04 Yp 2 Tey 7 Lriarh 9 U 0 y 70 Zhwxecy
04 Yp 2 Tey 7 Lriarh 9 U 0 y 70 Zhwxecy
04 Yp 2 Tey 7 Lriarh 9 U 0 y 70 Zhwxecy
LM2594/LM2594HV SIMPLE SWITCHER Power Converter 150 kHz 0.5A Step-Down Voltage
December 1999
LM2594/LM2594HV
SIMPLE SWITCHER ® Power Converter 150 kHz 0.5A
Step-Down Voltage Regulator
General Description The LM2594HV is for applications requiring an input voltage
up to 60V.
The LM2594/LM2594HV series of regulators are monolithic
integrated circuits that provide all the active functions for a
step-down (buck) switching regulator, capable of driving a Features
0.5A load with excellent line and load regulation. These de- n 3.3V, 5V, 12V, and adjustable output versions
vices are available in fixed output voltages of 3.3V, 5V, 12V, n Adjustable version output voltage range, 1.2V to 37V
and an adjustable output version, and are packaged in a (57V for the HV version) ± 4% max over line and load
8-lead DIP and a 8-lead surface mount package. conditions
Requiring a minimum number of external components, these n Available in 8-pin surface mount and DIP-8 package
regulators are simple to use and feature internal frequency n Guaranteed 0.5A output current
compensation†, a fixed-frequency oscillator, and improved n Input voltage range up to 60V
line and load regulation specifications. n Requires only 4 external components
The LM2594/LM2594HV series operates at a switching fre- n 150 kHz fixed frequency internal oscillator
quency of 150 kHz thus allowing smaller sized filter compo- n TTL Shutdown capability
nents than what would be needed with lower frequency n Low power standby mode, IQ typically 85 µA
switching regulators. Because of its high efficiency, the cop-
n High Efficiency
per traces on the printed circuit board are normally the only
n Uses readily available standard inductors
heat sinking needed.
n Thermal shutdown and current limit protection
A standard series of inductors (both through hole and sur-
face mount types) are available from several different manu-
facturers optimized for use with the LM2594/LM2594HV se- Applications
ries. This feature greatly simplifies the design of n Simple high-efficiency step-down (buck) regulator
switch-mode power supplies. n Efficient pre-regulator for linear regulators
Other features include a guaranteed ± 4% tolerance on out- n On-card switching regulators
put voltage under all conditions of input voltage and output n Positive to Negative convertor
load conditions, and ± 15% on the oscillator frequency. Ex-
ternal shutdown is included, featuring typically 85 µA
standby current. Self protection features include a two stage
frequency reducing current limit for the output switch and an
over temperature shutdown for complete protection under
fault conditions.
DS012439-1
SIMPLE SWITCHER and Switchers Made Simple™ are registered trademarks of National Semiconductor Corporation.
DS012439-2
www.national.com 2
LM2594/LM2594HV
Absolute Maximum Ratings (Note 1) Human Body Model (Note 2) 2 kV
If Military/Aerospace specified devices are required, Lead Temperature
please contact the National Semiconductor Sales Office/ M8 Package
Distributors for availability and specifications. Vapor Phase (60 sec.) +215˚C
Maximum Supply Voltage Infrared (15 sec.) +220˚C
LM2594 45V N Package (Soldering, 10 sec.) +260˚C
LM2594HV 60V Maximum Junction Temperature +150˚C
ON /OFF Pin Input Voltage −0.3 ≤ V ≤ +25V
Feedback Pin Voltage −0.3 ≤ V ≤+25V Operating Conditions
Output Voltage to Ground Temperature Range −40˚C ≤ TJ +125˚C
(Steady State) −1V
Supply Voltage
Power Dissipation Internally limited
LM2594 4.5V to 40V
Storage Temperature Range −65˚C to +150˚C
LM2594HV 4.5V to 60V
ESD Susceptibility
LM2594/LM2594HV-3.3
Electrical Characteristics
Specifications with standard type face are for TJ = 25˚C, and those with boldface type apply over full Operating Tempera-
ture Range.VINmax = 40V for the LM2594 and 60V for the LM2594HV.
Symbol Parameter Conditions LM2594/LM2594HV-3.3 Units
Typ Limit (Limits)
(Note 3) (Note 4)
SYSTEM PARAMETERS (Note 5) Test Circuit Figure 1
VOUT Output Voltage 4.75V ≤ VIN ≤ VINmax, 0.1A ≤ ILOAD ≤ 0.5A 3.3 V
3.168/3.135 V(min)
3.432/3.465 V(max)
η Efficiency VIN = 12V, ILOAD = 0.5A 80 %
LM2594/LM2594HV-5.0
Electrical Characteristics
Specifications with standard type face are for TJ = 25˚C, and those with boldface type apply over full Operating Tempera-
ture Range
Symbol Parameter Conditions LM2594/LM2594HV-5.0 Units
Typ Limit (Limits)
(Note 3) (Note 4)
SYSTEM PARAMETERS (Note 5) Test Circuit Figure 1
VOUT Output Voltage 7V ≤ VIN ≤ VINmax, 0.1A ≤ ILOAD ≤ 0.5A 5.0 V
4.800/4.750 V(min)
5.200/5.250 V(max)
η Efficiency VIN = 12V, ILOAD = 0.5A 82 %
LM2594/LM2594HV-12
Electrical Characteristics
Specifications with standard type face are for TJ = 25˚C, and those with boldface type apply over full Operating Tempera-
ture Range
Symbol Parameter Conditions LM2594/LM2594HV-12 Units
Typ Limit (Limits)
(Note 3) (Note 4)
SYSTEM PARAMETERS (Note 5) Test Circuit Figure 1
VOUT Output Voltage 15V ≤ VIN ≤ VINmax, 0.1A ≤ ILOAD ≤ 0.5A 12.0 V
11.52/11.40 V(min)
12.48/12.60 V(max)
η Efficiency VIN = 25V, ILOAD = 0.5A 88 %
3 www.national.com
LM2594/LM2594HV
LM2594/LM2594HV-ADJ
Electrical Characteristics
Specifications with standard type face are for TJ = 25˚C, and those with boldface type apply over full Operating Tempera-
ture Range
Symbol Parameter Conditions LM2594/LM2594HV-ADJ Units
Typ Limit (Limits)
(Note 3) (Note 4)
SYSTEM PARAMETERS (Note 5) Test Circuit Figure 1
VFB Feedback Voltage 4.5V ≤ VIN ≤ VINmax, 0.1A ≤ ILOAD ≤ 0.5A 1.230 V
VOUT programmed for 3V. Circuit of Figure 1 1.193/1.180 V(min)
1.267/1.280 V(max)
η Efficiency VIN = 12V, ILOAD = 0.5A 80 %
www.national.com 4
LM2594/LM2594HV
All Output Voltage Versions
Electrical Characteristics (Continued)
Note 2: The human body model is a 100 pF capacitor discharged through a 1.5k resistor into each pin.
Note 3: Typical numbers are at 25˚C and represent the most likely norm.
Note 4: All limits guaranteed at room temperature (standard type face) and at temperature extremes (bold type face). All room temperature limits are 100% produc-
tion tested. All limits at temperature extremes are guaranteed via correlation using standard Statistical Quality Control (SQC) methods. All limits are used to calculate
Average Outgoing Quality Level (AOQL).
Note 5: External components such as the catch diode, inductor, input and output capacitors, and voltage programming resistors can affect switching regulator sys-
tem performance. When the LM2594/LM2594HV is used as shown in the Figure 1 test circuit, system performance will be as shown in system parameters section
of Electrical Characteristics.
Note 6: The switching frequency is reduced when the second stage current limit is activated. The amount of reduction is determined by the severity of current over-
load.
Note 7: No diode, inductor or capacitor connected to output pin.
Note 8: Feedback pin removed from output and connected to 0V to force the output transistor switch ON.
Note 9: Feedback pin removed from output and connected to 12V for the 3.3V, 5V, and the ADJ. version, and 15V for the 12V version, to force the output transistor
switch OFF.
Note 10: VIN = 40V for the LM2594 and 60V for the LM2594HV.
Note 11: Junction to ambient thermal resistance with approximately 1 square inch of printed circuit board copper surrounding the leads. Additional copper area will
lower thermal resistance further. See application hints in this data sheet and the thermal model in Switchers Made Simple ® software.
DS012439-5 DS012439-6
DS012439-4
DS012439-8 DS012439-9
DS012439-7
5 www.national.com
LM2594/LM2594HV
Typical Performance Characteristics (Continued)
DS012439-10
DS012439-11 DS012439-12
DS012439-15
DS012439-13 DS012439-14
Feedback Pin
Bias Current
DS012439-16
www.national.com 6
LM2594/LM2594HV
Typical Performance Characteristics
Continuous Mode Switching Waveforms
VIN = 20V, VOUT = 5V, ILOAD = 400 mA Discontinuous Mode Switching Waveforms
L = 100 µH, COUT = 120 µF, COUT ESR = 140 mΩ VIN = 20V, VOUT = 5V, ILOAD = 200 mA
L = 33 µH, COUT = 220 µF, COUT ESR = 60 mΩ
DS012439-17
DS012439-18
A: Output Pin Voltage, 10V/div.
B: Inductor Current 0.2A/div. A: Output Pin Voltage, 10V/div.
C: Output Ripple Voltage, 20 mV/div. B: Inductor Current 0.2A/div.
C: Output Ripple Voltage, 20 mV/div.
Horizontal Time Base: 2 µs/div.
Horizontal Time Base: 2 µs/div.
DS012439-20
DS012439-19
A: Output Voltage, 50 mV/div. (AC)
A: Output Voltage, 50 mV/div. (AC) B: 100 mA to 200 mA Load Pulse
B: 200 mA to 500 mA Load Pulse
Horizontal Time Base: 200 µs/div.
Horizontal Time Base: 50 µs/div.
7 www.national.com
LM2594/LM2594HV
Typical Circuit and Layout Guidelines
Fixed Output Voltage Versions
DS012439-22
DS012439-23
www.national.com 8
LM2594/LM2594HV
LM2594/LM2594HV Series Buck Regulator Design Procedure (Fixed
Output)
PROCEDURE (Fixed Output Voltage Version) EXAMPLE (Fixed Output Voltage Version)
Given: Given:
VOUT = Regulated Output Voltage (3.3V, 5V or 12V) VOUT = 5V
VIN(max) = Maximum DC Input Voltage VIN(max) = 12V
ILOAD(max) = Maximum Load Current ILOAD(max) = 0.4A
1. Inductor Selection (L1) 1. Inductor Selection (L1)
A. Select the correct inductor value selection guide from Fig- A. Use the inductor selection guide for the 5V version shown
ures 4, 5 or Figure 6. (Output voltages of 3.3V, 5V, or 12V re- in Figure 5.
spectively.) For all other voltages, see the design procedure B. From the inductor value selection guide shown in Figure 5,
for the adjustable version. the inductance region intersected by the 12V horizontal line
B. From the inductor value selection guide, identify the induc- and the 0.4A vertical line is 100 µH, and the inductor code is
tance region intersected by the Maximum Input Voltage line L20.
and the Maximum Load Current line. Each region is identified C. The inductance value required is 100 µH. From the table
by an inductance value and an inductor code (LXX). in Figure 8, go to the L20 line and choose an inductor part
C. Select an appropriate inductor from the four manufactur- number from any of the four manufacturers shown. (In most
er’s part numbers listed in Figure 8. instance, both through hole and surface mount inductors are
available.)
2. Output Capacitor Selection (COUT) 2. Output Capacitor Selection (COUT)
A. In the majority of applications, low ESR (Equivalent Series A. See section on output capacitors in application infor-
Resistance) electrolytic capacitors between 82 µF and mation section.
220 µF and low ESR solid tantalum capacitors between 15 B. From the quick design component selection table shown
µF and 100 µF provide the best results. This capacitor should in Figure 2, locate the 5V output voltage section. In the load
be located close to the IC using short capacitor leads and current column, choose the load current line that is closest to
short copper traces. Do not use capacitors larger than the current needed in your application, for this example, use
220 µF. the 0.5A line. In the maximum input voltage column, select
For additional information, see section on output capaci- the line that covers the input voltage needed in your applica-
tors in application information section. tion, in this example, use the 15V line. Continuing on this line
B. To simplify the capacitor selection procedure, refer to the are recommended inductors and capacitors that will provide
quick design component selection table shown in Figure 2. the best overall performance.
This table contains different input voltages, output voltages, The capacitor list contains both through hole electrolytic and
and load currents, and lists various inductors and output ca- surface mount tantalum capacitors from four different capaci-
pacitors that will provide the best design solutions. tor manufacturers. It is recommended that both the manufac-
C. The capacitor voltage rating for electrolytic capacitors turers and the manufacturer’s series that are listed in the
should be at least 1.5 times greater than the output voltage, table be used.
and often much higher voltage ratings are needed to satisfy In this example aluminum electrolytic capacitors from several
the low ESR requirements for low output ripple voltage. different manufacturers are available with the range of ESR
D. For computer aided design software, see Switchers Made numbers needed.
Simple version 4.1 or later. 120 µF 25V Panasonic HFQ Series
120 µF 25V Nichicon PL Series
C. For a 5V output, a capacitor voltage rating at least 7.5V or
more is needed. But, in this example, even a low ESR,
switching grade, 120 µF 10V aluminum electrolytic capacitor
would exhibit approximately 400 mΩ of ESR (see the curve
in Figure 14 for the ESR vs voltage rating). This amount of
ESR would result in relatively high output ripple voltage. To
reduce the ripple to 1% of the output voltage, or less, a ca-
pacitor with a higher voltage rating (lower ESR) should be se-
lected. A 16V or 25V capacitor will reduce the ripple voltage
by approximately half.
9 www.national.com
LM2594/LM2594HV
LM2594/LM2594HV Series Buck Regulator Design Procedure (Fixed
Output) (Continued)
PROCEDURE (Fixed Output Voltage Version) EXAMPLE (Fixed Output Voltage Version)
3. Catch Diode Selection (D1) 3. Catch Diode Selection (D1)
A. The catch diode current rating must be at least 1.3 times A. Refer to the table shown in Figure 11. In this example, a
greater than the maximum load current. Also, if the power 1A, 20V, 1N5817 Schottky diode will provide the best perfor-
supply design must withstand a continuous output short, the mance, and will not be overstressed even for a shorted out-
diode should have a current rating equal to the maximum put.
current limit of the LM2594. The most stressful condition for
this diode is an overload or shorted output condition.
B. The reverse voltage rating of the diode should be at least
1.25 times the maximum input voltage.
C. This diode must be fast (short reverse recovery time) and
must be located close to the LM2594 using short leads and
short printed circuit traces. Because of their fast switching
speed and low forward voltage drop, Schottky diodes provide
the best performance and efficiency, and should be the first
choice, especially in low output voltage applications.
Ultra-fast recovery, or High-Efficiency rectifiers also provide
good results. Ultra-fast recovery diodes typically have re-
verse recovery times of 50 ns or less. Rectifiers such as the
1N4001 series are much too slow and should not be used.
4. Input Capacitor (CIN) 4. Input Capacitor (CIN)
A low ESR aluminum or tantalum bypass capacitor is needed The important parameters for the Input capacitor are the in-
between the input pin and ground to prevent large voltage put voltage rating and the RMS current rating. With a nominal
transients from appearing at the input. In addition, the RMS input voltage of 12V, an aluminum electrolytic capacitor with
current rating of the input capacitor should be selected to be a voltage rating greater than 18V (1.5 x VIN) would be
at least 1⁄2 the DC load current. The capacitor manufacturers needed. The next higher capacitor voltage rating is 25V.
data sheet must be checked to assure that this current rating The RMS current rating requirement for the input capacitor in
is not exceeded. The curve shown in Figure 13 shows typical a buck regulator is approximately 1⁄2 the DC load current. In
RMS current ratings for several different aluminum electro- this example, with a 400 mA load, a capacitor with a RMS
lytic capacitor values. current rating of at least 200 mA is needed. The curves
This capacitor should be located close to the IC using short shown in Figure 13 can be used to select an appropriate in-
leads and the voltage rating should be approximately 1.5 put capacitor. From the curves, locate the 25V line and note
times the maximum input voltage. which capacitor values have RMS current ratings greater
If solid tantalum input capacitors are used, it is recom- than 200 mA. Either a 47 µF or 68 µF, 25V capacitor could be
mended that they be surge current tested by the manufac- used.
turer. For a through hole design, a 68 µF/25V electrolytic capacitor
Use caution when using ceramic capacitors for input bypass- (Panasonic HFQ series or Nichicon PL series or equivalent)
ing, because it may cause severe ringing at the VIN pin. would be adequate. Other types or other manufacturers ca-
pacitors can be used provided the RMS ripple current ratings
For additional information, see section on input capaci-
are adequate.
tors in Application Information section.
For surface mount designs, solid tantalum capacitors are
recommended. The TPS series available from AVX, and the
593D series from Sprague are both surge current tested.
www.national.com 10
LM2594/LM2594HV
LM2594/LM2594HV Series Buck Regulator Design Procedure (Fixed
Output) (Continued)
11 www.national.com
LM2594/LM2594HV
LM2594/LM2594HV Series Buck Regulator Design Procedure (Adjustable
Output) (Continued)
PROCEDURE (Adjustable Output Voltage Version) EXAMPLE (Adjustable Output Voltage Version)
1. Programming Output Voltage (Selecting R1 and R2, as 1. Programming Output Voltage (Selecting R1 and R2, as
shown in Figure 1. shown in Figure 1 )
Use the following formula to select the appropriate resistor Select R1 to be 1 kΩ, 1%. Solve for R2.
values.
www.national.com 12
LM2594/LM2594HV
LM2594/LM2594HV Series Buck Regulator Design Procedure (Adjustable
Output) (Continued)
PROCEDURE (Adjustable Output Voltage Version) EXAMPLE (Adjustable Output Voltage Version)
4. Feedforward Capacitor (CFF) (See Figure 1 ) 4. Feedforward Capacitor (CFF)
For output voltages greater than approximately 10V, an addi- The table shown in Figure 3 contains feed forward capacitor
tional capacitor is required. The compensation capacitor is values for various output voltages. In this example, a 1 nF
typically between 50 pF and 10 nF, and is wired in parallel capacitor is needed.
with the output voltage setting resistor, R2. It provides addi-
tional stability for high output voltages, low input-output volt-
ages, and/or very low ESR output capacitors, such as solid
tantalum capacitors.
13 www.national.com
LM2594/LM2594HV
LM2594/LM2594HV Series Buck Regulator Design Procedure (Adjustable
Output) (Continued)
PROCEDURE (Adjustable Output Voltage Version) EXAMPLE (Adjustable Output Voltage Version)
6. Input Capacitor (CIN) 6. Input Capacitor (CIN)
A low ESR aluminum or tantalum bypass capacitor is needed The important parameters for the Input capacitor are the in-
between the input pin and ground to prevent large voltage put voltage rating and the RMS current rating. With a nominal
transients from appearing at the input. In addition, the RMS input voltage of 28V, an aluminum electrolytic aluminum elec-
current rating of the input capacitor should be selected to be trolytic capacitor with a voltage rating greater than 42V (1.5 x
at least 1⁄2 the DC load current. The capacitor manufacturers VIN) would be needed. Since the the next higher capacitor
data sheet must be checked to assure that this current rating voltage rating is 50V, a 50V capacitor should be used. The
is not exceeded. The curve shown in Figure 13 shows typical capacitor voltage rating of (1.5 x VIN) is a conservative guide-
RMS current ratings for several different aluminum electro- line, and can be modified somewhat if desired.
lytic capacitor values. The RMS current rating requirement for the input capacitor of
This capacitor should be located close to the IC using short a buck regulator is approximately 1⁄2 the DC load current. In
leads and the voltage rating should be approximately 1.5 this example, with a 400 mA load, a capacitor with a RMS
times the maximum input voltage. current rating of at least 200 mA is needed.
If solid tantalum input capacitors are used, it is recomended The curves shown in Figure 13 can be used to select an ap-
that they be surge current tested by the manufacturer. propriate input capacitor. From the curves, locate the 50V
Use caution when using ceramic capacitors for input bypass- line and note which capacitor values have RMS current rat-
ing, because it may cause severe ringing at the VIN pin. ings greater than 200 mA. A 47 µF/50V low ESR electrolytic
capacitor capacitor is needed.
For additional information, see section on input capaci-
tors in application information section. For a through hole design, a 47 µF/50V electrolytic capacitor
(Panasonic HFQ series or Nichicon PL series or equivalent)
would be adequate. Other types or other manufacturers ca-
pacitors can be used provided the RMS ripple current ratings
are adequate.
For surface mount designs, solid tantalum capacitors are
recommended. The TPS series available from AVX, and the
593D series from Sprague are both surge current tested.
To further simplify the buck regulator design procedure, Na-
tional Semiconductor is making available computer design
software to be used with the Simple Switcher line ot switch-
ing regulators. Switchers Made Simple (version 4.1 or later)
is available from National’s web site, www.national.com.
www.national.com 14
LM2594/LM2594HV
LM2594/LM2594HV Series Buck Regulator Design Procedure
INDUCTOR VALUE SELECTION GUIDES (For Continuous Mode Operation)
DS012439-24 DS012439-25
DS012439-26
DS012439-27
15 www.national.com
LM2594/LM2594HV
LM2594/LM2594HV Series Buck Regulator Design Procedure (Continued)
Coilcraft Inc. Phone (800) 322-2645 Nichicon Corp. Phone (708) 843-7500
FAX (708) 639-1469 FAX (708) 843-2798
Coilcraft Inc., Europe Phone +44 1236 730 595 Panasonic Phone (714) 373-7857
FAX +44 1236 730 627 FAX (714) 373-7102
Pulse Engineering Inc. Phone (619) 674-8100 AVX Corp. Phone (803) 448-9411
FAX (619) 674-8262 FAX (803) 448-1943
Pulse Engineering Inc., Phone +353 93 24 107 Sprague/Vishay Phone (207) 324-7223
Europe FAX +353 93 24 459 FAX (207) 324-4140
Renco Electronics Inc. Phone (800) 645-5828 FIGURE 10. Capacitor Manufacturers Phone Numbers
FAX (516) 586-5562
Schott Corp. Phone (612) 475-1173
FAX (612) 475-1786
www.national.com 16
LM2594/LM2594HV
LM2594/LM2594HV Series Buck Regulator Design Procedure (Continued)
VR 1A Diodes
Surface Mount Through Hole
Ultra Fast Schot- Ultra Fast
Schottky
tky
Recovery Recovery
20V All of 1N5817 All of these
these
diodes are SR102 diodes are
MBRS130 rated to at 1N5818 rated to at
30V least 60V. SR103 least 60V.
11DQ03
MBRS140 MURS120 1N5819 MUR120
40V 10BQ040 10BF10 SR104 HER101
10MQ040 11DQ04 11DF1
50V MBRS160 SR105
or 10BQ050 MBR150
more 10MQ060 11DQ05
MBRS1100 MBR160
10MQ090 SB160
SGL41-60 11DQ10
SS16
Block Diagram
DS012439-21
FIGURE 12.
17 www.national.com
LM2594/LM2594HV
Application Information (Continued) “Standard” electrolytic capacitors typically have much higher
ESR numbers, lower RMS current ratings and typically have
Feedback — Senses the regulated output voltage to com- a shorter operating lifetime.
plete the feedback loop. Because of their small size and excellent performance, sur-
ON /OFF — Allows the switching regulator circuit to be shut face mount solid tantalum capacitors are often used for input
down using logic level signals thus dropping the total input bypassing, but several precautions must be observed. A
supply current to approximately 80 µA. Pulling this pin below small percentage of solid tantalum capacitors can short if the
a threshold voltage of approximately 1.3V turns the regulator inrush current rating is exceeded. This can happen at turn on
on, and pulling this pin above 1.3V (up to a maximum of 25V) when the input voltage is suddenly applied, and of course,
shuts the regulator down. If this shutdown feature is not higher input voltages produce higher inrush currents. Sev-
needed, the ON /OFF pin can be wired to the ground pin or eral capacitor manufacturers do a 100% surge current test-
it can be left open, in either case the regulator will be in the ing on their products to minimize this potential problem. If
ON condition. high turn on currents are expected, it may be necessary to
limit this current by adding either some resistance or induc-
EXTERNAL COMPONENTS tance before the tantalum capacitor, or select a higher volt-
CIN — A low ESR aluminum or tantalum bypass capacitor is age capacitor. As with aluminum electrolytic capacitors, the
needed between the input pin and ground pin. It must be lo- RMS ripple current rating must be sized to the load current.
cated near the regulator using short leads. This capacitor
prevents large voltage transients from appearing at the in-
put, and provides the instantaneous current needed each
time the switch turns on.
The important parameters for the Input capacitor are the
voltage rating and the RMS current rating. Because of the
relatively high RMS currents flowing in a buck regulator’s in-
put capacitor, this capacitor should be chosen for its RMS
current rating rather than its capacitance or voltage ratings,
although the capacitance value and voltage rating are di-
rectly related to the RMS current rating.
The RMS current rating of a capacitor could be viewed as a
capacitor’s power rating. The RMS current flowing through
the capacitors internal ESR produces power which causes
the internal temperature of the capacitor to rise. The RMS
current rating of a capacitor is determined by the amount of
current required to raise the internal temperature approxi- DS012439-28
mately 10˚C above an ambient temperature of 105˚C. The
FIGURE 13. RMS Current Ratings for Low ESR
ability of the capacitor to dissipate this heat to the surround-
Electrolytic Capacitors (Typical)
ing air will determine the amount of current the capacitor can
safely sustain. Capacitors that are physically large and have
a large surface area will typically have higher RMS current OUTPUT CAPACITOR
ratings. For a given capacitor value, a higher voltage electro-
COUT — An output capacitor is required to filter the output
lytic capacitor will be physically larger than a lower voltage
and provide regulator loop stability. Low impedance or low
capacitor, and thus be able to dissipate more heat to the sur-
ESR Electrolytic or solid tantalum capacitors designed for
rounding air, and therefore will have a higher RMS current
switching regulator applications must be used. When select-
rating.
ing an output capacitor, the important capacitor parameters
The consequences of operating an electrolytic capacitor are; the 100 kHz Equivalent Series Resistance (ESR), the
above the RMS current rating is a shortened operating life. RMS ripple current rating, voltage rating, and capacitance
The higher temperature speeds up the evaporation of the ca- value. For the output capacitor, the ESR value is the most
pacitor’s electrolyte, resulting in eventual failure. important parameter.
Selecting an input capacitor requires consulting the manu- The output capacitor requires an ESR value that has an up-
facturers data sheet for maximum allowable RMS ripple cur- per and lower limit. For low output ripple voltage, a low ESR
rent. For a maximum ambient temperature of 40˚C, a gen- value is needed. This value is determined by the maximum
eral guideline would be to select a capacitor with a ripple allowable output ripple voltage, typically 1% to 2% of the out-
current rating of approximately 50% of the DC load current. put voltage. But if the selected capacitor’s ESR is extremely
For ambient temperatures up to 70˚C, a current rating of low, there is a possibility of an unstable feedback loop, re-
75% of the DC load current would be a good choice for a sulting in an oscillation at the output. Using the capacitors
conservative design. The capacitor voltage rating must be at listed in the tables, or similar types, will provide design solu-
least 1.25 times greater than the maximum input voltage, tions under all conditions.
and often a much higher voltage capacitor is needed to sat-
If very low output ripple voltage (less than 15 mV) is re-
isfy the RMS current requirements.
quired, refer to the section on Output Voltage Ripple and
A graph shown in Figure 13 shows the relationship between Transients for a post ripple filter.
an electrolytic capacitor value, its voltage rating, and the An aluminum electrolytic capacitor’s ESR value is related to
RMS current it is rated for. These curves were obtained from the capacitance value and its voltage rating. In most cases,
the Nichicon “PL” series of low ESR, high reliability electro- Higher voltage electrolytic capacitors have lower ESR values
lytic capacitors designed for switching regulator applications.
Other capacitor manufacturers offer similar types of capaci-
tors, but always check the capacitor data sheet.
www.national.com 18
LM2594/LM2594HV
Application Information (Continued)
INDUCTOR SELECTION
All switching regulators have two basic modes of operation;
continuous and discontinuous. The difference between the
two types relates to the inductor current, whether it is flowing
continuously, or if it drops to zero for a period of time in the
normal switching cycle. Each mode has distinctively different
operating characteristics, which can affect the regulators
performance and requirements. Most switcher designs will
operate in the discontinuous mode when the load current is
low.
The LM2594 (or any of the Simple Switcher family) can be
used for both continuous or discontinuous modes of opera-
tion.
In many cases the preferred mode of operation is the con-
DS012439-29
tinuous mode. It offers greater output power, lower peak
FIGURE 14. Capacitor ESR vs Capacitor Voltage Rating switch, inductor and diode currents, and can have lower out-
(Typical Low ESR Electrolytic Capacitor) put ripple voltage. But it does require larger inductor values
to keep the inductor current flowing continuously, especially
at low output load currents and/or high input voltages.
CATCH DIODE
To simplify the inductor selection process, an inductor selec-
Buck regulators require a diode to provide a return path for tion guide (nomograph) was designed (see Figure 4 through
the inductor current when the switch turns off. This must be Figure 7 ). This guide assumes that the regulator is operating
a fast diode and must be located close to the LM2594 using in the continuous mode, and selects an inductor that will al-
short leads and short printed circuit traces. low a peak-to-peak inductor ripple current to be a certain
Because of their very fast switching speed and low forward percentage of the maximum design load current. This
voltage drop, Schottky diodes provide the best performance, peak-to-peak inductor ripple current percentage is not fixed,
especially in low output voltage applications (5V and lower). but is allowed to change as different design load currents are
Ultra-fast recovery, or High-Efficiency rectifiers are also a selected. (See Figure 16.)
good choice, but some types with an abrupt turnoff charac-
teristic may cause instability or EMI problems. Ultra-fast re-
covery diodes typically have reverse recovery times of 50 ns
or less. Rectifiers such as the 1N4001 series are much too
slow and should not be used.
19 www.national.com
LM2594/LM2594HV
Application Information (Continued) may be a better choice. It would use an inductor that would
be physically smaller, and would need only one half to one
third the inductance value needed for a continuous mode de-
sign. The peak switch and inductor currents will be higher in
a discontinuous design, but at these low load currents
(200 mA and below), the maximum switch current will still be
less than the switch current limit.
Discontinuous operation can have voltage waveforms that
are considerable different than a continuous design. The out-
put pin (switch) waveform can have some damped sinusoi-
dal ringing present. (See photo titled; Discontinuous Mode
Switching Waveforms) This ringing is normal for discontinu-
ous operation, and is not caused by feedback loop instabili-
ties. In discontinuous operation, there is a period of time
where neither the switch or the diode are conducting, and
the inductor current has dropped to zero. During this time, a
small amount of energy can circulate between the inductor
and the switch/diode parasitic capacitance causing this char-
DS012439-31
acteristic ringing. Normally this ringing is not a problem, un-
FIGURE 16. (∆IIND) Peak-to-Peak less the amplitude becomes great enough to exceed the in-
Inductor Ripple Current put voltage, and even then, there is very little energy present
(as a Percentage of the Load Current) vs Load Current to cause damage.
By allowing the percentage of inductor ripple current to in- Different inductor types and/or core materials produce differ-
crease for low load currents, the inductor value and size can ent amounts of this characteristic ringing. Ferrite core induc-
be kept relatively low. tors have very little core loss and therefore produce the most
ringing. The higher core loss of powdered iron inductors pro-
When operating in the continuous mode, the inductor current
duce less ringing. If desired, a series RC could be placed in
waveform ranges from a triangular to a sawtooth type of
parallel with the inductor to dampen the ringing. The com-
waveform (depending on the input voltage), with the average
puter aided design software Switchers Made Simple (ver-
value of this current waveform equal to the DC output load
current. sion 4.1) will provide all component values for continuous
and discontinuous modes of operation.
Inductors are available in different styles such as pot core,
toroid, E-core, bobbin core, etc., as well as different core ma-
terials, such as ferrites and powdered iron. The least expen-
sive, the bobbin, rod or stick core, consists of wire wrapped
on a ferrite bobbin. This type of construction makes for a in-
expensive inductor, but since the magnetic flux is not com-
pletely contained within the core, it generates more
Electro-Magnetic Interference (EMl). This magnetic flux can
induce voltages into nearby printed circuit traces, thus caus-
ing problems with both the switching regulator operation and
nearby sensitive circuitry, and can give incorrect scope read-
ings because of induced voltages in the scope probe. Also
see section on Open Core Inductors.
The inductors listed in the selection chart include ferrite
DS012439-32
E-core construction for Schott, ferrite bobbin core for Renco
and Coilcraft, and powdered iron toroid for Pulse Engineer- FIGURE 17. Post Ripple Filter Waveform
ing.
Exceeding an inductor’s maximum current rating may cause OUTPUT VOLTAGE RIPPLE AND TRANSIENTS
the inductor to overheat because of the copper wire losses, The output voltage of a switching power supply operating in
or the core may saturate. If the inductor begins to saturate, the continuous mode will contain a sawtooth ripple voltage at
the inductance decreases rapidly and the inductor begins to the switcher frequency, and may also contain short voltage
look mainly resistive (the DC resistance of the winding). This spikes at the peaks of the sawtooth waveform.
can cause the switch current to rise very rapidly and force
The output ripple voltage is a function of the inductor saw-
the switch into a cycle-by-cycle current limit, thus reducing
tooth ripple current and the ESR of the output capacitor. A
the DC output load current. This can also result in overheat-
typical output ripple voltage can range from approximately
ing of the inductor and/or the LM2594. Different inductor
0.5% to 3% of the output voltage. To obtain low ripple volt-
types have different saturation characteristics, and this
age, the ESR of the output capacitor must be low, however,
should be kept in mind when selecting an inductor.
caution must be exercised when using extremely low ESR
The inductor manufacturers data sheets include current and capacitors because they can affect the loop stability, result-
energy limits to avoid inductor saturation. ing in oscillation problems. If very low output ripple voltage is
needed (less than 15 mV), a post ripple filter is recom-
DISCONTINUOUS MODE OPERATION mended. (See Figure 1.) The inductance required is typically
The selection guide chooses inductor values suitable for between 1 µH and 5 µH, with low DC resistance, to maintain
continuous mode operation, but for low current applications good load regulation. A low ESR output filter capacitor is also
and/or high input voltages, a discontinuous mode design required to assure good dynamic load response and ripple
www.national.com 20
LM2594/LM2594HV
Application Information (Continued) nomographs shown in Figure 4 through Figure 7 are used to
select an inductor value, the peak-to-peak inductor ripple
reduction. The ESR of this capacitor may be as low as de- current can immediately be determined. The curve shown in
sired, because it is out of the regulator feedback loop. The Figure 18 shows the range of (∆IIND) that can be expected
photo shown in Figure 17 shows a typical output ripple volt- for different load currents. The curve also shows how the
age, with and without a post ripple filter. peak-to-peak inductor ripple current (∆IIND) changes as you
When observing output ripple with a scope, it is essential go from the lower border to the upper border (for a given load
that a short, low inductance scope probe ground connection current) within an inductance region. The upper border rep-
be used. Most scope probe manufacturers provide a special resents a higher input voltage, while the lower border repre-
probe terminator which is soldered onto the regulator board, sents a lower input voltage (see Inductor Selection Guides).
preferable at the output capacitor. This provides a very short These curves are only correct for continuous mode opera-
scope ground thus eliminating the problems associated with tion, and only if the inductor selection guides are used to se-
the 3 inch ground lead normally provided with the probe, and lect the inductor value
provides a much cleaner and more accurate picture of the Consider the following example:
ripple voltage waveform.
VOUT = 5V, maximum load current of 300 mA
The voltage spikes are caused by the fast switching action of
VIN = 15V, nominal, varying between 11V and 20V.
the output switch and the diode, and the parasitic inductance
of the output filter capacitor, and its associated wiring. To The selection guide in Figure 5 shows that the vertical line
minimize these voltage spikes, the output capacitor should for a 0.3A load current, and the horizontal line for the 15V in-
be designed for switching regulator applications, and the put voltage intersect approximately midway between the up-
lead lengths must be kept very short. Wiring inductance, per and lower borders of the 150 µH inductance region. A
stray capacitance, as well as the scope probe used to evalu- 150 µH inductor will allow a peak-to-peak inductor current
ate these transients, all contribute to the amplitude of these (∆IIND) to flow that will be a percentage of the maximum load
spikes. current. Referring to Figure 18, follow the 0.3A line approxi-
mately midway into the inductance region, and read the
When a switching regulator is operating in the continuous
peak-to-peak inductor ripple current (∆IIND) on the left hand
mode, the inductor current waveform ranges from a triangu-
axis (approximately 150 mA p-p).
lar to a sawtooth type of waveform (depending on the input
voltage). For a given input and output voltage, the As the input voltage increases to 20V, it approaches the up-
peak-to-peak amplitude of this inductor current waveform re- per border of the inductance region, and the inductor ripple
mains constant. As the load current increases or decreases, current increases. Referring to the curve in Figure 18, it can
the entire sawtooth current waveform also rises and falls. be seen that for a load current of 0.3A, the peak-to-peak in-
The average value (or the center) of this current waveform is ductor ripple current (∆IIND) is 150 mA with 15V in, and can
equal to the DC load current. range from 175 mA at the upper border (20V in) to 120 mA at
the lower border (11V in).
If the load current drops to a low enough level, the bottom of
the sawtooth current waveform will reach zero, and the Once the ∆IIND value is known, the following formulas can be
switcher will smoothly change from a continuous to a discon- used to calculate additional information about the switching
tinuous mode of operation. Most switcher designs (irregard- regulator circuit.
less how large the inductor value is) will be forced to run dis- 1. Peak Inductor or peak switch current
continuous if the output is lightly loaded. This is a perfectly
acceptable mode of operation.
DS012439-33
21 www.national.com
LM2594/LM2594HV
Application Information (Continued) heat also depends on the size, quantity and spacing of other
components on the board. Furthermore, some of these com-
These magnetic lines of flux will induce a voltage into any ponents such as the catch diode will add heat to the PC
wire or PC board copper trace that comes within the induc- board and the heat can vary as the input voltage changes.
tor’s magnetic field. The strength of the magnetic field, the For the inductor, depending on the physical size, type of core
orientation and location of the PC copper trace to the mag- material and the DC resistance, it could either act as a heat
netic field, and the distance between the copper trace and sink taking heat away from the board, or it could add heat to
the inductor, determine the amount of voltage generated in the board.
the copper trace. Another way of looking at this inductive
coupling is to consider the PC board copper trace as one
turn of a transformer (secondary) with the inductor winding
as the primary. Many millivolts can be generated in a copper
trace located near an open core inductor which can cause
stability problems or high output ripple voltage problems.
If unstable operation is seen, and an open core inductor is
used, it’s possible that the location of the inductor with re-
spect to other PC traces may be the problem. To determine
if this is the problem, temporarily raise the inductor away
from the board by several inches and then check circuit op-
eration. If the circuit now operates correctly, then the mag-
netic flux from the open core inductor is causing the problem.
Substituting a closed core inductor such as a torroid or
E-core will correct the problem, or re-arranging the PC layout
may be necessary. Magnetic flux cutting the IC device
ground trace, feedback trace, or the positive or negative
traces of the output capacitor should be minimized. DS012439-35
THERMAL CONSIDERATIONS
The LM2594/LM2594HV is available in two packages, an
8-pin through hole DIP (N) and an 8-pin surface mount SO-8
(M). Both packages are molded plastic with a copper lead
frame. When the package is soldered to the PC board, the
copper and the board are the heat sink for the LM2594 and
the other heat producing components.
For best thermal performance, wide copper traces should be
used and all ground and unused pins should be soldered to
generous amounts of printed circuit board copper, such as a
ground plane (one exception to this is the output (switch) pin,
which should not have large areas of copper). Large areas of
copper provide the best transfer of heat (lower thermal resis-
tance) to the surrounding air, and even double-sided or mul- DS012439-34
www.national.com 22
LM2594/LM2594HV
Application Information (Continued) DELAYED STARTUP
The circuit in Figure 21 uses the the ON /OFF pin to provide
The curves shown in Figure 19 and Figure 20 show the a time delay between the time the input voltage is applied
LM2594 junction temperature rise above ambient tempera- and the time the output voltage comes up (only the circuitry
ture with a 500 mA load for various input and output volt- pertaining to the delayed start up is shown). As the input volt-
ages. This data was taken with the circuit operating as a age rises, the charging of capacitor C1 pulls the ON /OFF pin
buck switcher with all components mounted on a PC board high, keeping the regulator off. Once the input voltage
to simulate the junction temperature under actual operating reaches its final value and the capacitor stops charging, and
conditions. This curve is typical, and can be used for a quick resistor R2 pulls the ON /OFF pin low, thus allowing the cir-
check on the maximum junction temperature for various con- cuit to start switching. Resistor R1 is included to limit the
ditions, but keep in mind that there are many factors that can maximum voltage applied to the ON /OFF pin (maximum of
affect the junction temperature. 25V), reduces power supply noise sensitivity, and also limits
the capacitor, C1, discharge current. When high input ripple
voltage exists, avoid long delay time, because this ripple can
be coupled into the ON /OFF pin and cause problems.
This delayed startup feature is useful in situations where the
input power source is limited in the amount of current it can
deliver. It allows the input voltage to rise to a higher voltage
before the regulator starts operating. Buck regulators require
less input current at higher input voltages.
DS012439-36
UNDERVOLTAGE LOCKOUT
Some applications require the regulator to remain off until
FIGURE 21. Delayed Startup
the input voltage reaches a predetermined voltage. An und-
ervoltage lockout feature applied to a buck regulator is
shown in Figure 22, while Figure 23 and Figure 24 applies
the same feature to an inverting circuit. The circuit in Figure
23 features a constant threshold voltage for turn on and turn
off (zener voltage plus approximately one volt). If hysteresis
is needed, the circuit in Figure 24 has a turn ON voltage
which is different than the turn OFF voltage. The amount of
hysteresis is approximately equal to the value of the output
voltage. If zener voltages greater than 25V are used, an ad-
ditional 47 kΩ resistor is needed from the ON /OFF pin to the
ground pin to stay within the 25V maximum limit of the ON
DS012439-37 /OFF pin.
FIGURE 22. Undervoltage Lockout
for Buck Regulator INVERTING REGULATOR
The circuit in Figure 25 converts a positive input voltage to a
negative output voltage with a common ground. The circuit
operates by bootstrapping the regulators ground pin to the
negative output voltage, then grounding the feedback pin,
the regulator senses the inverted output voltage and regu-
lates it.
DS012439-38
23 www.national.com
LM2594/LM2594HV
Application Information (Continued)
DS012439-39
DS012439-40
Diode D1 is used to isolate input voltage ripple or noise from FIGURE 26. Inverting Regulator Typical Load Current
coupling through the CIN capacitor to the output, under light
or no load conditions. Also, this diode isolation changes the Because of differences in the operation of the inverting regu-
topology to closley resemble a buck configuration thus pro- lator, the standard design procedure is not used to select the
viding good closed loop stability. A Schottky diode is recom- inductor value. In the majority of designs, a 100 µH, 1A in-
mended for low input voltages, (because of its lower voltage ductor is the best choice. Capacitor selection can also be
drop) but for higher input voltages, a fast recovery diode narrowed down to just a few values. Using the values shown
could be used. in Figure 25 will provide good results in the majority of invert-
Without diode D3, when the input voltage is first applied, the ing designs.
charging current of CIN can pull the output positive by sev- This type of inverting regulator can require relatively large
eral volts for a short period of time. Adding D3 prevents the amounts of input current when starting up, even with light
output from going positive by more than a diode voltage. loads. Input currents as high as the LM2594 current limit (ap-
prox 0.8A) are needed for at least 2 ms or more, until the out-
www.national.com 24
LM2594/LM2594HV
Application Information (Continued) INVERTING REGULATOR SHUTDOWN METHODS
To use the ON /OFF pin in a standard buck configuration is
put reaches its nominal output voltage. The actual time de- simple, pull it below 1.3V ( @25˚C, referenced to ground) to
pends on the output voltage and the size of the output turn regulator ON, pull it above 1.3V to shut the regulator
capacitor. Input power sources that are current limited or OFF. With the inverting configuration, some level shifting is
sources that can not deliver these currents without getting required, because the ground pin of the regulator is no
loaded down, may not work correctly. Because of the rela- longer at ground, but is now setting at the negative output
tively high startup currents required by the inverting topology, voltage level. Two different shutdown methods for inverting
the delayed startup feature (C1, R1 and R2) shown in Figure regulators are shown in Figure 27 and Figure 28.
25 is recommended. By delaying the regulator startup, the
input capacitor is allowed to charge up to a higher voltage
before the switcher begins operating. A portion of the high in-
put current needed for startup is now supplied by the input
capacitor (CIN). For severe start up conditions, the input ca-
pacitor can be made much larger than normal.
DS012439-42
DS012439-43
FIGURE 28. Inverting Regulator Ground Referenced Shutdown using Opto Device
25 www.national.com
LM2594/LM2594HV
Application Information (Continued)
DS012439-44
DS012439-45
www.national.com 26
LM2594/LM2594HV
Physical Dimensions inches (millimeters) unless otherwise noted
27 www.national.com
LM2594/LM2594HV SIMPLE SWITCHER Power Converter 150 kHz 0.5A Step-Down Voltage
Regulator
Physical Dimensions inches (millimeters) unless otherwise noted (Continued)
National does not assume any responsibility for use of any circuitry described, no circuit patent licenses are implied and National reserves the right at any time without notice to change said circuitry and specifications.
This datasheet has been download from:
www.datasheetcatalog.com
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