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 auto-
matic-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 18-75V for "D48A" models) make them excel-
lent 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
(1)
(2)
(3)
(4)
(5)
IN
V
IN
+V
OUT
V
OUT
COMMON
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 UL/EN60950
Output voltages: 5, 12 or 15 Volts
Wide input voltage ranges:
4.7-7.25V, 9-18V or 18-75V
Small packages, 2" x 1" x 0.375"
Industry-standard pinouts
Fully isolated, 1500Vdc guaranteed
Guaranteed effi ciencies to 82%
40 to +100C operating temperature
Modifi cations and customs for OEM's
DATEL, Inc., Mansfi eld, MA 02048 (USA) Tel: (508)339-3000, (800)233-2765 Fax: (508)339-6356 Email: sales@datel.com Internet: www.datel.com
A - S E R I E S
A Series
7 - 1 0 W , D U A L O U T P U T D C / D C C O N V E R T E R S
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 18-75 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 18-75 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 18-75 15/247 81.5% 84% C2, P12
1
2
3
4
5
METAL CASE
INSULATED BASE
2.00
(50.80)
0.20 MIN
(5.08)
1.00
(25.40)
0.400
(10.16)
0.800
(20.32)
0.800
(20.32)
0.375
(9.53)
0.040 0.002 DIA.
(1.016 0.051)
BOTTOM VIEW
0.200
(5.08)
0.100
(2.54)
0.10
(2.54)
0.60
(15.24)
DIMENSIONS ARE IN INCHES (MM)
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
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.
Input Voltage Range:
D5 = 4.7-7.25 Volts (5V nominal)
D12 = 9-18 Volts (12V nominal)
D48 = 18-75 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
15
B WR
330 D12 A
-
/
-
O
u
tp
u
t
P
o
w
e
r (W
a
t
ts
)
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 60 65 70 75 80 85 90 95 100
A, B
C
B
C
F
A
R/N (mVp-p)
Regulation
(Max.)
Effi ciency
Package
V
OUT
I
OUT
V
IN
Nom.
Range
I
IN
(Case,
Model
(Volts) (mA) Typ.
Max. Line
Load
(Volts) (Volts) (mA) Min. Typ. Pinout)
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
I/O Connections
Pin Function
P12
1
+Input
2
Input
3
+Output
4
Common
5
Output
* Magnetic feedback.
T E C H N I C A L N O T E S
BWR Models
7 - 1 0 W , D U A L O U T P U T D C / D C C O N V E R T E R S
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
47F, 10V
"D12A" Models
20F, 35V
"D48A" Models
10F, 100V
To Reduce Output Ripple
5V Output
47F, 10V, Low ESR
12/15V Outputs
22F, 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
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.
Application-specifi c internal input/output fi ltering can be recommended or perhaps added
internally upon request. Contact DATEL Applications Engineering for details.
Devices can be screened or modifi ed for higher guaranteed isolation voltages.
Contact DATEL Applications Engineering for details.
D5A Models: Zener/transorb only
Performance/Functional Specifi cations
Typical @ T
A
= +25C under nominal line voltage and full-load conditions, unless noted.
Input
Input Voltage Range:
D5A Models 4.7-7.25 Volts (5V nominal)
D12A Models 9-18 Volts (12V nominal)
D48A Models 18-75 Volts (48V nominal)
Input Current See Ordering Guide
Input Filter Type
Pi
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/Load Regulation See Ordering Guide
Effi ciency See Ordering Guide
Isolation Voltage
1500Vdc, minimum (functional)
Isolation Capacitance 200pF
Current Limiting Auto-recovery
Overvoltage Protection
Zener/transorb clamps, magnetic feedback
Dynamic Characteristics
Transient Response (50% load step) 200sec max. to 1.5% of fi nal value
Switching Frequency 165kHz (15kHz)
Environmental
Operating Temperature (ambient):
Without Derating 40 to +65/70C (Model dependent)
With Derating to +100C (See Derating Curves)
Storage Temperature 40 to +105C
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 +105C
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
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
R
a
di
at
ed E
m
i
s
si
ons (
d
B
V/
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
R
a
di
at
ed E
m
i
ssi
ons (
d
B
V/
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 - 1 0 W , D U A L O U T P U T D C / D C C O N V E R T E R S
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
BWR Models
7 - 1 0 W , D U A L O U T P U T D C / D C C O N V E R T E R S
DS-0322A 02/03
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 +125C, 30C/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 +125C
Temperature/Humidity +85C, 85% humidity, 48 hours
Lead Integrity DATEL in-house procedure
Life Test +70C, 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
Vi
br
at
i
o
n
(
G'
s
)
Tem
p
er
at
ure (
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: (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
ISO 9001 REGISTERED
INNOVATION and EX C ELL E N C E
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