# 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://flux.ai/adrian95/gbu4m~1aj.md)

- Part Type: Diode
- Manufacturer Part Number: GBU4M
- Manufacturer Name: onsemi
- Datasheet URL: https://rocelec\.widen\.net/view/pdf/s2epgwqjmy/ONSM\-S\-A0003587643\-1\.pdf?t\.download=true&u=5oefqw
- Package: Through Hole
- License: https://creativecommons\.org/licenses/by/4\.0/
- Role Details: Rectifies filtered mains into the high\-voltage DC bus
- Role: Bridge Rectifier

**Pins:**
- \- [pin 4]
- \+ [pin 1]
- P2 [pin 2]
- P3 [pin 3]

### F1 — [178\.7017\.0001](https://flux.ai/adrian95/178p7017p0001.md)

- Manufacturer Name: Littelfuse
- Role Details: 5x20 mm mains fuse holder in series with line input
- Part Type: Circuit Protection Devices
- Role: Input Fuse Holder
- Datasheet URL: https://www\.littelfuse\.com/assetdocs/ato\-fkh\-datasheet?assetguid=52ab370f\-f59e\-4f6c\-87fb\-d18075289d4c
- Package: Through Hole
- License: https://creativecommons\.org/licenses/by/4\.0/
- Manufacturer Part Number: 178\.7017\.0001

**Pins:**
- 1 [pin 1]
- 2 [pin 2]

### J1 — [1732720](https://flux.ai/jecstronic/1732720~jel.md)

- Implementation Details: Dedicated PDLC output connector\. Keep separated from low\-voltage interfaces and route with high\-voltage spacing\.
- Role Details: Separated high\-voltage AC output to the PDLC film
- Manufacturer Name: Phoenix Contact
- Role: HV Output Connector
- License: https://creativecommons\.org/licenses/by/4\.0/
- Voltage: 70VAC
- Manufacturer Part Number: 1732720
- Datasheet URL: https://mm\.digikey\.com/Volume0/opasdata/d220001/medias/docus/644/1732720\.pdf
- Package: Terminal Block 7\.62mm
- Part Type: Connector

**Pins:**
- Pin\_1 [pin 1]
- Pin\_2 [pin 2]

### J2 — [282837\-3](https://flux.ai/adrian95/282837-3~5mc.md)

- Package: Through Hole
- License: https://creativecommons\.org/licenses/by/4\.0/
- Datasheet URL: https://www\.te\.com/usa\-en/product\-282837\-3\.datasheet\.pdf
- Manufacturer Name: TE Connectivity AMP Connectors
- Role: Mains Input Connector
- Manufacturer Part Number: 282837\-3
- Part Type: Connector
- Role Details: 110 VAC line, neutral, and earth entry for the mains front end

**Pins:**
- Pin\_1 [pin 1]
- Pin\_2 [pin 2]
- Pin\_3 [pin 3]

### PS1 — [HLK\-5M05](https://flux.ai/adrian95/hlk-5m05~37g.md)

- Manufacturer Part Number: HLK\-5M05
- Part Type: Power Source
- Role Details: Isolated AC\-DC auxiliary supply that generates the 5 V control source for U4 and the low\-voltage control domain\.
- Package: Module
- License: https://creativecommons\.org/licenses/by/4\.0/
- Role: Auxiliary Control Supply
- Manufacturer Name: HI\-LINK
- Datasheet URL: https://datasheet\.lcsc\.com/lcsc/2212011400\_HI\-LINK\-HLK\-5M05\_C209907\.pdf

**Pins:**
- \-VO [pin 3]
- \+VO [pin 4]
- AC1 [pin 1]
- AC2 [pin 2]

### Q1 — [IRLZ44NPBF\-HXY](https://flux.ai/adrian95/irlz44npbf-hxy~anp.md)

- License: https://creativecommons\.org/licenses/by/4\.0/
- Role Details: Primary\-side push\-pull switching device for the transformer drive
- Role: Inverter Switch
- Part Type: Transistor
- Manufacturer Name: HXY MOSFET
- Manufacturer Part Number: IRLZ44NPBF\-HXY
- Package: TO\-220
- Datasheet URL: https://www\.lcsc\.com/datasheet/C22367197\.pdf

**Pins:**
- D [pin 2]
- G [pin 1]
- S [pin 3]

### Q2 — [IRLZ44NPBF\-HXY](https://flux.ai/adrian95/irlz44npbf-hxy~anp.md)

- License: https://creativecommons\.org/licenses/by/4\.0/
- Role: Inverter Switch
- Part Type: Transistor
- Role Details: Primary\-side push\-pull switching device for the transformer drive
- Manufacturer Name: HXY MOSFET
- Manufacturer Part Number: IRLZ44NPBF\-HXY
- Package: TO\-220
- Datasheet URL: https://www\.lcsc\.com/datasheet/C22367197\.pdf

**Pins:**
- D [pin 2]
- G [pin 1]
- S [pin 3]

### RV1 — [TMOV20RP275E](https://flux.ai/adrian95/tmov20rp275e~y0.md)

- Manufacturer Part Number: TMOV20RP275E
- Role: Surge Protection
- Package: Through Hole
- Part Type: Varistors
- Datasheet URL: https://www\.littelfuse\.com/assetdocs/tmov\-itmov?assetguid=bd475732\-1071\-4352\-b8aa\-f78b0007eb05
- Manufacturer Name: Littelfuse Inc\.
- License: https://creativecommons\.org/licenses/by/4\.0/
- Role Details: 275 VAC MOV across mains line and neutral for surge suppression

**Pins:**
- 1 [pin 1]
- 2 [pin 2]

### T1 — [SM91502ALE](https://flux.ai/adrian95/sm91502ale~e7.md)

- Role Details: Center\-tapped transformer used between push\-pull MOSFET stage and PDLC output network
- Manufacturer Part Number: SM91502ALE
- Role: Step\-up Transformer
- Part Type: Transformer
- Package: SMD Transformer
- License: https://creativecommons\.org/licenses/by/4\.0/
- Manufacturer Name: Bourns Inc\.
- Datasheet URL: https://www\.bourns\.com/docs/Product\-Datasheets/SM91502AL\.pdf

**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://flux.ai/vasy_skral/stm32f030f4p6~dwn.md)

- Role: Controller MCU
- Manufacturer Part Number: STM32F030F4P6
- Package: TSSOP\-20
- License: https://creativecommons\.org/licenses/by/4\.0/
- 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
- Symbol Style: Parametric
- 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\.
- Part Type: Microcontroller
- Operating Voltage: 3\.3V
- Role Details: 3\.3 V control\-domain MCU that enables the inverter, monitors status/fault inputs, and provides debug/control logic\.
- Manufacturer Name: STMicroelectronics

**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://flux.ai/vasy_skral/sg3525~xd.md)

- Manufacturer Part Number: SG3525AP
- 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
- Part Type: Integrated Circuit
- Role: PWM Inverter Controller
- Symbol Style: Parametric
- License: https://creativecommons\.org/licenses/by/4\.0/
- 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\.
- Role Details: Drives complementary MOSFET gates for the transformer primary
- Package: SO\-16
- Manufacturer Name: STMicroelectronics

**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://flux.ai/adrian95/mcp1700t-3302e-tt~h60.md)

- Role Details: Converts PS1 isolated 5 V output into the 3\.3 V rail for the MCU and low\-voltage control circuitry\.
- Manufacturer Name: Microchip Technology
- Manufacturer Part Number: MCP1700T\-3302E/TT
- License: https://creativecommons\.org/licenses/by/4\.0/
- Part Type: Integrated Circuit
- Role: 3\.3V Control\-Domain LDO
- Package: SOT\-23
- Datasheet URL: https://datasheet\.octopart\.com/MCP1700T\-3302E/TT\-Microchip\-datasheet\-532260\.pdf

**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://flux\.ai/rgallizzi/110\-vac\-pdlc\-controller\~23](https://flux.ai/rgallizzi/110-vac-pdlc-controller~23).*

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*Generated from [https://flux\.ai/rgallizzi/110\-vac\-pdlc\-controller\~23](https://flux.ai/rgallizzi/110-vac-pdlc-controller~23)*