A-SERIES
A-Series, BWR Models
Dual Output
High-Reliability, 2" x 1"
7-10 Watt, DC/DC Converters
For full details go to
www.cd4power.com/rohs
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
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 efficiencies to 82%
–40 to +100°C operating temperature
Modifications and customs for OEM’s
Select models are RoHS compliant
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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 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 repeatable auto-
matic-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 18-75V 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 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.
+V
IN
(1)
+V
OUT
(3)
COMMON
(4)
–V
IN
(2)
–V
OUT
(5)
PWM
CONTROLLER
OPTO
ISOLATION
REFERENCE &
ERROR AMP
Figure 1. Simplified Schematic
Typical topology is shown.
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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
Output
Model
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*
➀
Input
Regulation (Max.)
Line
±0.3%
±0.3%
±0.3%
±0.3%
±0.3%
±0.3%
±0.3%
±0.3%
±0.3%
V
OUT
(Volts)
±5
±5
±5
±12
±12
±12
±15
±15
±15
I
OUT
(mA)
±700
±900
±700
±335
±415
±415
±275
±330
±330
R/N (mVp-p)
➁
Typ.
50
75
50
75
100
75
75
75
75
Max.
75
100
100
120
120
120
120
120
120
Load
➂
±1.0%
±1.0%
±1.0%
±1.0%
±1.0%
±1.0%
±1.0%
±1.0%
±1.0%
V
IN
Nom.
(Volts)
5
12
48
5
12
48
5
12
48
Range
(Volts)
4.7-7.25
9-18
18-75
4.7-7.25
9-18
18-75
4.7-7.25
9-18
18-75
I
IN
➃
(mA)
25/1772
25/930
15/180
40/1846
20/986
15/249
40/2089
25/980
15/247
Efficiency
Min.
76%
81%
79%
76%
83%
80.5%
75%
83%
81.5%
Typ.
79%
82%
81%
78%
84%
84%
79%
84%
84%
Package
(Case,
Pinout)
C2, P12
C2, P12
C2, P12
C2, P12
C2, P12
C2, P12
C2, P12
C2, P12
C2, P12
➀
Typical at T
A
= +25°C under nominal line voltage and full-load conditions unless otherwise noted.
➁ Ripple/Noise (R/N) measured over a 20MHz bandwidth.
➂
Balanced loads, 20% to 100% load.
➃
Nominal line voltage, no-load/full-load conditions.
* Magnetic feedback.
PART NUMBER STRUCTURE
MECHANICAL SPECIFICATIONS
B WR
-
15
/
330
-
D12 A
-
C
Output Configuration:
B = Bipolar
RoHS-6 Compliance
2.00
(50.80)
METAL CASE
0.375
(9.53)
Case C2
INSULATED BASE
0.20 MIN
(5.08)
0.800
(20.32)
Wide Range Input
A-Series
High Reliability
Input Voltage Range:
D5 = 4.7-7.25 Volts (5V nominal)
Nominal Output Voltages:
D12 = 9-18 Volts (12V nominal)
±5, ±12 or ±15 Volts
D48 = 18-75 Volts (48V nominal)
Maximum Output Current
in mA from each output
0.040 ±0.002 DIA.
(1.016 ±0.051)
0.60
(15.24)
0.100
(2.54)
0.800
(20.32)
3
1
1.00
(25.40)
4
0.400
(10.16)
2
5
Not all model combinations are available. Contact C&D Technologies.
TEMPERATURE DERATING
10
9
8
A, B
A
C
D
E, F
B
C
D, E
F
0.200
(5.08)
BOTTOM VIEW
DIMENSIONS ARE IN INCHES (MM)
0.10
(2.54)
Output Power (Watts)
7
6
5
4
3
2
1
0
–40
0
I/O Connections
Pin
1
2
3
4
5
Function P12
+Input
–Input
+Output
Common
–Output
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
E
C
F
D
A
A
D
A
B
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
).
40
45
50
55
60
65
70
75
80
85
90
95
10 0
Ambient Temperature (°C)
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2
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
BWR Models
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
Reverse-Polarity Protection
V
OUT
Accuracy
(50% load):
±5V Outputs
±12/15V Outputs
Temperature Coefficient
Ripple/Noise (20MHz BW)
➁
Line/Load Regulation
Efficiency
Isolation Voltage
➂
Isolation Capacitance
Current Limiting
Overvoltage Protection
➃
Transient Response (50% load step)
Switching Frequency
Operating Temperature (ambient):
Without Derating
With Derating
Storage Temperature
Dimensions
Shielding
Case Connection:
D5A and D12A Models
D48A Models
Case Material
Pin Material
Weight
Flammability
4.7-7.25 Volts (5V nominal)
9-18 Volts (12V nominal)
18-75 Volts (48V nominal)
See Ordering Guide
Pi
Yes (Instantaneous, 6A maximum)
Input Voltage:
D5 Models
D12 Models
D48 Models
Absolute Maximum Ratings
10 Volts
20 Volts
80Volts
Current must be <6A. Brief
duration only. Fusing recommended.
13 Volts, limited duration
28 Volts, limited duration
36 Volts, limited duration
Current limited. Max. current and
short-circuit duration are model
dependent.
–40 to +105°C
+300°C
Output
±1.5%, maximum
±1%, maximum
±0.02% per °C
See Ordering Guide
See Ordering Guide
See Ordering Guide
1500Vdc, minimum (functional)
200pF
Auto-recovery
Zener/transorb clamps, magnetic feedback
Input Reverse-Polarity Protection
Output Overvoltage Protection
±5V Outputs
±12V Outputs
±15V Outputs
Output Current
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.
Dynamic Characteristics
200µsec max. to ±1.5% of final value
165kHz (±15kHz)
T E C H N I C A L
N O T E S
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.
Filtering and Noise Reduction
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 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
"D12A" Models
"D48A" Models
47µF, 10V
20µF, 35V
10µF, 100V
Environmental
–40 to +65/70°C (Model dependent)
to +100°C (See Derating Curves)
–40 to +105°C
Physical
2" x 1" x 0.375" (51 x 25 x 9.5mm)
5-sided
Pin 2 (–V
IN
)
Pin 1 (+V
IN
)
Corrosion resistant steel with
non-conductive, epoxy-based black
enamel finish and palstic baseplate
RoHS: Gold-plated copper alloy with nickel
underplate
Non-RoHS: Solder-coated brass
1.3 ounces (37 grams)
UL 94V-0
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 C&D Applications Engineering for details.
➂ Devices can be screened or modified for higher guaranteed isolation voltages.
Contact C&D Applications Engineering for details.
➃
D5A Models: Zener/transorb only
To Reduce Output Ripple
±5V Output
47µF, 10V, Low ESR
±12/15V Outputs
22µF, 20V, Low ESR
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
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
3
+
C
OUT
4
COMMON
2
–INPUT
5
–OUTPUT
+
C
OUT
+OUTPUT
1
+
+INPUT
C
IN
If you’re designing with EMC in mind, please note that all of C&D’s BWR
7-10 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-15/330-D48A appear below. Published EMC test
reports are available for each model number. Contact C&D’s Applications
Engineering Department for more details.
BWR-15/330-D48A Radiated Emissions
FCC Part 15 Class B, 3 Meters
Converter Output = ±15Vdc @ ±300mA
80
70
60
Figure 2. Using External Capacitors to Reduce
Input/Output Ripple/Noise
Input Fusing
Radiated Emissions (dBµV/M)
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 7-10 Watt DC/DC Converters, you should use slow-blow type fuses with
values no greater than the following:
V
IN
Range
"D5A"
"D12A"
"D48A"
C U S T O M
FCC Class B Limit
50
40
30
20
10
0
–10
–20
Fuse Value
3A
2A
1A
Radiated Emissions
C A P A B I L I T I E S
100
1000
Frequency (MHz)
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
power converters available.
80
70
60
BWR-15/330-D48A Radiated Emissions
EN 55022 Class B, 10 Meters
Converter Output = ±15Vdc @ ±300mA
Radiated Emissions (dBµV/M)
50
EN 55022 Class B Limit
40
30
20
10
0
Radiated Emissions
–10
–20
100
1000
Frequency (MHz)
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4
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
BWR Models
changes, stresses are stepped up again and the cycle is repeated until the
"fundamental limit of the technology" is determined.
C&D 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 increas-
ing, random longitudinal and rotational vibration up to 20G’s with load cycling
and applied-voltage extremes added as desired. Many devices in C&D’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.
Qualification
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.
Qualification Testing
Qualification Test
HALT
High Temperature Storage
Thermal Shock
Temperature/Humidity
Lead Integrity
Life Test
Marking Permanency
End Point Electrical Tests
* Interim electrical test at 200 hours.
Quality and Reliability
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 guide-
lines 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 thor-
ough 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
Typical HALT Profile
100
80
60
Temperature (°C)
40
20
0
–20
–40
10
20
30
40
50
60
70
80
90
Test Time (minutes)
0
20
Random Vibration (G's)
40
Method/Comments
C&D in-house procedure
Max. rated temp., 1,000 hours
10 cycles, –55 to +125°C
+85°C, 85% humidity, 48 hours
C&D in-house procedure
+70°C, 500 hours*
C&D in-house procedure
Per product specification
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.
Rapid Response to Problems
C&D 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 refine our assembly operation to
yield one of the lowest product defect rates in the industry.
USA:
Canada:
UK:
France:
Tucson (Az), Tel: (800) 547 2537, email: sales@cdtechno.com
Toronto, Tel: (866) 740 1232, email: toronto@cdtechno.com
Milton Keynes, Tel: +44 (0)1908 615232, email: mk@cdtechno.com
Montigny Le Bretonneux, Tel: +33 (0)1 34 60 01 01, email: france@cdtechno.com
Tokyo, Tel: 3-3779-1031, email: sales_tokyo@cdtechno.com
Osaka, Tel: 6-6354-2025, email: sales_osaka@cdtechno.com
Website:
www.cd4power.jp
Shanghai, Tel: +86 215 027 3678, email: shanghai@cdtechno.com
Guangzhou, Tel: +86 208 221 8066, email: guangzhou@cdtechno.com
®
C&D Technologies, Inc.
11 Cabot Boulevard, Mansfield, MA 02048-1151 U.S.A.
Tel: (508) 339-3000 (800) 233-2765 Fax: (508) 339-6356
www.cd4power.com
ISO 9001 REGISTERED
Germany:
München, Tel: +49 (0)89-544334-0, email: ped.munich@cdtechno.com
Japan:
email: sales@cdtechno.com
DS-0322A
05/14/07
China:
© 2007 C&D Technologies, Inc.
C&D Technologies, Inc. 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.
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