A-SERIES
A-Series, BWR Models
Dual Output
For full details go to
www.cd4power.com/rohs
High-Reliability, 2" x 2"
15-20 Watt, DC/DC Converters
Features
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Low cost! Highly reliable!
Proven SMT-on-pcb construction
Qual tested; HALT tested; EMC tested
Designed to meet UL/ EN60950,
BASIC insulation (48V
IN
models)
mark available (48V
IN
models)
Output voltages: ±5, ±12 or ±15 Volts
Ultra-wide input voltage ranges:
4.7-7.5V, 9-36V or 18-75V
Small packages, 2" x 2" x 0.45"
Industry-standard pinouts
Fully isolated, 1500Vdc guaranteed
Guaranteed efficiencies to 82%
–40 to +100°C operating temperature
Modifications and customs for OEM’s
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For your mid-range power requirements, it’s hard to beat the combination of low
cost, proven reliability and outstanding electrical performance offered by the
15-20W, dual-output models of C&D’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 repeat-
able automatic-assembly techniques. Their superior durability is substantiated by a
rigorous in-house qualification program that includes HALT (Highly Accelerated Life
Testing).
The ultra-wide input voltage ranges of the A-Series duals (4.7-7.5V for "D5A"
models, 9-36V 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 (with specs as low as ±0.3% max. for
line and ±0.5% 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 are housed in standard
2" x 2" x 0.45" metal packages coated with electrically non-conductive materials.
They offer industry-standard pinouts and are ideally suited for high-volume com-
puter, telecom/datacom, instrumentation and ATE applications.
+V
IN
(1)
+V
OUT
(5)
COMMON
(6)
–V
IN
(2)
–V
OUT
(7)
ON/OFF
CONTROL
(4)
PWM
CONTROLLER
OPTO
ISOLATION
REFERENCE &
ERROR AMP
TRIM
(8)
Figure 1. Simplified Schematic
Typical topology is shown.
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A Series
1 5 - 2 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
Output
Model
BWR-5/1500-D5A
BWR-5/1700-D12A
BWR-5/1700-D48A
BWR-12/625-D5A
BWR-12/830-D12A
BWR-12/830-D48A
BWR-15/500-D5A
BWR-15/670-D12A
BWR-15/670-D48A
➀
➁
➂
➃
➀
Input
Regulation (Max.)
Line
±0.5%
±0.3%
±0.3%
±0.5%
±0.3%
±0.4%
±0.5%
±0.3%
±0.3%
V
OUT
(Volts)
±5
±5
±5
±12
±12
±12
±15
±15
±15
I
OUT
(mA)
±1500
±1700
±1700
±625
±830
±830
±500
±670
±670
R/N (mVp-p)
➁
Typ.
50
75
75
75
75
75
75
75
75
Max.
100
100
100
120
100
100
150
100
100
Load
➂
±1.0%
±0.5%
±0.5%
±1.0%
±0.5%
±0.5%
±1.0%
±0.5%
±0.5%
V
IN
Nom.
(Volts)
5
24
48
5
24
48
5
24
48
Range
(Volts)
4.7-7.5
9-36
18-75
4.7-7.5
9-36
18-75
4.7-7.5
9-36
18-75
I
IN
➃
(mA)
75/3750
15/753
15/377
75/3750
30/1000
15/510
75/3659
30/979
15/484
Efficiency
Min.
79%
80.5%
81%
79%
81.5%
81%
80%
82%
82%
Typ.
80%
83%
83%
81%
83%
83%
82%
83%
84%
Package
(Case,
Pinout)
C4, P7
C4, P7
C4, P7
C4, P7
C4, P7
C4, P7
C4, P7
C4, P7
C4, P7
Typical at T
A
= +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.
PA R T N U M B E R S T R U C T U R E
M E C H A N I C A L S P E C I F I C AT I O N S
B WR
-
12
/
830
-
D48 A
-
C
Output Configuration:
B
= Bipolar
Wide Range Input
Nominal Output Voltages:
±5, ±12 or ±15 Volts
RoHS-6 Compliant*
A-Series
High Reliability
Input Voltage Range:
D5
= 4.7-7.5 Volts (5V nominal)
D12
= 9-36 Volts (24V nominal)
D48
= 18-75 Volts (48V nominal)
2.00
(50.80)
ME T A L C A S E
0.45
(11.43)
Case C4
IN S U LA T E D B A S E
0.20 MIN
(5.08)
0.040 ±0.002 D IA .
(1.016 ±0.051)
Maximum Output Current
in mA from each output
1.800
(45.72)
0.10
(2.54)
* Contact C&D Technologies for availability
T E M P E R AT U R E D E R AT I N G
20
19
18
17
16
15
C
B
A
0.400
(10.16)
4
8
0.100
(2.54)
B O T T O M V IE W
DIMENSIONS ARE IN INCHES (MM)
0.200
(5.08)
5
1
2
6
7
1.200
(30.48)
3 E Q . SP. @
0.400 ( 10.16)
2.00
(50.80)
0.40
(10.16)
Output Power (Watts)
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
–40
0
40
45
50
55
60
65
70
75
80
85
90
95
100
BWR-5/1500-D5A
BWR-5/1700-D12A
BWR-5/1700-D48A
BWR-12/625-D5A
BWR-12/830-D12A
BWR-12/830-D48A
BWR-15/500-D5A
BWR-15/670-D12A
BWR-15/670-D48A
C
B
B
C
A
A
C
A
A
I/O Connections
Pin
1
2
3
4
5
6
7
8
Function P7
+Input
–Input
No Pin
On/Off Control
+Output
Common
–Output
Trim
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
).
Ambient Temperature (°C)
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2
A Series
1 5 - 2 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 @ T
A
= +25°C under nominal line voltage and full-load conditions, unless noted.
➀
Input
Input Voltage Range:
D5A Models
D12A Models
D48A Models
Input Current
Input Filter Type
➁
Overvoltage Shutdown:
D5A Models
D12A Models
D48A Models
Reverse-Polarity Protection
On/Off (Sync.) Control
(Pin 4)
➂
V
OUT
Accuracy
(50% load):
±5V Outputs
±9/12/15V Outputs
Temperature Coefficient
Ripple/Noise
(20MHz BW)
➁
Line/Load Regulation
Efficiency
Isolation Voltage
➃
Isolation Capacitance
Current Limiting
Overvoltage Protection
Transient Response
(50% load step)
Switching Frequency
Operating Temperature
(ambient):
Without Derating
With Derating
Storage Temperature
Flammability
Dimensions
Shielding
Case Connection:
D5A and D12A Models
D48A Models
Case Material
4.7-7.5 Volts (5V nominal)
9-36 Volts (24V nominal)
18-75 Volts (48V nominal)
See Ordering Guide
Pi
10 Volts
40 Volts
80 Volts
Yes (Instantaneous, 10A maximum)
TTL high = off, low (or open) = on
Input Voltage:
D5A Models
D12A Models
D48A Models
Absolute Maximum Ratings
12 Volts
44 Volts
88 Volts
Current must be <10A. Brief
duration only. Fusing recommended.
6.8 Volts, limited duration
15 Volts, limited duration
18 Volts, limited duration
Current limited. Max. current and
short-circuit duration are model
dependent.
–40 to +105°C
+300°C
Input Reverse-Polarity Protection
Output Overvoltage Protection
±5V Outputs
±12V Outputs
±15V Outputs
Output Current
Output
±1.5%, maximum
±1%, maximum
±0.02% per °C
See Ordering Guide
See Ordering Guide
See Ordering Guide
1500Vdc, minimum
550pF
Auto-recovery
Zener/transorb clamps, magnetic feedback
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.
TECHNICAL NOTES
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 5 and 7), with either output grounded.
The Common pin (pin 6) should be left open. Minimum 20% loading is
recommended under these conditions. The total output voltage span may be
externally trimmed as described below.
Filtering and Noise Reduction
All A-Series BWR 15-20 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 capac-
itors should be connected between their respective output pin (pin 5 or 7) and
Common (pin 6) 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
D12A Models
D48A Models
To Reduce Output Ripple
±5V Outputs
±9/12/15V Outputs
47µF, 16V
20µF, 50V
20µF, 100V
47µF, 10V, Low ESR
22µF, 20V, Low ESR
Dynamic Characteristics
200µsec max. to ±1.5% of final value
165kHz (±15kHz)
Environmental
–40 to +50/55/60°C (Model dependent)
to +100°C (See Derating Curves)
–40 to +105°C
UL 94V-0
Physical
2" x 2" x 0.45" (51 x 51 x 11.4mm)
5-sided
Pin 2 (–V
IN
)
Pin 1 (+V
IN
)
Corrosion resistant steel with
non-conductive, epoxy-based, black
enamel finish and plastic baseplate
Gold-plated copper alloy
2.7 ounces (75.6 grams)
Pin Material
Weight
➀
These 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 and perhaps added
internally upon request. Contact C&D Applications Engineering for details.
➂
Applying a voltage to the Control pin when no input power is applied to the converter can
cause permanent damage to the converter.
➃
"D48A" models have BASIC, "D5A" and "D12A" models have Functional insulation.
Devices can be screened or modified for higher guaranteed isolation voltages.
Contact C&D Applications Engineering for details.
In critical, space-sensitive applications, C&D may be able to tailor the internal
input/output filtering of these units to meet your specific requirements. Con-
tact our Applications Engineering Group for additional details.
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3
A Series
1 5 - 2 0 W, D UA L O U T P U T D C / D C C O N V E RT E R S
+OUTPUT
1
+
2
+INPUT
5
+
C
OUT
6
+OUTPUT
5
6
LOAD
8
20k
5-10
Turns
1
+INPUT
COMMON
TRIM
C
IN
COMMON
–INPUT
7
–OUTPUT
+
C
OUT
2
–INPUT
–OUTPUT
7
LOAD
Figure 2. Using External Capacitors to Reduce
Input/Output Ripple/Noise
Figure 3a. Trim Connections Using a Trimpot
Input Fusing
Certain applications and/or safety agencies may require the installation of
fuses at the inputs of power conversion components. For C&D A-Series
BWR 15-20 Watt DC/DC Converters, you should use slow-blow type fuses
with values no greater than the following:
V
IN
Range
D5A
D12A
D48A
On/Off Control
The On/Off Control pin (pin 4) may be used for remote on/off operation. A
TTL logic high (+2 to +5 Volts, 250µA max.) applied to pin 4 disables the
converter. A TTL logic low (0 to +0.8 Volts, 70µA max.), or no connection,
enables the converter. Control voltages should be referenced to pin 2
(–Input). Applying a voltage to the Control pin when no input power is applied
to the converter can cause permanent damage to the converter.
Synchronization
In critical applications employing multiple switching DC/DC converters, it may
be desirable to intentionally synchronize the switching of selected converters
(so the system noise can be reduced with notch filtering) or to purposely
desynchronize the converters (to lessen the current-carrying requirements on
intermediate dc buses). For multiple A-Series Converters, an external clock
can be applied to pin 4 (Control) of each device. It should be a square wave
with a maximum 1µsec "high" duration and an amplitude between +2V and
+5V (see On/Off Control) referenced to pin 2 (–Input). The frequency of the
synchronizing clock should be higher than that of any individual converter.
Therefore, it should be 185kHz ±5kHz.
Output Trimming
The total output voltage span, from +Output (pin 5) to –Output (pin 7) may
be trimmed ±5% via a single external trimpot or fixed resistor. The trimpot
should be connected as shown in Figure 3a with its wiper connected to pin 8
(Trim). A trimpot can be used to determine the value of a single fixed resistor
which should be connected as shown in Figures 3b and 3c. Connect the
resistor between pin 8 (Trim) and pin 5 (+Output) to trim "down" the output
voltages. Connect the resistor between pins 8 and 7 (–Output) to trim "up"
the output voltages. Fixed resistors should be metal-film types with absolute
TCR’s less than 100ppm/°C to ensure stability.
1
+INPUT
5
+OUTPUT
1
+INPUT
TRIM
2
–INPUT
COMMON
–OUTPUT
LOAD
8
6
7
LOAD
Fuse Value
6A
4A
2A
Figure 3b. Fixed-Value Trim Down Resistor
+OUTPUT
COMMON
TRIM
2
–INPUT
5
6
8
LOAD
7
LOAD
–OUTPUT
Figure 3c. Fixed-Value Trim Up Resistor
.
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4
C U S TO M C A PA B I L I T I E S
BWR-5/1700-D48A Radiated Emissions
EN 55022 Class B, 10 Meters
Converter Output = ±5Vdc @ ±1.6A
80
70
60
Radiated Emissions (dBµV/M)
C&D’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
E M I R A D I AT E D E M I S S I O N S
50
EN 55022 Class B Limit
40
30
20
10
0
Radiated Emissions
–10
–20
100
1000
Frequency (MHz)
Quality and Reliability
If you’re designing with EMC in mind, please note that all of C&D’s BWR
15-20 Watt A-Series DC/DC Converters have been characterized for radi-
ated 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 specifica-
tions can be supplied upon request. Radiated emissions plots to FCC and
CISPR 22 for model BWR-5/1700-D48A appear below. Published EMC test
reports are available for each model number. Contact C&D’s Applications
Engineering Department for more details.
BWR-5/1700-D48A Radiated Emissions
FCC Part 15 Class B, 3 Meters
Converter Output = ±5Vdc @ ±1.6A
80
70
60
The A-Series are the first DC/DC Converters to emerge from C&D’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.
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 qualification 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 C&D 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
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.
Radiated Emissions (dBµV/M)
FCC Class B Limit
50
40
30
20
10
0
–10
–20
Radiated Emissions
100
1000
Frequency (MHz)
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5
Toshiba Photorelays TLP3547 Review
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