S i 3 4 0 2 I S O- E VB
I SOLA TED E VALUATION B OAR D FOR TH E Si3402
1. Description
The Si3402 isolated evaluation boards (Si3402 ISO-EVB Rev 1.0) is a reference design for power supplies in
Power over Ethernet (PoE) Powered Device (PD) applications. The Si3402 is described more completely in the
data sheet and application notes. This document describes only the Si3402 ISO-EVB evaluation board. An
evaluation board demonstrating the non-isolated application is described in the Si3402-EVB User’s Guide.
2. Planning for Successful Designs
Silicon Labs strongly recommends the use of the schematic and layout databases provided with the evaluation
boards as the starting point for your design. Use of external components other than those described and
recommended in this document is generally discouraged. Refer to Table 2 on page 10 for more information on
critical component specifications. Careful attention to the recommended layout guidelines is required to enable
robust designs and full specification compliance. To help ensure design success, please submit your schematic
and layout databases to PoEInfo@silabs.com for review and feedback.
3. Si3402 Board Interface
Ethernet data and power are applied to the board through the RJ-45 connector (J1). The board may be powered by
the following:
Connecting a dc source to 1, 2 and 3, 6 (either polarity)
Connecting a dc source to 4, 5 and 7, 8 (either polarity)
Using an 802.3af-compliant PSE, such as Phihong PSA16U-480 (PoE)
The board itself has no Ethernet data transmission functionality. The dc output is at connectors J11(+) and J12(–).
Boards are generally shipped configured to produce +5 V but can be configured for +3.3 V or other output voltages
as shown in Table 2 on page 10. The Si3402 board schematics and layout are shown in Figures 1 through 6. The
Si3402 ISO-EVB is normally populated for 5 V output class 3 signature and without the diode bridge bypass
recommended for higher power levels. Use the ordering option Si3402 ISO-C4-EVB for 5 V output, class 4
signature and diode bridge bypass for higher power levels.
The feedback loop compensation has been optimized for 3.3, 5, 9, and 12 V output as well as with standard and
low ESR capacitors in the output filter section (Table 2 on page 10). The use of low ESR capacitors is
recommended for lower output ripple, improved load transient response and low temperature (below 0 °C)
operation.
Rev. 1.1 6/10
Copyright © 2010 by Silicon Laboratories
Si3402 ISO-EVB
12
11
11
12
10
13
13
10
14
14
9
9
15
15
8
8
1
L5
1
1
TDP
TDN
4
5
300 ohms
1
2
L3
300 ohms
1
2
L2
300 ohms
2
300 ohms
1
L4
1
RDN
3
7
1
CT
1
2
1
J5
HEADER 1
J6
HEADER 1
J7
HEADER 1
J8
HEADER 1
J9
HEADER 1
49.9K
2
HEADER 1
1
SP1
Vposf
CT2
CT1
U1
Vssa
Si3402
11
12
13
14
Connect transformer and
input filter caps together
minimizing area of return
loop and then connect
to Vpos plane.
0
J4
HEADER 1
1
ISOSSFT
Vdd
SSFT
EROUT
4
3
2
1
1N4148W
1000p
C19
2
1
Vssa
FA2805
T2
10:4 secondary
Figure 1. Si3402 Schematic—5 V, Class 3 PD
Vneg is a thermal plane as well as ESD and EMI.
Use thermal vias to at least 1 inch square plane
on backside 1 to 1.2mm pitch 0.3 to 0.33mm diameter.
Capacitors C10-C17 are for ESD immunity..
Place optional bypass diodes for high power applications (>10W) in parallel.
S1B
2
D11
1
MagJack
7
5
4
3
2
1
RDP
R2
1000p
S1B
2
C14
D10
1
J1
anode
S1B
2
D15
1
R1
1000p
S1B
2
C10
D14
1
1000p
S1B
2
C15
D9
1
anode
1000p
S1B
2
C11
D13
1
1000p
S1B
2
C16
D8
1
1000p
C13
1u C1
330
1000p
S1B
2
C12
D12
1
1000p
C17
C2
12uF
15
SP2
10
Vssa
1u C3
16
J3
C18
HSO
7
17
9
D1
D2
12,13 must be isolated from 14,15
0.1u
RDET
6
VSS1
Vneg
18
SWO
1u C4
20
19
VSS2
5
Vposs
RCL
8
R3
30.9
100n
C22
DFLT15A
1u
C23
FB
PLOSSb
R4
25.5K
R12 100
220n
Rev. 1.1
C21
2
1000p
C20
U4
PS2911
U5
R11
4.99K
R7
1
L1
TLV431
15n
C9
2.05K
R10
10
PDS1040
D3
10 C7
9 470p
7
8
10K
R8
1uH
2
D3 - Cathode pad dimensions
9.4mm x 7.2mm Anode pad
dimensions 2.7mm x 1.6mm.
Vout pos plane for EMI
100u C6
Vpos is a EMI and ESD plane. Use top layer.
R6
12.1K
R5
36.5K
1
CMAX
1000u
C5
CON1
J11
R9
3.01k
C8
560p
CON1
J12
1
Si3402 ISO-EVB
Figure 2. Si3402 Layout
Si3402 ISO-EVB
Rev. 1.1
3
Figure 3. Primary Side
Si3402 ISO-EVB
4
Rev. 1.1
Figure 4. Internal 1
Si3402 ISO-EVB
Rev. 1.1
5
Figure 5. Internal 2
Si3402 ISO-EVB
6
Rev. 1.1
Figure 6. Secondary Side
Si3402 ISO-EVB
Rev. 1.1
7
Si3402 ISO-EVB
4. Bill of Materials
The following bill of materials is for a 5 V, Class 3 design or a Class 4 design. Tables 2 and 3 list changes to the bill
of materials for other output voltages and classification levels. Refer to “AN296: Using the Si3400, Si3401, and
Si3402 PoE PD Controllers in Isolated and Non-Isolated Designs” and its accompanying Excel® spreadsheet utility
for more information.
Table 1. Si3402 ISO-EVB Bill of Materials
Item
NI
Qty
Reference
Value
Rating
Tol
Dielectric
PCB Footprint
Manufacturer Part Number
Manufacturer
1
3
C1,C3,C4
1 µF
100 V
10%
X7R
1210
GRM32ER72A105KA01
C1210X7R101105K
Murata
Venkel
2
1
C2
12 µF
100 V
Al Elec
thru hole
3
1
C5
1000 µF
6.3 V
4
1
C6
100 µF
6.3 V
5
1
C7
470 pF
6
1
C8
7
1
C9
81
8
100ME12AX
Panasonic
Sanyo
thru hole
ECA0JM102
Panasonic
X5R
CC1210
GRM32ER60J107ME20
C1210X5R6R3107K
Murata
Venkel
50 V
X7R
CC0805
C0805X7R101471K
Venkel
560 pF
16 V
X7R
CC0805
C0805X7R160561K
Venkel
15 nF
16 V
X7R
CC0805
C0805X7R160153K
Venkel
C10,C11,C12,
C13,C14,C15,
C16,C17
1000 pF
100 V
10%
CC0603
C0603X7R101102K
Venkel
1
C18
0.1 µF
100 V
10%
805
C0805X7R101104K
Venkel
9
2
C19,C20
1000 pF
3 kV
1808
C1808X7R302102K
Venkel
10
1
C21
220 nF
16 V
X7R
CC0805
C0805X7R160224K
Venkel
1
C22
100 nF
16 V
X7R
CC0805
C0805X7R160104K
Venkel
11
1
C23
1 µF
16 V
X7R
CC0805
C0805X7R160105K
Venkel
12
1
D1
1N4148W
100 V
SOD123
1N4148W
Diodes Inc.
13
1
D2
DFLT15A
15 V
DI123
DFLT15A
Diodes Inc.
14
1
D3
PDS1040
PDI5
PDS1040
Diodes Inc.
RJ45
SI-52003-F
RJSE1R8090B-R
BelFuse Delta
15
1
J1
MagJack
16
2
J11,12
CON1
101
Abbatron HH Smith
17
1
L1
1 µH
DO1608C-102MLC
Coilcraft
805
BLM21P331SG
Murata
805
CR0805-10W3300F
Venkel
18
4
L2,L3,L4, L5
300
19
1
R1
330
20
1
R2
49.9
Ferrite
100 V
805
CR0805-8W4992F
Venkel
805
CR0805-10W30R9F
Venkel (Class 4)
45.3
805
CR0805-10W45R3F
Venkel (Class 3)
25.5 k
805
CR0805-10W2552F
Venkel
30.9
21
22
1
R3
1
R4
23
1
R5
36.5 k
805
CR0805-10W36.5F
Venkel
24
1
R6
12.1 k
805
CR0805-10W1212F
Venkel
25
1
R7
2.05 k
805
CR0805-10W2051F
Venkel
26
1
R8
10 k
805
CR0805-10W1002F
Venkel
27
1
R9
3.01 k
805
CR0805-10W3011F
Venkel
28
1
R10
10
805
CR0805-10W10R0F
Venkel
29
1
R11
4.99 k
805
CR0805-10W4991F
Venkel
Notes:
1.
2.
8
EEUFC2A120
C10–C17 are populated by default. See the “Surge” section in AN296 for more information.
Bypass diodes D8–D15 are populated for the Class 4 option.
Rev. 1.1
Si3402 ISO-EVB
Table 1. Si3402 ISO-EVB Bill of Materials (Continued)
Item
NI
31
Qty
Reference
Value
1
R12
100
COILCRAFT
Rating
Tol
Dielectric
PCB Footprint
Manufacturer Part Number
Manufacturer
805
CR0805-10W1000F
Venkel
FA2805CL
Coilcraft
32
1
T1
transformer
33
1
U1
Si3402
5x5 QFN
4 pin SO 4.6x2.5
PS2911-1-L
NEC
TLV431
TI
S1B
Diodes Inc.
34
1
U2
PS2911
Opto
35
1
U3
TLV431
SOT23
TESTPOINT
37
NI
7
J3,J4,J5,J6,
J7,J8,J9
HEADER 1
372
NI
8
D8,D9,D10,D11,
D12,D13,D14,
D15
S1B
Notes:
1.
2.
1 A,
100 V
SMB
Silabs
C10–C17 are populated by default. See the “Surge” section in AN296 for more information.
Bypass diodes D8–D15 are populated for the Class 4 option.
Rev. 1.1
9
Si3402 ISO-EVB
Table 2. Component Selection for other Output Voltages and Filter Types
3.3 V output
Transformer*
EP10 FA2671
EP13 FA2924AL
Output Rectifier:
PDS1040
Reference
Any TLV431
Snubber:
R10, C7 470p,10
R5
R6
C6
C5
Panasonic
R7, R9, R12
C8,C9,C21
Standard ESR Output
Filter
24.3 k
14.7 k
100 µF
X5R
1000 µF
6.3 V
ECA0JM102
1 k, 3.01 k,
100
560 pF, 15 nF,
0.22 µF
Low ESR Output Filter
24.3 k
14.7 k
100 µF
X5R
560 µF
6.3 V
5.0 V Output
Transformer*
EP10 FA2672
EP13 FA2805CL
EEUFM0J561 1 k, 1 k, 47
Output Rectifier:
PDS1040
8200 pF,
100 nF, 0.47 µF
Reference
Any TLV431
Snubber:
R10, C7 470p,10
R5
R6
C6
C5
Panasonic
R7,
R9, R12
C8,C9,C21
Standard ESR Output
Filter
36.5 k
12.1 k
100 µF
X5R
1000 µF
6.3 V
ECA0JM102
2.05 k,
3.01 k, 47
560 pF, 15 nF,
0.22 µF
Low ESR Output Filter
36.5 k
12.1 k
100 µF
X5R
560 µF
6.3 V
EEUFM0J561
2.05 k, 1 k,
47
8200 pF,
100 nF, 0.47 µF
9.0 V Output
Transformer*
Output rectifier: PDS5100
Reference
EP10 FA2732
EP13 FA2925AL
Snubber:
Higher voltage e.g.,
TLV431ASNT1G
R5
R6
C6
R10, C7 68p,20
C5
Panasonic
R7, R9, R12
C8,C9,C21
Standard ESR Output
Filter
66.5 k 22 µF X5R
10.5 k
470 µF
16 V
ECA1M471
4.99 k,
2.05 k, 301
3300 pF, 47 nF,
0.22 µF
Low ESR Output Filter
66.5 k 22 µF X5R
10.5 k
330 µF
16 V
EEUFM1C331
4.99 k,
2.05 k, 1 k
8200 pF, 22 nF,
0.1 µF
12.0 V Output
Transformer*
Output rectifier: PDS5100
Reference
EP10 FA2732
EP13 FA2925AL
Snubber:
Higher voltage e.g.,
TLV431ASNT1G
R5
R6
C6
R10, C7 68p,20
C5
Panasonic
R7, R9, R12
C8,C9,C21
Standard ESR Output
Filter
88.7 k 22 µF X5R
10.2 k
470 µF
16 V
ECA1M471
4.99 k,
2.05 k, 301
3300 pF, 47 nF,
0.22 µF
Low ESR Output Filter
88.7 k 22 µF X5R
10.2 k
330 µF
16 V
EEUFM1C331
4.99 k,
2.05 k, 1 k
3300 pF, 22 nF,
0.1 µF
*Note: Coilcraft part number. EP13 core is recommended for >10 W output power and short circuit protection.
10
Rev. 1.1
Si3402 ISO-EVB
Table 3. Component Selection for Different Classification Levels
Class
R3
0
Open
1
127
2
69.8
3
45.3
4
30.9
Rev. 1.1
11
Si3402 ISO-EVB
APPENDIX—Si3402 ISO DESIGN AND LAYOUT CHECKLIST
Introduction
Although all four EVB designs are pre-configured as a Class 3 PD with a 5 V output, the schematics and layouts
can easily be adapted to meet a wide variety of common output voltages and power levels.
The complete EVB design databases for the standard 5 V/Class 3 configuration are located at
www.silabs.com/PoE under the “Documentation” link. Silicon Labs strongly recommends using these EVB
schematics and layout files as a starting point to ensure robust performance and to help avoid common mistakes in
the schematic capture and PCB layout processes.
Following are recommended design checklists that can assist in trouble-free development of robust PD designs:
Refer also to the Si3402 data sheet and AN296 when using the checklists below.
1. Design Planning Checklist:
a. Determine if your design requires an isolated or non-isolated topology. For more information, see
Section 4 of AN296.
b. To begin integrating the Si3402 into your schematics, download the schematic and layout database for
your particular isolation requirements from www.silabs.com/PoE.
c. Silicon Labs strongly recommends using the EVB schematics and layout files as a starting point as you
begin integrating the Si3402 into your system design process.
d. Determine your load’s power requirements (i.e., VOUT and IOUT consumed by the PD, including the
typical expected transient surge conditions). In general, to achieve the highest overall efficiency
performance of the Si3402, choose the highest voltage used in your PD and then post regulate to the
lower supply rails, if necessary.
e. If your PD design consumes >10 W, make sure you bypass the Si3402’s on-chip diode bridges with
external diode bridges or discrete diodes. Bypassing the Si3402’s on-chip diode bridges with external
bridges or discrete diodes is required to help spread the heat generated in designs dissipating >10 W.
f.
Based on your required PD power level, select the appropriate class resistor value by referring to Table 2
of AN296. This sets the Rclass resistor (R3 in Figure 1 on page 2).
g. The feedback loop stability has been checked over the entire load range for the specific component
choices in Table 1. Low ESR filter capacitors will give better load transient response and lower output
ripple so they are generally preferred. Silicon Laboratories recommends against component substitution
in the filtering and feedback path as this may result in unstable operation. Also, use care in situations
that have additional capacitive loading as this will also affect loop stability.
2. Calculate Design-Specific External Components (for all designs which are not for a 5 V, Class 3 output
configuration):
a. To help guide the selection of the other application-specific external component values needed for your
design’s isolation requirements, access the Excel spreadsheet utility at the following address:
https://www.silabs.com/products/power/poe/Pages/default.aspx
i. Use the “Non-isolated” worksheet if your design is intended for a non-isolated output supply.
ii. Use either the “Isolated Continuous” or the “Isolated Discontinuous” worksheets if your design is
for an isolated output supply (“continuous” versus “discontinuous” mode is determined by the
current value calculated in cell H11 of the spreadsheet).
b. If your design is a 5 V output Class 3 design, you do not need to change any external components.
c. To avoid potential performance issues for non-5 V output configurations, Silicon Labs strongly
recommends using the exact components and component values shown and calculated in the Excel
worksheets.
d. Begin entering your design targets in cells B9 through B13 of the Excel worksheet:
12
Rev. 1.1
Si3402 ISO-EVB
i. If using appropriate, select on-chip “diode bypass” option in cell B9 in the Excel spreadsheet utility.
By entering a “1” in this cell, the Si3402’s on chip diodes are assumed to be bypassed with
external diode bridges in your schematic. A “0” in this cell means the Si3402’s on-chip diode
bridges will be used.
ii. Enter VIN into cell B10. This voltage is the input voltage at the diode bridge output, which is 2 to
3 V less than the PSE input voltage, or typically 46 V.
iii. Enter your design’s desired output current, IO in Amperes, into cell B11.
iv. Enter your design’s desired output voltage, VO in Volts, in cell B12.
v. Enter your design’s maximum ambient operating temperature in °C into cell B13.
e. If you are using the “Non-isolated” worksheet:
i. The feedback resistor network values (R5 and R6) for your design are calculated and displayed in
cells G13 and G12, respectively. Use these resistor values to update your schematic.
ii. To use the default diode and inductor components used in the Si3402-EVB non-isolated
schematic, Silicon Labs strongly recommends leaving each default values “as-is” in cells B15
through B18.
iii. To ensure your design is operating within the acceptable operating ranges for all the external
components you use in your schematic, carefully review the calculated values found in cells B20
through B27.
iv. Carefully review the calculated values in the Summary section (cells B29 through B33).
1. Cell B29: PSE input voltage. Make sure the PSE input voltage is compatible with the PSE
intended to power your PD.
2. Cell B30: PSE input power. If the power is >12.95 W (more than the IEEE 802.3af limits),
then this cell is shaded in light RED and your PSE must be capable of sourcing the power
level shown in cell B30.
3. Cell B33: If the calculated junction temperature is >140 °C, then this cell is shaded in light
red. Consider bypassing the on-chip diodes to lower the effective junction temperature, or
reducing the output current (if possible). Other inputs in cells B9 through B13 may also need
to be adjusted to lower the calculated junction temperature.
f.
If you are using either of the “Isolated” worksheets, enter in the input values to determine if your design
will be operating in the “continuous” mode or the “discontinuous mode”:
i. Check the value of the current calculated in cell H11.
1. If your desired output current (B11) is less than the value shown in cell H11, then use the
“Isolated Discontinuous” worksheet.
2. If your desired output current (B11) is greater than the value shown in cell H11, then use
the “Isolated Continuous” worksheet.
ii. The feedback resistor network values (R5 and R6) for your design are calculated and displayed in
cells E12 and E13, respectively. Use these resistor values to update your schematic.
iii. Select transformer turns ratio: use 3.3, 2.5 or 1 as standard choices for 3.3, 5, and 12 V output,
respectively. Leave the rest of the options as defaults. If you have different output voltage, then
contact Silicon Labs for recommendations.
iv. To use the default transformer, snubber and diode components used in the Si3402 ISO-EVB
isolated schematic, Silicon Labs strongly recommends leaving each default values “as-is” in cells
B15 through B23. Always select the EP13 core if you require short circuit protection.
v. To ensure your design is operating within the acceptable operating ranges for all the external
components you use in your schematic, carefully review the calculated values found in cells B25
through B35.
Rev. 1.1
13
Si3402 ISO-EVB
vi. Carefully review the calculated values in the Summary section (cells B37 through B41):
1. Cell B37: PSE input voltage. Make sure the PSE input voltage is compatible with the PSE
intended to power your PD.
2. Cell B38: PSE input power. If the power is >12.95 W (more than the IEEE 802.3af limits),
then this cell is shaded in light RED and your PSE must be capable of sourcing the power
level shown in cell B30.
3. Cell B41: If the calculated junction temperature is >140 °C, then this cell is shaded in light
red. Consider bypassing the on-chip diodes to lower the effective junction temperature, or
reducing the output current (if possible). Other inputs in cells B9 through B13 may also need
to be adjusted to lower the calculated junction temperature.
3. General Design Checklist Items:
a. ESD caps (C10–C17 in Figure 1) are strongly recommended for designs where system-level ESD
(IEC6100-4-2) must provide >15 kV tolerance.
b. Never disable the soft start features. Make sure the soft start capacitor is in your schematics and
connected correctly.
c. If your design uses an AUX supply, make sure to include a 3 surge limiting resistor in series with the
AUX supply for hot insertion. Refer to AN296 when AUX supply is 48 V.
d. Silicon Labs strongly recommends the inclusion of a minimum load (250 mW) to avoid switcher pulsing
when no load is present, and to avoid false disconnection when less than 10 mA is drawn from the PSE.
If your load is not at least 250 mW, add a resistor load to dissipate at least 250 mW.
e. If using PLOSS function, make sure it’s properly terminated for connection in your PD subsystem. If
PLOSS is not needed, float this pin.
4. Layout Guidelines:
a. Make sure the VNEG pin of the Si3402 is connected to the backside of the QFN package with an
adequate thermal plane, as noted in the data sheet and AN296.
b. Keep the trace length from connecting to SWO and retuning to Vss1 and Vss2 as short as possible.
Make all of the power (high current) traces as short, direct, and thick as possible. It is a good practice on
a standard PCB board to make the traces an absolute minimum of 15 mils (0.381 mm) per Ampere.
c. Usually one standard via handles 200 mA of current. If the trace will need to conduct a significant
amount of current from one plane to the other use multiple vias.
d. Keep the circular area of the loop from the Switcher FET output to the inductor or transformer and
returning from the input filter capacitors (C1–C4) to Vss1 and Vss2 as small a diameter as possible.
Also, minimize the circular area of the loop from the output of the inductor or transformer to the Schottky
diode and retuning through the fist stage output filter capacitor back to the inductor or transformer as
small as possible. If possible, keep the direction of current flow in these two loops the same.
e. Connect the sense points to the output terminals directly to avoid load regulation issues related to IR
drops in the PSB traces. For the non-isolated case the sense points are Vposs and the sense resistor
R6. For the non-isolated case the sense points are R5 and the TLV431 pin 3.
f.
Keep the feedback and loop stability components as far from the transformer/inductor and noisy power
traces as possible.
g. If the outputs have a ground plane or positive output plane, do not connect the high current carrying
components and the filter capacitors through the plane. Connect them together and then connect to the
plane at a single point.
h. As a convenience in layout, please note that the IC is symmetrical with respect to CT1, CT2, SP1 and
SP2. These leads can be interchanged.
To help ensure first pass success, please submit your schematics and layout files to PoEInfo@silabs.com for
review. Other technical questions may be sent to this e-mail address as well.
14
Rev. 1.1
Si3402 ISO-EVB
DOCUMENT CHANGE LIST
Revision 0.2 to Revision 0.3
Updated schematics and BOM to latest
recommendations.
Updated artwork to correct errors and for improved
EMI.
Added component selection tables.
Revision 0.3 to Revision 0.4
Updated layout to Rev 1.2.
Updated "4. Bill of Materials‚" on page 8 for Rev D,
Si3400/01.
Added Si3401.
Revision 0.4 to Revision 0.5
Updated Figure 1, “Si3402 Schematic—5 V, Class 3
PD,” on page 2 to include ISOSSFT (pin 4) for the
isolated mode soft start feature (for revisions
beginning with Rev. E), Vssa support and ESD
improvements.
Updated "4. Bill of Materials‚" on page 8 per
schematic.
Revision 0.5 to Revision 0.6
Updated all Figures and Tables.
Updated BOM.
Added Appendix.
Revision 0.6 to Revision 0.7
Updated low ESR compensation for the 3.3 V and
5 V cases.
Revision 0.7 to Revision 0.8
Changed document title from
Si3400/Si3401ISO-EVB to Si3400/1/2 ISO-EVB.
Updated "4. Bill of Materials‚" on page 8.
Revision 0.8 to Revision 1.0
Added Si3402 ISO-C4-EVB
Removed Si3400/01 as the Si3402 replaces these.
Revision 1.0 to Revision 1.1
Updated schematic.
Rev. 1.1
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Si3402 ISO-EVB
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16
Rev. 1.1