When designing electrical equipment for international markets, engineers are forced to consider the requirements of a seemingly growing number of countries. If equipment is connected to the electrical grid, this includes additional safety requirements to isolate and protect people and property from dangerous voltage levels.

For designers in need of linear Class 2 transformers, Zettler offers a robust line of international power transformers with an industry leading 4200Vrms isolation rating.  A leading US appliance manufacturer recently chose Zettler Magnetics’ AHI01024 transformer for one of their products supplied globally. The appliance was designed for a commercial kitchen environment, meeting the high standards and daily routine of a busy restaurant.

The Zettler AHI series of laminated PCB transformers offer 115V or 230V input capability in 2.5VA, 5VA and 10VA configurations with outputs ranging from 5VAC to 36VAC.  They are UL Class 2 recognized, constructed with a UL Class B (130°C) insulation system, and conform to IEC/EN61558-1.  Custom options are also available.

Please contact us with any of your transformers needs and/or visit the Zettler Magnetics website for further details.

High Frequency Ferrite Transformers are a major component of switching power supplies, and choosing the right product configuration is a key element in any power supply design.

ZETTLER Magnetics’ proven formula of close customer engagements focused on individual design requirements, combined with highly cost-effective manufacturing automation is perfectly suited for many industry applications.

Application example: Household Appliances

Recently, an industry-leading home appliance manufacturer asked Zettler Magnetics to design a 2.6W switching power supply transformer with a wide input voltage range that meets several critical requirements including: electromagnetic interference performance to achieve EN55022, pass 85/85 temperature and humidity testing to meet IEC61558, and meet IEC60335 electrical performance and structural insulation requirements.

A team of Zettler Magnetics engineers custom-designed a transformer by performing double-layer shielding of the inner and outer layers, while using minimalist skeleton design.

The tailor-made transformer met the customer required design parameters, simplified materials during the design process, while also optimizing the electrical performance of the product, and enabling fully automated high-volume production.

 
Zettler Magnetics produces more than 40 million transformers per year and has power supplies ranging from more than 50 different form factors to 1W to 1KW. To support a wide range of applications from washing machines and kitchen appliances to lighting and the Internet of Things.

Application Spotlight, January 2019.

Zettler Magnetics continues to support the burgeoning Smart Lighting control market with its expanding range of Switch Mode Power Supplies.

ZETTLER’s 1 Watt Encapsulated SMPS was recently selected by a global leader in the Lighting industry. The application required a compact, cost effective plug & play solution with regulatory agency approvals. With an additional requirement for a zero-cross detection feature, ZETTLERS’s HP01SXX00WI-X module offered the ideal solution.

Lighting control is just one of the many Smart Home and IoT applications where Zettler’s SMPS modules are the ideal choice. These fully integrated, competitively priced plug & play modules offer excellent efficiency and EMI performance in a small form factor.

ZETTLER produces the entire range of SMPS modules, from 1W to 20W, in high volume at its wholly owned manufacturing facility in Xiamen, China.

Please contact us with any of your Switch Mode Power Supply needs and/or visit the
Zettler Magnetics website for further details.

About ZETTLER Magnetics, Inc.
Zettler Magnetics, Inc., a Zettler Group company, provides application-engineering, sales, distribution and customer service for a wide variety of top quality transformers and magnetics components in North America. We cater to a broad spectrum of customers in diverse industries and across many applications.

Zettler Magnetics Transformers include epoxy sealed power transformers encapsulated switch-mode modules, open frame, low profile, switching transformers and chokes, while toroids include current sensing, zero phase current sensor, current transformers, PFC chokes and large power line filter inductors. Zettler Magnetics has the design and manufacturing capability to provide custom designs for the most specialized applications. www.zettlermagnetics.com

Product Spotlight October 2018

Over recent years, Zettler Magnetics has expanded its range of High Frequency Ferrite Switching Transformers to now cover more than 50 different form factors, supporting power supply designs ranging from 1W to 1KW.

Selection of the appropriate structure is a critical element in any power supply design, which needs to consider a variety of electrical, safety and mechanical parameters.

Appropriate solutions therefore typically involve custom designs. At the same time, customers expect competitively priced solutions.

Zettler Magnetics response to this challenge is based on a two-pronged approach. An experienced team of transformer design-engineers closely engages with the customer in regard to individual design requirements, while highly automated production lines support a broad range of possible form factors, hence allowing us to manufacture high-volume custom designs at very competitive prices.

Example Application: Outdoor Lighting Control

Recently, an industry leader in Street Lighting Control requested Zettler Magnetics to design a 2.6 Watt wide input-range, custom switching transformer. The customer had unique requirements for operating temperature, UL Class B insulation, and physical size constraints within the Controller. Zettler was able to design a custom transformer meeting all of these design parameters. The bespoke design was tailored to suit Zettler’s high volume automated production line capabilities, resulting in a highly cost-effective solution for this transformer application.

Zettler Magnetics manufactures more than 40 million Switching Transformers each year to support a diverse range of applications from washing machines and kitchen appliances to Lighting and IoT. Many of these high-volume designs are manufactured on fully automated production lines in Zettler’s wholly owned manufacturing facility in Xiamen, China.

Please contact us with any of your Switching Transformer needs and/or visit the Zettler Magnetics website www.zettlermagnetics.com for further details.

About ZETTLER Magnetics, Inc.
ZETTLER Magnetics, Inc., a ZETTLER Group company, provides application-engineering, sales, distribution and customer service for a wide variety of top quality transformers and magnetics components in North America. We cater to a broad spectrum of customers in diverse industries and across many applications. ZETTLER Magnetics Transformers include epoxy sealed power transformers encapsulated switch-mode modules, open frame, low profile, switching transformers and chokes, while toroids include current sensing, zero phase current sensor, current transformers, PFC chokes and large power line filter inductors. Zettler Magnetics has the design and manufacturing capability to provide custom designs for the most specialized applications. www.zettlermagnetics.com

Application Spotlight May 2018

The Design

ZETTERs customer, a global leader in wireless communication protocols, selected a 1 watt SMPS from Zettler’s new HP01 series to power the control unit of their new wireless sensor solution for building automation and smart homes. The application wirelessly controls light switches, thermostats and almost any IoT device. The customer required a compact package, energy efficiency and competitive pricing to compete in the competitive market of wireless connectivity.

About the Power Supply

ZETTLER’S encapsulated SMPS series are a compact, energy efficient, plug & play solutions for the IoT market. Zettler’s versatile range of encapsulated switching power supplies offer a wide input range up to 90-305VAC for universal coverage, a high ambient temperature rating up to 85C at full rated load and an energy efficient low stand by power of custom solutions and zero cross detection are also available.

About ZETTLER Magnetics, Inc.

ZETTLER Magnetics, Inc., a ZETTLER Group company, provides application-engineering, sales, distribution and customer service for a wide variety of top quality transformers and magnetics components in North America. We cater to a broad spectrum of customers in diverse industries and across many applications. ZETTLER Magnetics Transformers include epoxy sealed power transformers encapsulated switch-mode modules, open frame, low profile, switching transformers and chokes, while toroids include current sensing, zero phase current sensor, current transformers, PFC chokes and large power line filter inductors. Zettler Magnetics has the design and manufacturing capability to provide custom designs for the most specialized applications. www.zettlermagnetics.com

Application Spotlight February 2018

The Design
Application solutions for residential security systems require highly reliable,
low-frequency power transformers with UL recognition. At the same time, the price
competitive nature of the residential security business also dictates the need for
low cost solutions. A leading manufacturer of home security systems recently put
these requirements to the ZETTLER Magnetics engineering team. In addition, the customer
also demanded a transformer in a compact size and with excellent heat dissipation
to accommodate the sleek and modern design of the control panel of the application.
ZETTLER’S 1.5VA BV series encapsulated transformer seamlessly met all these requirements while costing less than an electrically equivalent
laminated transformer.

About the transformer
ZETTLER’S versatile BV series of encapsulated transformers are less expensive than traditional laminated transformers while providing better
performance… the best of both worlds! Encapsulating the transformer in epoxy
improves isolation and heat dissipation, which allows for a smaller package size
that still meets UL’s stringent class II standards. Suitable for a wide range
of industrial control applications ZETTLER’s BV series [/encapsulated-power/]
is available in 115V or 230V inputs and from 0.35VA to 10VA. ZETTLER builds the
BV series, at our factory
in Southern China, on automated production lines which ensure consistent quality
at a very competitive price.

About ZETTLER Magnetics, Inc.
Zettler Magnetics, Inc., a Zettler Group company, provides application-engineering, sales, distribution and customer service for a wide variety of top quality transformers and magnetics components in North America. We cater to a broad spectrum of customers in diverse industries and across many applications.

Zettler Magnetics Transformers include epoxy sealed power transformers encapsulated switch-mode modules, open frame, low profile, switching transformers and chokes, while toroids include current sensing, zero phase current sensor, current transformers, PFC chokes and large power line filter inductors. Zettler Magnetics has the design and manufacturing capability to provide custom designs for the most specialized applications. www.zettlermagnetics.com

Application Spotlight November 2017

The Design

A global corporation in the dental industry approached ZETTLER for a reliable 40VA transformer to power their new range of Hydraulic Dental chairs. The application required a 120/208/240V input capability for international markets, custom lead lengths and colors for easy installation, and an inherently limited design with UL class II recognition and insulation system.

About the ZETTLER transformer

ZETTLER’s AHRV series of chassis mount transformers are UL Class II recognized and offered in a range of single, dual and triple input voltages, from 120V to 575V, and several mounting styles and termination options in a reliable easily to configure package. Ranging in power from 20VA to 100VA, these 50/60Hz transformers are found in high-power applications including: pumps, tank-less water heaters, motors, ovens, vending machines and lighting.

About ZETTLER Magnetics, Inc.

Zettler Magnetics, Inc., a Zettler Group company, provides application-engineering, sales, distribution and customer service for a wide variety of top quality transformers and magnetics components in North America. We cater to a broad spectrum of customers in diverse industries and across many applications.

Zettler Magnetics Transformers include epoxy sealed power transformers encapsulated switch-mode modules, open frame, low profile, switching transformers and chokes, while toroids include current sensing, zero phase current sensor, current transformers, PFC chokes and large power line filter inductors. Zettler Magnetics has the design and manufacturing capability to provide custom designs for the most specialized applications. www.zettlermagnetics.com

Application Spotlight September 2017

The Design
A leading home appliance manufacturer required a small, UL ready transformer for a next generation stove-top that would replace the rotary dials with a sleek touch-panel control that met their energy efficiency target. The customer’s “wish list” included a compact mechanical package, energy efficiency, universal input voltage capability and all at a low price point.

Established in the early 1900’s, the customer is one of America’s most recognized and trusted appliance manufactures, who still assembles over 70% of their products in the USA.

About the ZETTLER transformer

To meet the customer’s requirements, ZETTLER designed a high frequency ferrite transformer, also know as flyback or switch mode transformer. This style of transformer offers energy efficiency with a wide 90-264VAC input voltage range. The design was packaged in a compact E13 bobbin, with careful attention paid to UL spacing, creepage and material requirements.

ZETTLER Magnetics is able to quote most ferrite transformer customizations in 2 to 3 days, and provide samples in 10 to 12 days. We build our ferrite transformers in our industry leading, fully automated production facility in Xiamen, China, delivering consistently high quality at a competitive price.

About ZETTLER Magnetics, Inc.

Zettler Magnetics, Inc., a Zettler Group company, provides application-engineering, sales, distribution and customer service for a wide variety of top quality transformers and magnetics components in North America. We cater to a broad spectrum of customers in diverse industries and across many applications.

Zettler Magnetics Transformers include epoxy sealed power transformers encapsulated switch-mode modules, open frame, low profile, switching transformers and chokes, while toroids include current sensing, zero phase current sensor, current transformers, PFC chokes and large power line filter inductors. Zettler Magnetics has the design and manufacturing capability to provide custom designs for the most specialized applications. www.zettlermagnetics.com

Application Spotlight August 2017

The trend towards using renewable energies continues unabated, especially in a broad global push for rechargeable electric vehicles.

In the development of an IC CPD (In-Cable Control and Protecting Device) for the charging cable of an electrically powered vehicle, a leading automobile manufacturer, replaced a previous design element with a current sensor from the ACST series manufactured by ZETTLER Magnetics. The previous design featured a sensor in which the electrical conductor had to be routed through the core, resulting in significant assembly effort in association with high costs.

With the ACST series current sensor from ZETTLER Magnetics, the conductor (primary winding) is already integrated into the sensor, thereby allowing it to directly detect the current being applied to the printed circuit board. Another design requirement, increasing the cross-section of the primary winding necessary for detecting currents of up to 32A, was also realized. Apart from the height, it was possible to preserve the dimensions of max. 20.5 x 17.5 mm. The height had to be increased from 16.4 mm to 20.0 mm due to the attachment of an additional plastic hood to assure reliable insulation of the primary winding.

This application example demonstrates, once again, the versatility of Zettler Magnetics components, and our ability to find pragmatic and highly effective engineering solutions for our customers.

For more information about products manufactured by the ZETTLER Group that are used in e-mobility applications, please visit www.ZETTLERelectricvehiclerelays.com.

For similar solutions or to discuss the wide variety of application opportunities for the range of ZETTLER Magnetics Transformers, please contact us.

About ZETTLER Magnetics, Inc.

Zettler Magnetics, Inc., a Zettler Group company, provides application-engineering, sales, distribution and customer service for a wide variety of top quality transformers and magnetics components in North America. We cater to a broad spectrum of customers in diverse industries and across many applications.

Zettler Magnetics Transformers include epoxy sealed power transformers encapsulated switch-mode modules, open frame, low profile, switching transformers and chokes, while toroids include current sensing, zero phase current sensor, current transformers, PFC chokes and large power line filter inductors. Zettler Magnetics has the design and manufacturing capability to provide custom designs for the most specialized applications. www.zettlermagnetics.com