14V/28V to 5.1V 2.5A USB Power Supply

by Eric.
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2 layer board of 1.87x1.37 inches (47.52x34.82 mm).
Shared on May 27th, 2017 23:14.

Cost: $12.80 for three boards.

CORRECTION: If you built my earlier share of this PCB and got 0.5V output, it can be fixed by lifting the right-hand leg of R2 out of its hole and wiring it to ground at pin 3 of the MPM01 module (the PCB incorrectly routed R2 to Vout). This version is corrected and works without modification.

Description: 14V/28V to 5.1V DC/DC power supply for use as a USB charger in Experimental category aircraft. For use with my Single USB Charging Adapter board.

This board includes filter components (C1-C4, FB1-FB2) to eliminate switching noise at ADS-B/transponder and VHF communications frequencies. D1, M1 and R1 provide reverse polarity protection.

For anyone who wants to use this board in situations that don’t require noise filtering at 127MHz and 1.09GHz, you can eliminate FB1, FB2 and C1-C4. Instead, install wire links from the top pin of M1 to the top pin of FB1 (with board oriented as in the image above), and across the pins of FB2. If you don’t need reverse polarity protection, eliminate D1, M1 and R1 as well, and install the first wire link from the center pin of M1 to the top pin of FB1.

Alternative output voltages can be obtained by changing the value of R2. See the Sanken MPM01 datasheet and application note for details.

Bill of Materials: Click here for a Digi-Key shopping cart containing all necessary components.

  • C1, C2: TDK Corporation FG18C0G1H4R7CNT06 4.7pF 50V ceramic capacitor
  • C3, C4: TDK Corporation FG18C0G1H331JNT06 330pF 50V ceramic capacitor
  • C5: KEMET ESW108M050AM7AA 1,000uF 20% 50V aluminum electrolytic capacitor
  • C6, C7: KEMET ESY108M035AL4AA 1,000uF 20% 35V aluminum electrolytic capacitor
  • D1: Fairchild/ON Semiconductor 1N5247B 17V 5% 500mW Zener diode
  • FB1, FB2: Laird-Signal Integrity Products 28C0236-0EW-10 998-ohm @ 100MHz 5A ferrite bead
  • J1: Phoenix Contact 1985218 3.5mm-pitch 4-position wire-to-board spring terminal block
  • M1: Infineon Technologies IRFU530PBF 55V 31A P-channel MOSFET
  • R1: Stackpole Electronics RNMF14FTC10K0 10k-ohm 1/4W 1% resistor
  • R2: Stackpole Electronics RNMF14FTD499R 499-ohm 1/4W 1% resistor
  • U1: Sanken Semiconductor MPM01 DC-to-DC converter module, 9-40Vin, 1.8-12Vout, 3A
  • Box: Bud Industries PB-1558-BF black ABS flanged potting box, 2"L x 1.5"W

Note: Do not substitute alternate parts for C1-C4 or FB1-FB2. These components were selected for their specific frequency/impedance characteristics. Other parts, even of the same value, may not provide the same noise filtering at the desired frequencies.

Download: Click here to download a .PDF schematic of this board.

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