# 110 VAC PDLC Controller ## Description 110 VAC mains-input PDLC controller redesign for 25 W+ load with protected front end, rectified HV bus, auxiliary control supply, and preserved downstream square-wave output control. ## Project Details - **Owner:** rgallizzi - **Created:** 4/9/2026 - **Last Updated:** 5/6/2026 - **Visibility:** Public - **Stars:** 1 ## Key Components ### BR1 — [GBU4M](https://www.flux.ai/adrian95/gbu4m~1aj.md) - Manufacturer Part Number: GBU4M - Package: Through Hole - Part Type: Diode - Manufacturer Name: onsemi - Datasheet URL: https://rocelec.widen.net/view/pdf/s2epgwqjmy/ONSM-S-A0003587643-1.pdf?t.download=true&u=5oefqw - License: https://creativecommons.org/licenses/by/4.0/ - Role: Bridge Rectifier - Role Details: Rectifies filtered mains into the high-voltage DC bus **Pins:** - - [pin 4] - + [pin 1] - P2 [pin 2] - P3 [pin 3] ### F1 — [178.7017.0001](https://www.flux.ai/adrian95/178p7017p0001.md) - Role Details: 5x20 mm mains fuse holder in series with line input - Manufacturer Part Number: 178.7017.0001 - Role: Input Fuse Holder - License: https://creativecommons.org/licenses/by/4.0/ - Manufacturer Name: Littelfuse - Part Type: Circuit Protection Devices - Package: Through Hole - Datasheet URL: https://www.littelfuse.com/assetdocs/ato-fkh-datasheet?assetguid=52ab370f-f59e-4f6c-87fb-d18075289d4c **Pins:** - 1 [pin 1] - 2 [pin 2] ### J1 — [1732720](https://www.flux.ai/jecstronic/1732720~jel.md) - Package: Terminal Block 7.62mm - Role: HV Output Connector - Role Details: Separated high-voltage AC output to the PDLC film - License: https://creativecommons.org/licenses/by/4.0/ - Datasheet URL: https://mm.digikey.com/Volume0/opasdata/d220001/medias/docus/644/1732720.pdf - Manufacturer Part Number: 1732720 - Manufacturer Name: Phoenix Contact - Part Type: Connector - Implementation Details: Dedicated PDLC output connector. Keep separated from low-voltage interfaces and route with high-voltage spacing. - Voltage: 70VAC **Pins:** - Pin_1 [pin 1] - Pin_2 [pin 2] ### J2 — [282837-3](https://www.flux.ai/adrian95/282837-3~5mc.md) - Role: Mains Input Connector - Package: Through Hole - Datasheet URL: https://www.te.com/usa-en/product-282837-3.datasheet.pdf - Role Details: 110 VAC line, neutral, and earth entry for the mains front end - Part Type: Connector - Manufacturer Name: TE Connectivity AMP Connectors - Manufacturer Part Number: 282837-3 - License: https://creativecommons.org/licenses/by/4.0/ **Pins:** - Pin_1 [pin 1] - Pin_2 [pin 2] - Pin_3 [pin 3] ### PS1 — [HLK-5M05](https://www.flux.ai/adrian95/hlk-5m05~37g.md) - Datasheet URL: https://datasheet.lcsc.com/lcsc/2212011400_HI-LINK-HLK-5M05_C209907.pdf - Role: Auxiliary Control Supply - Part Type: Power Source - License: https://creativecommons.org/licenses/by/4.0/ - Role Details: Isolated AC-DC auxiliary supply that generates the 5 V control source for U4 and the low-voltage control domain. - Manufacturer Part Number: HLK-5M05 - Package: Module - Manufacturer Name: HI-LINK **Pins:** - -VO [pin 3] - +VO [pin 4] - AC1 [pin 1] - AC2 [pin 2] ### Q1 — [IRLZ44NPBF-HXY](https://www.flux.ai/adrian95/irlz44npbf-hxy~anp.md) - License: https://creativecommons.org/licenses/by/4.0/ - Role: Inverter Switch - Manufacturer Name: HXY MOSFET - Package: TO-220 - Part Type: Transistor - Datasheet URL: https://www.lcsc.com/datasheet/C22367197.pdf - Role Details: Primary-side push-pull switching device for the transformer drive - Manufacturer Part Number: IRLZ44NPBF-HXY **Pins:** - D [pin 2] - G [pin 1] - S [pin 3] ### Q2 — [IRLZ44NPBF-HXY](https://www.flux.ai/adrian95/irlz44npbf-hxy~anp.md) - Manufacturer Part Number: IRLZ44NPBF-HXY - Package: TO-220 - Datasheet URL: https://www.lcsc.com/datasheet/C22367197.pdf - Role Details: Primary-side push-pull switching device for the transformer drive - Part Type: Transistor - Role: Inverter Switch - Manufacturer Name: HXY MOSFET - License: https://creativecommons.org/licenses/by/4.0/ **Pins:** - D [pin 2] - G [pin 1] - S [pin 3] ### RV1 — [TMOV20RP275E](https://www.flux.ai/adrian95/tmov20rp275e~y0.md) - Role Details: 275 VAC MOV across mains line and neutral for surge suppression - Package: Through Hole - Manufacturer Name: Littelfuse Inc. - Part Type: Varistors - Datasheet URL: https://www.littelfuse.com/assetdocs/tmov-itmov?assetguid=bd475732-1071-4352-b8aa-f78b0007eb05 - Manufacturer Part Number: TMOV20RP275E - License: https://creativecommons.org/licenses/by/4.0/ - Role: Surge Protection **Pins:** - 1 [pin 1] - 2 [pin 2] ### T1 — [SM91502ALE](https://www.flux.ai/adrian95/sm91502ale~e7.md) - Role: Step-up Transformer - Manufacturer Name: Bourns Inc. - Package: SMD Transformer - Role Details: Center-tapped transformer used between push-pull MOSFET stage and PDLC output network - Part Type: Transformer - Datasheet URL: https://www.bourns.com/docs/Product-Datasheets/SM91502AL.pdf - Manufacturer Part Number: SM91502ALE - License: https://creativecommons.org/licenses/by/4.0/ **Pins:** - PRI_1 [pin 1] - PRI_2 [pin 2] - PRI_3 [pin 3] - SEC_1 [pin 4] - SEC_2 [pin 5] - SEC_3 [pin 6] ### U2 — [STM32F030F4P6](https://www.flux.ai/vasy_skral/stm32f030f4p6~dwn.md) - Operating Voltage: 3.3V - Package: TSSOP-20 - Role Details: 3.3 V control-domain MCU that enables the inverter, monitors status/fault inputs, and provides debug/control logic. - Datasheet URL: https://www.st.com/content/ccc/resource/technical/document/datasheet/a4/5d/0b/0e/87/c4/4d/71/DM00088500.pdf/files/DM00088500.pdf/jcr:content/translations/en.DM00088500.pdf - Manufacturer Part Number: STM32F030F4P6 - Part Type: Microcontroller - Role: Controller MCU - License: https://creativecommons.org/licenses/by/4.0/ - Symbol Style: Parametric - Manufacturer Name: STMicroelectronics - Implementation Details: Powered from the 3.3 V rail generated by U4 from PS1. Uses PA0 to enable inverter operation, PA1 for current/status sensing input, PA2 for power-good/status input, PA3 for fault input, and PA9/PA10 for UART debug. **Pins:** - BOOT0 [pin 1] - NRST [pin 4] - PA0 [pin 6] - PA1 [pin 7] - PA10 [pin 18] - PA13 [pin 19] - PA14 [pin 20] - PA2 [pin 8] - PA3 [pin 9] - PA4 [pin 10] - PA5 [pin 11] - PA6 [pin 12] - PA7 [pin 13] - PA9 [pin 17] - PB1 [pin 14] - PF0 [pin 2] - PF1 [pin 3] - VDD [pin 16] - VDDA [pin 5] - VSS [pin 15] ### U3 — [SG3525](https://www.flux.ai/vasy_skral/sg3525~xd.md) - Datasheet URL: https://www.st.com/content/ccc/resource/technical/document/datasheet/c0/12/98/4a/3b/1a/4b/8b/CD00000958.pdf/files/CD00000958.pdf/jcr:content/translations/en.CD00000958.pdf - Role: PWM Inverter Controller - Symbol Style: Parametric - Implementation Details: Configured as low-frequency push-pull inverter controller. RT/CT network targets PDLC drive frequency options around 25 Hz to 50 Hz with firmware-assisted enable control. - Manufacturer Part Number: SG3525AP - License: https://creativecommons.org/licenses/by/4.0/ - Part Type: Integrated Circuit - Package: SO-16 - Manufacturer Name: STMicroelectronics - Role Details: Drives complementary MOSFET gates for the transformer primary **Pins:** - COMP [pin 9] - CT [pin 5] - DISCH [pin 7] - GND [pin 12] - INV [pin 1] - NI [pin 2] - OSC [pin 4] - OUTA [pin 11] - OUTB [pin 14] - REF [pin 16] - RT [pin 6] - SD [pin 10] - SS [pin 8] - SYNC [pin 3] - VC [pin 13] - VIN [pin 15] ### U4 — [MCP1700T-3302E-TT](https://www.flux.ai/adrian95/mcp1700t-3302e-tt~h60.md) - License: https://creativecommons.org/licenses/by/4.0/ - Part Type: Integrated Circuit - Manufacturer Name: Microchip Technology - Package: SOT-23 - Role Details: Converts PS1 isolated 5 V output into the 3.3 V rail for the MCU and low-voltage control circuitry. - Role: 3.3V Control-Domain LDO - Datasheet URL: https://datasheet.octopart.com/MCP1700T-3302E/TT-Microchip-datasheet-532260.pdf - Manufacturer Part Number: MCP1700T-3302E/TT **Pins:** - GND [pin 1] - VI [pin 3] - VO [pin 2] *The full schematic, PCB layout, bill of materials, and interactive design are available at [https://www.flux.ai/rgallizzi/110-vac-pdlc-controller~23](https://www.flux.ai/rgallizzi/110-vac-pdlc-controller~23).* --- *Generated from [https://www.flux.ai/rgallizzi/110-vac-pdlc-controller~23](https://www.flux.ai/rgallizzi/110-vac-pdlc-controller~23)*