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

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
to Safety

ZETTLER Magnetics expands range of Power Modules

Product Spotlight April 2021

In recent years, ZETTLER Magnetics has greatly expanded its range of cost effective, plug and play AC-DC power modules. From additional power ratings, input and output voltages, extended temperature ratings to optional EMI shielding, the ZETTLER Magnetics portfolio is now one of the most diverse in the industry.

ZETTLER Magnetics power modulesThese fully encapsulated modules are ideal for a multitude of applications including smart energy solutions, indoor and outdoor lighting control, white goods, electric vehicle charging and IoT. The pre-certified solutions simplify power electronics design enabling faster time to market.

The ZETTLER Magnetics power module portfolio provides options such as our High Performance (HP) series to a lower cost(ZP) series both with an output power ranging from 1 Watt to 20 Watt. Additionally, the HP-X Series comes with integrated zero-cross detection. The output is electrically isolated from the mains input and monitors frequency and phase of the AC input. Our technology roadmap remains extensive with designs for 30 Watt and beyond.

Our updated downloadable PDF provides a complete overview of the entire module line-up from ZETTLER Magnetics, listing all pertinent key features with easy-to use links to all relevant data sheets.

Our power modules can also be customized. From mounting options, flying leads, shielding to specific electrical requirements. Please contact us to discuss your requirements.

ZETTLER Magnetics develops UVC LED Drivers for UVC Sanitizing Solutions

Product Spotlight, July 2020.

Driven by the global COVID-19 pandemic, demand for home and industrial appliances with sanitizing functions, such as air purifiers, UV lights, and embedded sanitizing devices for dish washers or washing machines has increased rapidly.

Due to new international regulations of the Minamata Convention, traditional UV sanitizing solutions using mercury-based UV tubes are in the process of being discontinued.

A new generation of UVC LEDs are the leading replacement technology, offering the necessary performance and cost benefits the industry demands. With appropriate power and duration of light exposure, the DNA/RNA of any virus or bacteria will be destroyed. In fact, tests have demonstrated that UVC can effectively kill the Covid-19 virus.

ZETTLER Magnetics has developed a complete UVC LED embedded solution for home appliance manufacturers. The solution includes the necessary driver/controller circuitry, transformer and enclosure for the module to be easily embedded into any appliance.

ZETTLER Magnetics UVC LED Module for  UVC Sanitizing SolutionsSolution features and benefits:

  • UVC 275nm type, 2mW-20mW light power
  • Embedded MCU, providing multiple I/O and A/D ports
  • Design flexibility, from driver component to complete module design
  • Capability to withstand 1.6MPa water pressure

ZETTLER Magnetics expands global manufacturing footprint with Vietnam factory

ZETTLER Magnetics is pleased to announce the operational launch of its new wholly owned manufacturing facility in Vietnam.

Southern Vietnam is rapidly becoming an important manufacturing hub within Asia and is the ideal location for ZETTLER Group to continue its strategic plans for global growth and geographic diversification.

The initial product lines to be manufactured at the Vietnam facility will be our wide range of Linear Transformers. Additional product groups will be identified in subsequent steps as we keep expanding the scope and size of this operation.

Located in the Long An Province of Ho Chi Minh City, ZETTLER Vietnam aims to replicate the tremendous success and growth of ZETTLER’s primary manufacturing facility situated in Xiamen, China.
With over 20,000 square feet of expandable manufacturing space, ZETTLER Vietnam is fully ISO9001 and UL Certified.

ZETTLER Group and Digi-Key Electronics partner in new Distribution Relationship

Starting in May 2020, ZETTLER Group North America’s three product divisions have entered a long-term supplier relationship with Digi-Key Electronics, a highly recognized global industry leader in electronics components distribution.
ZETTLER’s product lines include electromechanical relays (American ZETTLER, Inc.), LCD TFT display solutions (AZ Displays, Inc.) and transformer/magnetic components (ZETTLER Magnetics, Inc.).

Each of ZETTLER’s product divisions will have a variety of their most important component lines represented on Digi-Key’s highly user-friendly digital search engines. All products are available for immediate purchase through Digi-Key’s top-rated transactional website infrastructure. Products range from power relays for many different applications, to IPS color TFT displays to AC/DC power modules and power transformers across a variety of electrical parameters. Applications and industries span across HVAC-R, Automotive, Solar, EV-Charging, Smart Energy, Building Automation, Industrial, Medical, LED Lighting, Energy Distribution & Management, Telecom and many more.

Like Digi-Key Electronics, ZETTLER has long been known for technical innovation, product quality and service in support of customers seeking reliable component solutions. As globally recognized brands, Digi-Key and ZETTLER both share in the idea of offering engineers and product designers immediate access to a vast array of well stocked product offerings through an easy-to-access, engineering friendly digital environment.
The combination of ZETTLER products with Digi-Key’s powerful presence in the digital space, along with its impeccable track record in product availability and on-time delivery, will make this partnership a formidable force in the marketplace.

ZETTLER Group North America Company Relocation.

ZETTLER Group North America is pleased to announce that we will be moving operations to below address in Vista, California.
This includes all North American ZETTLER Group Divisions:

American ZETTLER, Inc.
ZETTLER Magnetics, Inc.
ZETTLER Controls, Inc.
AZ Displays, Inc.
ZETTLER Integrated Solutions, Inc.

2410 Birch Street
Vista, CA 92081 USA

Phone numbers and email addresses will remain the same.

For more contact information, please visit https://www.zettlerusa.com/contact-us/

Our existing office in Aliso Viejo, CA will cease operations on March 13th, 2020 and we will resume on March 16th, 2020 from our new office in Vista, CA.

Please direct all correspondence and shipments to the new Vista address going forward.

If you have any questions concerning our new location, please feel free to reach out to us.

Yours sincerely,

Max Moegling
Vice President, Finance and Administration

ZETTLER Magnetics expands Line of Switch-Mode Power Supply Modules

Company introduces High Performance SMPS series and patent-pending Zero-Cross features.


SMPS Zettler Magnetics

Aliso Viejo, CA, USA/Xiamen, China/ Hong Kong/Munich, Germany – April 4, 2017 – ZETTLER Magnetics announces the expansion of its successful line of AC-DC switch-mode power supply modules (SMPS) by introducing a special high-performance series.

In addition to the well-established benefits of the regular Zettler SMPS series that include easy plug-and-play, compact encapsulated design, universal input range, and ultra-low power consumption, the high performance HP series will feature extra wide ambient temperature capability, and an extended life time of MTBF> 1 million hours.

The HP series will initially be available for 1W-3 W output power, with various output voltages, and an extended input voltage range of 85VAC-305VAC.

A special subset of the new HP series, the ‘X-Series’, features a patent pending zero-cross detection and monitoring capability, which supports increased efficiency of power Thyristor circuits and extended component life time, e.g. for relays, if switching occurs at zero-crossing. In addition, certain sensing applications, such as those found in the ‘smart home’ market, require the elimination of 50/60 Hz noise which the zero-cross feature can help accomplish by synchronizing built-in A/D converters with the mains frequency.

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.

Zettler Magnetics has published a comprehensive Product PDF for its SMPS product lines that can be accessed and downloaded at: www.zettlermagnetics.com/encapsulated-switch-mode-power-modules/product-program/

For more information, please contact one of the global Zettler Magnetics companies listed here:www.zettler-group.com/magnetics-contacts/

About ZETTLER Magnetics, Inc.

Zettler Magnetics, a Zettler Group division, provides application-engineering, sales, distribution and customer service 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 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. www.zettlermagnetics.com

Encapsulated Power Transformers from Zettler Magnetics: Smaller, Cooler, Cheaper

Zettler is offering competitively priced sealed transformer solutions with Class 2 UL ratings – featuring smaller footprints and reduced heat emission for applications such as LED Lighting, Electric Metering, Motor Controls and Thermostats.

Aliso Viejo, California November 09, 2015

Engineers working on applications in LED Lighting, Electric Metering, Motor controls and Thermo Controls keep asking for transformer solutions with smaller footprints, less heat emission at lower prices, and, of course, a Class 2 UL rating.

BV Series - Encapsulated Power Transformers

Zettler Magnetics, a company with years of development experience in the design of encapsulated linear power transformers is responding to these requests with its top-of-class BV series of sealed transformers.

Zettler’s BV series encapsulated Class 2 UL rated transformers:

  • Deliver significant reduction in physical footprint compared to traditional open frame formats.
  • Have superior thermal characteristics that make them run up to 5 degrees C cooler in continuous duty, and up to 40 degrees C cooler in surge testing than previous generations, due to ultra-high winding efficiency and vacuum-sealed epoxy processes.
  • Feature an unrivaled 14kV surge withstand capability based on a patent pending Zettler split-bobbin design.
  • Provide minimized EMI noise without the added cost of a shield, as a result of proprietary assembly methods employed at Zettler Group’s China wholly owned manufacturing facilities.

With output loads ranging from 0.6-10VA, Zettler Magnetics’ BV series is perfect for a wide range of products including thermostats, lighting controls, and oxygen concentrators. Dielectric strength is 4200Vrms, and external insulation is optional for increased dielectric withstand between the component and the PCB. Zettler BV transformers are also ideally suited for the alternative energy market – Solar inverters and smart grid meters are just two possible applications.

Zettler’s highly automated production lines makes the BV series price competitive when compared to similarly-sized open frame models. BV series pricing starts under $1.00 in 10K quantities.

Samples are available on request. For more information, please visit our BV series webpage at /encapsulated-power

ZETTLER Magnetics power supplies expanded to offer 1W, 3W, 5W and 10 watt configurations

Switching Power Modules 1W, 3W, 5W and 10 wattAliso Viejo, Calif., June 9, 2015 – Zettler Magnetics, Inc. continues to expand its range of AC-DC switching power modules. Zettler Magnetics is proud to announce that its series of compact and cost effective power supplies has been expanded to offer 1W, 3W, 5W and 10 watt configurations.

“Zettler has drawn on our industry leading encapsulating technology to produce a range of power modules with the smallest possible foot print for their relevant power output,said Anthon Vermaerke, Product Manager, Zettler Magnetics. “Technology that befits the more than 100 years of technical excellence from Zettler.

The market’s enthusiasm of Zettler’s affordable AC-DC power modules, since the first 5W version was launched 5 years ago, has spurred the development of additional power options. Zettler’s ZP series with their universal 90-264VAC at 50Hz or 60Hz input, low standby power, low EMI, and UL or TUV agency approval on the most popular offerings give engineers a simple, low cost, drop in solution for most PCB applications.

Link: /encapsulated-switch-mode-modules/

About Zettler Magnetics, Inc.
Headquartered in Aliso Viejo, Calif., Zettler Magnetics, Inc. is widely recognized for its high standards in traditional craftsmanship, engineering excellence and its commitment to creating products of the highest quality. Zettler Magnetics offers a complete line of transformers including epoxy sealed power transformers, open frame, low profile, switching transformers and chokes. Zettler Magnetics has the design and manufacturing capability to provide custom designs for most specialized applications. The factory is an ISO 9001 approved facility and maintains UL and VDE safety approvals for many products. For more information please visit