Category Archives: Application Spotlight

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

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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		Conforms
to Safety
Standard		Connection
Type:
Single-phaseThree-phrase3-6mA15-30mA
APR00T0332WX-003440V32A32AActionNC5V/30mA-40-85℃IEC62955PIN
APE00T0332WX-001440V32A32AActionAction5V/30mA-40-85℃IEC62752PIN
APR00D0163WX-001440V63A32AActionNC5V/30mA-40-85℃IEC62955Hole
APE00D0163WX-001440V63A32AActionAction5V/30mA-40-85℃IEC62752Hole
APR00T0332WT-001440V32A32AActionNC5V/30mA-40-85℃IEC62955PIN
APE00T0332WT-001440V32A32AActionAction5V/30mA-40-85℃IEC62752PIN
APR00D0163WT-001440V63A32AActionNC5V/30mA-40-85℃IEC62955Hole
APE00D0163WT-001440V63A32AActionAction5V/30mA-40-85℃IEC62752Hole
APR00D0132WG-001440V32A32AActionNC5V/30mA-40-85℃IEC62955Hole
APE00D0332WG-010440V32A32AActionAction5V/30mA-40-85℃IEC62752Hole
APE00D0332WG-110440V32A32AActionAction12V/30mA-40-85℃IEC62752Hole
APR00D0332WG-001440V32A32AActionNC5V/30mA-40-85℃IEC62955Hole
APE00D0332WG-014440V32A32AActionAction5V/30mA-40-85℃IEC62752Hole
APE00D0332WG-114440V32A32AActionAction12V/30mA-40-85℃IEC62752Hole

ZETTLER Magnetics expands range of Ultrawide input Power Modules

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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.

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

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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.

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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.

Zettler Magnetics High Frequency Switching Transformers in 3 phase EV Charging Systems.

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Application Spotlight September 2019

Zettler Magnetics develops a high-frequency transformer for e-mobility market

The expansion of the electromobility market has provided consumers with choice in EV cars ranging in battery size and range.  Vehicles with larger battery sizes like the Tesla Model S provide users with over 300 miles of range, meaning a single charge can last an entire week for most users.  Other vehicles like the Nissan Leaf or Hyundai Ioniq provide less than half the range and charge times meaning some users could expect more frequent charges. When limited to 7kW single phase charging systems, the longer charge times force users to carefully manage their charging and travel times.The availability of 3 phase EV supply equipment (EVSE) simplifies the user experience by providing faster charge times ranging from roughly half the charge time for a 11kW EVSE to a third of the charge time for a 22kW EVSE.

high-frequency transformerA leading manufacturer in charging infrastructure approached ZETTLER Magnetics in need of a high-frequency transformer for its internal switch mode power supply (SMPS). The challenge for the engineers at ZETTLER was to develop a high-efficiency switching transformer for high input voltages up to 400VAC in a new 3-phase EV charging cable. ZETTLER Magnetics met these challenges with a custom designed high frequency switching transformer, providing for the smallest possible space while also complying with common UL and IEC61558 standards.

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. Please contact us with any of your switching transformer needs and/or visit the ZETTLER Magnetics website www.zettlermagnetics.com for further details.

ZETTLER Magnetics Inc. is not affiliated with or endorses any of the electric vehicle brands/models mentioned above, and makes no representations whatsoever to their performance parameters or on-road performance.Their mention in this application spotlight is purely for educational purposes.

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

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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.

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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.

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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.

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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

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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