POWERBOX Industrial Line
MAI21 Series
40W 2:1 Single, Dual and Triple Output
DC/DC Converter
Manual V10
Table of Contents
1. Introduction
P1
2. DC/DC converter features
P1
3. Electrical block diagram
P2
4. Technical specification
P3
5. Main features and functions
P9
5.1 Operating temperature range
P9
5.2 Over temperature protection (OTP)
P9
5.3 Output voltage adjustment
P9
5.4 Over current protection
P9
5.5 Output over voltage protection
P9
5.6 Remote On/Off
P9
5.7 UVLO (under voltage lock out)
P9
6. Applications
P10
6.1 Recommended layout, PCB footprint and soldering information P10
6.2 Power de-rating
P10
6.3 Efficiency VS load
P11
6.4 Input capacitance at the power module
P17
6.5 Test set-up
P17
6.6 Test set-up for dual positive output
P17
6.7 Output voltage adjustment
P18
6.8 Output voltage adjustment for dual positive output
P19
6.9 Output ripple and noise measurement
P19
6.10 Output capacitance
P19
7. Safety & EMC
P19
7.1 Input fusing and safety considerations
P19
7.2 EMC considerations
P20
8. Mechanical specifications
P22
8.1 Mechanical outline diagrams
P22
www.prbx.com
1. Introduction
The MAI21 series offer 40 watts of output power with Industry standard
package in a 2 x 2 x 0.40inches(50.8 x 50.8 x 10.2mm). The MAI21 series
has a 2:1 wide input voltage range of 9-18, 18-36 and 36-75VDC and
provides a precisely regulated output. This series has features such as
high efficiency, 1500VDC of isolation and allows an ambient operating
temperature range of –40°C to 85°C. The modules are fully protected
against UVLO (under voltage lock-out), over temperature conditions,
short circuit, and over-voltage conditions. Furthermore, the standard
functions include remote on/off control and output voltage trimming.
All models are very suitable for telecommunications, distributed power
architectures, battery operated equipment, industrial, and mobile
equipment applications.
2. DC/DC Converter Features
40W isolated output
High efficiency up to 92%
Fixed 350KHz sitching frequency
2 : 1 input range
Regulated outputs
Continuous short circuit protection
Six-sided metal case
2” x 2” size
Industry standard pin-out
1
POWERBOX Industrial Line
MAI21 Series
40W 2:1 Single, Dual and Triple Output
DC/DC Converter
Manual V10
3. Electrical Block Diagram
DRIVER
CIRCUIT
+VIN
(1)
+Vout
(5)
Common
(6)
DRIVER
CIRCUIT
Common
(7)
-VIN
(2)
-Vout
(8)
UVLO
CIRCUIT
REMOTE
ON/OFF
CIRCUIT
ON/OFF
(3)
(a) MAI21 Series for single output
OCP
CIRCUIT
OTP
CIRCUIT
OPTO
ISOLATION
REFERENCE
& ERROR AMP
(9)
Trim
(b) MAI21 Series for dual output
+5VOut
(8)
+VIN
(1)
PWM
CONTROLLER
+VOUT
(7)
+VIN
(1)
DRIVER
CIRCUI
Common
(5)(8)
DRIVER
CIRCUI
+Aux.Out
(4)
+3.3VOut
(4)
-VIN
(2)
Common
(5)(9)
UVLO
CIRCUIT
ON/OFF
(3)
REMOTE
ON/OFF
CIRCUIT
UVLO
CITCUIT
OCP
CIRCUIT
OTP
CIRCUIT
OPTO
ISOLATION
(c) MAI21 for dual positive output
www.prbx.com
-VIN
(2)
PWM
CONTROLLER
REFERENCE
& ERROR AMP
(6)
Trim
ON/OFF
(3)
REMOTE
ON/OFF
CIRCUIT
-Aux.Out
(6)
PWM
CONTROLLER
OCP
CIRCUIT
OTP
CIRCUIT
OPTO
ISOLATION
REFERENCE
& ERROR AMP
(d) MAI21 series for triple output
2
POWERBOX Industrial Line
MAI21 Series
40W 2:1 Single, Dual and Triple Output
DC/DC Converter
Manual V10
4. Technical Specifications
(All specifications are typical at nominal input, full load at 25°C unless otherwise noted.)
Absolute Maximum Ratings
Parameters
Notes and Conditions
Input voltage
Continuous
Transient
100ms
Operating ambient temperature De-rating, above 60 °C
Storage temperature
Input/output isolation voltage
1 minute
Input Characteristics
Parameters
Notes and Conditions
Operating input voltage
Input Under Voltage Lockout
Turn-on voltage threshold
Turn-off voltage threshold
Lockout hysteresis voltage
Maximum input current
100% Load, Vin=9V
100% Load, Vin =18V
100% Load, Vin =36V
www.prbx.com
Device
Min
Typical
Max
12Vin0
18
24Vin0
36
48Vin0
75
12Vin
25
24Vin
50
48Vin
100
All
-40
+85
All
-55
+125
All
1500
Units
VDC
VDC
VDC
VDC
VDC
VDC
°C
°C
VDC
Device
Min
Typical
Max
Units
12Vin
9
12
18
VDC
24Vin
182436VDC
48Vin
364875VDC
12Vin
8
8.5
8.8
VDC
24Vin
16.517 17.5VDC
48Vin33
34 34.5 VDC
12Vin
7.7
8
8.3
VDC
24Vin
15.516 16.5VDC
48Vin31.5 32.5 33
VDC
12Vin
0.6
VDC
24Vin0.9VDC
48Vin1.8VDC
12Vin
5100
mA
24Vin
2550
mA
48Vin
1270
mA
3
POWERBOX Industrial Line
MAI21 Series
40W 2:1 Single, Dual and Triple Output
DC/DC Converter
Manual V10
Parameters
Notes and Conditions
No-load input current
Off converter input current
Shutdown input idle current
Inrush current (I2t)
Input reflected ripple current
P-P thru 12uH inductor, 5Hz to 20Mhz
www.prbx.com
Device
Min
Typical
Max
Units
MAI 21 009
200
mA
MAI 21 012
200
mA
MAI 21 015
200
mA
MAI 21 030
200
mA
MAI 21 036
200
mA
MAI 21 042
100
mA
MAI 21 057
100
mA
MAI 21 045
200
mA
MAI 21 048
200
mA
MAI 21 051
200
mA
MAI 21 054
200
mA
MAI 21 010
100
mA
MAI 21 013
100
mA
MAI 21 016
110
mA
MAI 21 031
100
mA
MAI 21 037
100
mA
MAI 21 040
100
mA
MAI 21 043
100
mA
MAI 21 058
50
mA
MAI 21 046
100
mA
MAI 21 049
100
mA
MAI 21 052
100
mA
MAI 21 055
100
mA
MAI 21 011
50
mA
MAI 21 014
50
mA
MAI 21 017
60
mA
MAI 21 032
60
mA
MAI 21 038
60
mA
MAI 21 041
50
mA
MAI 21 044
50
mA
MAI 21 059
50
mA
MAI 21 047
50
mA
MAI 21 050
50
mA
MAI 21 053
50
mA
MAI 21 056
50
mA
All
10
mA
All 0.1A2s
All
30
mA
4
POWERBOX Industrial Line
MAI21 Series
40W 2:1 Single, Dual and Triple Output
DC/DC Converter
Manual V10
Output Characteristics
Parameters
Notes and Conditions
Device
Min
Typical
Max
Units
Output voltage set point
Vin=Nominal Vin, Io = Io_max, Tc=25°C 2.5VDC
2.475
2.5
2.525
VDC
Single output 3.3VDC
3.267
3.3
3.333
VDC
Dual output
5VDC
4.955.0 5.05VDC
12VDC
11.8812 12.12VDC
15VDC
14.8515 15.15VDC
Vin nominal, Io=Io_max, Tc=25°C
3.3VDC
3.267
3.3
3.333
VDC
Dual positive output
5VDC
4.85
5.0
5.15
VDC
Vin nominal, Io=Io_max, Tc=25°C
3.3VDC
3.267
3.3
3.333
VDC
Triple output
5VDC
4.955.0 5.05VDC
12VDC
11.412 12.6VDC
15VDC
14.2515 15.75VDC
Voltage balance
Vin nominal, Io=Io_max, Tc=25°C Dual ±2 %
Output voltage regulation
Load regulation
Io=Full Load to 10% full load Single
±0.5
%
Dual
±1 %
Dual positive output
5Vo=no load , 3.3Vo: full load to no load 3.3VDC
±1.5
%
3.3Vo=no load, 5Vo: full load to no load 5VDC
±4
%
Triple output
Main
±1
%
Io=full load to 10% full load
Auxiliary
±4
%
Line regulation
Vin=high line to low line, full load Single
±0.5
%
Dual
±0.5 %
Dual positive output, Vin=high to low line 3.3VDC
±0.5
%
3.3Vdc : Io=6A , 5Vdc : Io=4A
5VDC
±0.5
%
Triple output, Vin=high to low line
Main
±1
%
Io=full load
Auxiliary
±3
%
Temperature coefficient
TC=-40°C to +85°C
All
±0.02
%/°C
Output voltage ripple and noise
Peak-to-Peak
Full load, 0.1uF ceramic capacitor 20MHz 2.5VDC
50
mV
bandwidth, single and main output
3.3VDC
50
mV
5VDC
50
mV
12VDC
75
mV
15VDC
75
mV
Full load, 0.1uF ceramic capacitor 20MHz ±12Vdc 120
mV
bandwidth, dual output, auxiliary output ±15Vdc 150
mV
Full load, 0.1uF ceramic capacitor 20MHz 3.3VDC
100
mV
bandwidth, dual positive output
5VDC
100
mV
RMS
Full load, 0.1uF ceramic capacitor 2.5VDC
20
mV
20MHz bandwidth
3.3VDC
20
mV
5VDC
20
mV
www.prbx.com
5
POWERBOX Industrial Line
MAI21 Series
40W 2:1 Single, Dual and Triple Output
DC/DC Converter
Manual V10
Output Characteristics
Parameters
Notes and Conditions
Device
Min
Typical
Max
Operating output current range Single
2.5Vout
0
10000
3.3Vout0
10000
5Vout0
8000
12Vout0
3333
15Vout0
2666
Dual
±12Vout90
±1800
±15Vout70
±1400
Dual positive
3.3Vout
0
6000
10000
5Vout0
4000 7500
Triple
3.3Vout600
6000
±12Vout±40
±400
3.3Vout600
6000
±15Vout±30
±300
5Vout600
6000
±12Vout±40
±400
5Vout600
6000
±15Vout±30
±300
Output DC current limit inception Output voltage=90% ,nom output voltage
110
125
140
Maximum output capacitance
Single
2.5Vout
10000
3.3Vout
10000
5Vout
8000
12Vout
3300
15Vout
2700
Dual
±12Vout
1800
±15Vout
1400
Dual positive
3.3Vout
6800
5Vout
6800
Triple
3.3Vout
6000
±12Vout
400
3.3Vout
6000
±15Vout
330
5Vout
6000
±12Vout
400
5Vout
6000
±15Vout
330
Dynamic Characteristics
Parameters
Notes and Conditions
Device
Min
Typical
Max
Output voltage current transient
Step change in output current
75% Io.max to 100% Io.max., All
±5
0.1A/us main output
Setting time (within 1% Vout nominal)di/dt=0.1A/us main output
All
300
Turn-on delay and rise time
Turn-on delay time, Von/off to 90%Vo, set
All
5.5
from on/off control
Turn-on delay time, from input
Vin, min to 90%Vo, set
All
5.5
Output voltage rise time
10%Vo, set to 90%Vo, set
All
4.5
www.prbx.com
Units
mA
mA
mA
mA
mA
mA
mA
mA
mA
mA
mA
mA
mA
mA
mA
mA
mA
%
uF
uF
uF
uF
uF
uF
uF
uF
uF
uF
uF
uF
uF
uF
uF
uF
uF
Units
%
us
ms
ms
ms
6
POWERBOX Industrial Line
MAI21 Series
40W 2:1 Single, Dual and Triple Output
DC/DC Converter
Manual V10
Efficiency
Parameters
Notes and Conditions
100% load
12Vin single
12Vin dual
12Vin dual positive
12Vin triple
24Vin single
24Vin dual
24Vin dual positive
24Vin triple
48Vin single
48Vin dual
48Vin dual positive
48Vin triple
Device
Min
MAI 21 009
MAI 21 012
MAI 21 015
MAI 21 030
MAI 21 036
MAI 21 039
MAI 21 042
MAI 21 057
MAI 21 045
MAI 21 048
MAI 21 051
MAI 21 054
MAI 21 010
MAI 21 013
MAI 21 016
MAI 21 031
MAI 21 037
MAI 21 040
MAI 21 043
MAI 21 058
MAI 21 046
MAI 21 049
MAI 21 052
MAI 21 055
MAI 21 011
MAI 21 014
MAI 21 017
MAI 21 032
MAI 21 038
MAI 21 041
MAI 21 044
MAI 21 059
MAI 21 047
MAI 21 050
MAI 21 053
MAI 21 056
Isolation Characteristics
Parameters
Notes and Conditions
Input to output
1 minute
Isolation resistance
Isolation capacitance
Device
Min
Typical
Max
Units
All
1500
VDC
All
100
MΩ
All1000pF
www.prbx.com
Typical
Max
88
89
89
90
90
89
90
87
88
88
88
90
88
89
89
90
90
89
90
89.5
88
88
88
90
88
89
89
90
90
89
90
89.5
88
88
88
90
Units
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
7
POWERBOX Industrial Line
MAI21 Series
40W 2:1 Single, Dual and Triple Output
DC/DC Converter
Manual V10
Feature Characteristics
Parameters
Notes and Conditions
Device
Min
Typical
Max
Units
Switching frequency
All350KHz
ON/OFF control, negative remote On/Off logic
Logic low (module on)
Von/off at Ion/off=1.0mA All 0 1.8 V
Logic high (module off)
Von/off at Ion/off=0.0uA All 3.5
75 or open circuit
ON/OFF control, positive remote On/Off logic
Logic low (module off)
Von/off at Ion/off=1.0mA All 0 1.8 V
Logic high (module on)
Von/off at Ion/off=0.0uA All 3.5
75 or open circuit
ON/OFF current (for both remote on/off logic), Ion/off at Von/off=0.0V All 1
mA
Leakage current (for both remote on/off logic), logic high, Von/off=15V All 30 uA
Off converter input current
Shutdown input idle current
All
4
10
mA
Output voltage trim range
Pout=max rated power 40Watts
All
-10
+10
%
Output over voltage protection
2.5VDC
3.6
V
3.3VDC3.9V
5VDC6.2V
12VDC15V
15VDC18V
General Specifications
Parameters
Notes and Conditions
Device
Min
Typical
Max
Units
MTBF
Io=100% of Io, max: All
800
Khours
Ta=25°C per MIL-HDBK-217F
Weight
All65grams
Over-temperature shutdown
Case temperature
110
°C
www.prbx.com
8
POWERBOX Industrial Line
MAI21 Series
40W 2:1 Single, Dual and Triple Output
DC/DC Converter
Manual V10
5. Main Features and Functions
5.1 Operating Temperature Range
MAI21 series converters can be operated within a wide ambient
temperature range of -40°C to 85°C with de-rating. The consideration
must be given to the de-rating curves when ascertaining maximum
power that can be drawn from the converter. The maximum power
drawn from open frame models is influenced by the same factors, such
as:
• Input voltage range.
• Output load current.
• Forced air or natural convection.
• Mother board PCB design, especially ground and power planes.
5.6 Remote On/Off
The remote ON/OFF input feature of the converter allows external
circuitry to turn the converter ON or OFF. Active-high remote ON/OFF
is available as standard. The converter is turned on if the remote ON/
OFF pin is high (>3.5Vdc to 75Vdc or open circuit). Setting the pin low
(<1.8Vdc) will turn the converter ‘Off’. The signal level of the remote on/
off input is defined with respect to “-Vin”. If not using the remote on/off
pin, leave the pin open (module will be on). The part number suffix “N”
is negative remote ON/OFF version. The unit is turned off if the remote
ON/OFF pin is high (>3.5Vdc to 75Vdc or open circuit). The converter is
turned on if the ON/OFF pin input is low (<1.8Vdc). The recommended
ON/OFF drive circuit as shown as below figure.
5.2 Over Temperature Protection (OTP)
The MAI21 series converters are equipped with non-latching overtemperature protection. If the temperature exceeds a threshold of 110°C
(typical) the converter will shut down, disabling the output. When the
temperature has decreased the converter will automatically restart. The
over-temperature condition can be induced by a variety of reasons such
as external overload condition or a system fan failure.
5.3 Output Voltage Adjustment
Section 6.6 describes in detail as to how to trim the output voltage with
respect to its set point. The output voltage on single and dual models is
adjustable in the range from +10% to –10%. The output voltage on dual
positive models is adjustable in the range from +5% to -5%.
5.4 Over Current Protection
Remote ON/OFF Input Drive Circuit
5.7 UVLO (Unde Voltage Lock Out)
Input under voltage lockout is standard with the MAI21 unit. The unit will
shut down when the input voltage drops below a threshold, and the unit
will turn on when the input voltage goes to the upper threshold.
All different voltage models have full continuous short-circuit protection. To provide protection in a fault condition, the unit is equipped with
internal over-current protection. The unit operates normally once the
fault condition is removed. At the point of current-limit inception, the
converter will go into a hiccup mode protection.
5.5 Output Over Voltage Protection
The output overvoltage protection consists of circuitry that internally
zener diode clamps the output voltage. If a more accurate output over
voltage protection circuit is required then this can be used external
control the remote on/off pin.
www.prbx.com
9
POWERBOX Industrial Line
MAI21 Series
40W 2:1 Single, Dual and Triple Output
DC/DC Converter
Manual V10
6. Applications
6.2 Power De-Rating Curves
The system designer or the end user must ensure that other components
and metal in the vicinity of the converter meet the spacing requirements
to which the system is approved. Low resistance and low inductance
PCB layout traces are the norm and should be used where possible.
Due consideration must also be given to proper low impedance tracks
between power module, input and output grounds. The recommended
footprint and soldering profile is shown as below.
Note:
1.
9 8
7 6
5
Operating ambient temperature range: -40°C ~ 85°C with de-rating.
Derating Curve
120.0
100.0
Output Load(%)
6.1 Recommended Layout, PCB Footprint and Soldering
Information
80.0
60.0
40.0
Natural convection
20.0
4
TOP VIEW
0.0
-40
3
2
-20
0
20
40
60
Ambient Temperature( oC)
80
100
1
Recommend footprint for pcb layout
Lead Free Wave Soldering Profile
Temperature ( C )
300
250
200
150
100
50
0
0
50
100
150
Time (Seconds)
Recommended wave Soldering Profile
Soldering Materials : Sn/Cu/Ni
2. Ramp up rate during preheat : 1.4°C/Sec (From 50°C to
100°C )
3. Soaking temperature : 0.5°C/Sec (From 100°C to
130°C ), 60±20 seconds
4. Peak temperature : 260°C, above 250°C 3~6 Seconds
5. Ramp up rate during cooling : -10.0°C/Sec (From 260°C to
150°C )
www.prbx.com
10
POWERBOX Industrial Line
MAI21 Series
40W 2:1 Single, Dual and Triple Output
DC/DC Converter
Manual V10
6.3 Efficiency VS. Load
100%
MAI 21 009 (Eff Vs Io)
100%
90%
80%
80%
Efficiency (%)
Efficiency (%)
90%
70%
70%
60%
60%
9V%
12V
40%
2.000
4.000
6.000
Current
L oad
(A)
18V
8.000
40%
0.000
10.000
4.000
6.000
Current Load (A)
90%
80%
80%
Efficiency (%)
90%
Efficiency (%)
100%
8.000
10.000
70%
70%
60%
60%
9V
50%
1.600
3.200
4.800
Cu rren t Loa d (A)
6.400
12V
40%
8.000
18V
30%
0.000
MAI 21 036 (Eff Vs Io)
100%
9V
50%
1 2V
1 8V
40%
0.660
1.320
1.980
Cu rren t Load (A)
2.640
3.300
MAI 21 039 (Eff Vs Io)
100%
90%
80%
80%
Efficiency (%)
Efficiency (%)
90%
70%
60%
50%
9V
12V
40%
www.prbx.com
2.000
MAI 21 030 (Eff Vs Io)
MAI 21 015 (Eff Vs Io)
30%
0.000
18V
30%
100%
30%
0.000
9V
12V
50%
50%
30%
0.000
MAI 21 012 (Eff Vs Io)
18V
0.533
1.066
1.599
Current Load (A)
2.132
2.665
70%
60%
50%
9V
12V
40%
18V
30%
0.000
0.360
0.720
1.080
Current L oad (A)
1.440
1.800
11
POWERBOX Industrial Line
MAI21 Series
40W 2:1 Single, Dual and Triple Output
DC/DC Converter
Manual V10
MAI 32 010 (Eff Vs Io)
MAI 21 042 (Eff Vs Io)
90%
90%
80%
80%
Efficiency (%)
100%
Efficiency (%)
100%
70%
60%
50%
9V
12 V
40%
18 V
30%
0.000
100%
0.280
0.560
0.840
Cu rren t Loa d (A)
1.120
60%
2 4V
40%
3 6V
100%
80%
80%
60%
50%
18 V
24 V
40%
36 V
8.000
10.000
MAI 21 016 (Eff Vs Io)
2.000
4.000
6.000
Current Load (A)
8.000
10.000
30%
0.000
80%
80%
Efficiency (%)
90%
70%
60%
18V
50%
24V
40%
36V
1.998
Current Load (A)
36V
1.600
3.200
4.800
Cu rren t Load (A)
6.400
8.000
MAI 21 037 (Eff Vs Io)
90%
1.332
24V
40%
100%
0.666
18V
50%
MAI 21 031 (Eff Vs Io)
Efficiency (%)
6.000
60%
100%
www.prbx.com
4.000
Curre nt Load (A)
70%
70%
30%
0.000
2.000
Efficiency (%)
90%
Efficiency (%)
90%
30%
0.000
1 8V
50%
30%
0.000
1.400
MAI 21 013 (Eff Vs Io)
70%
2.664
3.330
70%
60%
50%
18V
24V
40%
36V
30%
0.000
0.533
1.066
1.599
Current L oad (A)
2.132
2.665
12
POWERBOX Industrial Line
MAI21 Series
40W 2:1 Single, Dual and Triple Output
DC/DC Converter
Manual V10
MAI 21 040 (Eff Vs Io)
100%
100%
90%
80%
Efficiency (%)
Efficiency (%)
90%
80%
70%
70%
60%
50%
18V
24V
40%
36V
30%
0.000
0.360
0.720
1.080
Current L oad (A)
1.440
60%
1.800
30%
0.000
0.280
0.560
0.840
Current L oad (A)
80%
80%
Efficiency (%)
90%
Efficiency (%)
90%
70%
1.120
1.400
70%
60%
50%
36V
48V
40%
75V
2.000
4.000
6.000
Current Load (A)
8.000
60%
36V
48V
50%
40%
10.000
30%
0.000
MAI 21 017 (Eff Vs Io)
75V
2.000
4.000
6.000
Current Load (A)
8.000
10.000
MAI 21 032 (Eff Vs Io)
100%
80%
Efficiency (%)
90%
80%
Efficiency (%)
90%
70%
60%
50%
36V
48V
40%
75V
www.prbx.com
36V
MAI 21 011 (Eff Vs Io)
100%
30%
0.000
24V
40%
MAI 21 011 (Eff Vs Io)
100%
18V
50%
100%
30%
0.000
MAI 21 043 (Eff Vs Io)
1.600
3.200
4.800
Cu rrent Load (A)
6.400
8.000
70%
60%
50%
36 V
48 v
40%
75 V
30%
0.000
0.660
1.320
1.980
Current L oad (A)
2.640
3.300
13
POWERBOX Industrial Line
MAI21 Series
40W 2:1 Single, Dual and Triple Output
DC/DC Converter
Manual V10
MAI 21 038 (Eff Vs Io)
MAI 21 041 (Eff Vs Io)
90%
90%
80%
80%
Efficiency (%)
100%
Efficiency (%)
100%
70%
70%
60%
50%
36 V
48 V
40%
75 V
30%
0.000
100%
0.533
1.066
1.599
Current Load (A)
2.132
60%
36V
48V
40%
75V
30%
0.000
2.665
MAI 21 044 (Eff Vs Io)
0.720
1.080
Current Load (A)
1.440
1.800
MAI 21 057 (Eff Vs Io)
90%
Efficiency (%)
Efficiency (%)
80%
80%
70%
60%
70%
36V
50%
48V
75V
40%
0.280
0.560
0.840
Current Load (A )
1.120
1.400
18 V
50%
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Current L oad (A)
MAI 21 058 (Eff Vs Io)
MAI 21 059 (Eff Vs Io)
90%
90%
80%
Efficiency (%)
100%
Efficiency (%)
9V
12 V
60%
100%
80%
70%
18 V
24 V
60%
36 V
50%
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Current L oad (A)
www.prbx.com
0.360
100%
90%
30%
0.000
50%
70%
36 V
48 V
60%
75 V
50%
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Current L oad (A)
14
POWERBOX Industrial Line
MAI21 Series
40W 2:1 Single, Dual and Triple Output
DC/DC Converter
Manual V10
MAI 21 045 (Eff Vs Io)
MAI 21 046 (Eff Vs Io)
90%
90%
80%
80%
70%
9V
1 2V
1 8V
60%
50%
10%
Efficiency (%)
100%
Efficiency (%)
100%
20% 30% 40% 50% 60% 70% 80% 90% 100%
Curren t Loa d (A)
70%
60%
50%
10%
MAI 21 047 (Eff Vs Io)
20% 30% 40% 50% 60% 70% 80% 90% 100%
Curren t Loa d (A)
90%
90%
Efficiency (%)
100%
Efficiency (%)
3 6V
MAI 21 048 (Eff Vs Io)
100%
80%
80%
70%
36 V
60%
48 V
75 V
50%
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Current Lo ad (A)
70%
12 V
18 V
50%
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Current Lo ad (A)
MAI 21 049 (Eff Vs Io)
MAI 21 050 (Eff Vs Io)
90%
90%
80%
Efficiency (%)
100%
Efficiency (%)
9V
60%
100%
80%
70%
18 V
60%
24 V
36 V
50%
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Current Lo ad (A)
www.prbx.com
1 8V
2 4V
70%
36 V
60%
48 V
75 V
50%
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Current Lo ad (A)
15
POWERBOX Industrial Line
MAI21 Series
40W 2:1 Single, Dual and Triple Output
DC/DC Converter
Manual V10
M A I 2 1 0 5 2 (E ff Vs Io)
MAI 21 051 (Eff Vs Io)
90%
90%
Efficiency (%)
100%
Efficiency (%)
100%
80%
80%
70%
9V
1 2V
60%
1 8V
50%
10% 20% 30%
40% 50% 60% 70% 80% 90% 100%
Curren t Load (A)
70%
60%
Current Lo ad (A)
M A I 2 1 0 5 3 (E ff Vs Io)
M A I 2 1 0 5 4 (E ff Vs Io)
90%
90%
80%
Efficiency (%)
100%
Efficiency (%)
36V
50%
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
100%
80%
70%
36 V
48 V
75 V
60%
70%
9V
12V
60%
18V
50%
50%
10% 20% 30%
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
40% 50% 60% 70% 80% 90% 100%
Current Lo ad (A)
Cu rren t Loa d (A)
M A I 2 1 0 5 5 (E ff Vs Io)
M A I 2 1 0 5 6 (E ff Vs Io)
90%
90%
80%
80%
70%
18 V
24 V
36 V
60%
50%
10% 20% 30%
Efficiency (%)
100%
Efficiency (%)
100%
www.prbx.com
18V
24V
40% 50% 60% 70% 80% 90% 100%
Cu rren t Loa d (A)
70%
36V
48V
60%
75V
50%
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Current Lo ad (A)
16
POWERBOX Industrial Line
MAI21 Series
40W 2:1 Single, Dual and Triple Output
DC/DC Converter
Manual V10
6.4 Input Capacitance at the Power Module
The value of line regulation is defined as:
The converters must be connected to low AC source impedance. To
avoid problems with loop stability source inductance should be low. Also,
the input capacitors (Cin) should be placed close to the converter input
pins to de-couple distribution inductance. However, the external input
capacitors are chosen for suitable ripple handling capability. Low ESR
capacitors are good choice. Circuit as shown as below represents typical
measurement methods for reflected ripple current. C1 and L1 simulate
a typical DC source impedance. The input reflected-ripple current is
measured by current probe to oscilloscope with a simulated source
Inductance (L1).
To Oscilloscope
L1
+Vin
Line.reg =
Where: VHL is the output voltage of maximum input voltage at full load.
VLL is the output voltage of minimum input voltage at full load.
A
+
Vin
-
C1
-
Cin
+Vin
A
+Vo
Trim
V
-Vin
+Vo
+
Vin
VHL −VLL
×100%
VLL
V
Load
-Vo
Test Setup
R-Load
6.6 Test Set-Up for Dual Positive Output
-Vin
-Vo
L1 : 12uF
C1: 220uF ESR<0.1ohm @100KHz
Cin: 33uF ESR<0.7ohm @100KHz
Input Reflected-Ripple Test Setup
6.5 Test Set-Up
The basic test set-up to measure parameters such as efficiency and
load regulation is shown as below. When testing the modules under any
transient conditions please ensure that the transient response of the
source is sufficient to power the equipment under test. We can calculate
the
· Efficiency
· Load regulation and line regulation.
The value of efficiency is defined as:
Vo × Io
η = Vin × Iin ×100%
Where:
Vo is output voltage,
Io is output current,
Vin is input voltage,
Iin is input current.
The value of load regulation is defined as:
Load.reg =
VFL −VNL
×100%
VNL
Where:
VFL is the output voltage at full load
VNL is the output voltage at no load
www.prbx.com
The basic test set-up to measure parameters such as efficiency and
load regulation is shown as below. When testing the modules under any
transient conditions please ensure that the transient response of the
source is sufficient to power the equipment under test. We can calculate
the
· Efficiency
· Load regulation and line regulation.
The value of efficiency is defined as:
η = (Vo1× Io1+(Vo2×Io2) ×100%
Vin × Iin
Where
Vo1 is +5.0V output voltage,
Vo2 is +3.3V output voltage,
Rated Load is +5V/4A , +3.3V/6A
Io1 is +5.0V output current 4A,
Io2 is +3.3V output current 6A,
Any combination at 5V/3.3V rated output current,
not to exceeded 40W of output power
Vin is input voltage,
Iin is input current.
The value of load regulation is defined as:
Load.reg =
VFL −VNL
×100%
VFL
Where
VFL is the output voltage at max. load
VNL is the output voltage at no load
other output at zero load
The value of line regulation is defined as:
Line.reg =
VHL −VLL
×100%
VLL
17
POWERBOX Industrial Line
MAI21 Series
40W 2:1 Single, Dual and Triple Output
DC/DC Converter
Manual V10
The value of Radj,up & Radj,down defined as:
2.5V models:
Where: VHL is the output voltage of maximum input voltage at
Rate load. VLL is the output voltage of minimum input
voltage at Rate load.
The value of load regulation is defined as:
Cross.reg =
2.877
− 8.25(ΚΩ)
∆Vo
2.923
Radj , down =
− 10.57(ΚΩ)
∆Vo
Radj , up =
VFL −V10%FL
×100%
VFL
Where
VFL is the output voltage at Max. load
V10%FL is the output voltage at 10% Max. load
other output at 10% Max. load
A
+
Vin
+Vin
3.3V models:
A
+5V Output
V
Load
+5V Return
+3.3V Output
V
-
Load
+3.3V Return
Dual Positive Test Setup
6.7 Output Voltage Adjustment
In order to trim the voltage up or down one needs to connect the trim
resistor either between the trim pin and - Vo for trim-up and between
trim pin and +Vo for trim-down. The output voltage trim range is ±10%.
This is shown as below:
+Vin
+Vout
Trim
R-Load
-Vsense
R adj,up
-Vout
Radj,down
Trim
-Vsense
-Vin
51
− 22(ΚΩ)
∆Vo
48.167
Radj , down =
− 28.8(ΚΩ)
∆Vo
Radj , up =
52.893
− 27(ΚΩ)
∆Vo
67.67
Radj , down =
− 35.06(ΚΩ)
∆Vo
Radj , up =
44.5
− 22(ΚΩ)
∆Vo
63.106
Radj , down =
− 30.9(ΚΩ)
∆Vo
Radj , up =
+Vout
+Vsense
12V models:
±12V models:
Trim up output voltage setup
+Vin
5.8
− 8.2(ΚΩ)
∆Vo
2.32Vo−5.8
Radj , down =
− 8.2(ΚΩ)
∆Vo
15V models:
+Vsense
-Vin
5V models:
Radj , up =
V
-Vin
3.151
− 9.1(ΚΩ)
∆Vo
5.172
Radj , down =
− 11.84(ΚΩ)
∆Vo
Radj , up =
-Vout
Trim down output voltage setup
R-Load
±15V models:
73.22
− 27(ΚΩ)
∆Vo
96.068
Radj , down =
− 38.3(ΚΩ)
∆Vo
Radj , up =
Where: Vo is the desired output voltage
∆Vo=ǀ Vo − Vonomǀ
www.prbx.com
18
POWERBOX Industrial Line
MAI21 Series
40W 2:1 Single, Dual and Triple Output
DC/DC Converter
Manual V10
To give an example of the above calculation, to set a voltage of
5.3Vdc using MAI 21 017, Radj,up is given by:
∆Vo=ǀ 5.0 − 5.3ǀ=0.3Vdc
Radj , up =
5.8
− 8.2=11.33 (ΚΩ)
0.3
Connect it between TRIM pin to –Vo pin.
6.9 Output Ripple and Noise Measurement
The test set-up for noise and ripple measurements is shown as below.
A coaxial cable was used to prevent impedance mismatch reflections
disturbing the noise readings at higher frequencies. Measurements are
taken with output appropriately loaded and all ripple/noise specifications
are from D.C. to 20MHz Band Width. The output ripple/noise is
measured with 0.1uF ceramic capacitor across output.
6.8 Output Voltage Adjustment for Dual Positive Output
In order to trim the voltage up or down one needs to connect the trim
resistor either between the trim pin and +3.3V Return for trim-up and
between trim pin and +3.3V Output for trim-down. The output voltage
trim range is ±5%. This is shown as below:
+5V Output
+Vin
R-Load
+5V Return
Trim
R adj,up
+3.3V Output
R-Load
-Vin
+3.3V Return
Trim up output voltage setup
+5V Output
+Vin
R-Load
+5V Return
Trim
R adj,down
R-Load
+3.3V Return
Trim down output voltage setup
The value of Radj,up & Radj,down defined as:
MAI21 dual positive model:
4.81
− 20(ΚΩ)
∆Vo
7.893
Radj , down =
− 23.85(ΚΩ)
∆Vo
Radj , up =
Where: Vo is the desired output voltage (+3.3V output)
∆Vo=ǀ Vo − Vonomǀ
To give an example of the above calculation, to set a voltage of 3.3Vdc
using MAI dual positive model, Radj,up is given by:
∆Vo=ǀ 3.465 − 3.3ǀ=0.16Vdc
Radj , up =
6.10 Output Capacitance
The MAI21 series converters provide unconditional stability with or
without external capacitors. For good transient response low ESR output
capacitors should be located close to the point of load. For high current
applications point has already been made in layout considerations for
low resistance and low inductance tracks. Output capacitors with its
associated ESR values have an impact on loop stability and bandwidth.
Powerbox converters are designed to work with load capacitance up-to
1000uF per amp. The maximum capacitance refer section 4 technical
specifications.
7. Safety & EMC
+3.3V Output
-Vin
Output test BNC at 50mm to 75mm(2” to 3”) from the module
C1 ： 0.1uF ceramic capacitor
Output Voltage Ripple and Noise Measurement Set-Up
4.811
− 20=9.16(ΚΩ)
0.165
7.1 Input Fusing and Safety Considerations
The MAI21 series converters have not an internal fuse. However, to
achieve maximum safety and system protection, always use an input
line fuse. We recommended a time delay fuse 8A for 12Vin models
4A for 24Vin models, and 2A for 48Vin models. The circuit as below is
recommended by a Transient Voltage Suppressor diode across the input
terminal to protect the unit against surge or spike voltage and input
reverse voltage.
FUSE
+Vin
+
Vin
-
+Vo
TVS
R-Load
-Vin
-Vo
Input Protection Circuit
Connect it between TRIM pin to +3.3V Return pin.
www.prbx.com
19
POWERBOX Industrial Line
MAI21 Series
40W 2:1 Single, Dual and Triple Output
DC/DC Converter
Manual V10
7.2 EMC Considerations
The figure shows a suggested configuration to meet the conducted
emission limits of EN55022 Class A and class B.
+Vin +Vo
+Vi
C1
L1
Note :
47uF/25V KY,22uF/50V KY, 22uF/50V KY,100uF/50V KY,
47uF/100V KY,
330uF/25V KY and 10uF/100V KMF Aluminum capacitors are made by
NIPPON CHEMI-CON.
+Vo
C2
-Vi
-Vin
-Vo
-Vo
Suggested Configuration for EN55022 Class A and Class B
Recommended component value for EN55022 Class A
Model No.
MAI 21 009
MAI 21 012
MAI 21 015
MAI 21 030
MAI 21 036
MAI 21 039
MAI 21 042
MAI 21 010
MAI 21 013
MAI 21 016
MAI 21 031
MAI 21 037
MAI 21 040
MAI 21 043
MAI 21 011
MAI 21 014
MAI 21 017
MAI 21 032
MAI 21 038
MAI 21 041
MAI 21 044
MAI 21 045 MAI 21 048 MAI 21 051 MAI 21 054 MAI 21 046 MAI 21 049 MAI 21 052 MAI 21 055 MAI 21 047 MAI 21 050 MAI 21 053 MAI 21 056 www.prbx.com
C1
47uF/25V KY 47uF/25V KY 47uF/25V KY 47uF/25V KY 47uF/25V KY 47uF/25V KY 47uF/25V KY NC NC NC NC NC
22uF/50V KY 22uF/50V KY NC NC NC NC NC 10uF/100V KMF
10uF/100V KMF 330uF/25V KY 330uF/25V KY 330uF/25V KY 330uF/25V KY NC 47uF/50V KY 47uF/50V KY 100uF/50V KY NC NC NC NC C2
L1
NC 8uH
NC 8uH
NC 8uH
NC 8uH
NC 8uH
NC 8uH
NC 8uH
100uF/50V KY SHORT
100uF/50V KY SHORT
100uF/50V KY SHORT
100uF/50V KY SHORT
100uF/50V KY SHORT
NC 8uH
NC 8uH
47uF/100V KY SHORT
47uF/100V KY SHORT
47uF/100V KY SHORT
47uF/100V KY SHORT
47uF/100V KY SHORT
NC 8uH
NC 8u
1210 10uF/25V X7R SHORT
1210 10uF/25V X7R SHORT
1210 10uF/25V X7R SHORT
1210 10uF/25V X7R SHORT
NC SHORT
NC SHORT
NC SHORT
NC SHORT
NC SHORT
NC SHORT
NC SHORT
NC SHORT
Conducted Emission of EN55022 class A for MAI 21 015
Conducted Emission of EN55022 class A for MAI 21 041
20
POWERBOX Industrial Line
MAI21 Series
40W 2:1 Single, Dual and Triple Output
DC/DC Converter
Manual V10
Recommended component value for EN55022 Class B
Model No.
MAI 21 009 MAI 21 012
MAI 21 015
MAI 21 030
MAI 21 036
MAI 21 010
MAI 21 013
MAI 21 016
MAI 21 031 MAI 21 037 MAI 21 011
MAI 21 014
MAI 21 017
MAI 21 032 MAI 21 038
MAI 21 045 MAI 21 048 MAI 21 051 MAI 21 054 MAI 21 047 MAI 21 050 MAI 21 053
MAI 21 056 MAI 21 047 MAI 21 050 MAI 21 053 MAI 21 056 C1
47uF/25V KY 47uF/25V KY 47uF/25V KY 47uF/25V KY 47uF/25V KY 22uF/50V KY 22uF/50V KY 22uF/50V KY 22uF/50V KY 22uF/50V KY 10uF/100V KMF 10uF/100V KMF 10uF/100V KMF 10uF/100V KMF
10uF/100V KMF 47uF/25V KY 47uF/25V KY 47uF/25V KY 47uF/25V KY 22uF/50V KY 22uF/50V KY 22uF/50V KY 22uF/50V KY 10uF/100V KMF 10uF/100V KMF 10uF/100V KMF 10uF/100V KMF C2
47uF/25V KY 47uF/25V KY 47uF/25V KY 47uF/25V KY 47uF/25V KY 22uF/50V KY 22uF/50V KY 22uF/50V KY 22uF/50V KY 22uF/50V KY 10uF/100V KMF 10uF/100V KMF 10uF/100V KMF 10uF/100V KMF 10uF/100V KMF NC NC NC NC NC NC NC NC NC NC NC NC L1
8uH
8uH
8uH
8uH
8uH
8uH
8uH
8uH
8uH
8uH
8uH
8uH
8uH
8uH
8uH
8uH
8uH
8uH
8uH
8uH
8uH
8uH
8uH
8uH
8uH
8uH
8uH
Conducted Emission of EN55022 class B for MAI 21 015
Conducted Emission of EN55022 class B for MAI 21 031
Conducted Emission of EN55022 class B for MAI 21 038
Conducted Emission of EN55022 class B for MAI 21 050
www.prbx.com
21
POWERBOX Industrial Line
MAI21 Series
40W 2:1 Single, Dual and Triple Output
DC/DC Converter
Manual V10
8. Mechanical Specifications
8.1 Mechanical Outline Diagrams
4
5
6 7
8 9
BOTTOM VIEW
1
2
3
Pi n
1
2
3
4
5
6
7
8
9
Single
+Vin
- Vin
ON / OFF
NC
- Sense
+Sense
+Vout
- Vout
Trim
PIN CONNECTION
Du a l
+Vin
- Vin
ON / OFF
No Pin
+Vout
Common
Common
- Vout
Trim
Dual Positive
+Vin
- Vin
ON / OFF
+3.3Vout
Com(3.3V RTN)
Trim
NC
+5Vout
Com(5V RTN)
Triple
+Vin
- Vin
ON / OFF
+Aux. Out
Common
- Aux. Out
+Vout
- Vout (Common)
NC
*NC : NO CONNECTION WITH PIN
All Dimensions In Inches[mm]
Tolerances
Inches:X.XX= ±0.0 ,X.XXX= ±0.010
Millimeters:X.X= ±0.5,X.XX= ±0.25
Pin Diameter : 1.0±0.05mm
www.prbx.com
2016.07.05
22