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

Application Spotlight May 2017

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.

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

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 – Application Spotlight, March 2017

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.

Power 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.