Help with LM2596 IC Burnout Issue

  • Thread starter Thread starter Akmalidin
  • Start date Start date
  • Tags Tags
    Ic
Click For Summary

Discussion Overview

The discussion revolves around issues related to the LM2596 IC burning out when used to step down voltage from a bike dynamo. Participants explore potential causes, including the nature of the dynamo's output and the circuit design, while seeking advice on how to prevent further failures.

Discussion Character

  • Technical explanation
  • Debate/contested
  • Exploratory

Main Points Raised

  • One participant reports repeated failures of the LM2596 IC when stepping down voltage from a 16V bike dynamo to 5V, suggesting a short circuit between the input and output pins.
  • Another participant questions the reliability of the dynamo, asking if it produces stable DC voltage without peaks or sparks, and notes the datasheet's mention of external circuitry for undervoltage lockout.
  • Concerns are raised about the nature of the dynamo's output, with a suggestion to monitor the voltage at the reservoir capacitor to identify maximum input voltage to the LM2596.
  • Participants discuss the possibility of large voltage transients occurring when disconnecting the dynamo from the battery, particularly in older motorcycle models.
  • One participant confirms the use of a bridge rectifier and filtering capacitor, asserting that the dynamo produces +DC voltage.
  • A question is posed about creating a constant current source for 5V at 1.5A, regardless of voltage changes from the dynamo.
  • Another participant mentions that some bicycle lighting generators function as permanent magnet alternators without regulators, which could produce AC voltage.
  • There is a request for more information about the bike or generator model to better understand the situation.

Areas of Agreement / Disagreement

Participants express differing views on the nature of the dynamo's output and the potential causes of the LM2596 failures. There is no consensus on the exact issue or solution, and multiple competing theories are presented.

Contextual Notes

Participants note the absence of a bridge rectifier in the provided schematic, which may be a critical factor in the discussion. The conversation also highlights the uncertainty regarding the dynamo's characteristics and the implications for circuit design.

Who May Find This Useful

Individuals working on projects involving voltage regulation from dynamo sources, particularly in automotive or bicycle applications, may find this discussion relevant.

Akmalidin
Messages
69
Reaction score
6
Hi,

I have been using lm2596 recently for my project and encountered weird issue with it.
I am using it to step down the voltage from my bike dynamo which is 16v down to 5V for my front and back tail lights. But it is getting burned I guess when I ride the bike and I had 3 times changed the lm2596 IC. Therefore, I don't know what is wrong with it. when it crashed, there was short circuit between in and out pin. Here is my schematics. Please let me know your opinions and give advice.

upload_2017-3-28_23-58-1.png
 
Engineering news on Phys.org
- Is that dynamo reliable? Without voltage peaks/sparks? DC?
- I could not find what this chip does when Vin < Vout. The datasheet suggests some external circuitry for undervoltage lockout, this might suggest that it has no protection for it?
 
  • Like
Likes   Reactions: Akmalidin
Akmalidin said:
I am using it to step down the voltage from my bike dynamo which is 16v down to 5V for my front and back tail lights.
How certain are you that the dynamo produces +DC and not AC or –DC ?
The LM2596 should survive 40 volts input.
Maybe install a power diode between the generator and the reservoir capacitor, C1. Monitor that capacitor voltage to identify the maximum input voltage to the LM2596.
 
Akmalidin said:
I am using it to step down the voltage from my bike dynamo which is 16v down to 5V for my front and back tail lights. But it is getting burned I guess when I ride the bike and I had 3 times changed the lm2596 IC.
Bike? As in motorcycle?
Dynamo? As in brushed DC generator? What is the nature of its voltage regulator?
If turning off the ignition key disconnects your dynamo from your battery (as on some old dynamo equipped Harleys) you can expect a very large voltage transient at the dynamo when you switch off the ignition. Try a big rectifieir across input to your 2956, cathode to positive .

If instead your "dynamo" is the rectified 3 phase permanent magnet alternator typical on modern bikes, be aware that in absence of voltage regulator they can put out 60 volts at high RPM when electrical demand is low.

That's two possibilities for you to investigate.
 
Last edited:
Yes , dynamo is reliable. And I am using bridge rectifier with filtering capacitor and lm2596 input capacitor also helps to reduce/eliminate the picks.
 
Hi, I am certain that it produces +Dc since i am using bridge rectifier and capacitor. Ok I will try to put diode.
 
Is there any way to make a constant current source for 5v 1.5 A regardless of voltage change in dynamo?
 
Can you give the make, model and year of your bike or the generator?
Do you know if it is a generator or an alternator?
 
sophiecentaur taught me that some little bicycle lighting generators are nothing more than a permanent magnet alternator, sans regulator or controls.
That of course would produce AC . Filtering would be the thermal lag of incandescent head and tail lamps.
We've no idea what he has.

Akmalidin said:
Hi, I am certain that it produces +Dc since i am using bridge rectifier and capacitor.

There's no bridge rectifier shown on your drawing. Would you add it, and values of your components?
Akmalidin said:
I am certain that it produces +Dc
It's what we think we know that gets us in trouble.
 

Similar threads

Replies
8
Views
2K
  • · Replies 5 ·
Replies
5
Views
4K
Replies
1
Views
3K
Replies
12
Views
3K
  • · Replies 3 ·
Replies
3
Views
2K
  • · Replies 10 ·
Replies
10
Views
3K
  • · Replies 5 ·
Replies
5
Views
2K
Replies
7
Views
5K
  • · Replies 15 ·
Replies
15
Views
2K
  • · Replies 2 ·
Replies
2
Views
2K