2 layers145.6 × 200 mm Aurora dsp icepower booster, the printed circuit board in 3D

Aurora dsp icepower booster

Q: How big is the Aurora dsp icepower booster PCB?

It measures 145.6 × 200 mm and has 2 copper layers, 1.6 mm thick.

Q: What parts does the Aurora dsp icepower booster use?

269 parts, built around the TEL 5-2422, LM4562NA, PESD5V0S1BL and BSS138. The full list of its parts is on this page, with links to each part's symbol and footprint where PCBKit's library has them.

Q: Where can I download the Aurora dsp icepower booster KiCad files?

From the jpsamuelson/aurora-icepower-booster repository on GitHub, at the commit this page was made from: the board is aurora-dsp-icepower-booster.kicad_pcb and its schematic aurora-dsp-icepower-booster.kicad_sch. PCBKit opens the board in the browser, with nothing to install.

Q: Can I use the Aurora dsp icepower booster design in my own project?

Its repository states no licence, so its author keeps all rights: ask jpsamuelson before reusing the design.

jpsamuelson/aurora-icepower-booster

Balanced buffer / booster between aurora-freeDSP and ICEpower xxxASX2 amps.

Open in PCBKit

Size: 145.6 × 200 mm
Copper layers: 2
Thickness: 1.6 mm
Parts: 269
Nets: 141
Pads: 717
Tracks, vias: 1,490, 332
Pours: 2
Routed: Yes
KiCad: KiCad 9.0 (file 20241229)
Created: 23 Mar 2026
Updated: 24 Mar 2026

Overview

Aurora dsp icepower booster is an open-source printed circuit board by jpsamuelson, from the jpsamuelson/aurora-icepower-booster repository on GitHub. It is a 2-layer board of 145.6 × 200 mm with 269 parts on 141 nets, routed with 1,490 tracks and 332 vias.

It is built around the TEL 5-2422, LM4562NA and PESD5V0S1BL, with the BSS138, BLM18PG221SN1 and SMBJ15CA among its other parts. Its parts include 113 resistors, 81 capacitors, 25 diodes, 15 ICs and 15 connectors. It belongs with the audio and music boards of this library.

Main components

README

README.md

Aurora DSP ICEpower Booster

6-Channel Balanced Audio Interface — Aurora FreeDSP → ICEpower Amplifier Modules

This board sits between an Aurora FreeDSP DSP processor and six ICEpower Class-D amplifier modules. It receives 6 balanced audio signals from the DSP, applies adjustable gain (0–11.3 dB), protects the signals, and outputs them as balanced XLR signals.

Schematic

Features

6 identical channels — balanced XLR input & output
LM4562 low-noise dual op-amps — THD+N 0.00003%, 2.7 nV/√Hz
0–11.3 dB gain in 8 steps via 3-bit DIP switch per channel
100 ms power-on muting — BSS138 MOSFET chain prevents pop noise
Remote enable via 3.5mm jack (Aurora FreeDSP compatible)
Full ESD protection — PESD5V0S1BL on all signal I/O, SMBJ15CA on remote
Isolated power supply — TRACO TEL5-2422 DC/DC → ADP7118/ADP7182 LDOs (±11V)
JLCPCB-ready — 2-layer FR-4, all components LCSC-available

Specifications

Parameter	Value
Channels	6 (identical)
Input	6× XLR Female, Pin 2 = Hot, Pin 3 = Cold, Pin 1 = GND
Output	6× XLR Male, Pin 2 = Hot, Pin 3 = Cold, Pin 1 = GND
Power Supply	24V DC (Barrel Jack)
Op-Amp Supply	±11V (low-noise LDO)
Gain Range	0 dB to +11.3 dB (8 steps via DIP switch)
Input Impedance	~10 kΩ balanced
Output Impedance	~47Ω (series R)
Input CMRR	~62 dB (4× 10kΩ 0.1% metal film)
SNR Target	> 100 dB
THD+N Target	< 0.01% @ 1 kHz
Remote Interface	KH-PJ-320EA-5P-SMT 3.5mm jack (Aurora FreeDSP Custom Out)
Manufacturing	JLCPCB, 2-Layer, FR-4, HASL, 145.6 × 200 mm

System Overview

mermaid

graph LR
    DSP["Aurora FreeDSP\n(6× XLR Out)"]
    BOARD["Aurora DSP\nICEpower Booster"]
    AMP1["ICEpower #1"]
    AMP2["ICEpower #2"]
    AMP3["ICEpower #3"]
    AMP4["ICEpower #4"]
    AMP5["ICEpower #5"]
    AMP6["ICEpower #6"]
    PSU["24V DC\nPower Supply"]
    REMOTE["FreeDSP\nRemote Out"]

    DSP -->|"CH1 XLR Balanced"| BOARD
    DSP -->|"CH2 XLR Balanced"| BOARD
    DSP -->|"CH3 XLR Balanced"| BOARD
    DSP -->|"CH4 XLR Balanced"| BOARD
    DSP -->|"CH5 XLR Balanced"| BOARD
    DSP -->|"CH6 XLR Balanced"| BOARD
    PSU -->|"24V"| BOARD
    REMOTE -->|"3.5mm Enable"| BOARD
    BOARD -->|"CH1 +Gain"| AMP1
    BOARD -->|"CH2 +Gain"| AMP2
    BOARD -->|"CH3 +Gain"| AMP3
    BOARD -->|"CH4 +Gain"| AMP4
    BOARD -->|"CH5 +Gain"| AMP5
    BOARD -->|"CH6 +Gain"| AMP6

Signal Chain Overview

All 6 channels are identical. Each channel consists of 5 stages:

mermaid

flowchart LR
    XIN["XLR IN\nJ3–J8"]
    ESD1["ESD Protection\nInput"]
    EMI["EMI Filter\n47Ω + 100pF"]
    DC["DC Blocking\n2.2µF C0G"]
    DIFF["Diff Receiver\nLM4562 Unit A"]
    GAIN["Gain Stage\nLM4562 Unit B"]
    MUTE["Muting\nBSS138"]
    DRV["Balanced Driver\nLM4562 (2nd IC)"]
    ZOB["Zobel\n10Ω + 100nF"]
    ESD2["ESD Protection\nOutput"]
    XOUT["XLR OUT\nJ9–J14"]

    XIN --> ESD1 --> EMI --> DC --> DIFF --> GAIN --> MUTE --> DRV --> ZOB --> ESD2 --> XOUT

Stage	Function	Key Components
1. ESD & EMI Filter	Overvoltage protection + RF filtering	PESD5V0S1BL, 47Ω + 100pF, 2.2µF C0G DC blocking
2. Diff Receiver	Balanced → single-ended, CMRR ~62 dB	LM4562 Unit A, 4× 10kΩ 0.1%
3. Gain Stage	Inverting amp, 0–11.3 dB adjustable	LM4562 Unit B, DIP switch + 3 parallel R
4. Muting	Power-on pop suppression, τ = 100 ms	BSS138 N-MOSFET, RC timing
5. Balanced Driver	Single-ended → balanced output	LM4562 (buffer + inverter), 47Ω series R, Zobel network

→ Full signal chain documentation with schematics and formulas

Gain Configuration

SW Pos 1 (30kΩ)	SW Pos 2 (15kΩ)	SW Pos 3 (7.5kΩ)	Gain (dB)
OFF	OFF	OFF	0.0 dB
OFF	OFF	ON	+2.5 dB
OFF	ON	OFF	+4.4 dB
OFF	ON	ON	+6.0 dB
ON	OFF	OFF	+7.4 dB
ON	OFF	ON	+8.5 dB
ON	ON	OFF	+9.5 dB
ON	ON	ON	+11.3 dB

$$G = \frac{R_f}{R_{in,eff}} \quad\text{with}\quad R_{in,eff} = R_{base} \parallel R_{pos1} \parallel R_{pos2} \parallel R_{pos3}$$

→ Full gain configuration details

PCB Layout

Parameter	Value
Board Size	145.6 × 200 mm
Layers	2 (F.Cu + B.Cu)
Footprints	269
Nets	135 in 5 net classes
Routing	Freerouting v2.0.1 — 1543 segments + 476 vias
GND Zones	F.Cu (solid connect) + B.Cu (thermal relief)
DRC	0 Errors, 0 Unconnected, 198 Warnings (cosmetic)

PCB Front

Net Class	Nets	Track Width	Clearance
Default	62	0.25 mm	0.2 mm
Audio_Input	30	0.3 mm	0.25 mm
Audio_Output	36	0.5 mm	0.2 mm
Audio_Power	0	0.8 mm	0.2 mm
Power	7	0.5 mm	0.2 mm

→ PCB layout details & DRC breakdown

Manufacturing

Production files are ready in the production/ directory:

Gerber + Drill — production/gerber/ (JLCPCB format, Protel extensions, tented vias)
BOM + Placement — production/assembly/ (JLCPCB SMT assembly format)

Validation

Method	Checks	Result
Method 1 — OrcadPCB2 netlist, component-centric	85/85	✅
Method 2 — KiCad-native netlist, net-centric (pintype/pinfunction)	177/177	✅

All component references, net names, and pin assignments in the documentation were extracted directly from the verified KiCad netlist and are sufficient to fully rebuild the schematic without the .kicad_sch file.

Documentation

Document	Description
Signal Chain	Detailed 5-stage signal path with Mermaid diagrams, formulas, and per-stage component tables
Power Supply	DC/DC converter, LDOs, ferrite beads, decoupling architecture
Muting & Remote Control	Remote enable logic, muting timing, SPDT switch modes
Gain Configuration	DIP switch table, gain formula, per-channel resistor mapping
Component Reference	Complete BOM with all 242 symbols: R, C, D, J, SW, Q, U, FB
Schematic Rebuild Guide	Step-by-step wiring instructions + full 6-channel component mapping
PCB Layout	Net classes, DRC status, routing details
Research: Balanced Audio ICs	THAT1240, DRV135, SSM2143, LM4562 comparison & JLCPCB availability
Research: THT Precision Components	0.1% resistors, C0G capacitors, THT sourcing guide

Project Structure

This project is self-contained — all footprints and 3D models are included locally.

text

├── aurora-dsp-icepower-booster.kicad_pro   # Project
├── aurora-dsp-icepower-booster.kicad_sch   # Schematic
├── aurora-dsp-icepower-booster.kicad_pcb   # PCB Layout
├── aurora-dsp-icepower-booster.kicad_sym   # Local symbols
├── aurora-dsp-icepower-booster.kicad_dru   # Custom design rules
├── footprints.pretty/                      # 21 footprints (local)
│   └── 3dshapes/                           # 19 STEP 3D models
├── production/
│   ├── gerber/                             # Manufacturing data
│   └── assembly/                           # BOM + placement data
├── docs/                                   # Detailed documentation
│   ├── signal-chain.md
│   ├── power-supply.md
│   ├── muting-and-remote.md
│   ├── gain-configuration.md
│   ├── component-reference.md
│   ├── schematic-rebuild-guide.md
│   ├── pcb-layout.md
│   └── research/
│       ├── balanced-audio-ic-comparison.md
│       └── tht-precision-components.md
└── scripts/                                # Build & validation scripts

Schematic: KiCad 9 — aurora-dsp-icepower-booster.kicad_sch Manufacturing: JLCPCB 2-Layer FR-4 HASL — Gerber files in production/gerber/

Parts

269

Qty	Value	Footprint	References
43	100nF C0G	C_0805_2012Metric	C1, C2, C10, C11, C12, C13, C14, C15, C18, C19, C22, C23, C26, C27, C28, C29 +27
36	10k 0.1%	R_0805_2012Metric	R2, R10, R11, R12, R13, R14, R15, R16, R17, R18, R19, R20, R21, R22, R23, R24 +20
24	47	R_0805_2012Metric	R58, R59, R60, R61, R62, R63, R76, R77, R78, R79, R100, R101, R102, R103, R104, R105 +8
24	PESD5V0S1BL	D_SOD-323	D2, D10, D11, D12, D13, D14, D15, D16, D17, D18, D19, D20, D21, D22, D23, D24 +8
20	10k	R_0805_2012Metric	R1, R64, R65, R66, R67, R68, R69, R70, R71, R106, R108, R109, R110, R111, R112, R113 +4
12	10	R_0805_2012Metric	R82, R83, R84, R85, R86, R87, R88, R89, R90, R91, R92, R93
12	100pF C0G	C_0805_2012Metric	C50, C51, C52, C53, C54, C55, C56, C57, C58, C59, C60, C61
12	2.2uF C0G	C_1206_3216Metric	C62, C63, C64, C65, C66, C67, C68, C69, C70, C71, C72, C73
12	LM4562	SOIC-8_3.9x4.9mm_P1.27mm	U2, U3, U4, U5, U6, U7, U8, U9, U10, U11, U12, U13
8	10uF X5R	C_0805_2012Metric	C24, C25, C74, C75, C76, C77, C78, C79
7	BSS138	SOT-23	Q1, Q2, Q3, Q4, Q5, Q6, Q7
6	15k	R_0805_2012Metric	R28, R32, R36, R40, R44, R48
6	30k	R_0805_2012Metric	R27, R31, R35, R39, R43, R47
6	7.5k	R_0805_2012Metric	R29, R33, R37, R41, R45, R49
6	XLR3_OUT	Connector_Audio:Jack_XLR_Neutrik_NC3MBH_Horizontal	J9, J10, J11, J12, J13, J14
4	MountingHole	MountingHole_3.2mm_M3	MH1, MH2, MH3, MH4
3	100k	R_0805_2012Metric	R56, R57, R107
2	100uF	C_1210_3225Metric	C20, C21
2	100uF/25V	C_1210_3225Metric	C16, C17
2	BLM18PG221	L_0805_2012Metric	FB1, FB2
1	10u	C_0805_2012Metric	C80
1	22nF C0G	C_0402_1005Metric	C81
1	24V DC	BarrelJack_Horizontal	J1
1	ADP7118ARDZ-11	SOIC127P600X175-9N	U14
1	ADP7182AUJZ-11	SOT-23-5	U15
1	ALWAYS/REMOTE	SW_E-Switch_EG1224_SPDT_Angled	SW1
1	Gain CH1	SW_DIP_SPSTx03_Slide_Omron_A6S-310x_W8.9mm_P2.54mm	SW2
1	Gain CH2	SW_DIP_SPSTx03_Slide_Omron_A6S-310x_W8.9mm_P2.54mm	SW3
1	Gain CH3	SW_DIP_SPSTx03_Slide_Omron_A6S-310x_W8.9mm_P2.54mm	SW4
1	Gain CH4	SW_DIP_SPSTx03_Slide_Omron_A6S-310x_W8.9mm_P2.54mm	SW5
1	Gain CH5	SW_DIP_SPSTx03_Slide_Omron_A6S-310x_W8.9mm_P2.54mm	SW6
1	Gain CH6	SW_DIP_SPSTx03_Slide_Omron_A6S-310x_W8.9mm_P2.54mm	SW7
1	REMOTE 3.5mm IN	aurora-dsp-icepower-booster:AUDIO-SMD_KH-PJ-320EA-5P-SMT	J2
1	REMOTE 3.5mm OUT	aurora-dsp-icepower-booster:AUDIO-SMD_KH-PJ-320EA-5P-SMT	J15
1	SMBJ15CA	D_SMB	D1
1	TEL5-2422	TEL5_DUAL_TRP	U1
1	XLR_IN_1	Connector_Audio:Jack_XLR_Neutrik_NC3FBH2_Horizontal	J3
1	XLR_IN_2	Connector_Audio:Jack_XLR_Neutrik_NC3FBH2_Horizontal	J4
1	XLR_IN_3	Connector_Audio:Jack_XLR_Neutrik_NC3FBH2_Horizontal	J5
1	XLR_IN_4	Connector_Audio:Jack_XLR_Neutrik_NC3FBH2_Horizontal	J6
1	XLR_IN_5	Connector_Audio:Jack_XLR_Neutrik_NC3FBH2_Horizontal	J7
1	XLR_IN_6	Connector_Audio:Jack_XLR_Neutrik_NC3FBH2_Horizontal	J8

Questions

How big is the Aurora dsp icepower booster PCB?

It measures 145.6 × 200 mm and has 2 copper layers, 1.6 mm thick.

What parts does the Aurora dsp icepower booster use?

269 parts, built around the TEL 5-2422, LM4562NA, PESD5V0S1BL and BSS138. The full list of its parts is on this page, with links to each part's symbol and footprint where PCBKit's library has them.

Where can I download the Aurora dsp icepower booster KiCad files?

From the jpsamuelson/aurora-icepower-booster repository on GitHub, at the commit this page was made from: the board is aurora-dsp-icepower-booster.kicad_pcb and its schematic aurora-dsp-icepower-booster.kicad_sch. PCBKit opens the board in the browser, with nothing to install.

Can I use the Aurora dsp icepower booster design in my own project?

Its repository states no licence, so its author keeps all rights: ask jpsamuelson before reusing the design.

Category and platform

Audio and music

Project files

Show this board on your page

A live frame, for any web page

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A picture

<img src="https://pcbkit.io/embed/boards/jpsamuelson-aurora-icepower-booster.jpg" alt="Aurora dsp icepower booster" width="1200" height="900">

A picture that opens the board, for a README

[![Aurora dsp icepower booster](https://pcbkit.io/embed/boards/jpsamuelson-aurora-icepower-booster.jpg?size=s)](https://pcbkit.io/boards/jpsamuelson-aurora-icepower-booster)

Source

Repository: jpsamuelson/aurora-icepower-booster
Board file: aurora-dsp-icepower-booster.kicad_pcb
Commit: 84fdd05
Licence: Not stated

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