Quoting wouter van ooijen <wouter@voti.nl>:

> I must design a circuit that switches 230VAC at 6A max (0-crossing
> switching). This is a bit above the currents I am familiar with (up to ~
> 1A).
>
> Is this within what can be done with a PCB, and how wide should the
> traces be? And for connectins to/from the PCB, can this be done with
> screw-type connectors, or should I use wires that end in a spade-type
> connector?
>
> Wouter van Ooijen
>
> -- -------------------------------------------
> Van Ooijen Technische Informatica: www.voti.nl
> consultancy, development, PICmicro products
> docent Hogeschool van Utrecht: www.voti.nl/hvu
>
>
>
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>

I have done this sucessfully recently.

Indeed, spade-type connectors work well, but high-current Mate-N-Locks  
also work very well. My client uses 19A gold-plated pins with  
mate-N-Lock connectors and they solve the connector problem. Keystone  
makes 0.110" and 0.187" spade connectors.

More important is the conductor width, thickness, and spacing for high  
voltage-high current conductors. We have our 4-layer PCBs made with  
2oz copper thickness for heavy conductors. NOTE: don't be told that  
1oz copper plus HASL equals 2oz copper; NOTHING (except silver) can  
replace copper as a conductor. We carry high current on the top and  
bottom (2oz) and use the inner layers for signals and low current  
(1oz). As long as you are careful to allow sufficient clearance with  
thruholes, it will work fine, passing 600V hipot tests every time.

For 15A we use 150mil" wide conductors made of 2oz copper. For 6A we  
use 150mil" made of 1oz copper, or 100mil" of 2oz copper. Make sure  
the thruhole size actually fits the Mate-N-lock receptacles closely;  
if you make a blob of solder bridge the space, you might later  
discover that the solder has melted under the current.

NOTE: we discovered that non-leaded solder makes poor high-current  
connections. We've dropped back to rosin-core 63/37 tin/lead solder,  
and will NOT return to it.




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