I had some time this evening to assemble a prototype for the power supply. It immediately drew 1amp and started to blow up a capacitor. Not good. I’m not completely sure what was wrong. The only deviation had been using a 1N5818 diode instead of a 1N5822 on the feedback circuit. I don’t think this is critical and it looks like it’s used to bleed down voltage when the circuit is off.
There were a number of minor things wrong, so I incorporated some changes and made v1.2 The input/output headers weren’t labeled and were too close together for screw terminals. The diode pads were drilled too small and too close together, i.e. I used the wrong package size. I also didn’t like the input and output side by side. I also changed the package layout for the IC. I’m not going to bend the thing over on it’s side. That’s silly for this application.
I ordered new boards from OSHPark tonight. Should have them in a couple of weeks.
The new board layouts:
Old board layouts: