SNVS074E May   2001  – May 2016 LM2591HV

PRODUCTION DATA.  

  1. 1 Features
  2. 2 Applications
  3. 3 Description
  4. 4 Revision History
  5. 5 Description (continued)
  6. 6 Pin Configuration and Functions
  7. 7 Specifications
    1. 7.1 Absolute Maximum Ratings
    2. 7.2 ESD Ratings
    3. 7.3 Recommended Operating Conditions
    4. 7.4 Thermal Information
    5. 7.5 Electrical Characteristics LM2591HV-3.3
    6. 7.6 Electrical Characteristics LM2591HV-5.0
    7. 7.7 Electrical Characteristics LM2591HV-ADJ
    8. 7.8 Electrical Characteristics All Output Voltage Versions
    9. 7.9 Typical Characteristics
  8. 8 Parameter Measurement Information
    1. 8.1 Test Circuits
  9. 9 Detailed Description
    1. 9.1 Overview
    2. 9.2 Functional Block Diagram
    3. 9.3 Feature Description
      1. 9.3.1 Delayed Start-Up
      2. 9.3.2 Undervoltage Lockout
    4. 9.4 Device Functional Modes
      1. 9.4.1 Shutdown Mode
      2. 9.4.2 Active Mode
  10. 10Application and Implementation
    1. 10.1 Application Information
      1. 10.1.1 Feedforward Capacitor
      2. 10.1.2 Input Capacitor
      3. 10.1.3 Output Capacitor
      4. 10.1.4 Catch Diode
      5. 10.1.5 Inverting Regulator
      6. 10.1.6 Inverting Regulator Shutdown Methods
    2. 10.2 Typical Application
      1. 10.2.1 Design Requirements
      2. 10.2.2 Detailed Design Procedure
        1. 10.2.2.1 Inductor Selection Procedure
      3. 10.2.3 Application Curves
  11. 11Power Supply Recommendations
  12. 12Layout
    1. 12.1 Layout Guidelines
    2. 12.2 Layout Examples
  13. 13Device and Documentation Support
    1. 13.1 Community Resources
    2. 13.2 Trademarks
    3. 13.3 Electrostatic Discharge Caution
    4. 13.4 Glossary
  14. 14Mechanical, Packaging, and Orderable Information

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10 Application and Implementation

NOTE

Information in the following applications sections is not part of the TI component specification, and TI does not warrant its accuracy or completeness. TI’s customers are responsible for determining suitability of components for their purposes. Customers should validate and test their design implementation to confirm system functionality.

10.1 Application Information

10.1.1 Feedforward Capacitor

CFF – A feedforward capacitor, shown across R2 in Test Circuits, is used when the output voltage is greater than 10 V or when COUT has a very low ESR. This capacitor adds lead compensation to the feedback loop and increases the phase margin for better loop stability.

If the output voltage ripple is large (>5% of the nominal output voltage), this ripple can be coupled to the feedback pin through the feedforward capacitor and cause the error comparator to trigger the error flag. In this situation, adding a resistor, RFF, in series with the feedforward capacitor, approximately 3 times R1, will attenuate the ripple voltage at the feedback pin.

10.1.2 Input Capacitor

CIN – A low ESR aluminum or tantalum bypass capacitor is needed between the input pin and ground pin. It must be placed near the regulator using short leads. This capacitor prevents large voltage transients from appearing at the input, 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 input 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 directly related to the RMS current rating. The voltage rating of the capacitor and its RMS ripple current capability must never be exceeded.

10.1.3 Output Capacitor

COUT – An output capacitor is required to filter the output and provide regulator loop stability. Low impedance or low ESR Electrolytic or solid tantalum capacitors designed for switching regulator applications must be used. When selecting an output capacitor, the important capacitor parameters are the 100-kHz Equivalent Series Resistance (ESR), the RMS ripple current rating, voltage rating, and capacitance value. For the output capacitor, the ESR value is the most important parameter. The ESR must generally not be less than 100 mΩ or there will be loop instability. If the ESR is too large, efficiency and output voltage ripple are effected, so ESR must be chosen carefully.

10.1.4 Catch Diode

Buck regulators require a diode to provide a return path for the inductor current when the switch turns off. This must be a fast diode and must be placed close to the LM2591HV using short leads and short printed-circuit traces.

Because of their very fast switching speed and low forward voltage drop, Schottky diodes provide the best performance, especially in low output voltage applications (5 V and lower). Ultra-fast recovery, or high-efficiency rectifiers are also a good choice, but some types with an abrupt turnoff characteristic may cause instability or EMI problems. Ultra-fast recovery diodes typically have reverse recovery times of 50 ns or less. The diode must be chosen for its average/RMS current rating and maximum voltage rating. The voltage rating of the diode must be greater than the DC input voltage (not the output voltage).

10.1.5 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 regulator's ground pin to the negative output voltage, then grounding the feedback pin. The regulator senses and regulates the inverted output voltage.

This example uses the LM2591HV-5.0 to generate a −5-V output, but other output voltages are possible by selecting other output voltage versions, including the adjustable version. Because this regulator topology can produce an output voltage that is either greater than or less than the input voltage, the maximum output current greatly depends on both the input and output voltage.

To determine how much load current is possible before the internal device current limit is reached (and power limiting occurs), the system must be evaluated as a buck-boost configuration rather than as a buck. The peak switch current in amperes, for such a configuration is given as Equation 1:

Equation 1. LM2591HV q_ipeak_nvs074.gif

where

  • L is in μH
  • and f is in Hz
  • The maximum possible load current ILOAD is limited by the requirement that IPEAK ≤ ICLIM

While checking for this, take ICLIM to be the lowest possible current limit value (minimum across tolerance and temperature is 1.2 A for the LM2591HV). Also to account for inductor tolerances, take the minimum value of inductance for L in Equation 1 (typically 20% less than the nominal value). Further, Equation 1 disregards the drop across the switch and the diode. This is equivalent to assuming 100% efficiency, which is never so. Therefore expect IPEAK to be an additional 10% to 20% higher than calculated from Equation 1.

See Application Note AN-1157 (SNVA022) for examples based on positive to negative configuration.

The maximum voltage appearing across the regulator is the absolute sum of the input and output voltage, and this must be limited to a maximum of 60 V. For example, when converting +20 V to −12 V, the regulator would see 32 V between the input pin and ground pin. The LM2591HV has a maximum input voltage spec of 60 V.

Additional diodes are required in this regulator configuration. Diode D1 is used to isolate input voltage ripple or noise from coupling through the CIN capacitor to the output, under light or no load conditions. Also, this diode isolation changes the topology to closely resemble a buck configuration thus providing good closed loop stability. A Schottky diode is recommended for low input voltages, (because of its lower voltage drop) but for higher input voltages, a fast recovery diode could be used.

Without diode D3, when the input voltage is first applied, the charging current of CIN can pull the output positive by several volts for a short period of time. Adding D3 prevents the output from going positive by more than a diode voltage.

LM2591HV 10129339.png
This circuit has hysteresis
Regulator starts switching at VIN= 13 V
Regulator stops switching at VIN= 8 V
Figure 24. Undervoltage Lockout With Hysteresis for Inverting Regulator
LM2591HV 10129340.png
CIN —68-μF, 25-V Tant. Sprague 595D
470 μF/50V Elec. Panasonic HFQ
COUT—47-μF, 20-V Tant. Sprague 595D
220-μF, 25-V Elec. Panasonic HFQ
Figure 25. Inverting −5-V Regulator With Delayed Start-Up

Because of differences in the operation of the inverting regulator, the standard design procedure is not used to select the inductor value. In the majority of designs, a 33-μH, 3-A inductor is the best choice. Capacitor selection can also be narrowed down to just a few values.

This type of inverting regulator can require relatively large amounts of input current when starting up, even with light loads. Input currents as high as the LM2591HV current limit (approx 4 A) are needed for at least 2 ms or more, until the output reaches its nominal output voltage. The actual time depends on the output voltage and the size of the output capacitor. Input power sources that are current-limited or sources that can not deliver these currents without getting loaded down, may not work correctly. Because of the relatively high start-up currents required by the inverting topology, the delayed start-up feature (C1, R1, and R2) shown in Figure 25 is recommended. By delaying the regulator start-up, the input capacitor is allowed to charge up to a higher voltage before the switcher begins operating. A portion of the high input current needed for start-up is now supplied by the input capacitor (CIN). For severe start-up conditions, the input capacitor can be made much larger than normal.

10.1.6 Inverting Regulator Shutdown Methods

Using the ON/OFF pin in a standard buck configuration is simple. To turn the regulator ON, pull the ON/OFF pin below 1.3 V (at 25°C, referenced to ground). To turn regulator OFF, pull the ON/OFF pin above 1.3 V. With the inverting configuration, some level shifting is required, because the ground pin of the regulator is no longer at ground, but is now setting at the negative output voltage level. Two different shutdown methods for inverting regulators are shown in Figure 26 and Figure 27.

LM2591HV 10129342.png Figure 26. Inverting Regulator Ground Referenced Shutdown
LM2591HV 10129386.png Figure 27. Inverting Regulator Ground Referenced Shutdown Using Opto Device

10.2 Typical Application

LM2591HV 10129301.gif Figure 28. Typical Application

10.2.1 Design Requirements

Table 1 lists the parameters for this design example.

Table 1. Example Parameters

PARAMETER EXAMPLE VALUE
Regulated output voltage, VOUT 20 V
Maximum input voltage, VIN(max) 24 V
Maximum load current, ILOAD(max) 1 A
Switching frequency, F Fixed at a nominal 150 kHz

10.2.2 Detailed Design Procedure

10.2.2.1 Inductor Selection Procedure

See Application Note AN-1197 (SNVA038) for detailed information on selecting inductors for buck converters. For a quick-start, the designer may refer to the nomographs provided in Figure 29 to Figure 31. To give designers more options of available inductors, the nomographs provide the required inductance and also the energy in the core expressed in microjoules (µJ), as an alternative to just prescribing custom parts. The following points must be highlighted:

  1. The energy values shown on the nomographs apply to steady operation at the corresponding x-coordinate (rated maximum load current). However, under start-up, without soft start, or a short circuit on the output, the current in the inductor will momentarily or repetitively hit the current limit ICLIM of the device, and this current could be much higher than the rated load, ILOAD. This represents an overload situation, and can cause the inductor to saturate (if it has been designed only to handle the energy of steady operation). However, most types of core structures used for such applications have a large inherent air gap (for example, powdered iron types or ferrite rod inductors), so the inductance does not fall off too sharply under an overload. The device is usually able to protect itself by preventing the current from exceeding ICLIM. However, if the DC input voltage to the regulator is over 40 V, the current can slew up so fast under core saturation that the device may not be able to act fast enough to restrict the current. The current can then rise without limit until the device is destroyed.

    2. NOTE

    To ensure reliability, TI recommends that, if the DC Input Voltage exceeds 40 V, the inductor must be sized to handle an instantaneous current equal to ICLIM without saturating, irrespective of the type of core structure or material
  2. The energy under steady operation is given in Equation 2:
    3. Equation 2. LM2591HV 10129370.gif

    where

    • L is in µH
    • IPEAK is the peak of the inductor current waveform with the regulator delivering ILOAD.

    These are the energy values shown in the nomographs. See Example 1.

  3. The energy under overload is given in Equation 3:
    4. Equation 3. LM2591HV 10129371.gif

    If VIN > 40 V, the inductor must be sized to handle eCLIM instead of the steady energy values. The worst case ICLIM for the LM2591HV is 3 A. The energy rating depends on the inductance. See Example 2.

  4. The nomographs were generated by allowing a greater amount of percentage current ripple in the inductor as the maximum rated load decreases (see Figure 32). This was done to allow smaller inductors to be used at light loads. However, Figure 32 shows only the median value of the current ripple. In reality there may be a great spread around this because the nomographs approximate the exact calculated inductance to standard available values. It is a good idea to refer to AN-1197 (SNVA038) for detailed calculations if a certain maximum inductor current ripple is required for various possible reasons. Also consider the rather wide tolerance on the nominal inductance of commercial inductors.
  5. Figure 31 shows the inductor selection curves for the Adjustable version. The y-axis is 'Et', in Vμsecs. It is the applied volts across the inductor during the ON time of the switch (VIN – VSAT – VOUT) multiplied by the time for which the switch is on in μs. See Example 3.

Example 1: (VIN ≤ 40 V) LM2591HV-5.0, VIN = 24 V, Output 5 V at 0.8 A

  1. A first pass inductor selection is based upon inductance and rated max load current. Choose an inductor with the inductance value indicated by the nomograph (see Figure 30) and a current rating equal to the maximum load current. Therefore, quick-select a 100-μH, 0.8-A inductor (designed for 150-kHz operation) for this application.
  2. Confirm that it is rated to handle 50 μJ (see Figure 30) by either estimating the peak current or by a detailed calculation as shown in AN-1197 (SNVA038). Also, confirm that the losses are acceptable.

Example 2: (VIN > 40 V) LM2591HV-5.0, VIN = 48 V, Output 5 V at 1 A

  1. A first pass inductor selection is based upon inductance and the switch currrent limit. We choose an inductor with the inductance value indicated by the nomograph (Figure 30) and a current rating equal to ICLIM. Therefore, quick-select a 100-μH, 3-A inductor (designed for 150-kHz operation) for this application.
  2. Confirm that it is rated to handle eCLIM by the procedure shown in AN-1197 (SNVA038) and that the losses are acceptable. Here eCLIM is calculated using Equation 4:
    3. Equation 4. LM2591HV 10129372.gif

Example 3: (VIN ≤ 40 V) LM2591HV-ADJ, VIN = 20 V, Output 10 V at 1 A

  1. Because input voltage is less than 40 V, a first pass inductor selection is based upon inductance and rated maximum load current. We choose an inductor with the inductance value indicated by the nomograph Figure 31 and a current rating equal to the maximum load. First, calculate Et for the given application. The duty cycle is calculated with Equation 5:
    2. Equation 5. LM2591HV 10129373.gif

    where

    • VD is the drop across the catch diode (≊ 0.5 V for a Schottky)
    • VSAT the drop across the switch (≊ 1.5 V)

    Substituting in the values gives Equation 6:

    Equation 6. LM2591HV 10129374.gif

    And the switch ON time is calculated with Equation 7:

    Equation 7. LM2591HV 10129375.gif

    where

    • f is the switching frequency in Hz

    So

    Equation 8. LM2591HV 10129376.gif

    Therefore, looking at Figure 29, quick-select a 100-μH, 1-A inductor (designed for 150-kHz operation) for this application.

  2. Confirm that the inductor is rated to handle 100 μJ (see Figure 31) by the procedure shown in AN-1197 (SNVA038) and that the losses are acceptable. (If the DC input voltage is greater than 40 V, consider eCLIM as shown in Example 2).

    3. NOTE

    Take VSAT as 1.5 V which includes an estimated resistive drop across the inductor.

    This completes the simplified inductor selection procedure. See AN-1197 (SNVA038), for more general applications and better optimization.

10.2.3 Application Curves

(For Continuous Mode Operation)
LM2591HV 10129365.png Figure 29. LM2591HV-3.3
LM2591HV 10129367.png Figure 31. LM2591HV-ADJ
LM2591HV 10129366.png Figure 30. LM2591HV-5.0
LM2591HV 10129368.png
Figure 32. Current Ripple Ratio