ZETTLER Magnetics EV-RCD Module supports Residual Current Protection Solution for EV Charger

Product Spotlight March 2024

With the rapid growth of the Electric Vehicle market, the demand of EV chargers has been increasing tremendously in these years. Based on types of electrical currents for charging, EV chargers are divided into AC chargers and DC chargers. Featured by compact size and easy installation, AC charger is generally most appropriate for residential units, workplaces and communities, to be installed in public parking lot/garages. With its high market demand, AC chargers currently are the mainstream in the market.

Generally, EV charging currents range from a few kilowatts to tens of kilowatts, highlighting the critical importance of safety protection in EV charging systems. Several countries have introduced rigorous safety regulations, emphasizing the necessity of leakage protection for EV chargers.

In electric vehicle charging, a large number of AC-DC conversion (rectifier/inverter) circuits exist. If a leakage fault occurs, there will be not only Type AC and pulsating direct residual current, but also DC residual current and smooth DC residual current generated by two-phase/three-phase rectification and filtering. Therefore, the leakage protection solution must be capable of detecting both AC and DC residual currents.

ZETTLER Magnetics has recently developed a series of EV-RCD module with leakage protection solution, which are suitable for Mode 2 and Mode 3 EV chargers under European standards.

Leakage detect Mechanism

The ZETTLER EV-RCD module adopts the principle of detecting differential current by the response of specific Amorphous cores to tiny magnetic field changes. When an electrical system is working perfectly, the vectorial sum of the currents on all current-carrying conductors of a supply line is equal to zero, and thus there is no magnetic field around the supply line.

If a residual current does occur and is drained outside of the supply line via an object or the ground due to an insulation fault, a differential current greater than zero will exist.

The ZETTLER EV-RCD modules use an Amorphous core with a high remanence ratio and integrates a self-excitation oscillation circuit to generate periodic oscillation. When the differential current passes through the core, the magnetic field would change, resulting in the variation on the oscillation waveform accordingly.

The ZETTLER modules will determine the differential current value and the type through the comparison of waveform variation and feedback AC and DC leakage signal correspondingly when the value exceeds the limitation of safety standard.

Compared with the traditional type A leakage protection products, the ZETTLER EV-RCD module has the following advantages:

  • Excellent accuracy: Detect 3-6 mA DC differential current, and send response signal according to safety requirements.
  • High surge-current withstand capacity: Withstand 3.000 Ainstantaneous current surge without damage.
  • The ability to detect various current types: Fulfill type B leakage detecting.

List of EV-RCD Modules

Model No.Rated
Input Voltage
Rated Input CurrentDC:AC:Digital I/O Operating
Temp. Range
to Safety

ZETTLER Magnetics expands range of Power Modules

Product Spotlight April 2021

In recent years, ZETTLER Magnetics has greatly expanded its range of cost effective, plug and play AC-DC power modules. From additional power ratings, input and output voltages, extended temperature ratings to optional EMI shielding, the ZETTLER Magnetics portfolio is now one of the most diverse in the industry.

ZETTLER Magnetics power modulesThese fully encapsulated modules are ideal for a multitude of applications including smart energy solutions, indoor and outdoor lighting control, white goods, electric vehicle charging and IoT. The pre-certified solutions simplify power electronics design enabling faster time to market.

The ZETTLER Magnetics power module portfolio provides options such as our High Performance (HP) series to a lower cost(ZP) series both with an output power ranging from 1 Watt to 20 Watt. Additionally, the HP-X Series comes with integrated zero-cross detection. The output is electrically isolated from the mains input and monitors frequency and phase of the AC input. Our technology roadmap remains extensive with designs for 30 Watt and beyond.

Our updated downloadable PDF provides a complete overview of the entire module line-up from ZETTLER Magnetics, listing all pertinent key features with easy-to use links to all relevant data sheets.

Our power modules can also be customized. From mounting options, flying leads, shielding to specific electrical requirements. Please contact us to discuss your requirements.

ZETTLER Magnetics expands range of Ultrawide input Power Modules

Driven by burgeoning indoor and outdoor applications in IIOT (Industrial Internet of Things), and following an earlier spotlight on components for 480VAC applications, ZETTLER Magnetics is pleased to announce the expansion of its range of Ultrawide input Power Modules.

The HPI10 series of Plug & Play 10W Power Modules support input requirements from 90-528VAC with various industry standard regulated outputs from 5VDC to 24VDC.

Designed to operate from -40 to +80 degrees Celsius, the 10W series offers the industry’s smallest footprint while meeting the requirements of UL 62368-1 safety standards.

HPI10 series

Recognizing the proliferation of high performance wireless communications in the target applications, the base of ZETTLER’s HPI10 Power Modules integrates a shield allowing system designers to easily implement a 6-sided shielded solution. The optional cover shield helps prevent noise from the power supply interfering with sensitive communications receivers e.g. Cellular, Wi-Fi etc.

ZETTLER’s range of Power Modules are designed with the smart city revolution in mind. From lighting, building management systems and energy measurement to EV charging and consumer products, these modules are the ideal solution.

ZETTLER Magnetics develops UVC LED Drivers for UVC Sanitizing Solutions

Product Spotlight, July 2020.

Driven by the global COVID-19 pandemic, demand for home and industrial appliances with sanitizing functions, such as air purifiers, UV lights, and embedded sanitizing devices for dish washers or washing machines has increased rapidly.

Due to new international regulations of the Minamata Convention, traditional UV sanitizing solutions using mercury-based UV tubes are in the process of being discontinued.

A new generation of UVC LEDs are the leading replacement technology, offering the necessary performance and cost benefits the industry demands. With appropriate power and duration of light exposure, the DNA/RNA of any virus or bacteria will be destroyed. In fact, tests have demonstrated that UVC can effectively kill the Covid-19 virus.

ZETTLER Magnetics has developed a complete UVC LED embedded solution for home appliance manufacturers. The solution includes the necessary driver/controller circuitry, transformer and enclosure for the module to be easily embedded into any appliance.

ZETTLER Magnetics UVC LED Module for  UVC Sanitizing SolutionsSolution features and benefits:

  • UVC 275nm type, 2mW-20mW light power
  • Embedded MCU, providing multiple I/O and A/D ports
  • Design flexibility, from driver component to complete module design
  • Capability to withstand 1.6MPa water pressure

ZETTLER Magnetics expands global manufacturing footprint with Vietnam factory

ZETTLER Magnetics is pleased to announce the operational launch of its new wholly owned manufacturing facility in Vietnam.

Southern Vietnam is rapidly becoming an important manufacturing hub within Asia and is the ideal location for ZETTLER Group to continue its strategic plans for global growth and geographic diversification.

The initial product lines to be manufactured at the Vietnam facility will be our wide range of Linear Transformers. Additional product groups will be identified in subsequent steps as we keep expanding the scope and size of this operation.

Located in the Long An Province of Ho Chi Minh City, ZETTLER Vietnam aims to replicate the tremendous success and growth of ZETTLER’s primary manufacturing facility situated in Xiamen, China.
With over 20,000 square feet of expandable manufacturing space, ZETTLER Vietnam is fully ISO9001 and UL Certified.

ZETTLER Group and Digi-Key Electronics partner in new Distribution Relationship

Starting in May 2020, ZETTLER Group North America’s three product divisions have entered a long-term supplier relationship with Digi-Key Electronics, a highly recognized global industry leader in electronics components distribution.
ZETTLER’s product lines include electromechanical relays (American ZETTLER, Inc.), LCD TFT display solutions (AZ Displays, Inc.) and transformer/magnetic components (ZETTLER Magnetics, Inc.).

Each of ZETTLER’s product divisions will have a variety of their most important component lines represented on Digi-Key’s highly user-friendly digital search engines. All products are available for immediate purchase through Digi-Key’s top-rated transactional website infrastructure. Products range from power relays for many different applications, to IPS color TFT displays to AC/DC power modules and power transformers across a variety of electrical parameters. Applications and industries span across HVAC-R, Automotive, Solar, EV-Charging, Smart Energy, Building Automation, Industrial, Medical, LED Lighting, Energy Distribution & Management, Telecom and many more.

Like Digi-Key Electronics, ZETTLER has long been known for technical innovation, product quality and service in support of customers seeking reliable component solutions. As globally recognized brands, Digi-Key and ZETTLER both share in the idea of offering engineers and product designers immediate access to a vast array of well stocked product offerings through an easy-to-access, engineering friendly digital environment.
The combination of ZETTLER products with Digi-Key’s powerful presence in the digital space, along with its impeccable track record in product availability and on-time delivery, will make this partnership a formidable force in the marketplace.

ZETTLER Group North America Company Relocation.

ZETTLER Group North America is pleased to announce that we will be moving operations to below address in Vista, California.
This includes all North American ZETTLER Group Divisions:

American ZETTLER, Inc.
ZETTLER Magnetics, Inc.
ZETTLER Controls, Inc.
AZ Displays, Inc.
ZETTLER Integrated Solutions, Inc.

2410 Birch Street
Vista, CA 92081 USA

Phone numbers and email addresses will remain the same.

For more contact information, please visit https://www.zettlerusa.com/contact-us/

Our existing office in Aliso Viejo, CA will cease operations on March 13th, 2020 and we will resume on March 16th, 2020 from our new office in Vista, CA.

Please direct all correspondence and shipments to the new Vista address going forward.

If you have any questions concerning our new location, please feel free to reach out to us.

Yours sincerely,

Max Moegling
Vice President, Finance and Administration

Electronic Components for 480VAC Applications (Part1/2).

Application Spotlight, February 2020.

In North America, 480VAC 3-phase is the most common power system found in industrial facilities, directly used to power electric motors or heavy loads such as resistive heating (boilers) and rectifiers, where high power DC is needed (data centers, battery charging). It is increasingly common for moderate to large commercial facilities like office buildings or campuses to run 480V 3 phase applications. From this multi-phase power system, 480V single phase circuits can also be used for lighting or building management applications.

Higher voltages mean lower current and less copper (great for the heavy loads) but it also means greater spaces between conductors and harder to find components. In Part 1 of this application spotlight, we explore components from ZETTLER Magnetics used in the conversion of 480VAC to lower voltages. For stepping down 480VAC to lower AC voltages like 24VAC commonly used in controls & automation, Zettler Magnetics offers a range of standard and custom linear 50/60Hz transformers including:

PCB mount transformers Chassis mount Class 2 transformers

For conversion to low voltage DC, typically in the range of 5 to 24VDC, ZETTLER Magnetics also offers:

Custom ferrite transformers for those designing their own switch-mode power supplies (Coming soon) AC-DC SMPS module with an ultrawide 100-480VAC input

Contact Us with your requirements and look out for Part 2 of this spotlight series where we explore electromechanical switches from ZETTLER capable of switching 480VAC circuits.

Flyback transformer from ZETTLER Magnetics for use in power tools.

According to a recent MarketsandMarkets report, the worldwide market for power tools is estimated to reach USD 41.7 billion in 2024 with a CAGR of 5.5%. Growing adoption of cordless power tools, rising demand for fastening tools in industrial environments, and growing construction industry in emerging economies are the key factors driving the growth of the power tools market.

Currently, drilling, fastening and screwdriving  tools hold the largest market share in the power tools market, and a similar trend is likely to continue during the forecast period. Within that segment residential and “Do-it-yourself” applications are  expanding strongly, driving demand for compact, and easy-to-handle products with robust performance. For manufacturers, this creates challenges in designing ergonomic, lightweight and easy-to-handle power tool products.

A leading power tool manufacturer needed an extremely compact flyback transformer in SMT construction for its next generation cordless charger. To ensure stable load regulation, the transformer required very low leakage inductance. In cooperation with the customer, ZETTLER Magnetics’ engineers were able to develop a transformer solution that meets these specifications in a small size, as well as in compliance with EMC regulations. Customized solutions at competitive prices are at the center of ZETTLER Magnetics’ commercial and engineering philosophy.

Please Contact Us For more information about similar applications and custom solutions, as well as about the comprehensive products from ZETTLER Magnetics.

Join ZETTLER Group on October 15th in Anaheim at the Future Electronics Tech Day!

Location: DoubleTree
Suites by Hilton Anaheim Resort – Convention Center, 2085 S. Harbor Blvd.
Anaheim, CA 92802

Event Date: Tuesday
October 15, 2019

RSVP: Register by Tuesday October 8, 2019

Join Zettler Group for this Free Event

Future Electronics invites you to attend the most advanced hands-on technical learning event in the region. This is a unique opportunity to gain exposure to new technology as you interact with over 50 of the industry’s top suppliers at the Technology Expo event. You can also choose to spend time in the classroom with deep-dive technical training taught by key technologists. Choose your own classes and customize your learning to your training needs.

Event Overview

Future Electronics is bringing together the largest group of leading technologists, from the industry’s top suppliers, to help you connect and learn about the latest technologies, tools, and services. The Technology Expo event will be open all day starting at 8:30am. We are offering 24 classes throughout the day ranging from the latest in edge computing, wireless, sensing, security, artificial intelligence, high performance analog, power, signal chain, connectors, IoT, and much more. We will be providing breakfast, lunch, and snacks throughout the day

Zettler Group

The Zettler Group will be exhibiting our latest product and service offerings for relays, magnetics, and customized LCD solutions. Meet our technical sales team and learn more about our products and latest offerings.