Electronic – How to join and connect two wires in one connector point professionaly in a high voltage PCB

connectorhigh voltagejumperpcb-designrelay

Regarding a HV (6KV) PCB design there is a part of the circuitry related to reed relay connection.

I have chosen a HV relay (datasheet) with flying lead connection in order to separate physically LV board from HV lines circuit.

The full circuit is only a signal distributor based on relays for input
multiplexing with output points. Hence, the HV PCB part could be very simple. I think it will only need connectors that receive the HV relay wires.

Full circuit consists of 8 points that:

  • Every point will be connected to B1 or B2 signal point towards Ai relay terminals.

  • But Every point (1..8) can't be connected (A1 and A2, A3 and A4, etc..) to B1 and B2 simultaneously. So it could fit well a DPST relay, but they do not exist for my electrical parameters. So we will use 2 relays per point: 1NO + 1NC or NO + NO. Hence we have Ai points, being i = 8 points x 2 relays.

  • Every one of the 8 points will have its connector interfacing the outside.

  • Important is that maximum current through these wires will be few mA.

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This involves the two wires, A1 and A2 must be joined somewhere in the system before contacting external connector. Every wire would be like these red one:

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So here is where I would like to know a professional even industrial way to join the two wires. I have never do it and I don't want to do sloppy job.

My first idea is:

  1. to create a simple PCB
  2. fit on PCB some special connectors that interconnect two signals internally (as a jumper) and
  3. put then 8 jumpers, with correct distances, clearances, creepages, whatever HV could need, and route them if needed to the external connectors (they are not defined yet).

A second idea is the same but using a kind of typical female connector with N pins -if it exists- instead connector couples being separated by clearance.


  1. Is it possible that someone has ways/strategies for doing this?

  2. Any suggestion for the appropriate jumper connectors, considering HV?

Best Answer

First try floating the cables using a bakelite or non-conductive stem in a single star joint then use a more robust AWG short single wire or two twisted enameled conductor straight to the ferrule. it's best to avoid soldering too. i'd do it that way.