AC-Mains Assembly
Live-line circuits, built safely.
AC-mains PCB assembly for SMPS, LED drivers, motor controls and line-connected consumer products. UL 94 V-0 substrate, IEC 60950 / 62368 creepage, 100% hi-pot test before shipment.
- AC range
- 90-305V
- V-0 base
- UL 94
- Hi-pot
- 4 kV
- Tested
- 100%
Safety by design
Four layout rules we never bend
Minimum 8 mm primary/secondary at 305 V · over-molded where necessary.
3 mm minimum physical air-gap · routing slots under optocouplers.
X2-class line fuse · thermal fuse on transformer · redundant for medical.
UL 94 V-0 substrate required for every AC board we ship.
100% tested, every board
Hi-pot, burn-in, ground-bond — not sample, every
AC boards are tested individually, not by SPC sample. Every unit goes through dielectric-withstand, insulation resistance and ground-bond verification before shipping.
- Hi-pot 3-4 kV AC / DC per spec
- Insulation resistance ≥ 100 MΩ
- Ground-bond ≤ 0.1 Ω
- Burn-in at rated load, 1-24 h
- Leakage current per IEC 60950
- Power-on check (input / output)
- Tagged barcode trace for every unit
- PDF report available on request
Capability
Published AC-assembly spec
| Electrical | |
| Input range | 90 – 305 V AC (universal) |
|---|---|
| Isolation | Reinforced · 4 kV AC / 5.6 kV DC hi-pot |
| Leakage | ≤ 250 µA per IEC 60950 / 62368 |
| Layout rules | |
| Creepage primary-secondary | ≥ 8 mm at 305 V, Pollution Degree 2 |
| Clearance | ≥ 3 mm physical air-gap |
| Solder-mask | Green · thick-coat over live traces |
| Board material | |
| Substrate | UL 94 V-0 rated FR-4 |
| Copper | 0.5 – 2 oz typical |
| CTI rating | ≥ 175 V typical · 600 V available |
| Testing | |
| Hi-pot | 100% dielectric-withstand per unit |
| Ground bond | 25 A · 6 V · ≤ 0.1 Ω |
| Burn-in | 1 – 24 h at rated load, optional per spec |
| Compliance | |
| Safety | UL 60950 · UL 62368 · IEC 61347 · EN 61558 |
| EMC | FCC Part 15B · EN 55032 pre-compliance support |
| Cert | ISO 9001 · IATF 16949 · ISO 13485 |
Frequently Asked Questions
AC PCBA FAQ
01Do you support UL-listed builds?
Yes. We build to UL 60950-1 / UL 62368-1 requirements and can ship PCBAs that drop into a customer’s existing UL file. For full UL listing of a finished product, we coordinate test-lab submittals (Intertek, TÜV, CSA) on your behalf.
02Can you do 100% hi-pot at production volume?
Yes — we run a dedicated dielectric-withstand station on every AC line. Throughput up to 800 units/hour per station.
03What about medical (IEC 60601) requirements?
Yes. For IEC 60601-grade we apply 2MOPP (means of patient protection) layout rules, redundant fusing and enhanced creepage (≥ 12 mm primary-secondary).
04Do you pot / encapsulate AC boards?
Yes — silicone, urethane and epoxy potting are in-house. We also do conformal coat for humid or outdoor applications.
Ready when you are
Send your Gerber & BOM — get a quote in 24 hours.
NDA available · Free DFM review · Senior engineer response.