2 layers27.9 × 16.5 mm
2 layers54.8 × 37.3 mm
Non Isolated AC DC Power Module
uttkarsh-chimane/Non-Isolated-AC-DC-Power-Module1Capacitive dropper-based AC-DC power supply (230V → ~5V DC) designed in KiCad with schematic, PCB layout, and 3D visualization.
- Size
- 54.8 × 37.3 mm
- Copper layers
- 2
- Thickness
- 1.6 mm
- Parts
- 18
- Nets
- 9
- Pads
- 37
- Tracks, vias
- 39, 0
- Pours
- 1
- Routed
- Yes
- KiCad
- KiCad 9.0 (file 20241229)
- Created
- 6 May 2026
- Updated
- 25 Sep 2026
Overview
Non Isolated AC DC Power Module is an open-source printed circuit board by uttkarsh-chimane, from the uttkarsh-chimane/Non-Isolated-AC-DC-Power-Module repository on GitHub, published under the MIT licence. It is a 2-layer board of 54.8 × 37.3 mm with 18 parts on 9 nets, routed with 39 tracks and 0 vias.
Its parts include 7 diodes, 4 capacitors, 4 resistors, 2 connectors and 1 IC. It belongs with the power boards of this library.
README
README.md⚡ Non-Isolated AC-DC Power Supply
230V AC to 5V DC
What I Built • Design Architecture • PCB Insights • Safety Note • Applications & Limitations
⚙️ What I Built
A capacitive dropper-based AC-DC power supply designed to step down 230V AC and provide a regulated low-voltage DC output (~5V, low current).
🚀 Overview
This design eliminates bulky transformers by using a reactive impedance (capacitor) to efficiently drop voltage.
It includes:
- Capacitive voltage dropper
- Full-wave bridge rectifier
- Filtering stage
- Zener-based regulation
- Linear voltage regulator for stable 5V output
📷 Project Preview
🧠 Design Architecture (Key Stages)
🔌 Input Stage
- 230V AC input via screw terminal
- Capacitor (C4) acts as voltage dropper
- Resistor (R3) for inrush current limiting
🔄 Rectification
- Bridge rectifier using 4× 1N4007 diodes
🔋 Filtering
- Bulk capacitor (1000µF) smooths DC
- Small capacitor (0.1µF) for noise suppression
⚖️ Regulation
- Zener diodes stabilize intermediate voltage
- 7805 linear regulator provides steady 5V output
🔌 Output Stage
- 470µF capacitor for ripple reduction
- LED indicator for power status
🧠 Architecture
[ 230V AC Input ]
│
▼
[ Voltage Dropper & Inrush Limit ] ➔ (Capacitor C4 + Resistor R3)
│
▼
[ Full-Wave Rectification ] ➔ (4× 1N4007 Diodes)
│
▼
[ Bulk & Noise Filtering ] ➔ (1000µF + 0.1µF Capacitors)
│
▼
[ Voltage Regulation ] ➔ (Zener Diodes + 7805 Regulator)
│
▼
[ Output Stage & Indicator ] ➔ (470µF Ripple Cap + Status LED) ➔ 5V DC Output📌 Key Takeaways
✔ Compact and cost-effective design ✔ Eliminates bulky transformers
❌ Non-isolated → serious safety limitations
⚠️ Suitable only for low-power, controlled environments due to direct mains interaction
🧩 PCB Design Insights
- Maintained separation between high-voltage and low-voltage sections
- Optimized component placement for shorter trace paths
- Considered spacing constraints for safer operation
- Used 3D visualization to validate layout decisions
⚠️ Safety Note
This is a non-isolated power supply:
- Output is directly referenced to mains
- Risk of electric shock is high
- Not suitable for open-use or human interaction
👉 Use only in enclosed, insulated systems
🧪 Applications
- Low-power embedded systems
- IoT nodes
- Indicator / control circuits
⚠️ Limitations
- No electrical isolation from mains
- Limited current capability
- Poor regulation under varying load
- Not suitable for high-power applications
🚀 Future Improvements
- Replace with isolated SMPS design
- Add fuse and MOV for protection
- Improve thermal handling
- Compact SMD version
🛠 Tools Used
Parts
18| Qty | Value | Footprint | References |
|---|---|---|---|
| 4 | 1N4007 | Diode_THT:D_DO-41_SOD81_P10.16mm_Horizontal | D1, D2, D3, D4 |
| 2 | 20K | Resistor_THT:R_Axial_DIN0207_L6.3mm_D2.5mm_P7.62mm_Horizontal | R1, R2 |
| 2 | D_Zener | Diode_THT:D_A-405_P7.62mm_Horizontal | D5, D6 |
| 2 | Screw_Terminal_01x02 | TerminalBlock_4Ucon:TerminalBlock_4Ucon_1x02_P3.50mm_Horizontal | J1, J2 |
| 1 | 0.1uf | Capacitor_THT:C_Disc_D4.7mm_W2.5mm_P5.00mm | C1 |
| 1 | 1000uf | Capacitor_THT:CP_Radial_D10.0mm_P5.00mm | C2 |
| 1 | 1M | Resistor_THT:R_Axial_DIN0207_L6.3mm_D2.5mm_P7.62mm_Horizontal | R3 |
| 1 | 2.2K | Resistor_THT:R_Axial_DIN0207_L6.3mm_D2.5mm_P7.62mm_Horizontal | R4 |
| 1 | 225K/2.2uf | Capacitor_THT:C_Rect_L18.0mm_W6.0mm_P15.00mm_FKS3_FKP3 | C4 |
| 1 | 470uf | Capacitor_THT:CP_Radial_D10.0mm_P3.80mm | C3 |
| 1 | LED | LED_THT:LED_D5.0mm | D7 |
| 1 | LM7805_TO220 | Package_TO_SOT_THT:TO-220-3_Vertical | U1 |
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Questions
How big is the Non Isolated AC DC Power Module PCB?
It measures 54.8 × 37.3 mm and has 2 copper layers, 1.6 mm thick.
What parts does the Non Isolated AC DC Power Module use?
18 parts. 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 Non Isolated AC DC Power Module KiCad files?
From the uttkarsh-chimane/Non-Isolated-AC-DC-Power-Module repository on GitHub, at the commit this page was made from: the board is hardware/Non-Isolated AC-DC Power Module.kicad_pcb and its schematic hardware/Non-Isolated AC-DC Power Module.kicad_sch. PCBKit opens the board in the browser, with nothing to install.
Can I use the Non Isolated AC DC Power Module design in my own project?
Its repository publishes it under the MIT licence: you may reuse it on that licence's terms (keep the author's notice, and for a copyleft licence share your changes alike).