®
®
A SUBSIDIARY OF C&D TECHNOLOGIES
Mixed Voltage, BWR Models
Dual Output
5V and 3.3V, 2" x 2"
33 Watt, DC/DC Converters
Features
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
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 require-
ments. 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 non-
conductive finish, these converters 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 filtering, 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 and on/off control function. Fully synchro-
nous output rectification renders high efficiency and no-load operation.
BWR power sharing modules offer low ripple and noise performance, high
efficiency (88%), 1500Vdc of isolation voltage, and are fully specified 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).
+INPUT
(1)
+5V OUTPUT
(5)
SWITCH
CONTROL
+3.3V OUTPUT
(7)
–INPUT
(2)
ON/OFF
CONTROL
(4)
PWM
CONTROLLER
OUTPUT
RETURN
(6)
ACTIVE
BLEEDER
OPTO
ISOLATION
UV & OV
COMPARATORS
THERMAL
SHUTDOWN
REFERENCE &
ERROR AMP
TRIM
(8)
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
XWR Series
3 3 W, D UA L O U T P U T, M I X E D - VO LTAG E D C / D C C O N V E R T E R S
Performance Specifications and Ordering Guide
V
OUT
(Volts)
5
3.3
5
3.3
5
3.3
➀
Input
Regulation (Max.)
➆
Package
(Case,
Pinout)
C4, P33
C4, P33
C4, P33
Model
BWR-5/6-3.3/7-D12
BWR-5/6-3.3/7-D24
BWR-5/6-3.3/7-D48
I
OUT
➁
(Amps)
6
7
6
7
6
7
Output
R/N (mVp-p)
➂
Typ.
40
95
40
95
40
95
Max.
100
140
100
140
100
140
Line
±1%
±0.5%
±1%
±0.5%
±1%
±0.5%
Load
➃
No Load
➅
±1.5%
±1%
±1.5%
±1%
±1.5%
±1%
±2.5%
±1.5%
±2.5%
±1.5%
±2.5%
±1.5%
➃
➄
➅
➆
V
IN
Nom.
(Volts)
12
24
48
Range
(Volts)
10-18
18-36
36-75
I
IN
➄
(mA)
70/3308
50/1615
25/780
Efficiency
Min.
83%
85%
85%
Typ.
86%
88%
88%
➀
Typical at T
A
= +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 specified with 1µF ceramic
output capacitors.
Tested from 10% load to 100% load (other output at 10% load).
Nominal line voltage, no load/balanced full-power condition.
Tested from no-load to 100% load (other output at no-load).
Output trim may impact 5V load regulation.
PA R T N U M B E R S T R U C T U R E
BWR
-
5
/
6
-
3.3
/
7
-
D48 LX
Dual Output/
Mixed-Voltage Series
V
1
Nominal Output Voltage:
5 Volts
I
1
Maximum Output Current:
6 Amps
Optional Functions
Input Voltage Range:
D12
= 10-18 Volts (12V nominal)
D24
= 18-36 Volts (24V nominal)
D48
= 36-75 Volts (48V nominal)
Optional Functions
BWR 33 Watt DC/DC's are designed with an On/Off Control
function with positive polarity in the pin 4 position.
L1
L2
Pin length: 0.110 in. (2.79mm) ±0.010
Pin length: 0.145 in. (3.68mm) ±0.010
Refer to the last page for additional options.
V
2
Nominal Output Voltage:
3.3 Volts
I
2
Maximum Output Current:
7 Amps
M E C H A N I C A L S P E C I F I C AT I O N S
2.00
(50.80)
METAL CASE
0.45
(11.43)
Case C4
INSULATED BASE
0.20 MIN
(5.08)
0.040 ±0.002 DIA.
(1.016 ±0.051)
1.800
(45.72)
0.10
(2.54)
I/O Connections
Pin
1
2
3
4
5
6
7
8
Function P33
+Input
–Input
No Pin
On/Off Control
+5V Output
Output Return
+3.3V Output
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).
0.200
(5.08)
5
1
2
0.400
(10.16)
4
6
7
1.200
(30.48)
3 EQ. SP. @
0.400 (10.16)
2.00
(50.80)
8
0.100
(2.54)
0.40
(10.16)
BOTTOM VIEW
DIMENSIONS ARE IN INCHES (MM)
2
3 3 W, D UA L O U T P U T, M I X E D - VO LTAG E D C / D C C O N V E R T E R S
BWR Models
Performance/Functional Specifications
Typical @ T
A
= +25°C under nominal line voltage, balanced "full-load" conditions, unless noted.
➀
Input
Input Voltage Range:
D12 Models
D24 Models
D48 Models
Overvoltage Shutdown:
➁
D12 Models
D24 Models
D48 Models
Start-Up Threshold:
➁
D12 Models
D24 Models
D48 Models
Undervoltage Shutdown:
➁
D12 Models
D24 Models
D48 Models
Input Current:
Normal Operating Conditions
Standby Mode:
Off, OV, UV, Thermal Shutdown
Input Reflected Ripple Current:
Source Impedance
D12 Models
D24/D48 Models
Internal Input Filter Type
Reverse-Polarity Protection:
➁
D12 Models
D24 Models
D48 Models
On/Off Control
(Pin 4):
➁ ➂ ➄
D12, D24 & D48 Models
10-18 Volts (12V nominal)
18-36 Volts (24V nominal)
36-75 Volts (48V nominal)
19-23 Volts (21V nominal)
37-42 Volts (40V nominal)
77-81 Volts (79V nominal)
9-10 Volts (9.3V nominal)
16.5-18 Volts (17V nominal)
34-36 Volts (35V nominal)
8.5-9.6 Volts (9.3V nominal)
16-17 Volts (16.5V nominal)
32.5-35 Volts (34V nominal)
See Ordering Guide
10mA typical
<0.1½, no external input filtering
200mAp-p (150mAp-p typical)
250mAp-p (225mAp-p typical)
Pi (0.022µF - 4.7µH - 2.46µF)
1 minute duration, 6A maximum
1 minute duration, 4A maximum
1 minute duration, 2A maximum
On = open or 13V to +V
IN
, I
IN
= 50µA max.
Off = 0-0.8V, I
IN
= 1mA max.
Short Circuit Current:
➁
5V Output
3.3V Output
Overvoltage Protection:
➁
5V Output
3.3V Output
Maximum Capacitive Loading
D12 Models
3.3V
5V
D24, D48 Models 3.3V
5V
Output (continued)
5 Amps average, continuous
6 Amps average, continuous
Magnetic feedback
6.8 volts
4.5Volts
1000µF
470µF
2000µF
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 V
OUT
On/Off to V
OUT
Switching Frequency
MTBF
➅
D12 Models
D24/D48 Models
Operating Temperature
(Ambient):
➁
Without Derating:
D12 Models
D24 Models
D48 Models
With Derating
Case Temperature:
Maximum Operational
For Thermal Shutdown
➁
Storage Temperature
Dimensions
Internal Case Connection:
D12/D24 Models
D48 Models
Case Material
20msec maximum
15msec maximum
285kHz (±15kHz)
Environmental
Bellcore, ground fixed, full power,
+25°C operating ambient temperature
1.3 million hours
1.67 million hours
–40 to +50°C
–40 to +60°C
–40 to +68°C
To +100°C (See Derating Curves)
+100°C
+110°C minimum, +117°C maximum
–40 to +120°C
Output
V
OUT
Accuracy:
5V Output
3.3V Output
Minimum Loading Per Specification
Ripple/Noise
(20MHz BW)
➁ ➃
Line/Load Regulation
➁
Efficiency
±3% maximum
±1.5% maximum
No load, see Performance Specifications
See Ordering Guide
See Ordering Guide
See Ordering Guide / Efficiency Curves
Physical
2" x 2" x 0.45" (50.8 x 50.8 x 11.43mm)
–Input (Pin 2)
+Input (Pin 1)
Corrosion resistant steel with
non-conductive, epoxy-based, black
enamel finish and plastic baseplate
Brass, solder coated
2.7 ounces (76.5 grams)
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
Isolation Voltage:
Input-to-Output
Isolation Capacitance
Isolation Resistance
±5%
1500Vdc minimum
470pF
100M½
Pin Material
Weight:
Primary to Secondary Insulation Level
D12/D24 Models
Operational
D48 Models
Basic
Temperature Coefficient
Current Limit Inception:
➁
5V @ 95% V
OUT
(3.3V @ 0A)
3.3V @ 98.5% V
OUT
(5V @ 0A)
±0.02%/per°C
7.6-9.0 Amps
11.3-12.7 Amps
➀
Balanced "full-load" is 5V @ 3.3A/3.3V @ 5A. All models are specified with external
1µF ceramic output capacitors.
➁
See Technical Notes/Graphs for details.
➂
Applying a voltage to On/Off Control (pin 4) when no input power is applied to the
converter may cause permanent damage.
➃
Output noise may be further reduced with the installation of additional external output
capacitors. See Technical Notes.
➄
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).
➅
Demonstrated MTBF available on request.
3
XWR Series
3 3 W, D UA L O U T P U T, M I X E D - VO LTAG E D C / D C C O N V E R T E R S
Absolute Maximum Ratings
Input Voltage:
Continuous:
"D12" Models
"D24" Models
"D48" Models
Transient (100msec): "D12" Models
"D24" Models
"D48" Models
23 Volts
42 Volts
81 Volts
25 Volts
50 Volts
100 Volts
Input Current must be limited. 1 minute
duration. Fusing recommended.
6 Amps
4 Amps
2 Amps
Current limited. Devices can withstand
an indefinite output short circuit.
+V
IN
–40 to +120°C
+300°C
Start-Up Time
The V
IN
to V
OUT
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 specified 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 specification defines the interval between the time at which the converter
is turned on and the fully loaded output voltage enters and remains within
its specified accuracy band. Similar to the V
IN
to V
OUT
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 specification listed
in the Performance/Functional Specifications 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 sufficiently 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 suffix) 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.
1
+INPUT
Input Reverse-Polarity Protection
➁
"D12" Models
"D24" Models
"D48" Models
Output Current
➁
On/Off Control (Pin 4) Max. Voltages
Referenced to –Input (pin 2)
Storage Temperature
Lead Temperature
(Soldering, 10 sec.)
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, 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 influenced 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 (1.5%).
The converters are specified 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 specifications. The bleeder is activated
gradually so as not to cause any erratic behavior on the converters outputs. A
slight degradation in efficiency will occur while this internal load is activated.
Filtering and Noise Reduction
The BWR 33 Watt Series Converters achieve their rated ripple and noise
specifications 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.
R
A
4
ON/OFF
CONTROL
R
B
D12
R
A
= 34.8kΩ, R
B
= 6.83kΩ
D24
R
A
= 100kΩ, R
B
= 9.74kΩ
D48
R
A
= 100kΩ, R
B
= 4.53kΩ
2
–INPUT
Figure 1. Internal Circuitry for On/Off Control
4
3 3 W, D UA L O U T P U T, M I X E D - VO LTAG E D C / D C C O N V E R T E R S
BWR Models
Current Limiting
When power demands from either output fall within 126% to 181% of the rated
output current, the DC/DC converter will go into a current limiting mode. In
this condition both output voltages will decrease proportionately with increases
in output current, thereby maintaining a somewhat constant power dissipa-
tion. This is commonly referred to as power limiting (see Figures 2a and
2b). Current limit inception is defined as the point where the full-power output
voltage falls below the specified tolerance. If the load current being drawn
from the converter is significant enough, the unit will go into a short circuit
condition. See "Short Circuit Condition."
Short Circuit Condition
When a converter is in current limit mode the output voltages will drop as the
output current demand increases (see figures 2a and 2b). If the output volt-
age drops too low, the magnetically coupled voltage used to develop primary
side voltages will also drop, thereby shutting down the PWM controller.
Following a time-out period of 5 to 15 milliseconds, the PWM will restart,
causing the output voltages to begin ramping to their appropriate values. If
the short-circuit condition persists, another shutdown cycle will be initiated.
This on/off cycling is referred to as "hiccup" mode. The hiccup cycling
reduces the average output current, thereby preventing internal temperatures
from rising to excessive levels. The BWR is capable of enduring an indefinite
short circuit output condition.
Thermal Shutdown
These BWR converters are equipped with Thermal Shutdown Circuitry. If
the internal temperature of the DC/DC converter rises above the designed
operating temperature, a precision temperature sensor will power down the
unit. When the internal temperature decreases below the threshold of the
temperature sensor the unit will self start.
V
IN
NOM, V
IN
LO All Models
V
IN
HI D12, D24 Models
V
IN
HI
D48 Models
Typical Current Limiting Characteristics for 3.3V Output
4
Ouput Voltages (Volts)
3
2
Output Overvoltage Protection
Both output voltages are monitored for an overvoltage condition via magnetic
coupling to the primary side. If either output voltage should rise to a level
which could be damaging to the load circuitry, the sensing circuitry will power
down the PWM controller causing the output voltages to decrease. Following
a time-out of 5 to 15 milliseconds the PWM will restart, causing the output
voltages to ramp to their appropriate values. If the fault condition persists,
and the output voltages again climb to excessive levels, the overvoltage
circuitry will initiate another shutdown cycle. This on/off cycling is referred
to as "hiccup" mode.
1
0
0
2
4
6
8
10
12
14
3.3 V
OUT
Average Ouput Current (Amps)
Figure 2a. Current Limiting Characteristics for 3.3V Output
Typical Current Limiting Characteristics for 5V Output
(3.3V Output @ 700mA)
5
4.5
4
3.5
3
Ouput Voltages (Volts)
2.5
2
1.5
1
0.5
0
0
1
2
3
4
5
6
7
8
9
5 V
OUT
Average Ouput Current (Amps)
V
IN
NOM, V
IN
LO
All Models
V
IN
HI D12, D24
Models
V
IN
HI
D48 Models
Figure 2b. Current Limiting Characteristics for 5V Output
5
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