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I am trying to regulate a 5V input, which drops to around 3.5V when a large load is applied. I need to keep the 5V steady, and I am willing to do this at the expense of current, which is why I thought that using a boost regulator is appropriate here.

Since my input voltage can be slightly above 5V when the load is small, and under 5V when the load is large, I think I need to use a SEPIC regulator. The datasheet for MIC2296 says that it can be used in this way, although it does not provide a sample schematic.

Here's what I have so far: enter image description here

enter image description here

There are two problems with it.

  1. It is unstable. A correct voltage is provided for the first minute or so (although it oscillates by ~200mV even during this period). The voltage at "FB" pin hovers around 1.2V (shouldn't it be @Vref, which is 1.24V?). After a minute the output voltage suddenly spikes and goes up to ~9V. Voltage at "FB" drops to ~0.9V. At this point I have to disconnect power, since my load resistor can't handle too much current.
  2. If I power on my actual circuit with this regulator and then activate the current hungry load, the regulator fails to keep the voltage at 5V and allows it to drop to < 4V, so the regulator is not doing its job of trading current for voltage. Why?

The load in the circuit will switch between a light load (~50mA) and a heavy load. The heavy load will be anywhere between 500mA and 800mA, depending on what my battery pack can provide at 5V.

What can I do troubleshoot these problems?

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  • \$\begingroup\$ You seem surprised. \$\endgroup\$ Apr 25, 2014 at 4:14
  • \$\begingroup\$ @IgnacioVazquez-Abrams: Why shouldn't I be surprised? The circuit is not working in accordance with my current understanding of the subject. Obviously my understanding is lacking, but this is why I would appreciate your help. \$\endgroup\$
    – Val Blant
    Apr 25, 2014 at 4:19
  • \$\begingroup\$ You can only trade current for voltage if you aren't actually using all the current available from the supply. \$\endgroup\$ Apr 25, 2014 at 4:20
  • \$\begingroup\$ @IgnacioVazquez-Abrams: Oh I see what you mean. I don't think that in this case the problem was that the battery was tapped out. I just did an experiment using a 5V wall adapter instead of the battery. Vout was 5V, with a test load resistor drawing 45mA. I then hooked up a parallel resistor that should have taken the current to 147mA. Obviously this is well withing the capabilities of a wall power adapter. What I observed was that the Vout first fell to 2.9V, then went back up to 5V, and finally increased to 9V, where I had to quickly unplug it. So it's back to the instability problem. \$\endgroup\$
    – Val Blant
    Apr 25, 2014 at 4:31
  • \$\begingroup\$ Can you tell why you have used C1 and L2 in your circuit? None of the sample circuits provided in the datasheet is using them. \$\endgroup\$
    – Avin
    Apr 25, 2014 at 6:29

2 Answers 2

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It's hard to trouble shoot these types of situations remotely. Let's start with your two problems, and see what can be said about them.

  1. "It is Unstable" Well, maybe not.

    • The 200mV on the output could just be ripple. Given the amount of ripple current, and enough ESR in \$C_{\text{out}}\$, that would be a reasonable amount of ripple. If the 200mV is at 600kHz, then it's ripple not oscillation.

    • \$V_{\text{FB}}\$ dropping from ~1.2V to ~0.9V would cause \$V_{\text{out}}\$ to shoot up (I'm actually surprised it doesn't go up more than that). The regulator would be reacting to raise \$V_{\text{FB}}\$ back to 1.2V. The only reason \$V_{\text{FB}}\$ stays at 1.2V is due to feedback and regulation. Also, you don't get to observe \$V_{\text{ref}}\$, it has to be inferred from \$V_{\text{FB}}\$. That this happens after "a minute or so" suggests that it is a thermal thing not an electronic thing. It is as though \$R_1\$ loses proper connection and that allows \$R_2\$ to pull \$V_{\text{FB}}\$ low. These peg type breadboards, with use, can get the contacts deformed so connections get intermittent or thermally sensitive. Do any of the parts get hot (especially \$\text{IC}_1\$, \$C_{\text{out}}\$, or \$D_1\$), and what happens if \$R_1\$ is removed?

  2. At higher loads "regulator fails to keep the voltage at 5V and allows it to drop to < 4V" ... "Why?" There are a bunch of possible causes.

    • First, switching power supplies convert power. If the supply were perfect \$P_{\text{out}}\$ would equal \$P_{\text{in}}\$. That means that for a constant load, if \$V_{\text{in}}\$ went down, \$I_{\text{in}}\$ would have to go up a corresponding amount. So, the input of a switching supply looks like a negative resistance (or impedance). If the source output resistance is not less than the supply input resistance, at the least the source voltage will be pulled down and commonly will oscillate.

    • There are all kind of possible problems with breadboards. Things like parasitic resistances and inductances (in the board and in the components) can have a big impact on SMPS operation. For example, the breakout board that \$\text{IC}_1\$ is mounted on could be a problem both thermally and inductively. MIC2296 needs an amount of copper pad to get rid of heat properly (usually specified on the datasheet, although I didn't see it).


Some things to expect from this regulator

For a SEPIC, output voltage to input voltage can be related as:

M = \$\frac{V_{\text{out}}}{V_{\text{in}}}\$ = \$\frac{D}{1-D}\$ where \$\ D\$ is duty cycle (in constant conduction mode)

also, \$\ D\$ = \$\frac{V_{\text{out}}}{V_{\text{in}}+V_{\text{out}}}\$

If \$V_{\text{in}}\$ = \$V_{\text{out}}\$, then \$\ D\$ will be 0.5. This gives an easy way to calculate the current for boundary conduction mode (BCM, where operation goes from CCM to DCM). Just calculate peak to peak ripple current in \$L_1\$ when \$V_{\text{in}}\$ is 5V and BCM current will be half that.

\$i_{L-\text{ppk}}\$ = \$\frac{D V_{\text{in}} T_s}{L}\$ ~ 400mA

So, with \$L_1\$ = 10uH, the boundary for continuous conduction will be \$I_{\text{in}}\$~200mA. Usually best to choose CCM or DCM since the loop dynamics are different. CCM dynamics are more complicated (2 poles +2 poles in a SEPIC), but if compensated for CCM will stay stable for DCM (just not optimal in DCM). An advantage of CCM is that peak currents are lower in the switch and inductors, and output ripple voltage is lower. If you want CCM down to 50mA, L will need to be about 40uH.

Average \$I_{\text{in}}\$ and \$I_{\text{out}}\$ are related as:

\$I_{\text{in}}\$ = \$\frac{D I_{\text{out}}}{1-D}\$

To get peak input current just add half the inductor ripple current.

Peak switch current would be \$I_{\text{in}}\$+\$I_{\text{out}}\$+\$i_{L-\text{ppk}}\$ since the switch sees the current of both inductors. MIC2296 has a max switch current of 1.2A (chip will limit current there).

And that's kind of tough, since at \$V_{\text{in}}\$ of 3V (and D of 0.625), \$I_{\text{out}}\$ will be limited to ~ 300mA.

Some good references for SEPIC are SLYT309 and SLUA158

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You don't specify clearly how large the load is in your application.

Trying to get a high frequency DCDC to work on a experiment board is not easy. Stray capacitances, no ground plane and god knows what.

For a SEPIC you could have a look at the LT3460 datasheet, at the last page is a schematic with component values.

A simple approach could be to use a linear regulator to keep the voltage below 5V and a step up regulator in front of it. You will loose efficiency of course. And the power loss might be too high for your application.

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  • \$\begingroup\$ The large load will be anywhere between 500mA and 800mA, depending on what my battery pack can provide at 5V. Efficiency is crucial here, since the whole thing is a solar panel project. \$\endgroup\$
    – Val Blant
    Apr 25, 2014 at 8:07
  • \$\begingroup\$ @ValBlant What is your load though? We need to understand what kind of load you have so that we can understand whether it's linear or non-linear in nature. \$\endgroup\$
    – horta
    Apr 25, 2014 at 10:22
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    \$\begingroup\$ It's worth pointing out to the op that the LT3460 isn't suitable for his application - it hasn't got the amperage capabilities. \$\endgroup\$
    – Andy aka
    Apr 25, 2014 at 11:06
  • \$\begingroup\$ @horta: The load is a circuit with an Arduino Mini, an LCD screen, and then another buck converter down to 1.8V, which is used to charge a AA NiMH battery via a constant current sink (an LED Driver chip). \$\endgroup\$
    – Val Blant
    Apr 25, 2014 at 12:51

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