ZETTLER Magnetics high frequency transformer in e-mobility application

Application Spotlight August 2019

Munich, Germany 20. August 2019 – The progressive development of electromobility drives increasingly advanced requirements on electronic components.

e-mobilityThe expansion of the charging infrastructure for electric vehicles is becoming increasingly important in all parts of the industrialized world. In addition to “classic” charging stations, manufacturers of charging cables, designed for charging mode 2, register a strong growth in market demand. This type of charging technology is popular not only because of its convenient size, but also because of the flexibility to be able to charge several vehicle types from different manufacturers with the same cable. As simple as the operation and design of the charging cable appears to be, the higher and more complicated are the electronics inside of such charging modules. The dominant component of integrated electronics in this case is the power supply, which is also linked to special requirements such as high power-density and constraints such as low installation space.

transformerA leading manufacturer in charging infrastructure approached ZETTLER Magnetics in need of a high-frequency transformer for its internal power supply (SMPS) to redesign its charging cable. The challenge for the engineers at ZETTLER was to develop a high-efficiency transformer for an extremely high input voltage range of up to 400 VAC in a 3-phase application without neutral conductor. With ZETTLER Magnetics’ custom designed high frequency transformer solution, these requirements were met in a design that provided for the smallest possible space, while also complying with common UL and IEC61558 standards.

For more information about similar applications, as well as about the comprehensive transformer solutions from ZETTLER Magnetics please contact:

ZETTLER Electronics, Europe
Junkersstr. 3
82178 Puchheim
Germany
phone: +49(0)89-800 97 135
office@zettlerelectronics.com

About ZETTLER Magnetics Europe
ZETTLER Magnetics Europe, a ZETTLER Group division, provides application-engineering, sales, distribution and customer service in the EMEA region for a wide variety of top-quality transformers and magnetics components. We cater to a broad spectrum of customers in diverse industries and across many applications. ZETTLER Magnetics has the design and manufacturing capability to provide custom designs for the most specialized applications. Our sales, marketing, technical support, quality control and customer service departments work closely with our team of experienced design engineers at our manufacturing plant to help define the needs of our customers, and to provide optimal technical solutions for the most demanding application requirements. ZETTLER Magnetics engineering departments and manufacturing facilities, located in Xiamen, China, are fully vertically integrated and wholly owned. Read more at www.ZETTLERmagnetics.eu

ZETTLER’s AHI transformers selected for use in food processing equipment

Zettler AHI transformers selected for use in food processing equipmentWhen 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.

Zettler Magnetics AHI01024 50/60Hz isolation transformerThe 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.

Customized Transformer Solutions by Zettler Magnetics for Household Appliances.

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.

Customized Transformer Solutions by Zettler Magnetics in Household AppliancesApplication 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.

Zettler Magnetics XM-E16187 power supply transformer.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.

ZETTLER Magnetics 1-Watt Switch Mode Power Supply in High Volume Smart Lighting application.

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 Megnetics HP01SXX00WI-X module

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.

Zettler Solutions for Indoor Lightening

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

Zettler Magnetics range of Ferrite Switching Transformers supports large spectrum of Custom Power Supply solutions.

Product Spotlight October 2018

High Frequency Ferrite Switching TransformerOver 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

Zettler custom switching transformer applicationRecently, 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

ZETTLER Magnetics 1W Switch Mode Power Supply selected for residential smart home system

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

ZETTLER Magnetics provides an Encapsulated Power Transformer for a residential security application

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

Switch mode power supply modules from ZETTLER Magnetics in intelligent street lighting concepts

Application Spotlight June 2018

Munich, Germany 20. of June 2018 –Future street lighting concepts and their intelligent control include far more functions than simply illuminating the surroundings. These include e.g. automatic regulation of the lighting level via sensors, charging functions for electro mobility or the integration of traffic control systems or the detection of parking space utilization.

For a leader in intelligent lighting control systems, ZETTLER Magnetics recently customized its standard ZP05 5 Watt power supply module series to meet all specific customer requirements. In particular, outstanding EMC values in the use of the controller for the power line communication convinced the customer to choose the Zettler power module in this application .

The components have a universal wide-range input of 85 to 265 VAC or 100 to 370 VDC and are available with common output voltages.

ZETTLER Magnetics SMPS are deployed in a wide range of applications such as smart home controls, wireless switching, lighting controls (incl. LED boards), test and measurement devices such as smart meters, as well as a variety of white goods and appliances.

For more information about similar applications, as well as about the comprehensive switch mode power supply solutions from ZETTLER Magnetics please contact us.

About ZETTLER Magnetics Europe – ZETTLER Magnetics Europe, a ZETTLER Group division, provides application-engineering, sales, distribution and customer service in the EMEA region for a wide variety of top quality transformers and magnetics components. We cater to a broad spectrum of customers in diverse industries and across many applications. ZETTLER Magnetics has the design and manufacturing capability to provide custom designs for the most specialized applications. Our sales, marketing, technical support, quality control and customer service departments work closely with our team of experienced design engineers at our manufacturing plant to help define the needs of our customers, and to provide optimal technical solutions for the most demanding application requirements. ZETTLER Magnetics engineering departments and manufacturing facilities, located in Xiamen, China, are fully vertically integrated and wholly owned. Read more at www.ZETTLERmagnetics.eu.

40VA Chassis Mount Transformer by ZETTLER Magnetics used in Dental Chair Application

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

Ferrite Transformer by ZETTLER Magnetics used in Home Appliance, Stove Top-Control Application

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