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PCB Connection Solutions in Practice

28 May 2025

365 Days of Maximum Reliability

In safety-critical systems, all components must operate reliably – 24/7, 365 days a year. This includes the PCB connection technology. In alarm systems, PCB terminal blocks and pluggable connectors are vital in transmitting essential signals for uninterrupted functionality.

They must perform 24/7, 365 days a year: security systems. Whether motion detectors, access control terminals, fire alarms or other alarm system components – security systems are designed to protect people and assets. Reliability is paramount – and that extends to the PCB connection technology.

TELENOT, based in Aalen, Germany, has been developing security solutions for commercial, industrial, public and private buildings for over 50 years. As a leading provider in the DACH region, TELENOT offers electronic security systems for intrusion detection, fire protection and access control. For PCB connections in its hiplex® intrusion control panels, TELENOT relies on WAGO.

Benefits of picoMAX^® eCOM:

Compact solution for signal transmission
Compatible with automated assembly
Space-saving, thanks to pole-independent stacking

picoMAX^® – The Compact Pluggable Connection System for Device Interfaces

The hiplex 8400H intrusion control panel handles access control readers, motion detectors, touch control units, as well as fire, water and gas detectors. Designed to meet the highest safety requirements, it features a modular design that adapts to any building configuration. “At the core of our system – the control panel – we use picoMAX® from WAGO,” says Armin Bullinger, Head of Development at TELENOT. picoMAX^® is the compact pluggable connection system that uses the contact force of a single Cr-Ni steel spring twice – for both connecting the conductor and the plug pin. This dual use of the spring makes picoMAX^® smaller than conventional systems. Available as a traditional connector or as picoMAX® eCOM, a pluggable PCB terminal block, it’s an ideal choice for automated production. Since its market launch in 2017, the hiplex 8400H has relied on picoMAX®, with more than 2 million contact points installed in the field. TELENOT had previously depended on picoMAX^® for earlier control panel generations.

Easy Installation with Spring Pressure and Pluggability

For the hiplex 8400H, TELENOT selected the eCOM variant. Unlike conventional connectors, picoMAX^® eCOM requires no pin housing, making it even more compact. “We chose the eCOM version because it can be stacked without losing any poles,” explains Bullinger. Numerous building sensors connect to the control panel, requiring many contact points. picoMAX^® is mounted on the system’s central PCB, connecting peripherals such as motion, gas, and water detectors, as well as access control components. Since picoMAX^® eCOM can be stacked without pole loss, TELENOT saves significant space on the PCB with this terminal block.

“Previously, we used solder terminals that required manual placement. Now, with picoMAX^®, that step is eliminated – it's fully integrated into our automated assembly process,” says Bullinger. He also notes that installers today prefer spring-pressure connections: “Our customers no longer want to solder – it's tedious and time-consuming, especially with fine-stranded conductors. Plus, spring technology offers better contact reliability than solder or screw terminals. The installation experience with picoMAX^® is simply better," he adds.

Optimized for Low-Voltage Applications

“One challenge was the extremely low current and voltage our control panel operates at,” recalls Bullinger. “We’re dealing with microamp currents and voltages below one volt.” While most PCB terminal block and connector specifications list only maximum values, WAGO’s accredited lab helped verify that picoMAX® terminal blocks work safely and reliably at ultra-low voltages.

“Thanks to WAGO’s collaborative approach and responsive support, we successfully addressed all technical challenges,” Bullinger says, describing the partnership between TELENOT and WAGO. TELENOT will also use picoMAX^® in the next generation of its hiplex intrusion control panel.

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picoMAX^® – One Family for All Applications – From Signal Level to Power Supply

picoMAX® is the compact pluggable connection system with a highly innovative design. The system uses a single CrNi steel spring to both connect the conductor and make contact with the pin – making it more compact than other connector systems and saving space on the PCB. picoMAX® can be used as a wire-to-board, board-to-wire, and wire-to-wire connection, or as a feedthrough solution.

The Terminal Block for Signal Level and Power Supply

The picoMAX^® Pluggable Connection System is available in 3.5 mm, 5.0 mm and 7.5 mm pin spacings, each as straight or angled PCB terminal blocks. For 3.5 mm pin spacing, conductor cross-sections from 0.2 to 1.5 mm² can be wired, which is ideal for signal wiring. At 5.0 mm and 7.5 mm pin spacing, cross-sections from 0.2 to 2.5 mm² are supported, making these versions suitable for power supply. Thanks to the proven Push-in CAGE CLAMP^® connection technology, solid conductors and ferruled conductors can be connected directly without tools.

Designed for Automated Soldering and Assembly

As a pluggable PCB terminal block, picoMAX^® eCOM is fully compatible with reflow soldering (THR) processes. Its female housing with conductor connection is made from temperature-resistant, glass-fiber-reinforced PPA. Silver-plated contacts provide secure soldering performance at high temperatures of up to 260 °C in a reflow oven. Tape-and-reel packaging further improves manufacturing efficiency, making the eCOM solution an excellent fit for high-volume automated production.