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

Posted on March 20, 2024 by Alexander Stoeckel

Product Spotlight March 2024

Munich, Germany March 20, 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 current power ranges from a few kilowatts up to tens of kilowatts. So safety protection is extremely critical for EV charging. Many countries have put forward corresponding safety regulations, especially on the importance to the leakage protection of EV chargers.

In electric vehicles charging, a large number of AC-DC conversion (rectifier/inverter) circuits exist. So 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.

So 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. Thus, being capable to detect both AC residual current and DC residual current is required for the leakage protection solution.

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.
        
        Being able to detect various current types: Fulfill type B leakage detecting.

List of EV-RCD Modules

Model No.	Rated Input Voltage	Rated Input Current		DC:	AC:	Inout Voltage/Current	Operating Temp. Range	Conforms to Safety Standard	Connection Type:
Model No.	Rated Input Voltage	Single-phase	Three-phrase	3-6mA	15-30mA	Inout Voltage/Current	Operating Temp. Range	Conforms to Safety Standard	Connection Type:
APR00T0332WX-003	440V	32A	32A	Action	NC	5V/30mA	-40-85℃	IEC62955	PIN
APE00T0332WX-001	440V	32A	32A	Action	Action	5V/30mA	-40-85℃	IEC62752	PIN
APR00D0163WX-001	440V	63A	32A	Action	NC	5V/30mA	-40-85℃	IEC62955	Hole
APE00D0163WX-001	440V	63A	32A	Action	Action	5V/30mA	-40-85℃	IEC62752	Hole
APR00T0332WT-001	440V	32A	32A	Action	NC	5V/30mA	-40-85℃	IEC62955	PIN
APE00T0332WT-001	440V	32A	32A	Action	Action	5V/30mA	-40-85℃	IEC62752	PIN
APR00D0163WT-001	440V	63A	32A	Action	NC	5V/30mA	-40-85℃	IEC62955	Hole
APE00D0163WT-001	440V	63A	32A	Action	Action	5V/30mA	-40-85℃	IEC62752	Hole
APR00D0132WG-001	440V	32A	32A	Action	NC	5V/30mA	-40-85℃	IEC62955	Hole
APE00D0332WG-010	440V	32A	32A	Action	Action	5V/30mA	-40-85℃	IEC62752	Hole
APE00D0332WG-110	440V	32A	32A	Action	Action	12V/30mA	-40-85℃	IEC62752	Hole
APR00D0332WG-001	440V	32A	32A	Action	NC	5V/30mA	-40-85℃	IEC62955	Hole
APE00D0332WG-014	440V	32A	32A	Action	Action	5V/30mA	-40-85℃	IEC62752	Hole
APE00D0332WG-114	440V	32A	32A	Action	Action	12V/30mA	-40-85℃	IEC62752	Hole

Application

ZETTLER Magnetics EV-RCD series provide options for integrated busbar or open hole and a diverse range of charging current levels to satisfy 16 A, 32 A, and 63 A applications.

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

ZETTLER Electronics, Europe
Junkersstr. 3
82178 Puchheim
Germany
phone: +49(0)89-800 97 0
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 Magnetics ACST current sensors used in Charging of Electric Vehicles

Posted on January 26, 2021 by Alexander Stoeckel

Application Spotlight January 2021

Munich, Germany January 27, 2021 – The use of precise, and often quite costly sensors, for the detection of the operating state in EV charging infrastructure, such as IC-CPD cables or wall boxes is not unusual. However, high levels of accuracy are not always required and therefore the use of high precision sensors may represent an unnecessary cost factor.

With the sensors of the ACST series, ZETTLER MAGNETICS offers components that enable practically loss-free detection of alternating currents. The sensors of the type ACST-200 (AC Current Sense Transformer), which have been tried and tested in industrial automation for years, are used in control and monitoring applications, for protective circuits or load detection systems. They detect whether the intended current is actually flowing or whether the current strength deviates significantly due to an overload, a defect or a wiring fault. The main application is in 50 Hz or 60 Hz systems.

Since the primary winding is integrated in the sensor, this saves assembly time and results in a clearly defined, compact component with small external dimensions. Due to the galvanically isolated acquisition of the measurement signal, the sensor can be implemented at any point in the circuit.

ZETTLER sensors have also been used in chargers for vehicles in the e-mobility sector for years. A market leader of this industry approached ZETTLER in need of a sensor for their new generations of chargers. The engineers at ZETTLER MAGNETICS modified the existing sensor ACST262-14 in order to meet the required ablility to use it in applications up to 36 amps. The insulation values required by the customer based on IEC 60664-1 with 6.5 mm clearance and 8.0 mm creepage distance could also be met with the new ACST262-16 sensor. The required area on the PCB for the component with the dimensions 20.5 mm x 17.5 mm remained unchanged compared to the ACST262-14. Only the height was changed by 2.0 mm and is therefore 22.0 mm.

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

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

Electronic components for 400 VAC applications (part 1/2)

Posted on March 17, 2020 by Alexander Stoeckel

Application Spotlight March 2020

Munich, Germany October 17., 2020 – The 400 VAC 3-phase grid is the most common power system found in industrial facilities, directly used to power electric motors or heavy loads such as resistive heating (boilers). Other applications are charging stations for hybrid and electric vehicles.

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 400 VAC to lower voltages. For stepping down 400 VAC to lower AC voltages like 24 VAC 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 24 VDC, 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

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

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

Flyback transformer from ZETTLER Magnetics for use in power tools

Posted on October 14, 2019 by Alexander Stoeckel

Application Spotlight October 2019

Munich, Germany October 15., 2019 – 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 world-leading manufacturer of tools needed an extremely compact flyback transformer in SMT construction for its new generation of power tools, with very low leakage inductance to ensure stable load regulation. In cooperation with the customer, ZETTLER Magnetics’ engineers were able to develop a transformer solution that meets all 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.

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

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

ZETTLER Magnetics high frequency transformer in e-mobility application

Posted on August 20, 2019 by Alexander Stoeckel

Application Spotlight August 2019

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

The 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.

A 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 0
office@zettlerelectronics.com

ZETTLER Magnetics ACST current sensors used in industrial automation equipment

Posted on March 25, 2019 by Alexander Stoeckel

Application Spotlight March 2019

Munich, Germany 26. April 2019 – In industrial automation, it is often necessary to detect operating conditions, e.g. to prevent overloading in the event of a fault and thereby prevent possible damage to people or machines.

A market leader in this industry came to ZETTLER because he was looking for a reliable and cost-effective solution for his new generation of motor starters, in order to get a feedback of the motor current to detect possible existing fault conditions.

ZETTLER Magnetics ACST-200 current sense transformer series do it perfectly. The compact components with the dimensions 20.5 mm x 17.5 mm x 16.4 mm (L x W x H) are available with 5.5 mm and 8.0 mm clearance and creepage distance. Both versions have a dielectric strength of 4000 Vrms between the primary and secondary side. The standard version ACST-262-15 with a ratio of 1: 1500 operates linearly in a current range from 400 mA_rms to 30 A_rms when using a 200 Ohm load resistor. The output signal is then 123.3 mV per ampere. Special versions, e.g. with a higher or lower current range are possible on request.

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

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

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

Posted on June 20, 2018 by Alexander Stoeckel

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.