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 [http://www.zettlermagnetics.com/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

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

ACST series current sensors in charging cables for electric vehicles

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

Zettler Magnetics Encapsulated Power Transformer used in a Central Vacuum System Application

Application Spotlight May 2017

app-may-1

A leading designer and manufacturer of central vacuum systems in the residential and commercial market required a low frequency power transformer that offers good heat dissipation, in a compact size, with a UL class II rating. The application also required protection from dust and lint which could present a fire hazard.

ZETTLER Magnetics’ 1VA BV series encapsulated transformer was ideally suited for this application, meeting all of the above requirements with the added bonus of costing less than an equivalent laminated transformer.

The BV series’ epoxy encapsulation provides superior isolation and heat dissipation. With small physical dimensions, yet still meeting UL’s stringent class II standards, this transformer is suitable for a wide range of industrial control applications.

app-may-2
ZETTLER Magnetics’ BV series is available in 115V or 230V inputs and from 0.35VA to 10VA.

ZETTLER Magnetics builds the BV series on fully automated production lines which ensure consistent quality at a very competitive price.

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

Zettler Magnetics Switch-Mode Power Supply Module used in Smart Energy Home Applications

Application Spotlight APRIL 2017

New forms of convenient solutions for smart energy and lighting are being developed rapidly. Applications of this kind require intelligent, robust and energy-saving power supplies.

Recently, an industry leading provider of innovative and reliable indoor and outdoor lighting and controls solutions worked with ZETTLER Magnetics on the design of a USB “Type C” wall socket that combines a traditional electric outlet with USB charging receptacles. ZETTLER Magnetics provided a 3 Watt Switch-Mode Power Supply (SMPS) module with a wide 90-305VAC input capability and a 85 C ambient temperature rating as the appropriate power supply solution. The device contains UL approved tamper resistant shutters to ensure compliance with the 2011 NEC Article 406.12, requiring all 125V receptacles in dwelling units to be tamper resistant.

ZETTLER’s new HP series high performance 1 Watt to 3 Watt power supplies are specifically designed to deliver universal and energy saving capabilities required in many new smart energy market applications. These high efficiency plug-and-play solutions for low power applications are cost effectively manufactured by ZETTLER Magnetics China fully automated lines.

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

 

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 Encapsulated Power Transformers used in Residential Electric Smart Meters

ZETTLER Magnetics – Application Spotlight, March 2017

BV Series - Encapsulated Power Transformers
A worldwide technology leader and manufacturer of electric meters required Zettler Magnetics’ assistance in the development of an encapsulated linear power transformer for a residential electric meter. While the industry standard for meter surge protection generally is 8kV, this customer required 10 kV.

Through creative engineering, Zettler Magnetics was able to actually achieve a repeatable 12 KV surge resistance with a version of its cost effective, Class 2 recognized BV series of encapsulated power transformers.

This breakthrough engineering effort on behalf of the customer improved and exceeded
industry ratings, winning Zettler Magnetics a considerable amount of repeat business
with this large account.

About ZETTLER Magnetics, Inc.
Located in Aliso Viejo, Southern California, 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, 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.

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.com.

Zettler Magnetics High Frequency Switching Transformers used in Indoor and Outdoor Lighting Controls

AMXC-506Power supplies lie at the core of many control applications in the lighting industry.

Recently, an industry leading global manufacturer of indoor/outdoor lighting and innovative provider of energy management solutions cooperated with Zettler Magnetics when designing a new power supply, requiring a high frequency switching transformer.

Zettler Magnetics application engineers quickly and cost effectively helped this customer to build, test, modify and proto-type the design – using products from its line of Ferrite Switching Transformers .

Built on Zettler’s new fully automated ferrite production line, these transformers have a universal 85-264 VAC input range, a 4kV primary-secondary insulation and conform to EN 61558 and EN 60950. They are 100 % production tested, and allow rapid prototyping with easy customization.

For similar applications or to discuss the wide variety of application opportunities for the range of Zettler Magnetics Transformers please contact the author.

About ZETTLER Magnetics, Inc.
Located in Aliso Viejo, Southern California, 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, 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.

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.com.