Figure 1. Simplifi ed Schematic
* "D24" models only
Dual Output
BWR Models
Miniature, 1" x 1"
5 Watt, DC/DC Converters
Features
The migration to distributed power is accelerating. The critical need for accurate
voltages, tight regulation and rapid transient response is propelling the move to
power processing at the "point-of-use" with low-power DC/DC converters physically
located right at their loads.
DATEL's miniature, full featured, 5 Watt BWR Models were specifi cally designed
for today's demanding distributed power architectures in aerospace, marine,
telecom and computer applications. The converters' small size (1" x 1" x 0.45"),
full 5 Watt output capability and low cost give system architects unprecedented
design and layout fl exibility.
Occupying less than 0.5in
3
total volume, these extremely compact, fully regulated
and isolated (1000Vdc) modules are available with 5, 12 or 15 Volt outputs.
Input voltage ranges are either 18-36 Volts ("D24" models) or 36-72 Volts ("D48"
models).
Although their overall size is 50-75% smaller than many similarly rated power
modules, these 1" x 1" BWR Models are exact, drop-in, pin-for-pin replacements for
many standard 2" x 1" and 2" x 2", 5 Watt modules. They achieve their small size
and low cost by exploiting a novel feedback approach that does not depend upon
traditional optocoupler techniques.
All models are 5-side shielded and have a non-conductive baseplate that permits
pc-card runs to be placed beneath the package. Units are assembled using
high-speed automated SMT techniques and are fully encapsulated with thermally
conductive potting compound. Every unit is electrically tested before and after
encapsulation, 100% burned-in under full load, hi-pot tested, and fi nal-electrical
tested prior to shipment. Every unit meets DATEL's traditional high standards for
quality and long-term reliability.
V
OUT
+V
OUT
COMMON
+V
(1)
(2)
(3)
(4)
(6)
IN
V
IN
PWM
*
DATEL, Inc., 11 Cabot Boulevard, Mansfi eld, MA 02048 (U.S.A.)
Tel: (508)339-3000, (800)233-2765 Fax: (508)339-6356 Email: datellit@mcimail.com
INNOVATION and EX C ELL E N C E
Small size, 1" x 1" x 0.45"
Full 5 Watts output power
No external components required
Drop-in replacements for many
standard, 2" x 1" DC/DC's
Wide input voltage ranges:
18-36V or 36-72V
Standard output voltages:
5, 12, 15 Volts
Guaranteed effi ciencies to 80%
Fully regulated and isolated
(1000Vdc guaranteed)
Output overvoltage protection and
current limiting
25 to +95
o
C operating temperature
Shielded cases (5 sides)
UL1950, CSA 22.2 No. 234, and IEC950
Modifi cations and customs for OEM's
M I N I A T U R E , 5 W A T T D C / D C C O N V E R T E R S
XWR Series
BWR-5/500-D24 5 500 100 150 2% 2% 24 18-36 25/282 75% 78% C7, P4
BWR-5/500-D48 5 500 100 120 2% 2% 48 36-72 25/141 75% 78% C7, P4
BWR-12/210-D24 12 210 100 150 2% 2% 24 18-36 25/264 80% 82% C7, P4
BWR-12/210-D48 12 210 100 150 2% 2% 24 18-36 25/133 80% 82% C7, P4
BWR-15/165-D24 15 165 100 150 2% 2% 24 18-36 25/260 80% 83% C7, P4
BWR-15/165-D48 15 165 100 150 2% 2% 24 18-36 25/130 80% 82% C7, P4
Pin Function P4
1
+Input
2
Input
3
+Output
4
Common
5
No
Pin
6
Output
O
u
tp
u
t
P
o
w
e
r (W
a
t
ts
)
Ambient Temperature (C)
25 0 35 40 45 50 55 60 65 70 75 80 85 90 95
5
4.5
4
3.5
3
2.5
2
1.5
1
0.5
0
3
1
2
4
6
5
0.20 MIN
(5.08)
1.00
(25.40)
1.00
(25.40)
0.400
(10.16)
0.200
(5.08)
0.800
(20.32)
0.800
(20.32)
0.45
(11.43)
BOTTOM VIEW
0.200
(5.08)
0.100
(2.54)
0.10
(2.54)
0.10
(2.54)
METAL CASE
INSULATED BASE
0.040 0.002 DIA.
(1.016 0.051)
DIMENSIONS ARE IN INCHES (MM)
2
I/O Connections
Notes:
For "D24" models, the case
is connected to pin 2 (V
IN
).
For "D48" models, the case
is connected to pin 1 (+V
IN
).
Case C7
Nominal Output Voltages:
5, 12 or 15 Volts
Maximum Output Current
in mA from each output
Input Voltage Range:
D24 = 18-36 Volts (24V nominal)
D48 = 36-72 Volts (48V nominal)
Wide Range Input
Output Confi guration:
B = Bipolar
15
B WR
165 D24
-
/
-
Typical at T
A
= +25C 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.
Performance Specifi cations and Ordering Guide
R/N (mVp-p)
Typ. Max.
V
OUT
(Volts)
Output
Package
(Case,
Pinout)
Effi ciency
Min. Typ.
Regulation (Max.)
Line
V
IN
Nom.
(Volts)
Range
(Volts)
Model
Input
I
OUT
(mA, Max.)
I
IN
(mA, Max.)
Load
P A R T N U M B E R S T R U C T U R E
T E M P E R A T U R E D E R A T I N G
M E C H A N I C A L S P E C I F I C A T I O N S
M I N I A T U R E , 5 W A T T D C / D C C O N V E R T E R S
BWR Models
3
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 3 and 6), with either output grounded. The
Common (pin 4) should be left open. Minimum 20% loading is recommended
under these conditions.
Filtering and Noise Reduction
All BWR 5 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 install-
ing low-ESR, tantalum or electrolytic capacitors across the input
and/or output terminals. Output capacitors should be connected between
their respective output pin (pin 3 or 6) and Common (pin 4) as shown in
Figure 2. The capacitors should be located as close to the power converters
as possible. Typical values are listed below. In many applications, using
values greater than those listed will yield better results.
To Reduce Input Ripple
"D24" Models
20F, 50V
"D48" Models
10F, 100V
To Reduce Output Ripple
5V Outputs
47F, 10V, Low ESR
12/15V Outputs
33F, 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.
Performance/Functional Specifi cations
Input
Input Voltage Range:
"D24" Models 18-36 Volts (24V nominal)
"D48" Models 36-72 Volts (48V nominal)
Input Current See Ordering Guide
Input Filter Type
LC on "D24" models
C on "D48" models
Reverse-Polarity Protection Yes (Instantaneous, 6A maximum)
Output
V
OUT
Accuracy (50% load):
5V Outputs 1.5%, maximum
12/15V Outputs 1%, maximum
Temperature Coeffi cient 0.02% per C
Ripple/Noise (20MHz BW)
See Ordering Guide
Line Regulation See Ordering Guide
Load Regulation See Ordering Guide
Effi ciency See Ordering Guide
Isolation Voltage
1000Vdc, minimum
Current Limiting Auto-recovery
Overvoltage Protection Zener/transorb clamps
Dynamic Characteristics
Transient Response (50% load step) 500sec max. to 1.5% of fi nal value
Switching Frequency 170kHz (10kHz)
Environmental
Operating Temperature (ambient):
Without Derating 25 to +60C
With Derating to +95C (See Derating Curve)
Storage Temperature 55 to +125C
Physical
Dimensions 1" x 1" x 0.45" (25.4 x 25.4 x 11.4mm)
Shielding 5-sided
Case Connection:
"D24" Models Pin 2 (V
IN
)
"D48" Models Pin 1 (+V
IN
)
Case Material Corrosion resistant steel with
epoxy-based enamel fi nish
Pin Material Brass, solder coated
Weight 0.7 ounces (20 grams)
Typical @ T
A
= +25C under nominal line voltage and full-load conditions, unless noted.
These power converters require a minimum 20% loading to maintain specifi ed regulation.
Operation under no-load conditions will not damage these devices, however they may not
meet all listed specifi cations.
Application-specifi c internal input/output fi ltering can be recommended and perhaps added
internally on request. Contact DATEL Applications Engineering for details.
Units can be screened or modifi ed for higher guaranteed isolation voltages.
Contact DATEL Applications Engineering for details.
Units can be screened for lower-temperature operation.
Contact DATEL Applications Engineering for details.
Input Voltage:
"D24" Models 44 Volts
"D48" Models 88 Volts
Input Reverse-Polarity Protection Current must be <6A. 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 55 to +125C
Lead Temperature (soldering, 10 sec.) +300C
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
T E C H N I C A L N O T E S
M I N I A T U R E , 5 W A T T D C / D C C O N V E R T E R S
XWR Series
4
Typical Performance Curves (T
A
= +25C)
The performance curves below were derived from actual test data for a single model number (BWR-15/165-D24).
Since all devices in this series have the same circuit topology, the performance curves are representative of all devices.
30.3
30.2
30.1
30.0
29.9
29.8
29.7
O
u
tput
V
o
l
t
age S
p
an (V
ol
ts)
Input Voltage (Volts)
36 40 44 48 52 56 60 64 68 72
Output Voltage vs. Input Voltage
(Full-load conditions. Nominal V
OUT
span = 30V)
85
84
83
82
81
80
79
36 42 48 54 60 66 72
E
f
f
i
ciency (%
)
Input Voltage (Volts)
Efficiency vs. Input Voltage
(Full-load conditions. Guaranteed efficiency = 80% at V
IN
= 48V
)
84
82
80
78
76
74
72
33 66 99 132 165
E
f
f
i
ciency (%
)
Output Currents (mA)
Efficiency vs. Output Load
(V
IN
= nominal = 48V. Guaranteed efficiency at full load = 80%)
15.20
15.15
15.10
15.05
15.00
14.95
14.90
14.85
14.80
35 55 75 95 115 135 155 175
O
u
tp
u
t
V
o
ltag
e (
V
o
lts)
V
OUT
Output Current (mA)
+V
OUT
V
OUT
Output Voltage vs. Load (Unbalanced)
(V
IN
= nominal = 24V. Load on +V
OUT
fixed at 165mA)
30.3
30.2
30.1
30.0
29.9
29.8
29.7
O
u
tput
V
o
l
t
age S
p
an (V
ol
ts)
Output Currents (mA)
35 45 55 65 75 85 95 105 115 125 135 145 155 165
Output Voltage vs. Load (Balanced)
(V
IN
= nominal = 48V. Nominal V
OUT
span = 30V)
L I N E R E G U L A T I O N
L O A D R E G U L A T I O N
E F F I C I E N C Y V S . I N P U T V O L T A G E A N D O U T P U T L O A D
M I N I A T U R E , 5 W A T T D C / D C C O N V E R T E R S
BWR Models
OUTPUT
+INPUT
INPUT
+OUTPUT
1
2
3
6
COMMON
4
C
IN
C
OUT
C
OUT
+
+
+
5
If you're designing with EMC in mind, please note that all of DATEL's BWR 5
Watt 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 specifi cations can
be supplied upon request. Radiated emissions plots to FCC and CISPR 22
appear below. Its performance is typical of all models in the Family.
Published EMC test reports are available for each model number. Contact
DATEL's Applications Engineering Department for details.
Figure 2. Using External Capacitors to Reduce
Input/Output Ripple/Noise
Input Fusing
Certain applications and/or safety agencies may require the installation of
fuses at the inputs of power conversion components. For DATEL BWR
5 Watt DC/DC Converters, you should use slow-blow type fuses with values
no greater than 0.5A.
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.
80
70
60
50
40
30
20
10
0
10
20
Frequency (MHz)
100
1000
Radiated Emissions
FCC Class B Limit
Radiated Emissions
FCC Part 15 Class B, 3 Meters
Converter Output = 15Vdc @ 132mA
R
a
di
at
ed
E
m
is
si
on
s
(d
B
V
/
M
)
Radiated Emissions
EN 55022 Class B, 10 Meters
Converter Output = 15Vdc @ 132mA
80
70
60
50
40
30
20
10
0
10
20
Frequency (MHz)
100
1000
Radiated Emissions
EN 55022 Class B Limit
R
a
di
at
ed
E
m
is
si
on
s
(d
B
V
/
M
)
C U S T O M C A P A B I L I T I E S
E M I R A D I A T E D E M I S S I O N S
DS0318 5/02
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: (01256)-880444
DATEL S.A.R.L. Montigny Le Bretonneux, France Tel: 01-34-60-01-01
DATEL GmbH Mnchen, Germany Tel: 89-544334-0
DATEL KK Tokyo, Japan Tel: 3-3779-1031, Osaka Tel: 6-6354-2025
DATEL, Inc. 11 Cabot Boulevard, Mansfi eld, 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 E
ISO-9001 REGISTERED
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