12V to 24V @ 1A Step-up switching regulator using LM2585

Schematic

Description

This is a DC-DC step-up converter based on LM2585-ADJ regulator manufactured by Texas Instruments. This IC was chosen for its simplicity of use, requiring minimal external components and for its ability to control the output voltage by defining the feedback resistors (R1,R2). NPN switching/power transistor is integrated inside the regulator and is able to withstand 3A maximum current and 65V maximum voltage. Switching frequency is defined by internal oscillator and it’s fixed at 100KHz.

LM2585_pinout
The power switch is a 3-A NPN device that can standoff 65 V. Protecting the power switch are current and thermal limiting circuits and an under-voltage lockout circuit. This IC contains a 100-kHz fixed-frequency internal oscillator that permits the use of small magnetics. Other features include soft start mode to reduce in-rush current during start-up, current mode control for improved rejection of input voltage, and output load transients and cycle-by-cycle current limiting. An output voltage tolerance of ±4%, within specified input voltages and output load conditions, is specified for the power supply system.

Specifications

  • Vin: 10-15V DC
  • Vout: 24V DC
  • Iout: 1A (can go up to 1.5A with forced cooling)
  • Switching Frequency: 100KHz

Schematic is a simple boost topology arrangement based on datasheet. Input capacitors and diode should be placed close enough to the regulator to minimize the inductance effects of PCB traces. IC1, L1, D1, C1,C2 and C5,C6 are the main parts used in voltage conversion. Capacitor C3 is a high-frequency bypass capacitor and should be placed as close to IC1 as possible.

All components are selected for their low loss characteristics. So capacitors selected have low ESR and inductor selected has low DC resistance.

At maximum output power, there is significant heat produced by IC1 and for that reason, we mounted it directly on the ground plane to achieve maximum heat dissipation.

Block Diagram

Measurements

CH1: Output Voltage ripple with 12V Input and 24V @ 500mA output – 5.3 Vpp – CH2: voltage at PIN 4 of IC1
CH1: Output Voltage ripple with 12V Input and 24V @ 1A output – 4.6Vpp – CH2: voltage at PIN 4 of IC1

Thermal Performance

Vin= 12V , Vout = 24V @ 500mA
Vin= 12V , Vout = 24V @ 1A

Photos

If you would like to receive a PCB, we can ship you one for 6$ (worldwide shipping) click here to contact us

Parts List

PartValuePackageMPNMouser No
C1 C233uF 25V 1Ω6.3 x 5.4mmUWX1E330MCL1GB647-UWX1E330MCL1
C30.1uF 50V 0Ω1206C1206C104J5RACTU80-C1206C104J5R
C41uF 25V1206C1206C105K3RACTU80-C1206C105K3R
C5 C6220uF 35V 0.15Ω10 x 10.2mmEEE-FC1V221P667-EEE-FC1V221P
D10.45 V 3A 40V SchottkySMBB340LB-13-F621-B340LB-F
IC1LM2585S-ADJTO-263LM2585S-ADJ/NOPB926-LM2585S-ADJ/NOPB
L1120 uH 0.04Ω30.5 x 25.4 x 22.1 mmPM2120-121K-RC542-PM2120-121K-RC
R128 KΩ1206ERJ-8ENF2802V667-ERJ-8ENF2802V
R2 R31.5 KΩ1206ERJ-8ENF1501V667-ERJ-8ENF1501V
R41 KΩ1206RT1206FRE07931KL603-RT1206FRE07931KL
LED1RED LED 20mA 2.1V0805599-0120-007F645-599-0120-007F

Connections

 

Gerber View

Simulation

We’ve done a simulation of the LM2585 step-up DC-DC converter using the TI’s WEBENCH online software tools and some of the results are presented here.

The first graph is the open-loop BODE graph. In this graph, we see a plot of GAIN vs FREQUENCY in the range 1Hz – 1M and PHASE vs FREQUENCY in the same range. This plot is useful as it gives us a detailed view of the stability of the loop and thus the stability and performance of our DC-DC converter.

simulation_1

Bode plot of open control loop

What’s interesting on this plot is the “phase margin” and “gain margin“. The gain margin is the gain for -180deg phase shift and phase margin is the phase difference from 180deg for 0db gain as shown in the plot above. For the system to be considered stable there should be enough phase margin (>30deg) for 0db gain or when phase is -180deg the gain should be less than 0db.

On the plot above we see that the phase margin is ~90deg and that ensures that the DC-DC converter will be stable over the measured range.

The next simulation graph is the Input Transient plot over time.

simulation_2

Input Transient simulation



In this plot, we see how the output voltage is recovering when the input voltage is stepped from 10V to 15V. We see that 4ms after the input voltage is stepped the output has recovered to the normal output voltage of 24V.

The next graph is the Load Transient.

simulation_3

Load Transient simulation

Load transient is the response of output voltage to sudden changes of load or Iout. We see that the output current suddenly changes from 0,1A to 1A and that the output voltage drops down to 23,2V until it recovers in about 3ms. We also see that when the load is reduced from 1A to 0,1A, output voltage spikes up to ~25,5V, then rings until it recovers to 24V in about 4ms.

The last graph shows the Steady State operation of DC-DC converter @ 1A output.

simulation_4

This graph shows the simulated output voltage ripple and inductor current. We see that output voltage ripple is ~0,6Vpp and the inductor current has a peak current of 2,4A. The inductor we used is rated at max 5,6A DC so it can easily withstand such operating current and without much heating of the coil.

Operating point data (Vin=13V, Iout=1A)

Operating Values
Pulse Width Modulation (PWM) frequency Frequency 100 kHz
Continuous or Discontinuous Conduction mode Mode Cont
Total Output Power Pout 24.0 W
Vin operating point Vin Op 13.00 V
Iout operating point Iout Op 1.00 A
Operating Point at Vin= 13.00 V,1.00 A
Bode Plot Crossover Frequency, indication of bandwidth of supply Cross Freq 819 Hz
Steady State PWM Duty Cycle, range limits from 0 to 100 Duty Cycle 48.3 %
Steady State Efficiency Efficiency 93.2 %
IC Junction Temperature IC Tj 65.2 °C
IC Junction to Ambient Thermal Resistance IC ThetaJA 34.9 °C/W
Current Analysis
Input Capacitor RMS ripple current Cin IRMS 0.14 A
Output Capacitor RMS ripple current Cout IRMS 0.48 A
Peak Current in IC for Steady State Operating Point IC Ipk 2.2 A
ICs Maximum rated peak current IC Ipk Max 3.0 A
Average input current Iin Avg 2.0 A
Inductor ripple current, peak-to-peak value L Ipp 0.50 A
Power Dissipation Analysis
Input Capacitor Power Dissipation Cin Pd 0.01 W
Output Capacitor Power Dissipation Cout Pd 0.035 W
Diode Power Dissipation Diode Pd 0.45 W
IC Power Dissipation IC Pd 1.0 W
Inductor Power Dissipation L Pd 0.16 W

Configuring Output Voltage

The output voltage is configured by R1, R2 according to the following expression (Vref=1,23V)

VOUT = VREF (1 + R1/R2)

If R2 has a value between 1k and 5k we can use this expression to calculate R1:

R1 = R2 (VOUT/VREF − 1)

For better thermal response and stability it is suggested to use 1% metal film resistors.

Measurements

measurements_1

measurements_2

Video

LM2585-ADJ Datasheet

lm2585

PCB

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Scott

how do I purchase the PCB for this?

Thomas A.

Hi! Thank you for this schematic. My only question is about PCB size needed for this (too huge for my application). I need a 24V output from a 12V battery, at 1A, but only by peaks (ie. 10ms of [email protected] every second, max).
After a simulation on WEBENCH, I need a [email protected],5A inductor (why don’t I get the same results as yours?). What if I use a [email protected],8A inductor? It should be OK given that the average output current should be less than 1% of 1A (10mA), no?
Thank you

Nadav M.

Thanks for a great write-up, Michail!

I’d like to use this module for running a NIcad 120x38mm fan, but have some concerns about the initial current draw. The fan is rated at 0.27A and 24V, however, I get the sense that it draws much more power than that during the start-up phase (it’s a heavy fan so the blades take a (relatively) significant amount of power to reach maximum speed. As to how much additional current is consumed at that stage, I don’t know, but wouldn’t be surprised if it reached something like 2.5-3A. Is there a simple way of modifying this module to withstand this level of current (I don’t mind paying for more robust parts etc.). Your advice on this would be much appreciated!

sambasivam

How to calculate inductor value? Give me some formulas if you know.

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