Hello.

In my "high current" MAX1771 PSU design I made several years ago, the
best results I got when I used a toroidal inductor with a current
rating of 10.3 A (Bourns 2200LL-470-RC), and a RSENSE peak current
setting of 5.33 A.  I tried other inductors, including a physically
smaller 2100LL series inductor (with a smaller current limit), but the
efficiency was not good as the 2200LL.  I don't know why.

Several notes that may help (based on my personal experience only):

- The FET drain tab is the source of a great amount of noise.  The FET
drain should be placed as far away from the FB pin trace as reasonably
possible.  An SMD (D2PAK) FET may be better than a TO-220 one because
of the horizontal placement on the PCB (also for better cooling of the
FET).
- I have never observed any interference from the inductor, but then I
use toroidal inductors which are supposed to be self-shielding.  I
once did get good results with an unshielded Bourns 1110 series
inductor, however.
- For RSENSE I use several 0.075 Ohm 1/4 W resistors in parallel.
They are cheaper than a single larger resistor, and it's easier to
adjust the peak current value.
- A diode between the REF and FB pins may help if the MAX1771 has
trouble starting up.  The MAX1771 can enter 12 V fixed output mode if
the supply voltage is larger than 12 volts and the voltage at the FB
pin is too low (because of the high input:output ratio of the voltage
divider).  On the other hand, many other people's designs seem to be
working fine without this diode.

My present design uses a Bourns 2200LL-470-V-RC inductor and an
FDB28N30TM FET (0.129 Ohm ON resistance).  The maximum power output in
a testbench situation was 24.9 W at 85 % efficiency with 14 V input
and 220 V output.  Board size is 50 mm x 40 mm.  I use three of these
units in parallel to provide 40 watts at 250 V in a (non-Nixie)
project.

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