LM2596

LM2596
SIMPLE SWITCHER® Power Converter 150 kHz
3A Step-Down Voltage Regulator

General Description current limit for the output switch and an over temperature
The LM2596 series of regulators are monolithic integrated shutdown for complete protection under fault conditions.
circuits that provide all the active functions for a step-down
(buck) switching regulator, capable of driving a 3A load with Features
excellent line and load regulation. These devices are available ƒ 3.3V, 5V, 12V, and adjustable output versions
in fixed output voltages of 3.3V, 5V, 12V, and an adjustable ƒ Adjustable version output voltage range, 1.2V to 37V ±4%
output version. max over line and load conditions
Requiring a minimum number of external components, these ƒ Available in TO-220 and TO-263 packages
regulators are simple to use and include internal frequency ƒ Guaranteed 3A output load current
compensation †, and a fixed-frequency oscillator. ƒ Input voltage range up to 40V
The LM2596 series operates at a switching frequency of 150kHz ƒ Requires only 4 external components
thus allowing smaller sized filter components than what would ƒ Excellent line and load regulation specifications
be needed with lower frequency switching regulators. Available ƒ 150KHz fixed frequency internal oscillator
in a standard 5-lead TO-220 package with several different lead ƒ TTL shutdown capability
bend options, and a 5-lead TO-263 surface mount package. ƒ Low power standby mode, IQ typically 80μA
A standard series of inductors are available from several ƒ High efficiency
different manufacturers optimized for use with the LM2596 ƒ Uses readily available standard inductors
series. This feature greatly simplifies the design of switch-mode ƒ Thermal shutdown and current limit protection
power supplies.
Other features include a guaranteed ±4% tolerance on output Applications
voltage under specified input voltage and output load conditions, ƒ Simple high-efficiency step-down (buck) regulator
and ±15% on the oscillator frequency. External shutdown is ƒ On-card switching regulators
included, featuring typically 80 μ A standby current. Self ƒ Positive to negative converter
protection features include a two stage frequency reducing Note: †Patent Number 5,382,918.

Typical Application (Fixed Output Voltage Versions)

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 LM2596

Connection Diagrams and Ordering Information

Bent and Staggered Leads, Through Hole Surface Mount Package

Package 5-Lead TO-263(s)
5-Lead TO-220(T)

Order Number LM2596S-3.3, LM2596S-5.0,

Order Number LM2596T-3.3, LM2596T-5.0, LM2596S-12 or LM2596S-ADJ
LM2596T-12 or LM2596T-ADJ See NS Package Number TS5B
See NS Package Number T05D

Absolute Maximum Ratings (Note 1)

If Military/Aerospace specified devices are required, please Human Body Model (Note 2) 2KV
contact the National Semiconductor Sales Lead Temperature
Office/Distributors for availability and specifications. S Package
Maximum Supply Voltage 45V Vapor Phase (60 sec.) +215℃
/OFF Pin Input Voltage -0.3≤V≤+25V Infrared (10 sec. ) +245℃
Feedback Pin Voltage -0.3≤V≤+25V T Package (Soldering, 10 sec.) +260℃
Output Voltage to Ground Maximum Junction Temperature +150℃
(Steady State) -1V Operating Conditions
Power Dissipation Internally limited Temperature Range -40℃≤TJ≤+125℃
Storage Temperature Range -65℃ to +150℃ Supply Voltage 4.5V to 40V
ESD Susceptibility

LM2596-3.3
Electrical Characteristics
Specifications with standard type face are for TJ =25℃, and those with boldface type apply over full Operating Temperature Range
LM2596-3.3
Units
Symbol Parameter Conditions Typ Limit
(Limits)
(Note 3) (Note 4)
SYSTEM PARAMETERS (Note 5) Test Circuit Figure1
VOUT Output Voltage 4.75V≤VIN≤40V, 0.2A≤ILOAD≤3A 3.3 V
3.168/3.135 V(min)
3.432/3.465 V(max)
η Efficiency VIN=12V, ILOAD =3A 73 %

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 LM2596

LM2596-5.0
Electrical Characteristics
Specifications with standard type face are for TJ =25℃, and those with boldface type apply over full Operating Temperature Range
LM2596-5.0
Units
Symbol Parameter Conditions Typ Limit
(Limits)
(Note 3) (Note 4)
SYSTEM PARAMETERS (Note 5) Test Circuit Figure1
VOUT Output Voltage 7V≤VIN≤40V, 0.2A≤ILOAD≤3A 5.0 V
4.800/4.750 V(min)
5.200/5.250 V(max)
η Efficiency VIN=12V, ILOAD =3A 80 %

LM2596-12
Electrical Characteristics
Specifications with standard type face are for TJ =25℃, and those with boldface type apply over full Operating Temperature Range
LM2596-12
Units
Symbol Parameter Conditions Typ Limit
(Limits)
(Note 3) (Note 4)
SYSTEM PARAMETERS (Note 5) Test Circuit Figure1
VOUT Output Voltage 15V≤VIN≤40V, 0.2A≤ILOAD≤3A 12.0 V
11.52/11.40 V(min)
12.48/12.60 V(max)
η Efficiency VIN=12V, ILOAD =3A 90 %

LM2596-ADJ
Electrical Characteristics
Specifications with standard type face are for TJ =25℃, and those with boldface type apply over full Operating Temperature Range
LM2596-ADJ
Units
Symbol Parameter Conditions Typ Limit
(Limits)
(Note 3) (Note 4)
SYSTEM PARAMETERS (Note 5) Test Circuit Figure1
VFB Feedback Voltage 4.5V≤VIN≤40V, 0.2A≤ILOAD≤3A 1.230 V
VOUT programmed for 3V. Circuit of 1.193/1.180 V(min)
Figure 1 1.267/1.280 V(max)
η Efficiency VIN=12V, VOUT=3V, ILOAD =3A 73 %

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 LM2596

All Output Voltage Versions

Electrical Characteristics
Specifications with standard type face are for TJ =25℃, and those with boldface type apply over full operating temperature range.
Unless otherwise specified, VIN = 12V for the 3.3V, 5V, and Adjustable version and VIN =24V for the 12V version. ILOAD =500mA
LM2596-XX
Units
Symbol Parameter Conditions Typ Limit
(Limits)
(Note 3) (Note 4)
DEVICE PARAMETERS
Ib Feedback Bias Current Adjustable Version Only, VFB = 1.3V 10 nA
50/100 nA(max)
fO Oscillator Frequency (Note 6) 150 kHz
127/110 kHz(min)
173/173 kHz(max)
VSAT Saturation Voltage IOUT = 3A (Notes 7,8) 1.16 V
1.4/1.5 V(max)
DC Max Duty Cycle (ON) (Note 8) 100 %
Min Duty Cycle (OFF) (Note 9) 0
ICL Current Limit Peak Current (Notes 7,8) 4.5 A
3.6/3.4 A(min)
6.9/7.5 A(max)
IL Output Leakage Current Output = 0V (Notes 7,9) 50 μA(max)
Output = -1V (Notes 10) 2 mA
30 mA(max)
IQ Quiescent Current (Note 9) 5 mA
10 mA(max)
ISTBY Standby Quiescent Current ON/OFF pin = 5V(OFF) (Note 10) 80 μA
200/250 μA(max)
JC Thermal Resistance TO-220 or TO-263 Package ,Junction to Case 2 ℃/W
JA TO-220 Package, Junction to Ambient (Note11) 50 ℃/W
JA TO-263 Package, Junction to Ambient (Note12) 50 ℃/W
JA TO-263 Package, Junction to Ambient (Note13) 30 ℃/W
JA TO-263 Package, Junction to Ambient (Note14) 20 ℃/W
ON/OFF CONTROL Test Circuit Figure 1
/OFF Pin Logic Input 1.3 V
VIH Threshold Voltage Low (Regulator ON) 0.6 V(max)
VIL High (Regulator OFF) 2.0 V(min)

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 LM2596

All Output Voltage Versions

Electrical Characteristics (Continued)
Specifications with standard type face are for TJ= 25℃, and those with boldface type apply over full Operating Temperature Range.
Unless otherwise specified, VIN = 12V for the 3.3V, 5V, and Adjustable version and VIN =24V for the 12V version. ILOAD =500mA.
LM2596-XX
Units
Symbol Parameter Conditions Typ Limit
(Limits)
(Note 3) (Note 4)
ON/OFF CONTROL Test Circuit Figure 1
IH /OFF Pin Input Current VLOGIC=2.5V (Regulator OFF) 5 μA
15 μA(max)
IL VLOGIC=0.5V (Regulator ON) 0.02 μA
5 μA(max)
Note 1: Absolute Maximum Ratings indicate limits beyond which damage to the device may occur. Operating Ratings indicate conditions for
which the device is intended to be functional, but do not guarantee specific performance limits. For guaranteed specifications and test
conditions, see the Electrical Characteristics.
Note 2: The human body model is a 100pF capacitor discharged through a 1.5K resistor into each pin.
Note 3: Typical numbers are at 25℃ 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 limit are 100% production 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 system performance. When the LM2596 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 overload.
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 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.
Note 11: Junction to ambient thermal resistance (no external heat sink) for the TO-220 package mounted vertically, with the leads
2
soldered to a printed circuit board with (1oz.) copper area of approximately 1 in .
2
Note 12: Junction to ambient thermal resistance with the TO-263 package tab soldered to a single printed circuit board with 0.5 in of
(1 oz.) copper area.
Note 13:Junction to ambient thermal resistance with the TO-263 package tab soldered to a single sided printed circuit board with 2.5
2
in of (1 oz) copper area.
Note 14: Junction to ambient thermal resistance with the TO-263 package tab soldered to a double sided printed circuit board with 3
2 2
in of (1 oz.) copper area on the LM2596S side of the board, and approximately 16 in of copper on the other side of the p-c
board. See Application Information in this data sheet and the thermal model in Switchers Mode Simple™ Version 4.3
software.

Typical Performance Characteristics (Circuit of Figure 1)

Normalized Line Regulation Efficiency
Output Voltage

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 LM2596

Typical Performance Characteristics (Circuit of Figure 1) (Continued)

Switch Saturation Switch Current Limit Dropout Voltage

Voltage

Operating Shutdown Minimum Operating

Quiescent Current Quiescent Current Supply Voltage

/OFF Threshold /OFF Pin Switching Frequency

Voltage Current (Sinking)

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 LM2596

Typical Performance Characteristics (Circuit of Figure 1) (Continued)

Feedback Pin
Bias Current

Typical Performance Characteristics

Continuous Mode Switching Waveforms Discontinuous Mode Switching Waveforms
VIN =20V, VOUT =5V, ILOAD =2A VIN =20V, VOUT =5V, ILOAD =500mA
L=32μH,COUT =220μF, COUT ESR =50mΩ L=10μH,COUT =330μF, COUT ESR =45mΩ

A: Output Pin Voltage, 10V/div. A: Output Pin Voltage, 10V/div.

B: Inductor Current 1A/div. B: Inductor Current 0.5A/div.
C: Output Ripple Voltage, 50m V/div. C: Output Ripple Voltage, 100m V/div.
Horizontal Time Base:2μs/div Horizontal Time Base:2μs/div

Load Transient Response for Continuous Mode Load Transient Response for Discontinuous Mode
VIN =20V, VOUT =5V, ILOAD =500mA TO 2A VIN =20V, VOUT =5V, ILOAD =500mA TO 2A
L=32μH,COUT =220μF, COUT ESR =50mΩ L=10μH,COUT =330μF, COUT ESR =45mΩ

A: Output Voltage, 100mV/div. (AC) A: Output Voltage, 100mV/div. (AC)

B: 500 mA to 2A Load Pulse B: 500 mA to 2A Load Pulse
Horizontal Time Base: 100μs/div. Horizontal Time Base: 200μs/div.

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 LM2596

Test Circuit and Layout Guidelines

CIN —470μF,50V, Aluminum Electrolytic Nichicon “PL Series”

COUT —220μF,25V, Aluminum Electrolytic Nichicon “PL Series”
D1— 5A, 40V Schottky Rectifier, 1N5825
L1— 68μH,L38

Adjustable Output Voltage Versions

VOUT =VREF ( 1 + R2/R1 )

Where VREF = 1.23V
R2 = R1 ( VOUT/ VREF -1)
Select R1 to be approximately 1 kΩ, use a 1% resistor for best stability
CIN —470μF,50V, Aluminum Electrolytic Nichicon “PL Series”
COUT —220μF,35V, Aluminum Electrolytic Nichicon “PL Series”
D1— 5A, 40V Schottky Rectifier, 1N5825
L1— 68μH,L38
R1 —1 kΩ,1%
CFF — See Application Information Section

FIGURE 1 . Standard Test Circuits and Layout Guides

As in any switching regulator, layout is very important. Rapidly to the location and positioning of this type of inductor. Allowing
switching currents associated with wiring inductance can the inductor flux to intersect sensitive feedback, IC ground path
generate voltage transients which can cause problems. For and COUT wiring can cause problems.
minimal inductance and ground loops, the wires indicated by When using the adjustable version, special care must be taken
heavy lines should be wide printed circuit traces and should be as to the location of the feedback resistors and the associated
kept as short as possible. For best results, external components wiring. Physically locate both resistors near the IC, and route the
should be located as close to the switcher IC as possible using wiring away from the inductor, especially an open core type of
ground plane construction or single point grounding. inductor. (See application section for more information.)
If open core inductors are used, special care must be taken as

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 LM2596

LM2596 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) = 3A
[Link] Selection (L1) [Link] Selection (L1)
A. Select the correct inductor value selection guide from A. Use the inductor selection guide for the 5V version shown in
Figures Figure 4, Figure 5, or Figure 6. (Output voltages of Figure 5.
3.3V, 5V, or 12V respectively.) For all other voltages, see the B. From the inductor value selection guide shown in Figure 5.
design procedure for the adjustable version. the inductance region intersected by the 12V horizontal line and
B. From the inductor value selection guide, identify the the 3A vertical line is 33μH, and the inductor code is L40.
inductance region intersected by the Maximum input Voltage C. The inductance value required is 33μH, From the table in
line and the Maximum Load Current Line. Each region is Figure8, go to the L40 line and choose an inductor part number
identified by an inductance value and an inductor code (LXX). from any of the four manufacturers shown. (In most instance,
C. Select an appropriate inductor from the four manufacturer’s both through hole and surface mount inductors are available.)
part numbers listed in Figure 8.
2 Output Capacitor Selection (COUT)
[Link] Capacitor Selection (COUT) A. See section on output capacitors in application information
A. In the majority of applications, low ESR (Equivalent Series section.
Resistance) electrolytic capacitors between 82μF and 820μF B. From the quick design component selection table shown in
and low ESR solid tantalum capacitors between 10μF and 470 Figure 2, locate the 5V output voltage section. In the load
μF provide the best results. This capacitor should be located current column, choose the load current line that is closest to
close to the IC using short capacitor leads and short copper the current needed in your application, for this example, use the
traces. Do not use capacitors larger than 820μF. 3A line. In the maximum input voltage column, select the line
For additional information, see section on output capacitors in that covers the input voltage needed in your application, in this
application information section. example, use the 15V line, Continuing on this line are
B. To simplify the capacitor selection procedure, refer to the recommended inductors and capacitors that will provide the
quick design component selection table shown in Figure 2. This best overall performance.
table contains different input voltages, output voltages, and load The capacitor list contains both through hole electrolytic and
currents, and lists various inductors and output capacitors that surface mount tantalum capacitors from four different capacitor
will provide the best design solutions. manufacturers. It is recommended that both the manufactures
C. The capacitor voltage rating for electrolytic capacitors should and the manufacturer’s series that are listed in the table be
be at least 1.5 times greater than the output voltage, and often used.
much higher voltage ratings are needed to satisfy the low ESR In this example aluminum electrolytic capacitors from several
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 4.3 or later. 330μF 35V Panasonic HFQ Series
330μF 35V Nichicon PL Series
C. For a 5 V output, a capacitor voltage rating at least 7.5V or
more is needed. But even a low ESR, switching grade, 220μF
10V aluminum electrolytic capacitor would exhibit
approximately 225mΩ 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 capacitor with a higher value or
with a higher voltage rating (lower ESR) should be selected. A
16V or 25V capacitor will reduce the ripple voltage by
approximately half.

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 LM2596

LM2596 Series Buck Regulator Design Procedure (Fixed Output) (Continued)

PROCEDURE (Fixed Output Voltage Version) EXAMPLE (Fixed Output Voltage Version)
3. Catch Diode Selection (D1) [Link] 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 5A,
greater than the maximum load current. Also, if the power supply 20V, 1N5823 Schottky diode will provide the best performance,
design must withstand a continuous output short, the diode and will not be overstressed even for a shorted output.
should have a current rating equal to the maximum current limit of
the LM2596. The most stressful condition for this diode is an [Link] Capacitor (CIN)
overload or shorted output condition. The important parameters for the input capacitor are the input
B. The reverse voltage rating of the diode should be at least 1.25 voltage rating and the RMS current rating. With a nominal input
times the maximum input voltage. voltage of 12V, an aluminum electrolytic capacitor with a voltage
C. This diode must be fast (short reverse recovery time) and must rating greater than 18V (1.5 x VIN) would be needed. The next
be located close to the LM2596 using short leads and short higher capacitor voltage rating is 25V.
printed circuit traces. Because of their fast switching speed and The RMS current rating requirement for the input capacitor in a
low forward voltage drop, Schottky diodes provide the best buck regulator is approximately 1/2 the DC load current. In this
performance and efficiency, and should be the first choice, example, with a 3A load, a capacitor with a RMS current rating of
especially in low output voltage applications. Ultra-fast recovery, at least 1.5A is needed. The curves shown in Figure 13 can be
or High-Efficiency rectifiers also provide good results. Ultra-fast used to select an appropriate input capacitor. From the curves,
recovery diodes typically have reverse recovery times of 50ns or locate the 35 V line and note which capacitor values have RMS
less. Rectifiers such as the 1N5400 series are much too slow and current ratings greater than 1.5A . A 680μF/35V capacitor could
should not be used. be used.
4. Input Capacitor (CIN) For a through hole design, a 680μF/35V electrolytic capacitor
A low ESR aluminum or tantalum bypass capacitor is needed (Panasonic HFQ series or Nichicon PL series or equivalent)
between the input pin and ground pin to prevent large voltage would be adequate. Other types or other manufacturers
transients from appearing at the input. This capacitor should be capacitors can be used provided the RMS ripple current ratings
located close to the IC using short leads. In addition, the RMS are adequate.
current rating of the input capacitor should be selected to be at For surface mount designs, solid tantalum capacitors can be
least 1/2 the DC load current. The capacitor manufacturers data used. But caution must be exercised with regard to the capacitor
sheet must be checked to assure that this current rating is not surge current rating (see Application Information on input
exceeded. The curve shown in Figure 13 shows typical RMS capacitors in this data sheet). The TPS series available from AVX,
current ratings for several different aluminum electrolytic and the 593D series from Sprague are both surge current tested.
capacitor values.
For an aluminum electrolytic, the capacitor voltage rating should
be approximately 1.5 times the maximum input voltage. Caution
must be exercised if solid tantalum capacitors are used (see
Application information on input capacitor). The tantalum
capacitor voltage rating should be 2 times the maximum input
voltage and it is recommended that they be surge current tested
by the manufacturer.
Use caution when using ceramic capacitors for input bypassing,
because it may cause severs ringing at the VIN pin.
For additional information, see section on input capacitors in
application information section.

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 LM2596

LM2596 Series Buck Regulator Design Procedure (Fixed Output) (Continued)

Conditions Inductor Output Capacitor
Through Hole Electrolytic Surface Mount Tantalum
Output Load Max Input Inductance Inductor Panasonic Nichicon AVX TPS Sprague
Voltage Current Voltage (μH) (#) HFQ Series PL Series Series 595D Series
(V) (A) (V) (μF/V) (μF/V) (μF/V) (μF/V)
3.3 3 5 22 L41 470/25 560/16 330/6.3 390/6.3
7 22 L41 560/35 560/35 330/6.3 390/6.3
10 22 L41 680/35 680/35 330/6.3 390/6.3
40 33 L40 560/35 470/35 330/6.3 390/6.3
2 6 22 L33 470/25 470/35 330/6.3 390/6.3
10 33 L32 330/35 330/35 330/6.3 390/6.3
40 47 L39 330/35 270/50 220/10 330/10
5 3 8 22 L41 470/25 560/16 220/10 330/10
10 22 L41 560/25 560/25 220/10 330/10
15 33 L40 330/35 330/35 220/10 330/10
40 47 L39 330/35 270/35 220/10 330/10
2 9 22 L33 470/25 560/16 220/10 330/10
20 68 L38 180/35 180/35 100/10 270/10
40 68 L38 180/35 180/35 100/10 270/10
12 3 15 22 L41 470/25 470/25 100/16 180/16
18 33 L40 330/25 330/25 100/16 180/16
30 68 L44 180/25 180/35 100/16 120/20
40 68 L44 180/25 180/35 100/16 120/20
2 15 33 L32 330/25 330/25 100/16 180/16
20 68 L38 180/25 180/35 100/16 120/20
40 150 L42 82/25 82/25 68/20 68/25
FIGURE 2. LM2596 Fixed Voltage Quick Design Component Selection Table

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 LM2596

LM2596 Series Buck Regulator Design Procedure (Adjustable Output)

PROCEDURE (Adjustable Output Voltage Version) EXAMPLE (Adjustable Output Voltage Version)
Given: Given:
VOUT =Regulated Output Voltage VOUT = 20V
VIN(max)= Maximum Input Voltage VIN(max)= 28V
ILOAD (max) = Maximum Load Current ILOAD (max) = 3A
F= Switching Frequency (Fixed at a nominal 150kHz). F= Switching Frequency (Fixed at a nominal 150 kHz).
1. Programming Output Voltage (Selecting R1 and R2, as
[Link] Output Voltage (Selecting R1 and R2, as shown shown in Figure 1)
in Figure 1) Select R1 to be 1kΩ, 1%. Solve for R2.
Use the following formula to select the appropriate resistor
values.
R2 = 1K (16.26-1)=15.26k, closest 1% value is 15.4kΩ
R2 = 15.4 kΩ
Select a value for R1 between 240Ω and 1.5KΩ. The lower
resistor values minimize noise pickup in the sensitive feedback
pin. (For the lowest temperature coefficient and the best 2. Inductor Selection (L1)
stability with time, use 1% metal film resistors.) A. Calculate the inductor Volt ymicrosecond constant (EyT ).

2. Inductor Selection (L1)

A. Calculate the inductor Voltymicrosecond constant EyT (Vyμ
S), from the following formula:
B. EyT=34.2 (V yμs)
C. ILOAD (max) = 3A
D. From the inductor value selection guide shown in Figure 7,
Where VSAT =internal switch saturation voltage =1.16V the inductance region intersected by the 34 (Vyμs) horizontal
and VD =diode forward voltage drop =0.5V line and the 3A vertical line is 47μH, and the inductor code is
B. Use the EyT value from the previous formula and match it L39.
with the EyT number on the vertical axis of the Inductor Value E. From the table in Figure 8, locate line L39, and select an
Selection Guide Shown in Figure 7. inductor part number from the list of manufacturers part
C. on the horizontal axis, select the maximum load current. numbers.
D. Identify the inductance region intersected by the EyT value
and the Maximum Load Current Value. Each region is identified
by an inductance value and an inductor code (LXX).
E. Select an appropriate inductor from the four manufacturer’s
part numbers listed in Figure 8.

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 LM2596

LM2596 Series Buck Regulator Design Procedure (Adjustable Output)

(Continued)
PROCEDURE (Adjustable Output Voltage Version) EXAMPLE (Adjustable Output Voltage Version)
[Link] Capacitor Selection (COUT) 3. Output Capacitor Selection (COUT)
A. In the majority of applications, low ESR electrolytic or solid A. See section on COUT in Application Information section.
tantalum capacitors between 82μF and 820μF provide the best
results. This capacitor should be located close to the IC using B. From the quick design table shown in Figure 3, locate the
short capacitor leads and short copper traces. Do not use output voltage column. From that column, locate the output
capacitors larger then 820μF. For additional information, see voltage closest to the output voltage in your application. In this
section on output capacitors in application information section. example, select the 24 V line, Under the output capacitor section,
select a capacitor from the list of through hole electrolytic or
B. To simplify the capacitor selection procedure, refer to the quick surface mount tantalum types from four different capacitor
design table shown in Figure 3. This table contains different manufacturers. It is recommended that both the manufacturers
output voltages, and lists various output capacitors that will and the manufacturers series that are listed in the table be used.
provide the best design solutions. In this example through hole aluminum electrolytic capacitors
from several different manufacturers are available.
C. The capacitor voltage rating should be at least 1.5 times 220μF/35V Panasonic HFQ Series
greater than the output voltage, and often much higher voltage 150μf/35V Nichicon PL Series
ratings are needed to satisfy the low ESR requirements needed
for low output ripple voltage. C. For a 20V output, a capacitor rating of at least 30V or more is
needed. In this example, either a 35V or 50V capacitor would
work. A 35V rating was chosen, although a 50V rating could also
[Link] Capacitor (CFF) (See Figure 1)
be used if a lower output ripple voltage is needed.
For output voltages greater than approximately 10V, an additional
Other manufacturers or other types of capacitors may also be
capacitor is required. The compensation capacitor is typically
used, provided the capacitor specifications (especially the
between 100pF and 33nF, and is wired in parallel with the output
100kHz ESR) closely match the types listed in the table. Refer to
voltage setting resistor, R2. It provides additional stability for high
the capacitor manufacturers data sheet for this information.
output voltages, low input-output voltages, and/or very low ESR
output capacitors, such as solid tantalum capacitors.
[Link] Capacitor (CFF)
The table shown in Figure 3 contains feed forward capacitor
values for various output voltages. In this example, a 560pF
This capacitor type can be ceramic, plastic, silver mica, etc. capacitor is needed.
(Because of the unstable characteristics of ceramic capacitors
mode with Z5U material, they are not recommended.)

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 LM2596

LM2596 Series Buck Regulator Design Procedure (Adjustable Output)

(Continued)
PROCEDURE (Adjustable Output Voltage Version) EXAMPLE (Adjustable Output Voltage Version)
[Link] Diode Selection (D1) 5. 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. Schottky diodes provide
greater than the maximum load current. Also, if the power supply the best performance, and in this example a 5A, 40V, 1N5825
design must withstand a continuous output short, the diode Schottky diode would be a good choice. The 5A diode rating is
should have a current rating equal to the maximum current limit of more than adequate and will not be overstressed even for a
the LM2596. The most stressful condition for this diode is an shorted output.
overload or shorted output condition.

B. The reverse voltage rating of the diode should be at least 1.25 [Link] Capacitor (CIN)
times the maximum input voltage. The important parameters for the input capacitor are the input
voltage rating and the RMS current rating. With a nominal input
C. This diode must be fast (short reverse recovery time) and must voltage of 28V, an aluminum electrolytic aluminum electrolytic
be located close to the LM2596 using short leads and short capacitor with a voltage rating greater than 42V (1.5X VIN) would
printed circuit traces. Because of their fast switching speed and be needed. Since the next higher capacitor voltage rating is 50V,
low forward voltage drop, Schottky diodes provide the best a 50V capacitor should be used. The capacitor voltage rating of
performance and efficiency, and should be the first choice, (1.5 x VIN) is a conservative guideline, and can be modified
especially in low output voltage applications. Ultra-fast recovery, somewhat if desired.
or High-Efficiency rectifiers are also a good choice, but some The RMS current rating requirement for the input capacitor of a
types with an abrupt turn-off characteristic may cause instability buck regulator is approximately 1/2 the DC load current. In this
or EMI problems. Ultra-fast recovery diodes typically have example, with a 3A load, a capacitor with a RMS current rating of
reverse recovery times of 50 ns or less. Rectifiers such as the at least 1.5A is needed.
1N4001 series are much too slow and should not be used. The curves shown in Figure 13 can be used to select an
appropriate input capacitor. From the curves, locate the 50V line
[Link] Capacitor (CIN) and note which capacitor values have RMS current ratings
A low ESR aluminum or tantalum bypass capacitor is needed greater than 1.5A. Either a 470 μF or 680 μF. 50V capacitor
between the input pin and ground to prevent large voltage could be used.
transients from appearing at the input. In addition, the RMS For a through hole design, a 680 μF/50V electrolytic capacitor
current rating of the input capacitor should be selected to be at (Panasonic HFQ series or Nichicon PL series or equivalent)
least 1/2 the DC load current. The capacitor manufacturers data would be adequate. Other types or other manufacturers
sheet must be checked to assure that this current rating is not capacitors can be used provided the RMS ripple current ratings
exceeded. The curve shown in Figure 13 shows typical RMS are adequate.
current ratings for several different aluminum electrolytic For surface mount designs, solid tantalum capacitors can be
capacitor values. used, but caution must be exercised with regard to the capacitor
This capacitor should be located close to the IC using short leads surge current rting (see Application Information or input
and the voltage rating should be approximately 1.5 times the capacitors in this data sheet). The TPS series available from AVX,
maximum input voltage. and the 593D series from Sprague are both surge current tested.
If solid tantalum input capacitors are used, it is recommended that To further simplify the buck regulator design procedure, National
they be surge current tested by the manufacturer. semiconductor is making available computer design software to
Use caution when using a high dielectric constant ceramic be used with the Simple Switcher line to switching regulators.
capacitor for input bypassing, because it may cause severe Switchers made simple (version 4.3 or later) is available on a
1
ringing at the VIN pin. 3 /2 “ diskette for IBM compatible computers.
For additional information, see section on input capacitors in
application information section.

[Link] 14
 LM2596

LM2596 Series Buck Regulator Design Procedure (Adjustable Output)

Output Through Hole Output Capacitor Surface Mount Output Capacitor
Voltage Panasonic Nichicon PL Feed forward AVX TPS Sprague Feed forward
(V) HFQ Series Series Capacitor Series 595D Series Capacitor
(μF/V) (μF/V) (μF/V) (μF/V)
2 820/35 820/35 33nF 330/6.3 470/4 33nF
4 560/35 470/35 10nF 330/6.3 390/6.3 10nF
6 470/25 470/35 3.3nF 220/10 330/10 3.3nF
9 330/25 330/25 1.5nF 100/16 180/16 1.5nF
12 330/25 330/25 1nF 100/16 180/16 1nF
15 220/35 220/35 680nF 68/20 120/20 680pF
24 220/35 150/35 560pF 33/25 33/25 220pF
28 100/50 100/50 390pF 10/35 15/50 220pF
FIGURE 3. Output Capacitor and Feed forward Capacitor Selection Table

LM2596 Series Buck Regulator Design Procedure

INDUCTOR VALUE SELECTION GUIDES (For Continuous Mode Operation)

FIGURE 4. LM2596-3.3 FIGURE 6. LM2596-12

FIGURE 5. LM2596-5.0 FIGURE 7. LM2596-ADJ

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 LM2596

LM2596 Series Buck Regulator Design Procedure (Continued)

Inductance Cur- Schott Renco Pulse Engineering Coilcraft
(μH) Rent Through Surface Through Hole Surface Through Surface Surface
(A) Hole Mount Mount Hole Mount Mount
L15 22 0.99 67148350 67148460 RL-1284-22-43 RL1500-22 PE-53815 PE-53815-s DO3308-223
L21 68 0.99 67144070 67144450 RL-5471-5 RL1500-68 PE-53821 PE-53821-s DO3316-683
L22 47 1.17 67144080 67144460 RL-5471-6 — PE-53822 PE-53822-s DO3316-473
L23 33 1.40 67144090 67144470 RL-5471-7 — PE-53823 PE-53823-s DO3316-333
L24 22 1.70 67148370 67148480 RL-1283-22-43 — PE-53824 PE-53825-s DO3316-223
L25 15 2.10 67148380 67148490 RL-1283-15-43 — PE-53825 PE-53824-s DO3316-153
L26 330 0.80 67144100 67144480 RL-5471-1 — PE-53826 PE-53826-s DO5022P-334
L27 220 1.00 67144110 67144490 RL-5471-2 — PE-53827 PE-53827-s DO5022P-224
L28 150 1.20 67144120 67144500 RL-5471-3 — PE-53828 PE-53828-s DO5022P-154
L29 100 1.47 67144130 67144510 RL-5471-4 — PE-53829 PE-53829-s DO5022P-104
L30 68 1.78 67144140 67144520 RL-5471-5 — PE-53830 PE-53830-s DO5022P-683
L31 47 2.20 67144150 67144530 RL-5471-6 — PE-53831 PE-53831-s DO5022P-473
L32 33 2.50 67144160 67144540 RL-5471-7 — PE-53932 PE-53932-s DO5022P-333
L33 22 3.10 67148390 67148500 RL-1283-22-43 — PE-53933 PE-53933-s DO5022P-223
L34 15 3.40 67148400 67148790 RL-1283-15-43 — PE-53934 PE-53934-s DO5022P-153
L35 220 1.70 67144170 — RL-5473-1 — PE-53935 PE-53935-s —
L36 150 2.10 67144180 — RL-5473-4 — PE-54036 PE-54036-s —
L37 100 2.50 67144190 — RL-5472-1 — PE-54037 PE-54037-s —
L38 68 3.10 67144200 — RL-5472-2 — PE-54038 PE-54038-s —
L39 47 3.50 67144210 — RL-5472-3 — PE-54039 PE-54039-s —
L40 33 3.50 67144220 67148290 RL-5472-4 — PE-54040 PE-54040-s —
L41 22 3.50 67144230 67148300 RL-5472-5 — PE-54041 PE-54041-s —
L42 150 2.70 67148410 — RL-5473-4 — PE-54042 PE-54042-s —
L43 100 3.40 67144240 — RL-5473-2 — PE-54043 —
L44 68 3.40 67144250 — RL-5473-3 — PE-54044 —
FIGURE 8. Inductor Manufacturers Part Numbers

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 LM2596

LM2596 Series Buck Regulator Design Procedure (Continued)

VR 3A Diodes 4A-6A Diodes

Surface Mount Through Hole Surface Mount Through Hole
Schottky Ultra Fast Schottky Ultra Fast Schottky Ultra Fast Schottky Ultra Fast
Recovery Recovery Recovery Recovery
20V All of these 1N5820 All of All of these SR502 All of these
SK32 diodes are SR302 these diodes are 1N5823 diodes are
reted to at MBR320 diodes are reted to at SB520 reted to at
30V 30WQ03 least 50V. 1N5821 reted to at least 50V. least 50V.
SK33 MBR330 least 50V. 50WQ03 SR503
31DQ03 1N5824
40V 1N5822 SB530 MUR620

SK34 MURS320 SR304 MUR320 50WQ04 MURS320 SR504 HER601

MBRS340 30WF10 MBR340 50WF10 1N5825

30WQ04 31DQ04 SB540
50V SK35 SR305
or MBRS360 MBR350 50WQ05 SB550
More 30WQ05 31DQ05 50SQ080
FIGURE 11 . Diode Selection Table

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 LM2596

Block Diagram

FIGURE 12
Application Information

PIN FUNCTIONS and the RMS current rating. Because of the relatively high RMS currents
+VIN —This is the positive input supply for the IC switching regulator. A flowing in a buck regulator’s input capacitor, this capacitor should be
suitable input bypass capacitor must be present at this pin to minimize chosen for its RMS current rating rather than its capacitance or voltage
voltage transients and to supply the switching currents needed by the ratings, although the capacitance value and voltage rating are directly
regulator. related to the RMS current rating.
Ground — Circuit ground. The RMS current rating of a capacitor could be viewed as a capacitor’s
Output — Internal switch. The voltage at this pin switches between power rating. The RMS current flowing through the capacitors internal
(+VIN - VSAT) and approximately -0.5V, with a duty cycle of ESR produces power which causes the internal temperature of the
approximately VOUTNIN. To minimize coupling to sensitive circuitry, the capacitor to rise. The RMS current rating of a capacitor is determined by
PC board copper area connected to this pin should be kept to a the amount of current required to raise the internal temperature
minimum. approximately 10℃ above an ambient temperature of 105℃. The ability
Feedback — Senses the regulated output voltage to complete the of the capacitor to dissipate this heat to the surrounding air will
feedback loop. determine the amount of current the capacitor can safely sustain.
/OFF — Allows the switching regulator circuit to be shut down using Capacitors that are physically large and have a large surface area will
logic level signals thus dropping the total input supply current to typically have higher RMS current ratings. For a given capacitor value, a
approximately 80μA. Pulling this pin below a threshold voltage of higher voltage electrolytic capacitor will be physically larger than a lower
approximately 1.3V turns the regulator on, and pulling this pin above voltage capacitor, and thus be able to dissipate more heat to the
surrounding air, and therefore will have a higher RMS current rating.
1.3V (up to a maximum of 25V) shuts the regulator down. If this
The consequences of operating an electrolytic capacitor above the RMS
shutdown feature is not needed, the /OFF pin can be wired to the
current rating is a shortened operating life. The higher temperature
ground pin or it can be left open, in either case the regulator will be in the
speeds up the evaporation of the capacitor’s electrolyte, resulting in
ON condition. eventual failure.
Selecting an input capacitor requires consulting the manufacturers data
EXTERNAL COMPONENTS sheet for maximum allowable RMS ripple current. For a maximum
INPUT CAPACITOR ambient temperature of 40℃, a general guideline would be to select a
CIN — A low ESR aluminum or tantalum bypass capacitor is needed capacitor with a ripple current rating of approximately 50% of the DC
between the input pin and ground pin. It must be located near the load current. For ambient temperatures up to 70℃, a current rating of
regulator using short leads. This capacitor prevents large voltage 75% of the DC load current would be a good choice for a conservative
transients from appearing at the input, and provides the instantaneous design. The capacitor voltage rating must be at least 1.25 times greater
current needed each time the switch turns on. than the maximum input voltage, and often a much higher voltage
The important parameters for the input capacitor are the voltage rating capacitor is needed to satisfy the RMS current requirements.

[Link] 18
 LM2596
A graph shown in Figure 13 shows the relationship between an The output capacitor requires an ESR value that has an upper and lower
electrolytic capacitor value, its voltage rating, and the RMS current it is limit. For low output ripple voltage, a low ESR value is needed. This
rated for. These curves were obtained from the Nichicon “PL” series of value is determined by the maximum allowable output ripple voltage,
low ESR, high reliability electrolytic capacitors designed for switching typically 1% to 2% of the output voltage. But if the selected capacitor’s
regulator applications. ESR is extremely low, there is a possibility of an unstable feedback loop,
Other capacitor manufacturers offer similar types of capacitors, but resulting in an oscillation at the output. Using the capacitors listed in the
always check the capacitor data sheet. tables, or similar types, will provide design solutions under all conditions.
“Standard” electrolytic capacitors typically have much higher ESR If very low output ripple voltage (less than 15mV) is required, refer to the
numbers, lower RMS current ratings and typically have a shorter section on Output Voltage Ripple and Transients for a post ripple filter.
operating lifetime. An aluminum electrolytic capacitor’s ESR value is related to the
Because of their small size and excellent performance, surface mount capacitance value and its voltage rating. In most case, higher voltage
solid tantalum capacitors are often used for input bypassing, but several electrolytic capacitors have lower ESR values (see Figure 14). Often,
precautions must be observed. A small percentage of solid tantalum capacitors with much higher voltage ratings may be needed to provide
capacitors can short if the inrush current rating is exceeded. This can the low ESR values required for low output ripple voltage.
happen at turn on when the input voltage is suddenly applied, and of The output capacitor for many different switcher designs often can be
course, higher input voltages produce higher inrush currents. Several satisfied with only three or four different capacitor values and several
capacitor manufacturers do a 100% surge current testing on their different voltage ratings. See the quick design component selection
products to minimize this potential problem. If high turn on currents are tables in Figure 2 and 4 for typical capacitor values, voltage ratings, and
expected, it may be necessary to limit this current by adding either some manufacturers capacitor types.
resistance or inductance before the tantalum capacitor, or select a Electrolytic capacitors are not recommended for temperatures below -25
higher voltage capacitor. As with aluminum electrolytic capacitors, the ℃. The ESR rises dramatically at cold temperatures and typically rises
RMS ripple current rating must be sized to the load current. 3X @ -25℃ and as much as 10X at -40℃. See curve shown in Figure
15.
FEEDFORWARD CAPACITOR Solid tantalum capacitors have a much better ESR spec for cold
(Adjustable Output Voltage Version) temperatures and are recommended for temperatures below -25℃.
CFF —A Feed forward Capacitor CFF, shown across R2 in Figure 1 is
used when the output voltage is greater than 10V 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. For CFF
selection, see the design procedure section.

FIGURE 14. Capacitor ESR vs Capacitor Voltage Rating (Typical

Low ESR Electrolytic Capacitor)

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
located close to the LM2596 using short leads and short printed circuit
FIGURE 13. RMS Current Ratings for Low ESR Electrolytic
traces.
Capacitors (Typical)
Because of their very fast switching speed and low forward voltage drop,
Schottky diodes provide the best performance, especially in low output
OUTPUT CAPACITOR voltage applications (5V and lower). Ultra- fast recovery,
COUT — An output capacitor is required to filter the output and provide or High-Efficiency rectifiers are also a good choice, but some types with
regulator loop stability. Low impedance or low ESR Electrolytic or solid an abrupt turn off characteristic may cause instability or EMI problems.
tantalum capacitors designed for switching regulator applications must Ultra-fast recovery diodes typically have reverse recovery times of 50ns
be used. When selecting an output capacitor, the important capacitor or less. Rectifiers such as the 1N5400 series are much too slow and
parameters are; the 100KHz Equivalent Series Resistance (ESR), the should not be used.
RMS ripple current rating, voltage rating, and capacitance value. For the
output capacitor, the ESR value is the most important parameter.

[Link] 19
 LM2596

Application Information (Continued)

FIGURE 15 . Capacitor ESR Change vs Temperature

FIGURE 16. (△I IND ) Peak-to-Peak Inductor Ripple Current
INDUCTOR SELECTION (as a Percentage of the load current)
All switching regulators have two basic modes of operation; Vs Load Current
continuous and discontinuous. The difference between the two By allowing the percentage of inductor ripple current to increase
types relates to the inductor current, whether it is flowing for low load currents, the inductor value and size can be kept
continuously, or if it drops to zero for a period of time in the relatively low.
normal switching cycle. Each mode has distinctively different When operating in the continuous mode, the inductor current
operating characteristics, which can affect the regulators waveform ranges from a triangular to a sawtooth type of
waveform (depending on the input voltage), with the average
performance and requirements. Most switcher designs will
value of this current waveform equal to the DC output load
operate in the discontinuous mode when the load current is low.
current.
The LM2596 (or any of the Simple Switcher family) can be used Inductors are available in different styles such as pot core, toroid,
for both continuous or discontinuous modes of operation. E-core, bobbin core, etc., as well as different core materials,
In many cases the preferred mode of operation is the continuous such as ferrites and powdered iron. The least expensive, the
mode. It offers greater output power, lower peak switch, inductor bobbin, rod or stick core, consists of wire wound on a ferrite
and diode currents, and can have lower output ripple voltage. bobbin, This type of construction makes for an inexpensive
But it does require large inductor values to keep the inductor inductor, but since the magnetic flux is not completely contained
current flowing continuously, especially at low output load within the core, it generates more Electro-Magnetic Interference
currents and / or high input voltages. (EMI). This magnetic flux can induce voltages into nearby
To simplify the inductor selection process, an inductor selection printed circuit traces, thus causing problems with both the
switching regulator operation and nearby sensitive circuitry, and
guide (nomograph ) was designed ( see figure 4 through 8). This
can give incorrect scope readings because of induced voltages
guide assumes that the regulator is operating in the continuous
in the scope probe. Also see section on Open Core Inductors.
mode, and selects an inductor that will allow a peak-to-peak When multiple switching regulators are located on the same PC
inductor ripple current to be a certain percentage of the board, open core magnetics can cause interference between
maximum design load current. This peak-to-peak inductor ripple two or more of the regulator circuits, especially at high currents.
current percentage is not fixed, but is allowed to change as A torroid or E-core inductor (closed magnetic structure) should
different design load currents are selected. (See Figure 16.) be used in these situations.
The inductors listed in the selection chart include ferrite E-core
construction for Schott, ferrite bobbin core for Renco and
Coilcraft, and powdered iron toroid for Pulse Engineering.
Exceeding an inductor’s maximum current rating may cause the
inductor to overheat because of the copper wire losses, or the
core may saturate. If the inductor begins to saturate, the
inductance decreases rapidly and the inductor begins to look
mainly resistive (the DC resistance of the winding). This can
cause the switch current to rise very rapidly and force the switch
into a cycle-by-cycle current limit, thus reducing the DC output
load current. This can also result in overheating of the inductor
and/or the LM2596. Different inductor types have different
saturation characteristics, and this should be kept in mind when
selecting an inductor.
The inductor manufacturer’s data sheets include current and
energy limits to avoid inductor saturation.

[Link] 20
 LM2596

Application information (Continued)

DISCONTINUOUS MODE OPERATION must be low, however, caution must be exercised when using
The selection guide chooses inductor values suitable for continuous extremely low ESR capacitors because they can affect the loop
mode operation, but for low current applications and/or high input stability, resulting in oscillation problems. If very low output ripple
voltages, a discontinuous mode design may be a better choice. It voltage is needed (less than 20mV), a post ripple filter is
would use an inductor that would be physically smaller, and would recommended. (See Figure 1.) The inductance required is typically
need only one half to one third the inductance value needed for a between 1µH and 5µH, with low DC resistance, to maintain good
continuous mode design. The peak switch and inductor currents will load regulation. A low ESR output filter capacitor is also required to
be higher in a discontinuous design, but at these low load currents assure good dynamic load response and ripple reduction. The ESR
(1A and below), the maximum switch current will still be less than of this capacitor may be as low as desired, because it is out of the
the switch current limit. regulator feedback loop. The photo shown in Figure 17 shows a
Discontinuous operation can have voltage waveforms that are typical output ripple voltage, with and without a post ripple filter.
considerable different than a continuous design. The output pin When observing output ripple with a scope, it is essential that a
(switch) waveform can have some damped sinusoidal ringing short, low inductance scope probe ground connection be used. Most
present. (See Typical Performance Characteristics photo titled scope probe manufacturers provide a special probe terminator
Discontinuous Mode Switching Waveforms) This ringing is normal which is soldered onto the regulator board, preferable at the output
for discontinuous operation, and is not cause by feedback loop capacitor. This provides a very short scope ground thus eliminating
instabilities. In discontinuous operation, there is a period of time the problems associated with the 3 inch ground lead normally
where neither the switch or the diode are conducting, and the provided with the probe, and provides a much cleaner and more
inductor current has dropped to zero. During this time, a small accurate picture of the ripple voltage waveform.
amount of energy can circulate between the inductor and the The voltage spikes are caused by the fast switching action of the
switch/diode parasitic capacitance causing this characteristic ringing. output switch and the diode, and the parasitic inductance of the
Normally this ringing is not a problem, unless the amplitude be output filter capacitor, and its associated wiring. To minimize these
comes great enough to exceed the input voltage, and even then, voltage spikes, the output capacitor should be designed for
there is very little energy present to cause damage. switching regulator applications, and the lead lengths must be kept
Different inductor types and /or core materials produce different very short. Wiring inductance, stray capacitance, as well as the
amounts of this characteristic ringing. Ferrite core inductors have scope probe used to evaluate these transients, all contribute to the
very little core loss and therefore produce the most ringing. The amplitude of these spikes.
higher core loss of powdered iron inductors produce less ringing. If When a switching regulator is operating in the continuous mode, the
desired, a series RC could be placed in parallel with the inductor to inductor current waveform ranges from a triangular to a sawtooth
dampen the ringing. The computer aided design software Switchers type of waveform (depending on the input voltage). For a given input
Mode Simple (version 4.3) will provide all component values for and output voltage, the peak-to-peak amplitude of this inductor
continuous and discontinuous modes of operation. current waveform remains constant. As the load current increases
or decreases, the entire sawtooth current waveform also rises and
falls. The average value (or the center) of this current waveform is
equal to the DC load current.
If the load current drops to a low enough level, the bottom of the
sawtooth current waveform will reach zero, and the switcher will
smoothly change from a continuous to a discontinuous mode of
operation. Most switcher designs (irregardless how large the
inductor value is) will be forced to run discontinuous if the output is
lightly loaded. This is a perfectly acceptable mode of operation.

2 µsec /div
DSO12583-32

FIGURE [Link] Ripple Filter Waveform

OUTPUT VOLTAGE RIPPLE AND TRANSIENTS
The output voltage of a switching power supply operating in the
continuous mode will contain a sawtooth ripple voltage at the
switcher frequency, and may also contain short voltage spikes at the
peaks of the sawtooth waveform.
The output ripple voltage is a function of the inductor sawtooth ripple
current and the ESR of the output capacitor. A typical output ripple
voltage can range from approximately 0.5% to 3% of the output
FIGURE 18. Peak-to-Peak Inductor Ripple Current vs Load Current
voltage. To obtain low ripple voltage, the ESR of the output capacitor
In a switching regulator design, knowing the value of the

[Link] 21
 LM2596
peak-to-peak inductor ripple current (△I IND ) can be useful for OPEN CORE INDUCTORS
determining a number of other circuit parameters. Parameters such Another possible source of increased output ripple voltage or
as, peak inductor or peak switch current, minimum load current unstable operation is from an open core inductor. Ferrite bobbin or
before the circuit becomes discontinuous, output ripple voltage and stick inductors have magnetic lines of flux flowing through the air
output capacitor ESR can all be calculated from the peak-to-peak from one end of the bobbin to the other end. These magnetic lines
△IIND. When the inductor nomographs shown in Figure 4 through 8 of flux will induce a voltage into any wire or PC board copper trace
are used to select an inductor value, the peak-to-peak inductor that comes within the inductor’s magnetic field. The strength of the
ripple current can immediately be determined. The curve shown in magnetic field, the orientation and location of the PC copper trace to
Figure 18 shows the range of (△I IND) that can be expected for the magnetic field, and the distance between the copper trace and
different load currents. The curve also shows how the peak-to-peak the inductor, determine the amount of voltage generated in the
inductor ripple current (△I IND) changes as you go from the lower copper trace. Another way of looking at this inductive coupling is to
border to the upper border (for a given load current) within an consider the PC board copper trace as one turn of a transformer
inductance region. The upper border represents a higher input (secondary) with the inductor winding as the primary. Many millivolts
voltage, while the lower border represents a lower input voltage (see can be generated in a copper trace located near an open core
Inductor Selection Guides). inductor which can cause stability problems or high output ripple
These curves are only correct for continuous mode operation, and voltage problems.
only if the inductor selection guides are used to select the inductor If unstable operation is seen, and an open core inductor is used, it’s
value possible that the location of the inductor with respect to other PC
Consider the following example: traces may be the problem. To determine if this is the problem,
VOUT =5V, maximum load current of 2.5A temporarily raise the inductor away from the board by several
VIN=12V, nominal, varying between 10V and 16V. inches and then check circuit operation. If the circuit now operates
The selection guide in Figure 5 shows that the vertical line for a 2.5A correctly, then the magnetic flux from the open core inductor is
load current, and the horizontal line for the 12V input voltage causing the problem. Substituting a closed core inductor such as a
intersect approximately midway between the upper and lower torroid or E-core will correct the problem, or re-arranging the PC
borders of the 33µH inductance region. A 33µH inductor will allow a layout may be necessary. Magnetic flux cutting the IC device ground
peak-to-peak inductor current ( △ I IND) to flow that will be a trace, feedback trace, or the positive or negative traces of the output
percentage of the maximum load current. Referring to Figure 18, capacitor should be minimized.
follow the 2.5A line approximately midway into the inductance region, Sometimes, locating a trace directly beneath a bobbin inductor will
and read the peak-to-peak inductor ripple current (△I IND) on the left provide good results, provided it is exactly in the center of the
hand axis (approximately 620mA p-p). inductor (because the induced voltages cancel themselves out), but
As the input voltage increases to 16V, it approaches the upper if it is off center one direction or the other, then problems could arise.
border of the inductance region, and the inductor ripple current If flux problems are present, even the direction of the inductor
increases. Referring to the curve in Figure 18, it can be seen that for winding can make a difference in some circuits.
a load current of 2.5A, the peak-to-peak inductor ripple current (△I This discussion on open core inductors is not to frighten the user,
IND) is 620mA with 12V in, and can range from 740mA at the upper but to alert the user on what kind of problems to watch out for when
border (16V in) to 500mA at the lower border (10V in). using them. Open core bobbin or “stick” inductors are an
Once the △I IND value is known, the following formulas can be used inexpensive, simple way of making a compact efficient inductor, and
to calculate additional information about the switching regulator they are used by the millions in many different applications.
circuit. THERMAL CONSIDERATIONS
1. Peak Inductor or peak switch current The LM2596 is available in two packages, a 5-pin TO-220 (T) and a
5-pin surface mount TO-263 (S).
The TO-220 package needs a heat sink under most conditions. The
size of the heatsink depends on the input voltage, the output voltage,
2. Minimum load current before the circuit becomes the load current and the ambient temperature. The curves in Figure
discontinuous 19 show the LM2596T junction temperature rises above ambient
temperature for a 3A load and different input and output voltages.
The data for these curves was taken with the LM2596T (TO-220
package) operating as a buck switching regulator in an ambient
3. Output Ripple Voltage = (△I IND) x (ESR of COUT)=0.62A x temperature of 25℃ (still air). These temperature rise numbers are
0.1Ω =62 mV p-p all approximate and there are many factors that can affect these are
4. many factors that can affect these temperatures. Higher ambient
temperatures require more heat sinking.
The TO-263 surface mount package tab is designed to be soldered
to the copper on a printed circuit board. The copper and the board
are the heat sink for this package and the other heat producing
components, such as the catch diode and inductor. The PC board
copper area that the package is soldered to should be at least 0.4
2
in , and ideally should have 2 or more square inches of 2 oz.
(0.0028) in ) copper. Additional copper area improves the thermal
characteristics, but with copper areas greater than approximately 6

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 LM2596
2
in , only small improvements in heat dissipation are realized. If
further thermal improvements are needed, double sided, multilayer
Circuit Data for Temperature Rise Curve
PC board with large copper areas and / or airflow are
recommended. TO-220 Package (T)
The curves shown in Figure 20 show the LM2596S (TO-263 Capacitors Through hole electrolytic
package) junction temperature rise above ambient temperature
Inductor Through hole, Renco
with a 2A load for various input and output voltages. This data
was taken with the circuit operating as a buck switching Diode Through hole, 5A 40V, Schottky
regulator with all components mounted on a PC board to PC board 3 square inches single sided 2 oz.
simulate the junction temperature under actual operating
conditions. This curve can be used for a quick check for the copper (0.0028”)
approximate junction temperature for various conditions, but be FIGURE 19 . Junction Temperature Rise, To-220
aware that there are many factors that can affect the junction
temperature. When load currents higher than 2A are used,
double sided or multilayer PC boards with large copper areas
and / or airflow might be needed, especially for high ambient
temperatures and high output voltages.
For the best thermal performance, wide copper traces and
generous amounts of printed circuit board copper should be
used in the board layout. (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 resistance) to the surrounding air, and moving air lowers
the thermal resistance even further.
Package thermal resistance and junction temperature rise
numbers are all approximate, and there are many factors that
will affect these numbers. Some of these factors include board
size, shape, thickness, position, location, and even board
temperature. Other factors are, trace width, total printed circuit
copper area, copper thickness, single- or double-sided,
multilayer board and the amount of solder on the board. The
effectiveness of the PC board to dissipate heat also depends on
the size, quantity and spacing of other components on the board,
as well as whether the surrounding air is still or moving. Circuit Data for Temperature Rise Curve
Furthermore, some of these components such as the catch
TO-263 Package (s)
diode will add heat to the PC board and the heat can vary as the
input voltage changes. For the inductor, depending on the Capacitors Surface mount tantalum, molded “D” size
physical size, type of Core material and the DC resistance, it Inductor Surface mount, Pulse Engineering, 68µH
could either act as a heat sink taking heat away from the board,
Diode Surface mount, 5A 40V, Schottky
or it could add heat to the board.
PC board 9 square inches single sided 2 oz. copper
(0.0028”)
FIGURE 20 . Junction Temperature Rise, To-263

Figure 21. Delayed Startup

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 LM2596

Application Information (Continued) 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 the inverted output voltage and regulates it.

FIGURE 22. Under voltage Lockout for Buck Regulator

DELAYED STARTUP
The circuit in figure 21 uses the /OFF pin to provide a time
delay between the time the input voltage is applied and the time This circuit has an ON/OFF threshold of approximately 13V.
the output voltage comes up (Only the circuitry pertaining to the FIGURE 23. Undervoltage Lockout for Inverting Regulator
delayed start up is shown). As the input voltage rises, the
charging of capacitor C1 pulls the /OFF pin high, keeping
This example uses the LM2596-5.0 to generate a -5V output,
the regulator off. Once the input voltage reaches its final value
but other output voltages are possible by selecting other output
and the capacitor stops charging, and resistor R2 pulls the
voltage versions, including the adjustable version. Since this
/OFF pin low, thus allowing the circuit to start switching.
regulator topology can produce an output voltage that is either
Resistor R1 is included to limit the maximum voltage applied to
greater than or less than the input voltage, the maximum output
the /OFF (maximum of 25V), reduces power supply noise
current greatly depends on both the input and output voltage.
sensitivity, and also limits the capacitor, C1, discharge current.
The curve shown in Figure 26 provides a guide as to the amount
When high input ripple voltage exists, avoid long delay time,
of output load current possible for the different input and output
because this ripple can be coupled into the /OFF pin and
voltage conditions.
cause problems.
The maximum voltage appearing across the regulator is the
This delayed startup feature is useful in situations where the
absolute sum of the input and output voltage, and this must be
input power source is limited in the amount of current it can
limited to a maximum of 40V. For example, when converting +20
deliver. It allows the input voltage to rise to a higher voltage
V to -12V, the regulator would see 32V between the input pin
before the regulator starts operating. Buck regulators require
and ground pin. The LM2596 has a maximum input voltage spec
less input current at higher input voltages.
of 40V.
Additional diodes are required in this regulator configuration.
UNDERVOLTAGE LOCKOUT
Diode D1 is used to isolate input voltage ripple or noise from
Some applications require the regulator to remain off until the
coupling through the CIN capacitor to the output, under light or
input voltage reaches a predetermined voltage. An undervoltage
no load conditions. Also, this diode isolation changes the
lockout feature applied to a buck regulator is shown in Figure 22,
topology to closely resemble a buck configuration thus providing
while Figure 23 and 24 applies the same feature to an inverting
good closed loop stability. A schottky diode is recommended for
circuit. The circuit in Figure 23 features a constant threshold
low input voltages, (because of its lower voltage drop) but for
voltage for turn on and turn off (zener voltage plus approximately
higher input voltages, a fast recovery diode could be used.
one volt). If hysteresis is needed, the circuit in Figure 24 has a
Without diode D3, when the input voltage is first applied, the
turn ON voltage which is different than the turn OFF voltage.
charging current of CIN can pull the output positive by several
The amount of hysteresis is approximately equal to the value of
volts for a short period of time. Adding D3 prevents the output
the output voltage. If zener voltages greater than 25V are used,
from going positive by more than a diode voltage.
an additional 47kΩ resistor is needed from the /OFF pin to
the ground pin to stay within the 25V maximum limit of
the /OFF pin.

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 LM2596

Application information (Continued)

This circuit has hysteresis

Regulator starts switching at VIN =13V
Regulator stops switching at VIN =8V
FIGURE 24. Undervoltage Lockout with Hysteresis for Inverting Regulator

CIN —68µF/25V Tant. Sprague 595D

470µF/50V Elec. Panasonic HFQ
COUT —47µF/20V Tant. Sprague 595D
220µF/25V Elec. Panasonic HFQ
FIGURE 25. Inverting -5V Regulator with Delayed Startup
of input current when starting up, even with light loads. Input
currents as high as the LM2596 current limit (approx 4.5A) 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. Bacause of the
relatively high startup currents required by the inverting topology,
the delayed startup feature (C1, R1 and R2) shown in Figure 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 input current needed for
startup is now supplied by the input capacitor (CIN). For severe start
up conditions, the input capacitor can be made much large than
normal.

FIGURE 26. Inverting Regulator Typical Load Current INVERTING REGULATOR SHUTDOWN METHODS
Because of differences in the operation of the inverting regulator, To use the /OFF pin in a standard buck configuration if simple,
the standard design procedure is not used to select the inductor pull it below 1.3V (@25 ℃, referenced to ground) to turn regulator
value. In the majority of designs, a 33µH, 3.5A inductor is the best ON, pull it above 1.3V to shut the regulator OFF. With the inverting
choice. Capacitor selection can also be narrowed down to just a few configuration, some level shifting is required, because the ground
values. Using the values shown in Figure 25 will provide good pin of the regulator is no longer at ground, but is now setting at the
results in the majority of inverting designs. negative output voltage level. Two different shutdown methods for
This type of inverting regulator can require relatively large amounts inverting regulators are shown in Figure 27 and 28.

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 LM2596

Application Information (Continued)

FIGURE 27. Inverting Regulator Ground Referenced Shutdown

FIGURE 28. Inverting Regulator Ground Referenced Shutdown using Opto Device
TYPICAL THROUGH HOLE PC BOARD LAYOUT, FIXED OUTPUT (1X SIZE), DOUBLE SIDED

CIN — 470µF,50V. Aluminum Electrolytic Panasonic,” HFQ Series”

COUT — 330µF,35V . Aluminum Electrolytic Panasonic,” HFQ Series”
D1 — 5A, 40V Schottky Rectifier, 1N5825
L1 — 47µF, L39, Renco, Through Hole
Thermalloy Heat Sink #7020

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 LM2596

Application Information (Continued)

TYPICAL THROUGH HOLE PC BOAD LAYOUT, ADJUSTABLE OUTPUT (1X SIZE), DOUBLE SIDED

CIN — 470µF,50V. Aluminum Electrolytic Panasonic,” HFQ Series”

COUT — 220µF,35V . Aluminum Electrolytic Panasonic,” HFQ Series”
D1 — 5A, 40V Schottky Rectifier, 1N5825
L1 — 47µF, L39, Renco, Through Hole
R1— 1KΩ,1%
R2 — Use formula in Design Procedure
CFF — See Figure 3.
Thermalloy Heat Sink #7020
FIGURE 29. PC Board Layout

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 LM2596

Physical Dimensions inches (millimeters) unless otherwise noted

5-Lead TO-220 (T)

Order Number LM2596T-3.3, LM2596T-5.0,
LM2596T-12 or LM2596T-ADJ
NS Package Number T05D

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 LM2596

Physical Dimensions inches (millimeters) unless otherwise noted

TS5B (REV B)
5-Lead TO-263 Surface Mount Package (S)
Order Number LM2596-3.3, LM2596S-5.0,
LM2596S-12 or LM2596S-ADJ
NS Package Number TS5B

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