Category Archives: Application Spotlight

Customized ZETTLER AZEV132 relay for e-mobility charging applications according to IEC62752 Mode 2

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Application Spotlight, November 2020.

Due to the growing market for electric vehicles, the demand for charging infrastructure products is increasing rapidly. During the initial phases of the e-mobility rollout, mostly purely functional Mode 2 charging cables in accordance with IEC62752 were required. Today, manufacturers are also paying more and more attention to an attractive design with a high recognition value. There is also a strong focus on reducing the size of such devices.

A market leader in the field of high-end charging infrastructure approached ZETTLER because they desired a relay according to IEC62752 for its new generation of mode 2 charging cables with additional customized design features. Based on the experience and variety of reliable ZETTLER relays, a customized version was built according to the customer’s needs. The customer is highly satisfied with the resulting individualized relay solution, packaged in a tailor-made housing and printed in its own design.

ZETTLERs AZEV132 relay is a 1-pole power PCB relays, initially developed specifically for use in accordance with IEC62752 and, more importantly, to meet the exceedingly stringent short-circuit withstand-current requirements of this standard. These relays also have a monitoring contact to allow detection of any possible welding issues with the main contacts. The relays are approved at UL, CUR and TÜV with ratings of up to 40 A with 6k switching cycles (32 A with 50k switching cycles) for the normally open load contact and 10 mA at 12 VDC with 50k switching cycles for the normally closed monitoring contact.

A new version with switching capability of up to 50A, our AZEV140, is planned for series production in 2021.

For samples and data sheets of ZETTLER EV charging relays or similar solutions or to discuss the wide variety of application opportunities for the range of ZETTLER Relays, please contact us.

Electronic Components for 480VAC Applications (Part 2/2)

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Application Spotlight, July 2020.

Previously in Part 1 of this series, we explored electromagnetic components from ZETTLER Magnetics used in the conversion of 480VAC to lower AC (or DC) voltages. In Part 2, we explore electromechanical components from American ZETTLER that are capable of switching or isolating high voltage circuits operating at 480VAC. This ranges from bulky definite purpose contactors which handle the higher power loads more commonly associated with 480VAC circuits down to miniature power (latching) relays popular in lighting.

These robust switches offer safety approvals and certified ratings well suited for a number of applications including refrigeration, air conditioning, heating, elevators, food service equipment, cranes, hoists, welding machines, power supplies, vending machines, lighting, pumps and compressors.

Perspective:  A smaller XMC0 contactor next to AZSR1200, AZSR190, AZ2800, and AZ576 power relays.
Featured Products   Load Ratings
XMC0 Definite Purpose Contactors are available in various pole configurations with options for auxiliary contacts, micro switches, and mechanical interlocks 25-90 FLA up to 600VAC
125-450 LRA at 480VAC
AZSR1200, AZSR1180, and AZSR1160 single pole PCB mount power relays are well suited for solar inverter applications Make/break 40A, carry up to 200A, 920VAC (85 C)
50 make/break cycles up to 200A, 920VAC (85 C)
AZSR190 and AZSR165 single pole PCB relays are common in both solar and EVSE applications Up to 55A at 480VAC (85 C) for 30k cycles
Up to 100A at 480VAC (85 C) for 1k cycles
AZ2800 (panel mount) and AZ2850 (PCB mount) are popular double-pole power relays available in DPST and DPDT configurations 8 FLA or 10A general use on normally open contacts up to 600VAC
2 FLA or 2A general use on both normally open and closed contacts at 480VAC
AZ576 (non-latching) and AZ576P (latching) miniature power relays in single pole configurations are great for lighting and other smaller loads on 277, 347 or 480VAC circuits 3.7A std. ballast at 480VAC (105 C)
2.7A elec. ballast at 480VAC (105 C)
1HP rating at 480VAC (85 C)

AZSR131 relays from ZETTLER for use in E-mobility wallbox charger.

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Application Spotlight, February 2020.

Global plug-in electric vehicles sales for the first half of 2019 reached more than 1.1 million units- a 46% increase over prior year. Estimated global sales for 2020 are projected to reach 4 million units, reaching 12 million units in 2025, and 21 million in 2030.
AZSR131 relays from ZETTLER for use in E-mobility wallbox chargerThis positive trend is also evident in associated sales of charging infrastructure solutions. In particular, wall charging stations – so-called “wallboxes” – that enable EV charging with AC voltage according to charging mode 3 (IEC 61851-1) are and will continue to be in extraordinary demand. They facilitate charging of electric vehicles with voltages up to 400V, and are used in protected areas such as parking garages, carports or private homes.
ZETTLER AZSR131 EV charging relay
A supplier of wallboxes contacted ZETTLER in Europe, because of their need for a relay compliant with the requirements of IEC 61851-1 for a new generation of EV charging wallboxes. The relays of ZETTLER’s AZSR131 series have a normally open contact (1 form A) and are UL and TÜV approved with 35A 277VAC and 30,000 switching cycles or 33A 277VAC and 50,000 switching cycles with TÜV. The relays are available in the standard version with 1.8mm contact gap and in a special version with up to 2.3mm. The relays are also available in a version in accordance with the extended household appliance standard IEC 60335-1 (GWT). This component solution in the EV charging space along with others, such as the new AZEV132 EV charging relay, keeps ZETTLER relays at the forefront in this significant green energy growth segment.
Please Contact Us for samples and data sheets of these new ZETTLER EV charging relays or similar solutions or to discuss the wide variety of application opportunities for the range of ZETTLER Relays.

New ZETTLER relay series AZEV116 / 132 meets stringent requirements of IEC62752 for Mode 2 charging of Electric Vehicles (EV).

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November 2019

Electromobility is progressing steadily and the plans of many car manufacturers to ultimately exit internal combustion engine technology are becoming ever more concrete.
American zettler relays for relay for EV charging systems

As with almost all emerging technologies, application-specific standards for EV charging have continuously evolved over the years as safety concerns and impacts to the electric utility grid were considered. For early pioneers of electrical vehicle supply equipment (EVSE) or charging stations, this meant constant re-engineering of existing systems to meet regional standards and uncertainty around future certification requirements.

For the charging of electric vehicles using household or CEE sockets, the IEC62752 standard offers system designers a welcome sense of clarity on what future regulations are likely to require. Charge mode 2 (Level 2 charging / IC-CPD) addresses necessary control and safety requirements for charging cables along with considerations for the type of currents and service life these products will endure.
American Zettler AZEV116 and AZEV132 relays

Fortunately for hardware designers of EVSE systems, ZETTLER’s new relay series AZEV116 and AZEV132 were developed specifically for use in accordance with IEC62752 and, more importantly, to meet the exceedingly stringent short-circuit withstand-current requirements of this standard. These relays also have an isolated signal monitoring contact to allow detection of any possible welding issues with the main contacts.

Highlights:

  • Designed for charging systems of charge mode 2 (IEC62752).
  • Normally open (1 Form A) with wide contact gap ≥ 2.25 mm.
  • Dielectric strength (coil/power contact) 4,000 Vrms.
  • Galvanic isolated signal monitoring contact (1 Form B).
  • UL, CUR and TUV approvals.

AZEV116:

  • Electrical lifetime: 50,000 switching cycles 16 A, 277 VAC @ 85C
  • Short-circuit withstand: ≥ 1.02 kA; ≥ 2.5 kA²s

AZEV132:

  • Electrical lifetime: 50,000 switching cycles 32 A, 277 VAC @ 85C
  • Short-circuit withstand: ≥ 1.5 kA; ≥ 6.0 kA²s

Please Contact Us for samples and data sheets of these new ZETTLER EV charging relays or similar solutions or to discuss the wide variety of application opportunities for the range of ZETTLER Relays.

ZETTLER’ s AZ2150 use in poultry feeding systems.

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Application Spotlight, July 2019.

Electronic tools are increasingly used in many agricultural applications. In the field of animal feeding and livestock farming technology, environmental influences such as heavy contamination impose very specific requirements on the ability of electronic components to withstand these conditions.
ZETTLER´s AZ2150 use in poultry feeding systemsA market leader in the field of poultry feeding systems approached ZETTLER seeking a solution for the motor control of a screw conveyor that could withstand these extreme conditions. Based on the customer request, an epoxy sealed relay of the AZ2150 series was selected to isolate and protect the electrical contact from the external environment, ensuring a long life even under the given difficult environmental condition.
ZETTLER AZ2150 power relayAll common contact arrangements (1 Form A, 1 Form B and 1 Form C) are available for this relay. The switching capacity extends to up to 40 A at 250 V. Numerous contact ratings are approved by UL and VDE for several load types.
For similar solutions or to discuss the wide variety of application please contact us.

American Zettler’s AZSR165 in a Hybrid-Solar-Inverter System with Scalable Battery Storage

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Application Spotlight October 2018

Solar inverter solutions including scalable battery storage options are becoming increasingly popular.
One of the application challenges in these systems is to connect/disconnect the battery block to/from the inverter’s control circuitry.
A major clean home automation company approached Zettler seeking a solution that required switching of a 125 VDC battery while carrying load and charge currents of up to 50 Amps. Typically this would be an application scenario for high power DC contactors.
In close cooperation with customer engineering, Zettler’s team found an appropriate solution through reduction of the switching current down to 1.5 Amps by means of smart software controls. This measure fully enables AZSR165, a cost-effective solar AC relay, to fulfill the requirements of switching the DC path.
This elegant application-extension for one of many Zettler AC solar relays provided significant cost savings compared to the use of a DC contactor.
Datasheet: AZSR165
For this an many other application examples of American Zettler relays, please visit www.azettler.com
About American Zettler
American Zettler, Inc., a Zettler Group company, produces over fifty different types of relays to meet the many requirements of commercial and industrial applications. Because of their high reliability, American Zettler relays are used in a wide range of demanding applications including telecommunication and security systems, solar inverters and electric vehicle charging equipment, home appliances, lighting and energy management controls, HVAC/R, industrial controls and many other types of electric and electronic equipment. www.azettler.com

American Zettler responds to increasing DC power demand with AZDC105

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Application Spotlight July 2018

Aliso Viejo, California, USA, 13 July 2018 -In response to an increasing demand for DC power switching and high power battery charging, American Zettler is proud to release the AZDC105 series relay. The AZDC105 is the first in what will be a large family of relays designed to switch a variety of DC loads.  Recently, it seems everything has a battery. As battery sizes increase, the problem becomes how to safely isolate the batteries from their charging circuit in the event of a fault.
The AZDC105 is rated to 150A@60VDC by both UL and TUV, and it has Class F insulation standard to maintain integrity at high temperatures.  This PCB-mounted relay features internal magnets for arc-extinguishing, thus allowing for an extended life expectancy.  A wide (3.0mm) contact gap and a 1 form X (double make) contact configuration help the AZDC105 to maintain a contact-to-contact dielectric strength of 4kV.
The AZDC105 is ideal for high draw DC applications such as:  battery operated carts; inverter pre-charging; refrigerated transport; and electric vehicle charging.
Data Sheet: AZDC105
About American Zettler
American Zettler, Inc., a Zettler Group company, produces over fifty different types of relays to meet the many requirements of commercial and industrial applications. Because of their high reliability, American Zettler relays are used in a wide range of demanding applications including telecommunication and security systems, solar inverters and electric vehicle charging equipment, home appliances, lighting and energy management controls, HVAC/R, industrial controls and many other types of electric and electronic equipment. www.azettler.com

 

Wide-gap ‘sugar cube’ relay in actuator application for medical beds

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Application Spotlight April 2018

Innovative technical adaptations of existing and proven relay series that have been in the market for decades often help in meeting new application requirements, while keeping cost as low as possible.
A manufacturer of electric linear actuators used in medical beds and other applications was looking for a drive adjustment solution, that required a low-cost relay in common design that had to meet specific technical specs. The standard series AZ943 could meet all of these, except for the requirement of an increased contact gap
of at least 0.8 mm. ZETTLER’s engineering team delivered on this additional requirement by facilitating a technical adjustment to the relay series.
The resulting new AZ943W series is characterized by the increased contact gap of at least 0.8 mm. The relays are available as changeover (SPDT) and normally open (SPST). They have a switching capacity of up to 10 A at 277 VAC or 10 A at 30 VDC at a maximum ambient temperature of + 70 C. The electrical life is specified with up to 20,000 switching cycles.
For similar solutions or to discuss the wide variety of application opportunities for the range of American Zettler relays, please contact the author.
Datasheet: AZ943W
Datasheet: AZ943 (standard version)
About American Zettler
American Zettler, Inc., a Zettler Group company, produces over fifty different types
of relays to meet the many requirements of commercial and industrial applications.
Because of their high reliability, American Zettler relays are used in a wide range
of demanding applications including telecommunication and security systems, solar inverters and electric vehicle charging equipment, home appliances, lighting and energy management controls, HVAC/R, industrial controls and many other types of electric and electronic equipment. www.azettler.com.

American Zettler’s AZ2280 power relay in R290 refrigeration application

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Application Spotlight February 2018

The trend in cooling applications away from refrigerants like R134a towards products like R290 continues at a fast pace. Propane-based refrigerants provide many advantages with respect to the environment, but with the significant caveat that propane is flammable. This presents challenges when using R290 around electronics.
A major player in the refrigerated vending machine industry approached American Zettler for a relay to be used in their propane-based systems. An IP67 certified seal provides engineers the safety they need to meet regulatory requirements in this application. In addition to adequate sealing, though, the relay also needed to have the flexibility to switch multiple load types.
The AZ2280 was an easy solution. With a wide range of UL ratings from general use to motor load to resistive, the workhorse AZ2280 can switch virtually any load a vending machine or refrigerated display case might require.
With an industry standard footprint, rugged Class F construction, and a 40A@277VAC rated contact, the IP67-rated AZ2280 can be used in an unlimited number of applications. For a complete data sheet, follow this link: https://www.azettler.com/electromechanical-relay/az2280/.
About American Zettler
American Zettler, Inc., a Zettler Group company, produces over fifty different types of relays to meet the many requirements of commercial and industrial applications. Because of their high reliability, American Zettler relays are used in a wide range of demanding applications including telecommunication and security systems, solar inverters and electric vehicle charging equipment, home appliances, lighting and energy management controls, HVAC/R, industrial controls and many other types of electric and electronic equipment. www.azettler.com

American Zettler’s “workhorse” relay AZ576 provides solutions for switching ballast loads in street lighting project.

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Relay Applications in Public and Commercial Lightning

Application Spotlight July 2017

American Zettler’s “workhorse” relay AZ576 provides solutions for switching ballast loads in street lighting project.
The lighting applications market continues to grow and diversify. The increased use of electronic ballasts requires relays to switch ever increasing inrush current and at higher voltages. In addition, designers are looking to build one circuit which meets the needs of many different countries’ system voltages.
A manufacturer of consumer and commercial lighting systems required a relay for a North American roadway lighting project. The relay needed to switch electronic ballast loads at 347VAC and 480VAC for use throughout the continent. The AZ576 was up to the challenge! Nominally rated for 20A@277VAC resistive (30K cycles, 85 C), the AZ576 successfully passed both standard and electronic ballast load testing to switch 3.7A@347VAC and 2.7A@480VAC (10K cycles, 105 C).
Beyond its suitability as a relay for the lighting industry, the AZ576 also carries ratings for: general use, pilot duty, Tungsten, HP, standard ballast, and TV. Housed in a small, industry-standard package and footprint, the AZ576 is a “workhorse” ideally suited for the needs of many applications and markets.
Datasheet: AZ576
About American Zettler
American Zettler, Inc., a Zettler Group company, produces over fifty different types of relays to meet the many requirements of commercial and industrial applications. Because of their high reliability, American Zettler relays are used in a wide range of demanding applications including telecommunication and security systems, solar inverters and electric vehicle charging equipment, home appliances, lighting and energy management controls, HVAC/R, industrial controls and many other types of electric and electronic equipment. www.azettler.com