Parts list
C1, 2
: 100nF, 250VAC polypropylene (RS 190-8539)
C3
: 680uF, 450V electrolytic
C4, 5, 6, 7, 8, 9, 10, 11
: 470nF, 630V polypropylene
C12, 13
: 1uF, 50V ceramic multilayer (RS 126-067)
C14
: 3.3nF, 1.6kV polypropylene
C15, 16
: 10nF, 250VAC polypropylene (RS 190-8472)
C17, 18, 19, 20, 21, 22
: 1000uF, 25V low ESR electrolytic (RS 105-997)
C23, 24
: 2200uF, 16V low ESR electrolytic (RS105-947)
C25, 26, 27, 28, 29, 30
: 100nF, 50V ceramic
C31
: 470nF, 50V ceramic multilayer
C32
: 22uF, 50V electrolytic
C33
: 10uF, 50V electrolytic
C34
: 1uF, 50V electrolytic
C35
: 33nF, 50V polyester
C36
: 4.7nF, 50V polyester
C37
: 330nF, 50V polyester or ceramic multilayer
C38
: 100æF, 10V electrolytic
D1
: Rectifier bridge, 1kV, 8A. GBPC810 or similiar.
D2, 4, 17
: Ultrafast diode, 1kV, 1A. UF4007 or similiar. Lower
voltage (down to 100V) is acceptable.
D3, 5
: Ultrafast diode 1kV, 3A. UF5408 or similiar.
D6, 7, 8, 9
: Dual Schottky diode, 100V, 30A total. PBYR30100CT
or similiar. Single diode would also be suitable.
D10, 11, 12, 13, 14, 15, 16, 18 : 1N4148 switching diode
FB1, 2
: Amidon FB-73-801 ferrite bead, slipped over wire.
FB3..14
: Amidon FB-73-2401 ferrite beads, slipped six each
over the two 13.8VDC output cables.
L1
: Common mode choke, 8mH each winding, 6A.
I used junk box specimen. RS 288-159 is suitable.
L2:
: 20uH, 60A choke. 15 turns on Amidon T-157-26
toroid. Wound with ten #16 enameled wires
in parallel.
L3:
: 5uH (uncritical), 60A choke. 10 turns on ferrite solenoid,
10mm diameter, 50mm long. Wound with two #11
wires in parallel.
LED1
: Dual LED, green-red, common cathode
M1
: 12V 5W brushless DC fan, 120 x 120 x 25mm
NTC1, 2
: Inrush current limiter, 2.5R cold resistance (RS 191-2005)
P1
: CEE-22 male connector with integrated fuse holder
and EMI filter, 250VAC, 6A, (RS 210-291)
Q1, 2
: High voltage switching transistor, BUH1215 or similiar.
Must resist at least 400Vceo , and maintain a
beta of over 12 at a current level of 8A. (RS 859-874)
Q3, 4
: BC639-16 transistor. Must resist 100V and 0.5A.
Q5
: BD683 darlington transistor
R1, 5
: 10R, 5W low inductance preferred
R2, 6
: 180kR, 0.5W carbon
R3, 7, 19
: 1R, 1W carbon
R4, 8
: 2,7kR, 0.25W carbon
R9
: 47R, 5W low inductance preferred
R10, 11
: 1.8R, 2W low inductance preferred
R12
: 180R, 0.5W carbon
R13
: 3.3kR, 0.25W carbon
R14
: 1.5kR, 0.5W carbon
R15, 16
: 3.9kR, 0.25W carbon
R17, 18, 32, 33, 36, 38
: 1kR, 0.25W carbon
R20
: 22R, 0.5W carbon
R21, 22, 23, 24
: 4.7kR, 0.25W carbon
R25, 27, 29
: 22kR, 0.25W carbon
R26
: 4.3kR, 0.25W carbon
R28
: 13kR, 0.25W carbon
R30
: 12kR, 0.25W carbon
R31
: 10kR, 0.25W carbon
R34
: 1MR, 0.25W carbon
R35, 37
: 27kR, 0.25W carbon
R39
: 33R, 2W carbon
SW1
: 2-pole power switch, 250VAC, 10A
T1
: Primary 15 turns, secondary 2+2 turns. Wound with
copper foil and mylar sheet. Uses four Amidon
EA-77-625 ferrite E-cores (8 halves). Equivalents
include Thomson GER42x21x15A, Phillips 768E608,
TDK EE42/42/15. See text for winding instructions.
T2
: Secondary is 100+100 turns #36 enamel wire. Primary
is one turn #15 plastic insulated cable, wound on
secondary. Wound on Amidon EE24-25-B bobbin. Uses an
Amidon EA-77-250 core. Equivalents are Thomson
GER25x10x6, Phillips 812E25Q, TDK EE25/19.
T3
: Control winding is 26+26 turns #27 enamel wire.
Base windings are 8 turns #20 each. Collector winding
is one turn #15 plastic insulated cable. Bobbin and
core like T2. See text.
U1
: Pulse width modulator IC, LM3524, SG3524, UC3524 or
similiar.
U2
: Quad single supply operational amplifier, LM324
or similar.
U3
: 5V voltage reference, LM336Z-5.0 or similiar.
VR1, 2, 3
: 1kR PCB mounted trimpot
Miscellaneous:
Printed circuit board
Two pole screw terminal for 40A
Power cable
6 ceramic insulators for the power transistors and Schottky diodes
6 M3 nylon screws and nuts
3mm and 1mm aluminum sheet, 10x10x1mm aluminum angle stock, some wire
mesh,
4 rubber feet, and assorted hardware for building the box.
A lot of enthusiasm!