Assembled Industrial IO Board With Relay Bank And Pluggable Terminals
An assembled industrial input and output board with a bank of relays and two rows of pluggable screw terminal blocks. Boards that carry field wiring have to tolerate installation forces that no signal board ever sees.
What This Board Is
Every terminal on this board will be screwed down by an electrician with a screwdriver and some force behind it. That load goes into the solder joints, the pads and the laminate. Relay coils switch inductive loads that put transients back into the board. Building this well starts with the bare board: plated hole wall thickness, pad size and laminate quality all matter more here than on a controller board.
- PCBA
- See specification
What You Get From This Build
- Plated hole wall thickness of 0.025 mm supports the mechanical load that terminal blocks put on pads
- Separated high and low voltage sections designed into the layout, then verified at assembly
- Relay banks fitted and their coil and contact circuits checked before shipping
- Laminate rated 94V-0 self-extinguishing, which is what control panel standards ask for
Who Specifies This Board
- Control panel builders and machine integrators
- Building management system manufacturers
- Process instrumentation OEMs with field wiring terminations
- Equipment makers replacing a hand-wired relay board with a PCBA
Four Failures This Build Is Designed Against
Each one is a real way this class of board goes wrong, and the tolerance or process decision that prevents it.
Pads lifting when terminals are tightened
Terminal block pads are large and the plated barrel wall is held at 0.025 mm, so the joint carries the screwdriver torque rather than the pad alone.
Insufficient clearance between field and logic sides
Isolation resistance is verified above 10 to the power 12 ohms, and the layout keeps the two sections physically separated.
Relay coils kicking back into the logic
Suppression components are placed as part of the assembly, not left to be fitted on site.
Laminate that does not meet panel standards
The rigid laminate is 94V-0 rated self-extinguishing, as published in our capacity table.
Technical Specification
Product detail from the catalogue record, followed by the published process capability for the PCBA family. Anything the legacy catalogue did not record is marked TBC rather than filled in.
| Item | Technical specification |
|---|---|
| Product name | Industrial IO PCBA With Relays And Terminal Blocks |
| Legacy catalogue reference | PCBA-5 |
| Product family | PCBA |
| Surface finish | See specification |
| Assembly technology | Surface mount, through-hole and mixed technology |
| Substrates assembled | Rigid FR4, aluminium metal core and flexible circuits |
| Bare board testing | Open and short test at 50 to 300 V before assembly |
| Component sourcing | Turnkey, consigned or mixed |
| Functional test | TBC — quoted against your test specification |
| Conformal coating | TBC — confirm the coating specification with your enquiry |
| Minimum order quantity | TBC — not recorded on the legacy catalogue |
| Lead time | TBC — confirmed per enquiry |
What The Board Is Made Of
| Material | Specification |
|---|---|
| Bare board | Rigid FR4, aluminium metal core or flexible circuit, fabricated in the same plant |
| Solder | Lead-free process, RoHS compliant |
| Components | Supplied by us on turnkey, or consigned by you |
| Stencil | Cut to the released paste layer of the same board revision |
| Packing | Packed on our own packing machines to your specification |
What Can Be Changed
- Turnkey, consigned or mixed component supply
- Rigid, aluminium or flexible substrates
- Mixed surface mount and through-hole builds
- Hand-fitted magnetics and mechanical parts
- Device programming, subject to confirmation
- Packing to your goods-in specification
How This Board Is Made
Eight stages on equipment sourced from the USA, Japan, Germany and Israel. Every stage listed runs inside our own plant.
Data and BOM review
Manufacturer part numbers checked and alternates agreed in writing before buying.
Bare board
Fabricated in the same plant and open and short tested at 50 to 300 V.
Stencil
Cut to the paste layer of the same released revision as the board.
Paste and placement
Solder paste printed, then surface mount devices placed.
Reflow
Profiled for the substrate, with flexible circuits carried flat in tooling.
Through-hole and manual
Connectors, magnetics and hand-fitted parts as separate operations with their own inspection.
Inspection
Assembled boards inspected before packing.
Packing
Packed on our own packing machines to your goods-in specification.
What Is Checked Before It Ships
- Bare board open and short tested at 50 to 300 V before any component is placed
- Stencil and board matched to the same released revision
- Post-reflow inspection before through-hole and manual operations
- Mechanical parts such as sockets and terminal blocks inspected as mechanical parts
- Functional test quoted and run against your own test specification
What The Plant Holds
- ISO 9001:2000. Quality management system certification recorded by the company. Current revision year available on request.
- ISO 14001:1996. Environmental management system certification recorded by the company.
- UL. Certification recorded by the company. File number available on request.
- RoHS and lead free. Listed in the company environmental policy alongside pollution prevention and resource reduction.
Certificate numbers, issue dates and current revision years are not published on the legacy site. Ask for copies with your enquiry and they will be sent with the quotation.
How It Compares With The Alternatives
Three boards from our own catalogue, side by side, so the trade-off is visible rather than argued.
| Assembly | Technology | Distinguishing feature | Best suited to |
|---|---|---|---|
| Industrial IO PCBA With Relays And Terminal Blocks | Mixed THT and SMD | Relays and terminals | Control panels |
| Interface PCBA With D-Sub And Ethernet Ports | Mixed THT and SMD | Serial and Ethernet | Host interface cards |
| 2 Layer Rigid PCB | Bare board | Lead-free HASL | Boards you assemble yourself |
What To Send With Your Enquiry
Four things that decide whether the quote comes back right the first time.
- Give the terminal block manufacturer part number and the tightening torque the installer will apply.
- State the standard the panel is built to, so creepage and clearance can be reviewed against it.
- Mark the boundary between the field wiring side and the logic side on the assembly drawing.
- Say whether the pluggable terminal plugs ship fitted or loose.
Industrial IO PCBA With Relays And Terminal Blocks Questions
Can you fit pluggable terminal blocks and ship the plugs separately?
Yes. Tell us which parts ship fitted and which ship loose in the same carton.
What creepage distance can you hold between tracks?
Minimum trace space is 0.075 mm as a process limit, but creepage on a mains referenced board is a layout decision. Give us the standard you are working to and we will review the artwork against it.
Is the laminate flame rated?
Yes, 94V-0 self-extinguishing on the rigid line and 94V-0 on the aluminium line.
Do you conformal coat boards for panel environments?
Tell us the coating specification and the areas to be masked and we will confirm what we can support.
Other Boards In The PCBA Family
Boards built on the same line, with the same tolerances, in a different configuration.
Assembled Interface Board With Serial Ethernet And Edge Connector
Assembled Embedded Controller With Microcontroller Ethernet And Storage
Assembled Motherboard With Expansion Slot And Rear Port Cluster
Assembled Power Converter With Toroidal Inductor And LED Output Board
Where This Board Is Used
The fields the legacy catalogue records for this class of board.
This Board In Context
Get Industrial IO PCBA With Relays And Terminal Blocks Priced Against Your Own Files
Send Gerber RS-274X with an NC drill file, or an ODB++ package, with the layer count, thickness, copper weight, surface finish and quantity. We check it against the published capability before quoting.