LM2588 LM2588 SIMPLE SWITCHER 5A Flyback Regulator with Shutdown Literature Number: SNVS117C LM2588 SIMPLE SWITCHER (R) 5A Flyback Regulator with Shutdown General Description Features The LM2588 series of regulators are monolithic integrated circuits specifically designed for flyback, step-up (boost), and forward converter applications. The device is available in 4 different output voltage versions: 3.3V, 5.0V, 12V, and adjustable. Requiring a minimum number of external components, these regulators are cost effective, and simple to use. Included in the datasheet are typical circuits of boost and flyback regulators. Also listed are selector guides for diodes and capacitors and a family of standard inductors and flyback transformers designed to work with these switching regulators. The power switch is a 5.0A NPN device that can stand-off 65V. Protecting the power switch are current and thermal limiting circuits, and an undervoltage lockout circuit. This IC contains an adjustable frequency oscillator that can be programmed up to 200 kHz. The oscillator can also be synchronized with other devices, so that multiple devices can operate at the same switching frequency. Other features include soft start mode to reduce in-rush current during start up, and current mode control for improved rejection of input voltage and output load transients and cycle-by-cycle current limiting. The device also has a shutdown pin, so that it can be turned off externally. An output voltage tolerance of 4%, within specified input voltages and output load conditions, is guaranteed for the power supply system. Requires few external components Family of standard inductors and transformers NPN output switches 5.0A, can stand off 65V Wide input voltage range: 4V to 40V Adjustable switching frequency: 100 kHz to 200 kHz External shutdown capability Draws less than 60 A when shut down Frequency synchronization Current-mode operation for improved transient response, line regulation, and current limit n Internal soft-start function reduces in-rush current during start-up n Output transistor protected by current limit, under voltage lockout, and thermal shutdown n System output voltage tolerance of 4% max over line and load conditions n n n n n n n n n Typical Applications n n n n Flyback regulator Forward converter Multiple-output regulator Simple boost regulator Connection Diagrams Bent, Staggered Leads 7-Lead TO-220 (T) Top View Bent, Staggered Leads 7-Lead TO-220 (T) Side View 01242018 01242017 Order Number LM2588T-3.3, LM2588T-5.0, LM2588T-12 or LM2588T-ADJ See NS Package Number TA07B SIMPLE SWITCHER (R) and Switchers Made Simple (R) (c) 2005 National Semiconductor Corporation are registered trademarks of National Semiconductor Corporation. DS012420 www.national.com LM2588 SIMPLE SWITCHER 5A Flyback Regulator with Shutdown July 2005 LM2588 Connection Diagrams (Continued) 7-Lead TO-263 (S) Top View 7-Lead TO-263 (S) Side View 01242020 01242019 Order Number LM2588S-3.3, LM2588S-5.0, LM2588S-12 or LM2588S-ADJ Tape and Reel Order Number LM2588SX-3.3, LM2588SX-5.0, LM2588SX-12 or LM2588SX-ADJ See NS Package Number TS7B Ordering Information Package Type NSC Package Order Number Drawing 7-Lead TO-220 Bent, Staggered Leads TA07B LM2588T-3.3, LM2588T-5.0, LM2588T-12, LM2588T-ADJ 7-Lead TO-263 TS7B LM2588S-3.3, LM2588S-5.0, LM2588S-12, LM2588S-ADJ 7-Lead TO-263 Tape and Reel TS7B LM2588SX-3.3, LM2588SX-5.0, LM2588SX-12, LM2588SX-ADJ www.national.com 2 Lead Temperature If Military/Aerospace specified devices are required, please contact the National Semiconductor Sales Office/ Distributors for availability and specifications. Maximum Junction Temperature (Soldering, 10 sec.) (Note 3) -0.4V VIN 45V Input Voltage Internally Limited Compensation Pin Voltage -0.4V VCOMP 2.4V 150C Minimum ESD Rating -0.4V VSW 65V Switch Voltage Switch Current (Note 2) 260C (C = 100 pF, R = 1.5 k) 2 kV Operating Ratings 4V VIN 40V Supply Voltage Feedback Pin Voltage -0.4V VFB 2 VOUT Output Switch Voltage 0V VSW 60V ON /OFF Pin Voltage -0.4V VSH 6V Output Switch Current ISW 5.0A -0.4V VSYNC 2V Junction Temperature Range -40C TJ +125C Sync Pin Voltage Power Dissipation (Note 3) Internally Limited Storage Temperature Range -65C to +150C LM2588-3.3 Electrical Characteristics Specifications with standard type face are for TJ = 25C, and those in bold type face apply over full Operating Temperature Range. Unless otherwise specified, VIN = 5V. Symbol Parameters Conditions Typical Min Max Units 3.3 3.17/3.14 3.43/3.46 V 20 50/100 mV 20 50/100 mV SYSTEM PARAMETERS Test Circuit of Figure 1 (Note 4) VOUT Output Voltage VIN = 4V to 12V ILOAD = 400 mA to 1.75A VOUT/ Line Regulation VIN = 4V to 12V Load Regulation VIN = 12V VIN VOUT/ ILOAD = 400 mA ILOAD ILOAD = 400 mA to 1.75A Efficiency VIN = 12V, ILOAD = 1A 75 % UNIQUE DEVICE PARAMETERS (Note 5) VREF VREF Output Reference Measured at Feedback Pin Voltage VCOMP = 1.0V Reference Voltage VIN = 4V to 40V 3.3 3.242/3.234 3.358/3.366 2.0 V mV Line Regulation GM AVOL Error Amp ICOMP = -30 A to +30 A Transconductance VCOMP = 1.0V Error Amp VCOMP = 0.5V to 1.6V Voltage Gain RCOMP = 1.0 M (Note 6) 1.193 0.678 260 151/75 2.259 mmho V/V LM2588-5.0 Electrical Characteristics Specifications with standard type face are for TJ = 25C, and those in bold type face apply over full Operating Temperature Range. Unless otherwise specified, VIN = 5V. Symbol Parameters Conditions Typical Min Max Units 5.0 4.80/4.75 5.20/5.25 V 20 50/100 mV 20 50/100 mV SYSTEM PARAMETERS Test Circuit of Figure 1 (Note 4) VOUT Output Voltage VOUT/ Line Regulation VIN = 4V to 12V ILOAD = 500 mA to 1.45A VIN VOUT/ ILOAD = 500 mA Load Regulation VIN = 12V Efficiency VIN = 12V, ILOAD = 750 mA ILOAD VIN = 4V to 12V ILOAD = 500 mA to 1.45A 80 % UNIQUE DEVICE PARAMETERS (Note 5) 3 www.national.com LM2588 Absolute Maximum Ratings (Note 1) LM2588 LM2588-5.0 Electrical Characteristics (Continued) Specifications with standard type face are for TJ = 25C, and those in bold type face apply over full Operating Temperature Range. Unless otherwise specified, VIN = 5V. Symbol VREF VREF Parameters Output Reference Conditions Measured at Feedback Pin Voltage VCOMP = 1.0V Reference Voltage VIN = 4V to 40V Typical Min Max Units 5.0 4.913/4.900 5.088/5.100 V 3.3 mV Line Regulation GM AVOL Error Amp ICOMP = -30 A to +30 A Transconductance VCOMP = 1.0V Error Amp VCOMP = 0.5V to 1.6V Voltage Gain RCOMP = 1.0 M (Note 6) 0.750 0.447 165 99/49 1.491 mmho V/V LM2588-12 Electrical Characteristics Specifications with standard type face are for TJ = 25C, and those in bold type face apply over full Operating Temperature Range. Unless otherwise specified, VIN = 5V. Symbol Parameters Conditions Typical Min Max Units 12.0 11.52/11.40 12.48/12.60 V 20 100/200 mV 20 100/200 mV SYSTEM PARAMETERS Test Circuit of Figure 2 (Note 4) VOUT Output Voltage VIN = 4V to 10V ILOAD = 300 mA to 1.2A VOUT/ Line Regulation VIN = 4V to 10V Load Regulation VIN = 10V VIN VOUT/ ILOAD = 300 mA ILOAD ILOAD = 300 mA to 1.2A Efficiency VIN = 10V, ILOAD = 1A 90 % UNIQUE DEVICE PARAMETERS (Note 5) VREF VREF Output Reference Measured at Feedback Pin Voltage VCOMP = 1.0V Reference Voltage VIN = 4V to 40V 12.0 11.79/11.76 12.21/12.24 7.8 V mV Line Regulation GM AVOL Error Amp ICOMP = -30 A to +30 A Transconductance VCOMP = 1.0V Error Amp VCOMP = 0.5V to 1.6V Voltage Gain RCOMP = 1.0 M (Note 6) 0.328 0.186 70 41/21 0.621 mmho V/V LM2588-ADJ Electrical Characteristics Specifications with standard type face are for TJ = 25C, and those in bold type face apply over full Operating Temperature Range. Unless otherwise specified, VIN = 5V. Symbol Parameters Conditions Typical Min Max Units 12.0 11.52/11.40 12.48/12.60 V 20 100/200 mV 20 100/200 mV SYSTEM PARAMETERS Test Circuit of Figure 2 (Note 4) VOUT Output Voltage VIN = 4V to 10V ILOAD = 300 mA to 1.2A VOUT/ Line Regulation VIN VOUT/ ILOAD = 300 mA Load Regulation VIN = 10V Efficiency VIN = 10V, ILOAD = 1A ILOAD VIN = 4V to 10V ILOAD = 300 mA to 1.2A www.national.com 90 4 % (Continued) Specifications with standard type face are for TJ = 25C, and those in bold type face apply over full Operating Temperature Range. Unless otherwise specified, VIN = 5V. Symbol Parameters Conditions Typical Min Max Units 1.230 1.208/1.205 1.252/1.255 V UNIQUE DEVICE PARAMETERS (Note 5) VREF VREF Output Reference Measured at Feedback Pin Voltage VCOMP = 1.0V Reference Voltage VIN = 4V to 40V 1.5 mV Line Regulation GM AVOL IB Error Amp ICOMP = -30 A to +30 A Transconductance VCOMP = 1.0V Error Amp VCOMP = 0.5V to 1.6V Voltage Gain RCOMP = 1.0 M (Note 6) Error Amp VCOMP = 1.0V 3.200 1.800 670 400/200 125 6.000 mmho V/V 425/600 nA Input Bias Current All Output Voltage Versions Electrical Characteristics (Note 5) Specifications with standard type face are for TJ = 25C, and those in bold type face apply over full Operating Temperature Range. Unless otherwise specified, VIN = 5V. Symbol IS Parameters Input Supply Current Conditions Typical Max Units 11 15.5/16.5 mA ISWITCH = 3.0A 85 140/165 mA VSH = 3V 16 100/300 A Switch Off Min (Note 8) IS/D Shutdown Input Supply Current VUV Input Supply RLOAD = 100 3.30 3.05 3.75 V 100 85/75 115/125 kHz Undervoltage Lockout fO Oscillator Frequency Measured at Switch Pin RLOAD = 100, VCOMP = 1.0V Freq. Adj. Pin Open (Pin 1) RSET = 22 k fSC Short-Circuit Measured at Switch Pin Frequency RLOAD = 100 200 kHz 25 kHz VFEEDBACK = 1.15V VEAO Error Amplifier Upper Limit Output Swing (Note 7) 2.8 Lower Limit 2.6/2.4 0.25 V 0.40/0.55 V (Note 8) IEAO Error Amp (Note 9) Output Current 165 110/70 260/320 A 11.0 8.0/7.0 17.0/19.0 A 98 93/90 (Source or Sink) ISS Soft Start Current DMAX Maximum Duty Cycle VFEEDBACK = 0.92V VCOMP = 1.0V RLOAD = 100 % (Note 7) IL Switch Leakage Switch Off Current VSWITCH = 60V VSUS Switch Sustaining Voltage dV/dT = 1.5V/ns VSAT Switch Saturation Voltage ISWITCH = 5.0A 15 300/600 65 0.7 5 A V 1.1/1.4 V www.national.com LM2588 LM2588-ADJ Electrical Characteristics LM2588 All Output Voltage Versions Electrical Characteristics (Note 5) (Continued) Specifications with standard type face are for TJ = 25C, and those in bold type face apply over full Operating Temperature Range. Unless otherwise specified, VIN = 5V. Symbol ICL VSTH ISYNC VSHTH ISH JA Parameters Conditions NPN Switch Current Limit Synchronization FSYNC = 200 kHz Threshold Voltage VCOMP = 1V, VIN = 5V Synchronization VIN = 5V Pin Current VCOMP = 1V, VSYNC = VSTH Typical Min Max Units 6.5 5.0 9.5 A 0.75 0.625/0.40 0.875/1.00 V 200 A 100 ON /OFF Pin (Pin 1) VCOMP = 1V Threshold Voltage (Note 10) ON /OFF Pin (Pin 1) VCOMP = 1V Current VSH = VSHTH Thermal Resistance T Package, Junction to Ambient 1.6 1.0/0.8 2.2/2.4 V 40 15/10 65/75 A 65 (Note 11) JA T Package, Junction to Ambient 45 (Note 12) JC T Package, Junction to Case 2 JA S Package, Junction to Ambient 56 C/W (Note 13) JA S Package, Junction to Ambient 35 (Note 14) JA S Package, Junction to Ambient 26 (Note 15) JC S Package, Junction to Case 2 Note 1: Absolute Maximum Ratings indicate limits beyond which damage to the device may occur. These ratings apply when the current is limited to less than 1.2 mA for pins 1, 2, 3, and 6. Operating ratings indicate conditions for which the device is intended to be functional, but device parameter specifications may not be guaranteed under these conditions. For guaranteed specifications and test conditions, see the Electrical Characteristics. Note 2: Note that switch current and output current are not identical in a step-up regulator. Output current cannot be internally limited when the LM2588 is used as a step-up regulator. To prevent damage to the switch, the output current must be externally limited to 5A. However, output current is internally limited when the LM2588 is used as a flyback regulator (see the Application Hints section for more information). Note 3: The junction temperature of the device (TJ) is a function of the ambient temperature (TA), the junction-to-ambient thermal resistance (JA), and the power dissipation of the device (PD). A thermal shutdown will occur if the temperature exceeds the maximum junction temperature of the device: PD x JA + TA(MAX) TJ(MAX). For a safe thermal design, check that the maximum power dissipated by the device is less than: PD [TJ(MAX) - TA(MAX)]/JA. When calculating the maximum allowable power dissipation, derate the maximum junction temperature -- this ensures a margin of safety in the thermal design. Note 4: External components such as the diode, inductor, input and output capacitors can affect switching regulator performance. When the LM2588 is used as shown in Figure 1 and Figure 2, system performance will be as specified by the system parameters. Note 5: All room temperature limits are 100% production tested, and all limits at temperature extremes are guaranteed via correlation using standard Statistical Quality Control (SQC) methods. Note 6: A 1.0 M resistor is connected to the compensation pin (which is the error amplifier output) to ensure accuracy in measuring AVOL. Note 7: To measure this parameter, the feedback voltage is set to a low value, depending on the output version of the device, to force the error amplifier output high and the switch on. Note 8: To measure this parameter, the feedback voltage is set to a high value, depending on the output version of the device, to force the error amplifier output low and the switch off. Note 9: To measure the worst-case error amplifier output current, the LM2588 is tested with the feedback voltage set to its low value (specified in (Note 7)) and at its high value (specified in (Note 8)). Note 10: When testing the minimum value, do not sink current from this pin -- isolate it with a diode. If current is drawn from this pin, the frequency adjust circuit will begin operation (see Figure 41). Note 11: Junction to ambient thermal resistance (no external heat sink) for the 7 lead TO-220 package mounted vertically, with 12 inch leads in a socket, or on a PC board with minimum copper area. Note 12: Junction to ambient thermal resistance (no external heat sink) for the 7 lead TO-220 package mounted vertically, with 12 inch leads soldered to a PC board containing approximately 4 square inches of (1 oz.) copper area surrounding the leads. Note 13: Junction to ambient thermal resistance for the 7 lead TO-263 mounted horizontally against a PC board area of 0.136 square inches (the same size as the TO-263 package) of 1 oz. (0.0014 in. thick) copper. Note 14: Junction to ambient thermal resistance for the 7 lead TO-263 mounted horizontally against a PC board area of 0.4896 square inches (3.6 times the area of the TO-263 package) of 1 oz. (0.0014 in. thick) copper. Note 15: Junction to ambient thermal resistance for the 7 lead TO-263 mounted horizontally against a PC board copper area of 1.0064 square inches (7.4 times the area of the TO-263 package) of 1 oz. (0.0014 in. thick) copper. Additional copper area will reduce thermal resistance further. See the thermal model in Switchers Made Simple (R) software. www.national.com 6 LM2588 Typical Performance Characteristics Supply Current vs Temperature Reference Voltage vs Temperature 01242002 01242003 Reference Voltage vs Supply Voltage Supply Current vs Switch Current 01242004 01242005 Current Limit vs Temperature Feedback Pin Bias Current vs Temperature 01242007 01242006 7 www.national.com LM2588 Typical Performance Characteristics (Continued) Switch Saturation Voltage vs Temperature Switch Transconductance vs Temperature 01242008 01242009 Oscillator Frequency vs Temperature Error Amp Transconductance vs Temperature 01242010 01242011 Error Amp Voltage Gain vs Temperature Short Circuit Frequency vs Temperature 01242012 www.national.com 01242013 8 LM2588 Typical Performance Characteristics (Continued) Shutdown Supply Current vs Temperature ON /OFF Pin Current vs Voltage 01242014 01242015 Oscillator Frequency vs Resistance 01242016 Flyback Regulator 01242001 9 www.national.com LM2588 Test Circuits 01242021 CIN1 -- 100 F, 25V Aluminum ElectrolyticCIN2 -- 0.1 F CeramicT -- 22 H, 1:1 Schott #67141450D -- 1N5820COUT -- 680 F, 16V Aluminum ElectrolyticCC -- 0.47 F CeramicRC -- 2k FIGURE 1. LM2588-3.3 and LM2588-5.0 01242022 CIN1 -- 100 F, 25V Aluminum ElectrolyticCIN2 -- 0.1 F CeramicL -- 15 H, Renco #RL-5472-5D -- 1N5820COUT -- 680 F, 16V Aluminum ElectrolyticCC -- 0.47 F CeramicRC -- 2kFor 12V Devices: R1 = Short (0) andR2 = OpenFor ADJ Devices: R1 = 48.75k, 0.1% andR2 = 5.62k, 0.1% FIGURE 2. LM2588-12 and LM2588-ADJ www.national.com 10 LM2588 Block Diagram 01242023 For Fixed Versions 3.3V, R1 = 3.4k, R2 = 2k5.0V, R1 = 6.15k, R2 = 2k12V, R1 = 8.73k, R2 = 1kFor Adj. VersionR1 = Short (0), R2 = Open FIGURE 3. Block Diagram lapses, reversing the voltage polarity of the primary and secondary windings. Now rectifier D1 is forward biased and current flows through it, releasing the energy stored in the transformer. This produces voltage at the output. The output voltage is controlled by modulating the peak switch current. This is done by feeding back a portion of the output voltage to the error amp, which amplifies the difference between the feedback voltage and a 1.230V reference. The error amp output voltage is compared to a ramp voltage proportional to the switch current (i.e., inductor current during the switch on time). The comparator terminates the switch on time when the two voltages are equal, thereby controlling the peak switch current to maintain a constant output voltage. Flyback Regulator Operation The LM2588 is ideally suited for use in the flyback regulator topology. The flyback regulator can produce a single output voltage, such as the one shown in Figure 4, or multiple output voltages. In Figure 4, the flyback regulator generates an output voltage that is inside the range of the input voltage. This feature is unique to flyback regulators and cannot be duplicated with buck or boost regulators. The operation of a flyback regulator is as follows (refer to Figure 4): when the switch is on, current flows through the primary winding of the transformer, T1, storing energy in the magnetic field of the transformer. Note that the primary and secondary windings are out of phase, so no current flows through the secondary when current flows through the primary. When the switch turns off, the magnetic field col- 11 www.national.com LM2588 Flyback Regulator Operation (Continued) 01242024 As shown in Figure 4, the LM2588 can be used as a flyback regulator by using a minimum number of external components. The switching waveforms of this regulator are shown in Figure 5. Typical Performance Characteristics observed during the operation of this circuit are shown in Figure 6. FIGURE 4. 12V Flyback Regulator Design Example Typical Performance Characteristics 01242060 A: Switch Voltage, 10V/div B: Switch Current, 5A/div C: Output Rectifier Current, 5A/div D: Output Ripple Voltage, 100 mV/div AC-Coupled FIGURE 5. Switching Waveforms www.national.com 12 LM2588 Typical Performance Characteristics (Continued) 01242061 FIGURE 6. VOUT Response to Load Current Step component except the transformer. For the transformer part numbers and manufacturers' names, see the table in Figure 13. For applications with different output voltages -- requiring the LM2588-ADJ -- or different output configurations that do not match the standard configurations, refer to the Switchers Made SimpleTM software. Typical Flyback Regulator Applications Figure 7 through 12 show six typical flyback applications, varying from single output to triple output. Each drawing contains the part number(s) and manufacturer(s) for every 01242025 FIGURE 7. Single-Output Flyback Regulator 13 www.national.com LM2588 Typical Flyback Regulator Applications (Continued) 01242026 FIGURE 8. Single-Output Flyback Regulator 01242027 FIGURE 9. Single-Output Flyback Regulator www.national.com 14 LM2588 Typical Flyback Regulator Applications (Continued) 01242028 FIGURE 10. Dual-Output Flyback Regulator 01242029 FIGURE 11. Dual-Output Flyback Regulator 15 www.national.com LM2588 Typical Flyback Regulator Applications (Continued) 01242030 FIGURE 12. Triple-Output Flyback Regulator TRANSFORMER SELECTION (T) Figure 13 lists the standard transformers available for flyback regulator applications. Included in the table are the turns ratio(s) for each transformer, as well as the output voltages, input voltage ranges, and the maximum load currents for each circuit. Applications Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Transformers T1 T1 T1 T2 T3 T4 18V-36V VIN 4V-6V 4V-6V 8V-16V 4V-6V 18V-36V VOUT1 3.3V 5V 12V 12V 12V 5V IOUT1 (Max) 1.8A 1.4A 1.2A 0.3A 1A 2.5A 1 1 1 0.35 N1 2.5 0.8 VOUT2 -12V -12V 12V IOUT2 (Max) 0.3A 1A 0.5A 2.5 0.8 N2 0.8 VOUT3 -12V IOUT3 (Max) 0.5A N3 0.8 FIGURE 13. Transformer Selection Table www.national.com 16 Transformer Type LM2588 Typical Flyback Regulator Applications (Continued) Manufacturers' Part Numbers Coilcraft Coilcraft (Note 16) Pulse (Note 17) Renco Schott (Note 16) Surface Mount Surface Mount (Note 18) (Note 19) T1 Q4434-B Q4435-B PE-68411 RL-5530 67141450 T2 Q4337-B Q4436-B PE-68412 RL-5531 67140860 T3 Q4343-B -- PE-68421 RL-5534 67140920 T4 Q4344-B -- PE-68422 RL-5535 67140930 Note 16: Coilcraft Inc.,: Phone: (800) 322-2645 1102 Silver Lake Road, Cary, IL 60013: Fax: (708) 639-1469 European Headquarters, 21 Napier Place: Phone: +44 1236 730 595 Wardpark North, Cumbernauld, Scotland G68 0LL: Note 17: Pulse Engineering Inc.,: 12220 World Trade Drive, San Diego, CA 92128: European Headquarters, Dunmore Road: Tuam, Co. Galway, Ireland: Fax: (619) 674-8262 Phone: +353 93 24 107 Fax: +353 93 24 459 Note 18: Renco Electronics Inc.,: Phone: (800) 645-5828 60 Jeffryn Blvd. East, Deer Park, NY 11729: Note 19: Schott Corp.,: Fax: +44 1236 730 627 Phone: (619) 674-8100 Fax: (516) 586-5562 Phone: (612) 475-1173 1000 Parkers Lane Road, Wayzata, MN 55391: Fax: (612) 475-1786 FIGURE 14. Transformer Manufacturer Guide TRANSFORMER FOOTPRINTS Figure 15 through 32 show the footprints of each transformer, listed in Figure 14. T3 T1 01242033 Top View 01242031 Top View FIGURE 17. Coilcraft Q4343-B FIGURE 15. Coilcraft Q4434-B T4 T2 01242032 Top View 01242034 Top View FIGURE 16. Coilcraft Q4337-B FIGURE 18. Coilcraft Q4344-B 17 www.national.com LM2588 Typical Flyback Regulator Applications (Continued) T2 T1 01242038 Top View 01242035 Top View FIGURE 22. Pulse PE-68412 (Surface Mount) FIGURE 19. Coilcraft Q4435-B (Surface Mount) T3 T2 01242039 Top View 01242036 Top View FIGURE 23. Pulse PE-68421 (Surface Mount) FIGURE 20. Coilcraft Q4436-B (Surface Mount) T4 T1 01242040 Top View 01242037 Top View FIGURE 24. Pulse PE-68422 (Surface Mount) FIGURE 21. Pulse PE-68411 (Surface Mount) www.national.com 18 LM2588 Typical Flyback Regulator Applications (Continued) T1 T1 01242045 Top View FIGURE 29. Schott 67141450 01242041 Top View T2 FIGURE 25. Renco RL-5530 T2 01242046 Top View FIGURE 30. Schott 67140860 01242042 Top View T3 FIGURE 26. Renco RL-5531 T3 01242047 Top View FIGURE 31. Schott 67140920 01242043 Top View FIGURE 27. Renco RL-5534 T4 01242044 Top View FIGURE 28. Renco RL-5535 19 www.national.com LM2588 Typical Flyback Regulator Applications (Continued) T4 01242048 Top View FIGURE 32. Schott 67140930 VIN/L, storing energy in the inductor. When the switch turns off, the lower end of the inductor flies above VIN, discharging its current through diode (D) into the output capacitor (COUT) at a rate of (VOUT - VIN)/L. Thus, energy stored in the inductor during the switch on time is transferred to the output during the switch off time. The output voltage is controlled by adjusting the peak switch current, as described in the flyback regulator section. Step-Up (Boost) Regulator Operation Figure 33 shows the LM2588 used as a step-up (boost) regulator. This is a switching regulator that produces an output voltage greater than the input supply voltage. A brief explanation of how the LM2588 Boost Regulator works is as follows (refer to Figure 33). When the NPN switch turns on, the inductor current ramps up at the rate of 01242049 FIGURE 33. 12V Boost Regulator By adding a small number of external components (as shown in Figure 33), the LM2588 can be used to produce a regulated output voltage that is greater than the applied input www.national.com voltage. The switching waveforms observed during the operation of this circuit are shown in Figure 34. Typical performance of this regulator is shown in Figure 35. 20 LM2588 Typical Performance Characteristics 01242062 A: Switch Voltage,10V/div B: Switch Current, 5A/div C: Inductor Current, 5A/div D: Output Ripple Voltage, 100 mV/div, AC-Coupled FIGURE 34. Switching Waveforms 01242063 FIGURE 35. VOUT Response to Load Current Step ber(s) and manufacturer(s) for every component. For the fixed 12V output application, the part numbers and manufacturers' names for the inductor are listed in a table in Figure 37. For applications with different output voltages, refer to the Switchers Made Simplesoftware. Typical Boost Regulator Applications Figure 36 and 38 through 40 show four typical boost applications -- one fixed and three using the adjustable version of the LM2588. Each drawing contains the part num- 21 www.national.com LM2588 Typical Boost Regulator Applications (Continued) 01242050 FIGURE 36. +5V to +12V Boost Regulator Figure 37 contains a table of standard inductors, by part number and corresponding manufacturer, for the fixed output regulator of Figure 36. Note 20: Coilcraft Inc.,: Coilcraft (Note 20) Pulse (Note 21) Renco (Note 22) Schott (Note 23) R4793-A PE-53900 RL-5472-5 67146520 Phone: (800) 322-2645 1102 Silver Lake Road, Cary, IL 60013: Fax: (708) 639-1469 European Headquarters, 21 Napier Place: Phone: +44 1236 730 595 Wardpark North, Cumbernauld, Scotland G68 0LL: Note 21: Pulse Engineering Inc.,: 12220 World Trade Drive, San Diego, CA 92128: European Headquarters, Dunmore Road: Tuam, Co. Galway, Ireland: Fax: (619) 674-8262 Phone: +353 93 24 107 Fax: +353 93 24 459 Note 22: Renco Electronics Inc.,: Phone: (800) 645-5828 60 Jeffryn Blvd. East, Deer Park, NY 11729: Note 23: Schott Corp.,: Fax: +44 1236 730 627 Phone: (619) 674-8100 Fax: (516) 586-5562 Phone: (612) 475-1173 1000 Parkers Lane Road, Wayzata, MN 55391: Fax: (612) 475-1786 FIGURE 37. Inductor Selection Table www.national.com 22 LM2588 Typical Boost Regulator Applications (Continued) 01242051 FIGURE 38. +12V to +24V Boost Regulator 01242052 FIGURE 39. +24V to +36V Boost Regulator 23 www.national.com LM2588 Typical Boost Regulator Applications (Continued) 01242053 *The LM2588 will require a heat sink in these applications. The size of the heat sink will depend on the maximum ambient temperature. To calculate the thermal resistance of the IC and the size of the heat sink needed, see the "Heat Sink/Thermal Considerations" section in the Application Hints. FIGURE 40. +24V to +48V Boost Regulator FREQUENCY ADJUSTMENT The switching frequency of the LM2588 can be adjusted with the use of an external resistor. This feature allows the user to optimize the size of the magnetics and the output capacitor(s) by tailoring the operating frequency. A resistor connected from pin 1 (the Freq. Adj. pin) to ground will set the switching frequency from 100 kHz to 200 kHz (maximum). As shown in Figure 41, the pin can be used to adjust the frequency while still providing the shut down function. A curve in the Performance Characteristics Section graphs the resistor value to the corresponding switching frequency. The table in Figure 42 shows resistor values corresponding to commonly used frequencies. However, changing the LM2588's operating frequency from its nominal value of 100 kHz will change the magnetics selection and compensation component values. Application Hints LM2588 SPECIAL FEATURES 01242054 RSET(k) FIGURE 41. Shutdown Operation SHUTDOWN CONTROL A feature of the LM2588 is its ability to be shut down using the ON /OFF pin (pin 1). This feature conserves input power by turning off the device when it is not in use. For proper operation, an isolation diode is required (as shown in Figure 41). The device will shut down when 3V or greater is applied on the ON /OFF pin, sourcing current into pin 1. In shut down mode, the device will draw typically 56 A of supply current (16 A to VIN and 40 A to the ON /OFF pin). To turn the device back on, leave pin 1 floating, using an (isolation) diode, as shown in Figure 41 (for normal operation, do not source or sink current to or from this pin -- see the next section). Frequency (kHz) Open 100 200 125 47 150 33 175 22 200 FIGURE 42. Frequency Setting Resistor Guide 01242055 FIGURE 43. Frequency Synchronization www.national.com 24 PROGRAMMING OUTPUT VOLTAGE (SELECTING R1 AND R2) Referring to the adjustable regulator in Figure 45, the output voltage is programmed by the resistors R1 and R2 by the following formula: where VREF = 1.23V VOUT = VREF (1 + R1/R2) (Continued) FREQUENCY SYNCHRONIZATION Another feature of the LM2588 is the ability to synchronize the switching frequency to an external source, using the sync pin (pin 6). This feature allows the user to parallel multiple devices to deliver more output power. Resistors R1 and R2 divide the output voltage down so that it can be compared with the 1.23V internal reference. With R2 between 1k and 5k, R1 is: where VREF = 1.23V R1 = R2 (VOUT/VREF - 1) A negative falling pulse applied to the sync pin will synchronize the LM2588 to an external oscillator (see Figure 43 and 44). Use of this feature enables the LM2588 to be synchronized to an external oscillator, such as a system clock. This operation allows multiple power supplies to operate at the same frequency, thus eliminating frequency-related noise problems. For best temperature coefficient and stability with time, use 1% metal film resistors. SHORT CIRCUIT CONDITION Due to the inherent nature of boost regulators, when the output is shorted (see Figure 45 ), current flows directly from the input, through the inductor and the diode, to the output, bypassing the switch. The current limit of the switch does not limit the output current for the entire circuit. To protect the load and prevent damage to the switch, the current must be externally limited, either by the input supply or at the output with an external current limit circuit. The external limit should be set to the maximum switch current of the device, which is 5A. In a flyback regulator application (Figure 46 ), using the standard transformers, the LM2588 will survive a short circuit to the main output. When the output voltage drops to 80% of its nominal value, the frequency will drop to 25 kHz. With a lower frequency, off times are larger. With the longer off times, the transformer can release all of its stored energy before the switch turns back on. Hence, the switch turns on initially with zero current at its collector. In this condition, the switch current limit will limit the peak current, saving the device. 01242064 FIGURE 44. Waveforms of a Synchronized 12V Boost Regulator The scope photo in Figure 44 shows a LM2588 12V Boost Regulator synchronized to a 200 kHz signal. There is a 700 ns delay between the falling edge of the sync signal and the turning on of the switch. 01242056 FIGURE 45. Boost Regulator 25 www.national.com LM2588 Application Hints LM2588 Application Hints (Continued) 01242057 FIGURE 46. Flyback Regulator and other flyback regulator circuits throughout the datasheet). The schematic in Figure 46 shows another method of clamping the switch voltage. A single voltage transient suppressor (the SA51A) is inserted at the switch pin. This method clamps the total voltage across the switch, not just the voltage across the primary. FLYBACK REGULATOR INPUT CAPACITORS A flyback regulator draws discontinuous pulses of current from the input supply. Therefore, there are two input capacitors needed in a flyback regulator -- one for energy storage and one for filtering (see Figure 46). Both are required due to the inherent operation of a flyback regulator. To keep a stable or constant voltage supply to the LM2588, a storage capacitor (100 F) is required. If the input source is a recitified DC supply and/or the application has a wide temperature range, the required rms current rating of the capacitor might be very large. This means a larger value of capacitance or a higher voltage rating will be needed for the input capacitor. The storage capacitor will also attenuate noise which may interfere with other circuits connected to the same input supply voltage. In addition, a small bypass capacitor is required due to the noise generated by the input current pulses. To eliminate the noise, insert a 1.0 F ceramic capacitor between VIN and ground as close as possible to the device. If poor circuit layout techniques are used (see the "Circuit Layout Guideline" section), negative voltage transients may appear on the Switch pin (pin 5). Applying a negative voltage (with respect to the IC's ground) to any monolithic IC pin causes erratic and unpredictable operation of that IC. This holds true for the LM2588 IC as well. When used in a flyback regulator, the voltage at the Switch pin (pin 5) can go negative when the switch turns on. The "ringing" voltage at the switch pin is caused by the output diode capacitance and the transformer leakage inductance forming a resonant circuit at the secondary(ies). The resonant circuit generates the "ringing" voltage, which gets reflected back through the transformer to the switch pin. There are two common methods to avoid this problem. One is to add an RC snubber around the output rectifier(s), as in Figure 46. The values of the resistor and the capacitor must be chosen so that the voltage at the Switch pin does not drop below -0.4V. The resistor may range in value between 10 and 1 k, and the capacitor will vary from 0.001 F to 0.1 F. Adding a snubber will (slightly) reduce the efficiency of the overall circuit. The other method to reduce or eliminate the "ringing" is to insert a Schottky diode clamp between pins 5 and 4 (ground), also shown in Figure 46. This prevents the voltage at pin 5 from dropping below -0.4V. The reverse voltage rating of the diode must be greater than the switch off voltage. SWITCH VOLTAGE LIMITS In a flyback regulator, the maximum steady-state voltage appearing at the switch, when it is off, is set by the transformer turns ratio, N, the output voltage, VOUT, and the maximum input voltage, VIN (Max): VSW(OFF) = VIN (Max) + (VOUT +VF)/N where VF is the forward biased voltage of the output diode, and is typically 0.5V for Schottky diodes and 0.8V for ultrafast recovery diodes. In certain circuits, there exists a voltage spike, VLL, superimposed on top of the steady-state voltage (see Figure 5, waveform A). Usually, this voltage spike is caused by the transformer leakage inductance and/or the output rectifier recovery time. To "clamp" the voltage at the switch from exceeding its maximum value, a transient suppressor in series with a diode is inserted across the transformer primary (as shown in the circuit in Figure 4 www.national.com 26 former. However, there exists some physical limitations that prevent the turns ratio, and thus the output voltage, from increasing to infinity. The physical limitations are capacitances and inductances in the LM2588 switch, the output diode(s), and the transformer -- such as reverse recovery time of the output diode (mentioned above). (Continued) NOISY INPUT LINE CONDITION A small, low-pass RC filter should be used at the input pin of the LM2588 if the input voltage has an unusually large amount of transient noise, such as with an input switch that bounces. The circuit in Figure 47 demonstrates the layout of the filter, with the capacitor placed from the input pin to ground and the resistor placed between the input supply and the input pin. Note that the values of RIN and CIN shown in the schematic are good enough for most applications, but some readjusting might be required for a particular application. If efficiency is a major concern, replace the resistor with a small inductor (say 10 H and rated at 200 mA). 01242058 STABILITY FIGURE 47. Input Line Filter All current-mode controlled regulators can suffer from an instability, known as subharmonic oscillation, if they operate with a duty cycle above 50%. To eliminate subharmonic oscillations, a minimum value of inductance is required to ensure stability for all boost and flyback regulators. The minimum inductance is given by: OUTPUT VOLTAGE LIMITATIONS The maximum output voltage of a boost regulator is the maximum switch voltage minus a diode drop. In a flyback regulator, the maximum output voltage is determined by the turns ratio, N, and the duty cycle, D, by the equation: VOUT N x VIN x D/(1 - D) The duty cycle of a flyback regulator is determined by the following equation: where VSAT is the switch saturation voltage and can be found in the Characteristic Curves. Theoretically, the maximum output voltage can be as large as desired -- just keep increasing the turns ratio of the trans- 01242059 FIGURE 48. Circuit Board Layout CIRCUIT LAYOUT GUIDELINES As in any switching regulator, layout is very important. Rapidly switching currents associated with wiring inductance generate voltage transients which can cause problems. For minimal inductance and ground loops, keep the length of the leads and traces as short as possible. Use single point grounding or ground plane construction for best results. Separate the signal grounds from the power grounds (as indicated in Figure 48). When using the Adjustable version, physically locate the programming resistors as near the regulator IC as possible, to keep the sensitive feedback wiring short. 27 www.national.com LM2588 Application Hints LM2588 Application Hints HEAT SINK/THERMAL CONSIDERATIONS Adding the junction temperature rise to the maximum ambient temperature gives the actual operating junction temperature: In many cases, a heat sink is not required to keep the LM2588 junction temperature within the allowed operating temperature range. For each application, to determine whether or not a heat sink will be required, the following must be identified: 1) Maximum ambient temperature (in the application). If the operating junction temperature exceeds the maximum junction temperatue in item 3 above, then a heat sink is required. When using a heat sink, the junction temperature rise can be determined by the following: TJ = PD * (JC + Interface + Heat Sink) (Continued) TJ = TJ + TA. 2) Maximum regulator power dissipation (in the application). 3) Maximum allowed junction temperature (125C for the LM2588). For a safe, conservative design, a temperature approximately 15C cooler than the maximum junction temperature should be selected (110C). 4) LM2588 package thermal resistances JA and JC (given in the Electrical Characteristics). Total power dissipated (PD) by the LM2588 can be estimated as follows: Again, the operating junction temperature will be: TJ = TJ + TA As before, if the maximum junction temperature is exceeded, a larger heat sink is required (one that has a lower thermal resistance). Included in the Switchers Made Simple design software is a more precise (non-linear) thermal model that can be used to determine junction temperature with different input-output parameters or different component values. It can also calculate the heat sink thermal resistance required to maintain the regulator junction temperature below the maximum operating temperature. Boost: To further simplify the flyback regulator design procedure, National Semiconductor is making available computer design software Switchers Made Simple. Software is available on a (312") diskette for IBM compatible computers from a National Semiconductor sales office in your area or the National Semiconductor Customer Response Center (1-800-272-9959). VIN is the minimum input voltage, VOUT is the output voltage, N is the transformer turns ratio, D is the duty cycle, and ILOAD is the maximum load current (and ILOAD is the sum of the maximum load currents for multiple-output flyback regulators). The duty cycle is given by: Boost: where VF is the forward biased voltage of the diode and is typically 0.5V for Schottky diodes and 0.8V for fast recovery diodes. VSAT is the switch saturation voltage and can be found in the Characteristic Curves. When no heat sink is used, the junction temperature rise is: TJ = PD * JA. www.national.com 28 LM2588 Physical Dimensions inches (millimeters) unless otherwise noted Order Number LM2588T-3.3, LM2588T-5.0, LM2588T-12 or LM2588T-ADJ NS Package Number TA07B Order Number LM2588S-3.3, LM2588S-5.0, LM2588S-12 or LM2588S-ADJ Tape and Reel Order Number LM2588SX-3.3, LM2588SX-5.0, LM2588SX-12 or LM2588SX-ADJ NS Package Number TS7B 29 www.national.com LM2588 SIMPLE SWITCHER 5A Flyback Regulator with Shutdown Notes 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. For the most current product information visit us at www.national.com. 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