any unstable on/off

situations from occurring at a single input voltage.

Input voltages exceeding the input overvoltage shutdown specifi cation listed

in the Performance/Functional Specifi cations will cause the device to shut-

down. A built-in hysteresis of 0.6 to 1.6 Volts for all models will not allow the

converter to restart until the input voltage is suffi ciently reduced.

On/Off Control

The On/Off Control (pin 4) may be used for remote on/off operation. As

shown in Figure 1, the control pin is referenced to the –Input (pin 2) and will

be internally pulled to a high state. The standard BWR model (no suffi x) is

designed so that it is enabled when the control pin is left open and disabled

when the control pin is pulled low (less than +0.8V relative to –Input).

Dynamic control of the on/off function is best accomplished with a mechanical

relay or an open-collector/open-drain circuit (optically isolated if appropriate).

The drive circuit should be able to sink approximately 1 mA for logic low.

The on/off control function is designed such that the converter can be

disabled while the input power is ramping up, and then "released" once the

input has stabilized.

Figure 1. Internal Circuitry for No Suffi x Models

4

2

1

R

A

RB

+INPUT

–INPUT

ON/OFF
CONTROL

D12 RA = 34.8kΩ, RB = 6.83kΩ
D24 R

A = 100kΩ, RB = 9.74kΩ

D48 R

A = 100kΩ, RB = 4.53kΩ