D2596HV
150kHz 3A Step-Down HV Voltage Regulator
General Description
The D2596HV series of regulators are monolithic integrated circuit
that provides all the active functions for a step-down (buck) switching
regulator, capable of driving 3A load with excellent line and load
TO220T-5L
regulation. The D2596HV available in fixed output voltages of 3.3V,
5V, 12Vand an adjustable output version.
Requiring a minimum number of external components, these
TO263-5L
regulators are simple to use and include internal frequency compensation and a fixed-frequency oscillator.
The D2596HV series operates at a switching frequency of 150 kHz thus allowing smaller sized filter
components than what would be needed with lower frequency switching regulators. A standard of inductors
optimized for use with the D2596HV are available from several different manufacturers. This feature greatly
simplifies the design of switch-mode power supplies.
Other features include a guaranteed ±4% tolerance on output voltage within specified input voltages and
output load conditions, and ±15% on the oscillator frequency. External shutdown is included, featuring 50µA
(typical) standby current. The output switch includes cycle-by-cycle current limiting, as well as thermal shutdown
for full protection under fault conditions.
The D2596HV is available in TO220T-5L and TO263-5L package.
Features
3.3V, 5V, 12V and Adjustable Output Versions
High Efficiency
Wide Input Voltage Range up to 60V for HV Version
Guaranteed 3A Output Current
Requires only 4 External Components
150 kHz Fixed Frequency Internal Oscillator
TTL Shutdown Capability, Low Power Standby Mode
Uses Readily Available Standard Inductors
Thermal Shutdown and Current Limit Protection
Adjustable Version Output Voltage Range, 1.23V to 57V ±4% Max Over Line and Load Conditions
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D2596HV
Applications
Simple High-Efficiency Step-Down (Buck) Regulator
Efficient Pre-Regulator for Linear Regulators
On-Card Switching Regulators
Positive to Negative Converter (Buck-Boost)
Functional Block Diagram
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D2596HV
Pin Configuration
TO220T-5L
TO263-5L
Pin Description
Pin Number
Pin Name
1
VIN
2
OUTPUT
3
GND
4
FEEDBACK
5
ON / OFF
Function Description
This is the positive input supply for the IC switching regulator.
A suitable input bypass capacitor must be present at this pin to minimize
voltage transients and to supply the switching currents needed by the
regulator.
Internal switch, the voltage at this pin switches between (+VIN VSAT)
and approximately -0.5V. To minimize coupling to sensitive circuitry,
the PC board copper area connected to this pin should be kept to a
minimum.
Circuit Ground
Senses the regulated output voltage to complete the feedback loop
Allows the switching regulator circuit to be shut down using logic level
signals.
Absolute Maximum Ratings
Parameter Name
Symbol
Value
Unit
VIN
63
V
ON / OFF
-0.3V≤V≤+VIN
V
Output Voltage to Ground(steady state)
VOUT
-1
V
Power Dissipation
PDMAX
Internally Limited
Storage Temperature Range
Tstg
-65~+150
℃
Maximum Junction Temperature
TJA
150
℃
ESD Susceptibility (Human Body Model)
ESD
2
kV
Lead Temperature (Soldering, 10 Seconds)
TL
260
℃
Maximum Supply Voltage
ON / OFF Pin Input Voltage
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D2596HV
Recommended Operating Conditions
Parameter Name
Symbol
Value
Unit
Supply Voltage
VIN
6~60
V
Operating temperature range
Topr
-40~+125
℃
Electrical Characteristics
(Unless otherwise specified: TJ = 25°C)
Parameter Name
Symbol
Test Conditions
Ib
Adjustable version only,
VOUT=5V
Min
Typ
Max
Units
50
100
nA
150
173
kHz
1.4
1.8
V
Device Parameters
Feedback Bias Current
Oscillator Frequency
VSAT Saturation Voltage
Max. Duty Cycle(ON)
Current Limit
fo
VSAT
DC
ICL
Output Leakage Current
IL
Quiescent Current
IQ
Standby Quiescent Current
ISTBY
127
IOUT=3A
(Note 1)
93
98
3.6
4.5
6.9
A
2
mA
7.5
30
mA
5
10
mA
50
200
µA
Output=0V
Output=-1V
ON / OFF pin=5V(OFF)
%
ON / OFF Control
ON / OFF Pin Logic
Input Level
ON / OFF Pin Input Current
VIH
VOUT=0V
VIL
IIH
VOUT=nominal output
voltage
ON / OFF pin=5V(OFF)
IIL
ON / OFF pin=0V(ON)
2.0
V
0.8
V
12
30
µA
0
10
µA
Note 1: The oscillator frequency reduces to approximately 11 kHz in the event of an output short or an overload which causes the
regulated output voltage to drop approximately 40% from the nominal output voltage. This self protection feature lowers the average
power dissipation of the IC by lowering the minimum duty cycle from 5% down to approximately 2%.
Output pin sourcing current. No diode, inductor or capacitor connected to output.
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D2596HV
Parameter Name
Symbol
Test Conditions
Min
Typ
Max
Units
VIN=12V, IO=500mA
6V≤VIN≤60V
0.5A≤ILOAD≤3A
VIN=12V, ILOAD=3A
3.234
3.3
3.366
V
3.168
3.3
3.450
V
VIN=12V, IO=500mA
8V≤VIN≤60V
0.5A≤ILOAD≤3A
VIN=12V, ILOAD=3A
4.90
5.00
5.10
V
4.80
5.00
5.20
V
VIN=25V, IO=500mA
15V≤VIN≤60V
0.5A≤ILOAD≤3A
VIN=25V, ILOAD=3A
11.76
12.000
12.24
V
11.52
12.00
12.48
V
Test Conditions
Min
Typ
Max
Units
1.217
1.230
1.243
V
1.193
1.230
1.267
V
D2596HV-3.3V
Output Voltage
VOUT
η
Efficiency
73
%
D2596HV-5.0V
Output Voltage
VOUT
η
Efficiency
77
%
D2596HV-12V
Output Voltage
VOUT
η
Efficiency
Parameter Name
Symbol
88
%
D2596HV-ADJ
Output Voltage
VOUT
Efficiency
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η
VIN=12V,IO=500mA,
VOUT=5V
8V≤VIN≤60V, VOUT=5V
0.5A≤ILOAD≤3A
VIN=12V,ILOAD=3A,
VOUT=5V
CHMC
77
%
Dec 2019 Rev. 2.0
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D2596HV
Test Circuit
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D2596HV
Typical Application
Application Information
Input Capacitor (CIN)
A low ESR aluminum or tantalum bypass capacitor is needed between the input pin and ground pin. It must
be located near the regulator using short leads. This capacitor prevents large voltage transients from appearing at
the input, and provides the instantaneous current needed each time the switch turns on.
The important parameters for the Input capacitor are the voltage rating and the RMS current rating. Because
of the relatively high RMS currents flowing in a buck regulator's input capacitor, this capacitor should be chosen
for its RMS current rating rather than its capacitance or voltage ratings, although the capacitance value and
voltage rating are directly related to the RMS current rating.
The RMS current rating of a capacitor could be viewed as a capacitor's power rating. The RMS current
flowing through the capacitors internal ESR produces power which causes the internal temperature of the
capacitor to rise. The RMS current rating of a capacitor is determined by the amount of current required to raise
the internal temperature approximately 10°C above an ambient temperature of 105°C. The ability of the capacitor
to dissipate this heat to the surrounding air will determine the amount of current the capacitor can safely sustain.
Capacitors that are physically large and have a large surface area will typically have higher RMS current ratings.
For a given capacitor value, a higher voltage electrolytic capacitor will be physically larger than a lower voltage
capacitor, and thus be able to dissipate more heat to the surrounding air, and therefore will have a higher RMS
current rating. The consequences of operating an electrolytic capacitor above the RMS current rating is a
shortened operating life. The higher temperature speeds up the evaporation of the capacitor's electrolyte, resulting
in eventual failure.
Selecting an input capacitor requires consulting the manufacturers data sheet for maximum allowable RMS
ripple current. For a maximum ambient temperature of 40°C, a general guideline would be to select a capacitor
with a ripple current rating of approximately 50% of the DC load current. For ambient temperatures up to 70°C, a
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D2596HV
current rating of 75% of the DC load current would be a good choice for a conservative design. The capacitor
voltage rating must be at least 1.25 times greater than the maximum input voltage, and often a much higher
voltage capacitor is needed to satisfy the RMS current requirements.
Because of their small size and excellent performance, surface mount solid tantalum capacitors are often used
for input bypassing, but several precautions must be observed. A small percentage of solid tantalum capacitors can
short if the inrush current rating is exceeded. This can happen at turn on when the input voltage is suddenly
applied, and of course, higher input voltages produce higher inrush currents. Several capacitor manufacturers do a
100% surge current testing on their products to minimize this potential problem. If high turn on currents are
expected, it may be necessary to limit this current by adding either some resistance or inductance before the
tantalum capacitor, or select a higher voltage capacitor. As with aluminum electrolytic capacitors, the RMS ripple
current rating must be sized to the load current.
With most electrolytic capacitors, the capacitance value decreases and the ESR increases with lower
temperatures and age. Paralleling a ceramic or solid tantalum capacitor will increase the regulator stability at cold
temperatures. For maximum capacitor operating lifetime, the capacitor’s RMS ripple current rating should be
greater than
t
1.2 ON
T
Where
and
I LOAD
tON VOUT
for a buck regulator
T
VIN
tON
| VOUT |
for a buck-boost regulator.
T
| VOUT | VIN
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D2596HV
Inductor Selection (L1)
All switching regulators have two basic modes of operation: continuous and discontinuous. The difference
between the two types relates to the inductor current, whether it is flowing continuously, or if it drops to zero for
a period of time in the normal switching cycle. Each mode has distinctively different operating characteristics,
which can affect the regulator performance and requirements. Most switcher designs will operate in the
discontinuous mode when the load current is low.
The D2596HV can be used for both continuous and discontinuous modes of operation.
In many cases the preferred mode of operation is the continuous mode. It offers greater output power, lower
peak switch, inductor and diode currents, and can have lower output ripple voltage. But it does require larger
inductor values to keep the inductor current flowing continuously, especially at low output load currents and/or
high input voltages.
To simplify the inductor selection process, an inductor selection guide (nomograph) was designed. This
guide assumes that the regulator is operating in the continuous mode, and selects an inductor that will allow a
peak-to-peak inductor ripple current to be a certain percentage of the maximum design load current. This
peak-to-peak inductor ripple current percentage is not fixed, but is allowed to change as different design load
currents are selected.
By allowing the percentage of inductor ripple current to increase for low load currents, the inductor value and
size can be kept relatively low.
When operating in the continuous mode, the inductor current waveform ranges from a triangular to a
sawtooth type of waveform (depending on the input voltage), with the average value of this current waveform
equal to the DC output load current.
Inductors are available in different styles such as pot core, toroid, E-core, bobbin core, etc., as well as
different core materials, such as ferrites and powdered iron. The least expensive, the bobbin, rod or stick core,
consists of wire wound on a ferrite bobbin.
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D2596HV
This type of construction makes for an inexpensive inductor, but since the magnetic flux is not completely
contained within the core, it generates more Electro-Magnetic Interference (EMl).
This magnetic flux can induce voltages into nearby printed circuit traces, thus causing problems with both
the switching regulator operation and nearby sensitive circuitry, and can give incorrect scope readings because of
induced voltages in the scope probe.
When multiple switching regulators are located on the same PC board, open core magnetics can cause
interference between two or more of the regulator circuits, especially at high currents. A torroid or E-core inductor
(closed magnetic structure) should 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 D2596HV. 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.
Feed-forward Capacitor (CFF, Adjustable Output Voltage Version)
A Feed-forward Capacitor CFF, shown across R2 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.
Catch Diode (D1)
Buck regulators require a diode to provide a return path for the inductor current when the switch is off. This
must be a fast diode and must be located close to the D2596HV using short leads and short printed circuit traces.
Because of their fast switching speed and low forward voltage drop, Schottky diodes provide the best efficiency,
especially in low output voltage switching regulators (less than 5V). Ultra-fast Recovery, or High-Efficiency
rectifiers are also a good choice, but some types with an abrupt turnoff characteristic may cause instability or
EMI problems. Ultra-fast recovery diodes typically have reverse recovery times of 50 ns or less. Rectifiers such
as the 1N5400 series are much too slow and should not be used..
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D2596HV
Output Capacitor (COUT)
An output capacitor is required to filter the output and provide regulator loop stability. Low impedance or
low ESR Electrolytic or solid tantalum capacitors designed for switching regulator applications must be used.
When selecting an output capacitor, the important capacitor parameters are; the 100 kHz Equivalent Series
Resistance (ESR), the RMS ripple current rating, voltage rating, and capacitance value. For the output capacitor,
the ESR value is the most important parameter.
The output capacitor requires an ESR value that has an upper and lower limit. For low output ripple voltage,
a low ESR value is needed. This value is determined by the maximum allowable output ripple voltage, typically
1% to 2% of the output voltage. But if the selected capacitor's ESR is extremely low, there is a possibility of an
unstable feedback loop, resulting in an oscillation at the output. Using the capacitors listed in the tables, or
similar types, will provide design solutions under all conditions.
An aluminum electrolytic capacitor’s ESR value is related to the capacitance value and its voltage rating. In
most cases, higher voltage electrolytic capacitors have lower ESR values. Often, capacitors with much higher
voltage ratings may be needed to provide the low ESR values required for low output ripple voltage.
The output capacitor for many different switcher designs often can be satisfied with only three or four
different capacitor values and several different voltage ratings.
Electrolytic capacitors are not recommended for temperatures below −25°C. The ESR rises dramatically at
cold temperatures and typically rises 3X @ −25°C and as much as 10X at −40°C.
Solid tantalum capacitors have a much better ESR spec for cold temperatures and are recommended for
temperatures below −25°C.
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D2596HV
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 voltage. To
obtain low ripple voltage, the ESR of the output capacitor must be low, however, caution must be exercised when
using extremely low ESR capacitors because they can affect the loop stability, resulting in oscillation problems. If
very low output ripple voltage is needed (less than 20 mV), a post ripple filter is recommended.
The inductance required is typically between 1μH and 5μH, with low DC resistance, to maintain good load
regulation. A low ESR output filter capacitor is also required to assure good dynamic load response and ripple
reduction. The ESR of this capacitor may be as low as desired, because it is out of the regulator feedback loop.
When observing output ripple with a scope, it is essential that a short, low inductance scope probe ground
connection be used. Most scope probe manufacturers provide a special probe terminator which is soldered onto
the regulator board, preferable at the output capacitor. This provides a very short scope ground thus eliminating
the problems associated with the 3 inch ground lead normally provided with the probe, and provides a much
cleaner and more accurate picture of the ripple voltage waveform.
The voltage spikes are caused by the fast switching action of the output switch and the diode, and the
parasitic inductance of the output filter capacitor, and its associated wiring. To minimize these voltage spikes, the
output capacitor should be designed for switching regulator applications, and the lead lengths must be kept very
short. Wiring inductance, stray capacitance, as well as the scope probe used to evaluate these transients, all
contribute to the amplitude of these spikes.
When a switching regulator is operating in the continuous mode, the inductor current waveform ranges from
a triangular to a sawtooth type of waveform (depending on the input voltage). For a given input and output voltage,
the peak-to-peak amplitude of this inductor 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.
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D2596HV
In a switching regulator design, knowing the value of the peak-to-peak inductor ripple current (ΔIIND) can be
useful for determining a number of other circuit parameters. Parameters such as, peak inductor or peak switch
current, minimum load current before the circuit becomes discontinuous, output ripple voltage and output
capacitor ESR can all be calculated from the peak-to-peak ΔIIND. When the inductor nomographs are used to select
an inductor value, the peak-to-peak inductor ripple current can immediately be determined. the range of (ΔIIND)
that can be expected for different load currents. The curve also shows how the peak-to-peak inductor ripple
current (ΔIIND) changes as you go from the lower border to the upper border (for a given load current) within an
inductance region. The upper border represents a higher input voltage, while the lower border represents a lower
input voltage.
These curves are only correct for continuous mode operation, and only if the inductor selection guides are
used to select the inductor value. Consider the following example:
VOUT = 5V, maximum load current of 2.5A
VIN = 12V, nominal, varying between 10V and 16V.
That the vertical line for a 2.5A load current, and the horizontal line for the 12V input voltage intersect
approximately midway between the upper and lower borders of the 33μH inductance region. A 33μH inductor will
allow a peak-to-peak inductor current (ΔIIND) to flow that will be a percentage of the maximum load current.
follow the 2.5A line approximately midway into the inductance region, and read the peak-to-peak inductor ripple
current (ΔIIND) on the left hand axis (approximately 620mA pp).
As the input voltage increases to 16V, it approaches the upper border of the inductance region, and the
inductor ripple current increases. it can be seen that for a load current of 2.5A, the peak-to-peak inductor ripple
current (ΔIIND) is 620mA with 12V in, and can range from 740mA at the upper border (16V in) to 500mA at the
lower border (10V in).
Once the ΔIIND value is known, the following formulas can be used to calculate additional information about
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D2596HV
the switching regulator circuit.
1. Peak Inductor or peaks switch current ( I LOAD
I IND
0.62
) (2.5 A
) 2.81A
2
2
2. Minimum load current before the circuit becomes discontinuous
I IND 0.62
0.31A
2
2
3. Output Ripple Voltage = (ΔIIND)×(ESR of COUT) = 0.62A×0.1Ω = 62 mV p-p
4. ESR of COUT =Output Ripple Voltage(ΔVOUT)/ ΔIIND=0.062V/0.62A=0.1Ω
Feedback Connection
The D2596HV (fixed voltage versions) feedback pin must be wired to the output voltage point of the
switching power supply. When using the adjustable version, physically locate both output voltage programming
resistors near the D2596HV to avoid picking up unwanted noise. Avoid using resistors greater than 100kΩ
because of the increased chance of noise pickup.
ON / OFF Input
For normal operation, the ON / OFF pin should be grounded or driven with a low-level TTL voltage
(typically below 1.6V). To put the regulator into standby mode, drive this pin with a high-level TTL or CMOS
signal. The ON / OFF pin can be safely pulled up to +VIN without a resistor in series with it. The ON / OFF pin
should not be left open.
Thermal Considerations
The D2596HV is available in two packages. The TO220T-5L package needs a heat sink under most
conditions. The size of the heatsink depends on the input voltage, the output voltage, the load current and the
ambient temperature. D2596HV 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 D2596HV (TO220T package) operating as
a buck switching regulator in an ambient temperature of 25°C (still air). These temperature rise numbers are all
approximate and there are many factors that can affect these temperatures. Higher ambient temperatures require
more heat sinking. The TO263-5L 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 in2, 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 in2, only
small improvements in heat dissipation are realized. If further thermal improvements are needed, double sided,
multilayer PC board with large copper areas and/or airflow are recommended.
D2596HV (TO263 package) junction temperature rise above ambient temperature with a 2A load for various
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D2596HV
input and output voltages. This data was taken with the circuit operating as a buck switching regulator with all
components mounted on a PC board to simulate the junction temperature under actual operating conditions. This
curve can be used for a quick check for the approximate junction temperature for various conditions, but be 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. Furthermore, some of these components such as
the catch diode will add heat to the PC board and the heat can vary as the input voltage changes. For the
inductor, depending on the physical size, type of core material and the DC resistance, it could either act as a
heat sink taking heat away from the board, or it could add heat to the board.
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D2596HV
Junction Temperature Rise
Capacitors
Inductor
Diode
PC Board
TO220T-5L
Through hole electrolytic
Through hole, Renco
Through hole, 5A 40V, Schottky
3 square inches single sided 2 oz. copper
(0.0028”)
TO263-5L
Surface mount tantalum, molded “D” size
Surface mount, Pulse Engineering, 68μH
Surface mount, 5A 40V, Schottky
9 square inches single sided 2 oz. copper
(0.0028”)
Inductor Value Selection Guides ( For Continuous Mode Operation)
D2596HV-3.3
D2596HV-12
D2596HV-5.0
D2596HV-ADJ
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D2596HV
Inductor Selection Guide
Diode Selection Guide
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D2596HV
Outline Dimensions
TO220T-5L:
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D2596HV
TO263-5L:
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D2596HV
Statements
Silicore Technology reserves the right to make changes without further notice to any products or
specifications herein. Before customers place an order, customers need to confirm whether datasheet
obtained is the latest version, and to verify the integrity of the relevant information.
Failure or malfunction of any semiconductor products may occur under particular conditions, customers
shall have obligation to comply with safety standards when customers use Silicore Technology products to
do their system design and machine manufacturing, and take corresponding safety measures in order to
avoid potential risk of failure that may cause personal injury or property damage.
The product upgrades without end, Silicore Technology will wholeheartedly provide customers integrated
circuits that have better performance and better quality.
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