High-Safety AC/DC Modules for Industrial and EV Environments: Zettler Magnetics Power Solutions

Introduction – Power Modules Built for Harsh Environments and High-Safety Demands

Designing reliable electronics for industrial or EV applications means facing more than just electrical load requirements. Power supplies must cope with extreme input conditions, electrical noise, mechanical constraints, and the need for system-level safety compliance.

Zettler Magnetics offers a family of AC/DC power modules tailored specifically for these environments. With wide input voltage ranges (up to 305 VAC), surge immunity up to 2.5 kV, and certifications including UL, TUV, CE and CB, these modules are built for safe, long-life operation even in the most demanding conditions.

In this article, we highlight selected modules from the ZPL, ZPI and ZPO families that help engineers reduce design risk while meeting safety requirements in EV charging, factory automation, outdoor control units, and more.

Features of Zettler AC/DC Modules Addressing the Challenge

Zettler Magnetics’ high-performance AC/DC modules are engineered to simplify power design in environments where safety, reliability, and compliance are paramount. These compact, board-mount modules combine high surge immunity, thermal stability, and built-in protection features to support robust system operation in uncontrolled conditions.

Wide Input Range for Global Applications

Modules such as the ZPL20SXX00WS and ZPO40SXX00WAH operate over a wide input range from 90 VAC to 305 VAC, allowing them to function reliably across global power grids, even in regions with unstable mains supply or extended brownouts. This wide tolerance is critical for EV chargers and outdoor control boxes operating in remote or infrastructure-limited environments.

Surge and EMI Resilience

All featured modules integrate EMI filtering and meet EN61000-4-5 surge immunity up to 2.5 kV (L-N). This provides protection against line surges caused by industrial switching events or grid disturbances. Such immunity is essential for ensuring long-term reliability in EV charging points, smart street lighting, and motor-driven systems.

Certified Safety for Compliance-Driven Markets

The modules are fully certified to UL, TUV, CE and CB standards, helping customers streamline their system-level approvals. Several models, including the ZPO40SXX00WAH, meet Over-Voltage Category IV and 5000 m altitude ratings, aligning with EN62477 — a key requirement for installations on supply lines or in elevated outdoor deployments.

Integrated Protection Functions

Protection features include:

• Overvoltage Protection (OVP)

• Short Circuit Protection (SCP)

• Overtemperature Protection (OTP)

• Undervoltage Protection (UVP) in selected models

• Auto-restart functionality after recovery from faults

These internal mechanisms help prevent damage to downstream electronics and support safer fault recovery.

Compact, Thermally Stable Design

Zettler modules are available in compact packages with operating temperatures from –40°C to +85°C. Select series, such as the ZPI30SXX00WN-0SF, are also phosphorus-free and silicon-free, which supports environmental compliance and material compatibility with demanding housing designs.

Technical Specifications – Zettler AC/DC Modules for Harsh Environments

ZPL20SXX00WS Series – 20 W Class Industrial Power Module

Model	Output Voltage	Rated Current	Input Voltage Range	Surge Protection	Certifications	Dimensions (mm)
ZPL20S0500WS	5 V	4000 mA	90–305 VAC	2.5 kV L-N	UL, TUV, CE, CB	52.4 × 27.2 × 31
ZPL20S1200WS	12 V	1670 mA
ZPL20S1500WS	15 V	1330 mA
ZPL20S1800WS	18 V	1110 mA
ZPL20S2400WS	24 V	830 mA

Features: Built-in EMI filter, OVP, SCP, OTP, –40°C to +85°C, compact footprint

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ZPI30SXX00WN-0SF Series – 30 W Silicon-Free Industrial Module

Model	Output Voltage	Rated Current	Input Voltage Range	Surge Protection	Special Properties	Dimensions (mm)
ZPI30S1200WN-0SF	12 V	2500 mA	90–264 VAC	2.5 kV L-N	Organic silicon & phosphorus free	69.4 × 39.0 × 24
ZPI30S1500WN-0SF	15 V	2000 mA
ZPI30S1800WN-0SF	18 V	1660 mA
ZPI30S2400WN-0SF	24 V	1250 mA

Features: Advanced OVP/UVP/OTP, compact design for rugged or environmentally sensitive applications

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ZPO40SXX00WAH Series – 40 W OVC IV Rated Module

Model	Output Voltage	Rated Current	Input Voltage Range	Surge Protection	Overvoltage Category	Dimensions (mm)
ZPO40S1200WAH	12 V	3330 mA	90–305 VAC	2.5 kV L-N	OVC IV (EN62477)	64.1 × 45.6 × 23.5
ZPO40S1500WAH	15 V	2660 mA
ZPO40S2400WAH	24 V	1660 mA
ZPO40S4800WAH	48 V	830 mA

Features: Wide temperature range, built for installation at the mains interface and elevated altitudes (5000 m)

Industry Applications and Use Cases

Zettler’s AC/DC power modules are purpose-built for environments where electrical safety, surge resilience and compact design are non-negotiable. Below are key application sectors where these modules enable safer, more reliable embedded systems.

EV Charging Infrastructure and Wallboxes

As residential and commercial EV charging expands, designers must comply with strict EMC, surge and safety standards. Modules like the ZPO40SXX00WAH are ideal for AC-side electronics in EV wallboxes, IC-CPD cables, or Mode 3 charging piles, offering:

• Overvoltage Category IV compliance

• Operation from 90 to 305 VAC

• Built-in EMI filtering and surge immunity up to 2.5 kV

Their compact size and full safety approvals simplify integration in space-constrained PCBs located near high-current circuits.

Industrial Control and Automation Systems

Factory environments often expose electronics to unstable mains power, switching surges and wide ambient temperature swings. Zettler’s ZPL20SXX00WS modules are well suited for powering PLC nodes, motor controllers, and safety relays, offering:

• Full input protection (OVP/SCP/OTP)

• Wide temperature operation from –40°C to +85°C

• Global certifications to reduce system approval overhead

These features ensure long-term stability even on noisy or oversubscribed electrical installations.

Outdoor and High-Altitude Equipment

Control units for smart lighting, weather monitoring stations, or renewable energy converters must survive environmental extremes and electrical faults. Modules such as the ZPI30SXX00WN-0SF and ZPO40SXX00WAH meet these needs with:

• Altitude ratings up to 5000 m

• Surge protection to EN61000-4-5 standards

• Organic silicon-free options for compatibility with specialised coatings or enclosures

Their compact construction makes them ideal for pole-mounted or wall-integrated applications where physical access is limited.

Conclusion – Power Supply Safety Without Compromise

Designing for electrical safety in industrial and EV environments is no longer optional — it’s essential. From voltage transients to temperature extremes and compliance requirements, every aspect of the power supply design must be robust and certifiable.

Zettler Magnetics delivers a wide range of AC/DC power modules that meet this need head-on. With wide input tolerance, built-in surge immunity, global safety certifications, and compact form factors, these modules offer engineers a straightforward path to safe, production-ready embedded systems.

Whether you're building an EV wallbox, a factory control system, or an outdoor automation unit, Zettler's high-safety modules help you meet regulatory demands, reduce design risk and protect your users.

For full specifications, samples or design advice, contact Ineltek to discuss your application.