ETC BWR-15/275-D5A

®
®
INNOVATION and EXCELLENCE
Dual Output
A-Series, BWR Models
High-Reliability, 2" x 1"
7-10 Watt, DC/DC Converters
A-SERIES
Features
■
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 efficiencies to 82%
■
–40 to +100°C operating temperature
■
Modifications and customs for OEM’s
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
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 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 filtering 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.
+VIN
+VOUT
COMMON
–VOUT
–VIN
PWM
CONTROLLER
OPTO
ISOLATION
REFERENCE &
ERROR AMP
Figure 1. Simplified Schematic
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
A Series
7 - 1 0 W, D UA L O U T P U T D C / D C C O N V E RT E R S
Performance Specifications and Ordering Guide
➀
Output
VOUT
(Volts)
Model
Input
R/N (mVp-p) ➁
IOUT
(Amps)
Typ.
Regulation (Max.)
Max.
Load ➂
Line
VIN Nom.
(Volts)
Range
(Volts)
IIN ➃
(mA)
Typ.
Package
(Case,
Pinout)
Efficiency
Min.
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
➀
➁
➂
➃
Typical at TA = +25°C under nominal line voltage and full-load conditions unless otherwise noted.
Ripple/Noise (R/N) measured over a 20MHz bandwidth.
Balanced loads, 20% to 100% load.
Nominal line voltage, no-load/full-load conditions.
PART NUMBER STRUCTURE
* Magnetic feedback.
MECHANICAL SPECIFICATIONS
B WR - 15 / 330 - D12 A
Output Configuration:
B = Bipolar
A-Series
High Reliability
2.00
(50.80)
METAL CASE
Input Voltage Range:
D5 = 4.7-7.25 Volts (5V nominal)
D12 = 9-18 Volts (12V nominal)
D48 = 18-72 Volts (48V nominal)
Wide Range Input
Nominal Output Voltages:
±5, ±12 or ±15 Volts
0.375
(9.53)
Case C2
INSULATED BASE
0.040 ±0.002 DIA.
(1.016 ±0.051)
0.20 MIN
(5.08)
Maximum Output Current
in mA from each output
0.60
(15.24)
0.800
(20.32)
3
1
1.00
(25.40)
TEMPERATURE DERATING
0.100
(2.54)
4
0.800
(20.32)
2
0.400
(10.16)
5
10
A, B
9
C
A
0.10
(2.54)
D
8
Output Power (Watts)
BOTTOM VIEW
0.200
(5.08)
B
C
D, E
E, F
7
F
6
5
BWR-5/700-D5A
BWR-5/900-D12A
BWR-5/700-D48A
BWR-12/335-D5A
BWR-12/415-D12A
BWR-12/415-D48A
BWR-15/275-D5A
BWR-15/330-D12A
BWR-15/330-D48A
4
3
2
I/O Connections
Pin
1
2
3
4
5
E
C
F
D
A
A
D
A
B
1
0
–40
0
40
45
50
55
60
65
70
75
80
85
90
95
100
Ambient Temperature (°C)
2
Function P12
+Input
–Input
+Output
Common
–Output
Notes:
For "D5A" and "D12A"models, the
case is connected to pin 2 (–VIN).
For "D48A" models, the case
is connected to pin 1 (+VIN).
BWR Models
7 - 1 0 W, D UA L O U T P U T D C / D C C O N V E RT E R S
Performance/Functional Specifications
Typical @ TA = +25°C under nominal line voltage and full-load conditions, unless noted. ➀
Absolute Maximum Ratings
Input
Input Voltage Range:
D5A Models
D12A Models
D48A Models
4.7-7.25 Volts (5V nominal)
9-18 Volts (12V nominal)
18-72 Volts (48V nominal)
Input Voltage:
D5 Models
D12 Models
D48 Models
Input Current
See Ordering Guide
Input Reverse-Polarity Protection
Input Filter Type ➁
Pi
Reverse-Polarity Protection
Yes (Instantaneous, 6A maximum)
±1.5%, maximum
±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 ➂
1500Vdc, minimum
Isolation Capacitance
200pF
Current Limiting
Auto-recovery
Overvoltage Protection ➃
Zener/transorb clamps, magnetic feedback
Current must be <6A. Brief
duration only. Fusing recommended.
Output Overvoltage Protection
±5V Outputs
±12V Outputs
±15V Outputs
Output
VOUT Accuracy (50% load):
±5V Outputs
±12/15V Outputs
10 Volts
20 Volts
80Volts
13 Volts, limited duration
28 Volts, limited duration
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 Specifications Table is not implied.
T E C H N I C A L
N O T E S
Dynamic Characteristics
Transient Response (50% load step)
200µsec max. to ±1.5% of final value
Switching Frequency
165kHz (±15kHz)
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 3 and 5), with either output grounded.
The Common pin (pin 4) should be left open. Minimum 20% loading is
recommended under these conditions.
Environmental
Operating Temperature (ambient):
Without Derating
With Derating
Storage Temperature
–40 to +65/70°C (Model dependent)
to +100°C (See Derating Curves)
–40 to +105°C
Physical
Dimensions
2" x 1" x 0.375" (51 x 25 x 9.5mm)
Filtering and Noise Reduction
Shielding
5-sided
Case Connection:
D5A and D12A Models
D48A Models
Pin 2 (–VIN)
Pin 1 (+VIN)
All A-Series BWR 7-10 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 low-ESR
tantalum or electrolytic capacitors across the output terminals. Output capacitors 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.
Case Material
Corrosion resistant steel with
non-conductive, epoxy-based black
enamel finish and palstic baseplate
Pin Material
Brass, solder coated
Weight
1.3 ounces (37 grams)
➀ These power converters require a minimum 20% loading on each output to maintain
specified regulation. Operation under no-load conditions will not damage these devices;
however they may not meet all listed specifications.
➁ Application-specific internal input/output filtering can be recommended or perhaps added
internally upon request. Contact DATEL Applications Engineering for details.
➂ Devices can be screened or modified for higher guaranteed isolation voltages.
Contact DATEL Applications Engineering for details.
➃ D5A Models: Zener/transorb only
To Reduce Input Ripple
"D5A" Models
"D12A" Models
"D48A" Models
47µF, 10V
20µF, 35V
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 filtering of these units to meet your specific requirements. Contact our Applications Engineering Group for additional details.
3
A Series
7 - 1 0 W, D UA L O U T P U T D C / D C C O N V E RT E R S
E M I R A D I AT E D E M I S S I O N S
+OUTPUT
3
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 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-15/330-D48A appear below. Published EMC test reports are
available for each model number. Contact DATEL’s Applications Engineering
Department for more details.
+
1
+INPUT
COUT
4
+
COMMON
CIN
2
+
–INPUT
COUT
5
–OUTPUT
Figure 2. Using External Capacitors to Reduce
Input/Output Ripple/Noise
BWR-15/330-D48A Radiated Emissions
FCC Part 15 Class B, 3 Meters
Converter Output = ±15Vdc @ ±300mA
80
70
Input Fusing
60
VIN Range
"D5A"
"D12A"
"D48A"
Radiated Emissions (dBµV/M)
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:
Fuse Value
3A
2A
1A
FCC Class B Limit
50
40
30
20
10
0
Radiated Emissions
–10
–20
C U S T O M
1000
100
C A P A B I L I T I E S
Frequency (MHz)
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!
BWR-15/330-D48A Radiated Emissions
EN 55022 Class B, 10 Meters
Converter Output = ±15Vdc @ ±300mA
80
Our experienced applications and design staffs; quick-turn prototype capability; highly automated, SMT assembly facilities; and in-line SPC qualitycontrol 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.
70
Radiated Emissions (dBµV/M)
60
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.
50
EN 55022 Class B Limit
40
30
20
10
0
Radiated Emissions
–10
–20
1000
100
Frequency (MHz)
4
BWR Models
7 - 1 0 W, D UA L O U T P U T D C / D C C O N V E RT E R S
Quality and Reliability
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.
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.
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.
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.
Qualification
2. To design with safety margins by adhering to a strict set of derating
guidelines and performing theoretical worst-case analyses.
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.
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.
Qualification Testing
Qualification Test
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 early 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
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
* Interim electrical test at 200 hours.
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.
Typical HALT Profile
100
40
80
Method/Comments
HALT
20
40
20
0
0
Rapid Response to Problems
Random Vibration (G's)
Temperature (°C)
60
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.
–20
–40
10
20
30
40
50
60
70
80
90
Test Time (minutes)
®
®
INNOVATION and EXCELLENCE
ISO 9001 REGISTERED
DS-0322
02/01
DATEL (UK) LTD. Tadley, England Tel: (01256)-880444
DATEL S.A.R.L. Montigny Le Bretonneux, France Tel: 01-34-60-01-01
DATEL GmbH München, Germany Tel: 89-544334-0
DATEL KK Tokyo, Japan Tel: 3-3779-1031, Osaka Tel: 6-6354-2025
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
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.
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