Part1. What Is a Pluggable Terminal Block?
- A male header that is soldered to a PCB board, and
- A female socket that connects to field wiring.
When these two components are plugged together, they form a complete and reliable electrical interface. These connectors are widely used in industrial automation, PLCs, building automation systems, instrumentation, and energy equipment where fast, reliable, and modular wiring is essential.
🔗 Matching the Header and Socket: Key Compatibility Factors
To ensure safety and performance, pluggable terminal blocks must be used in properly matched pairs. Here’s what to watch for when pairing them:
|
Component Aspect |
Matching Requirements |
|
Number of Poles |
Must be identical (e.g., 2P, 3P, 8P, 24P, etc.) |
|
Pitch (Spacing) |
Common standards: 2.5mm, 2.54mm, 3.5mm, 3.81mm, 5.0mm, 5.08mm,7.5mm, 7.62mm (ensure PCB compatibility) |
|
Mating Direction |
Vertical (180°), Right-angle (90°), or Slanted (45°) |
|
Housing Design |
Includes coding ribs, locking clips, anti-mismatch features |
When using pluggable terminal blocks, it’s essential to pair the male header and female socket correctly to ensure secure electrical performance and long-term reliability. At AOSI, we provide a wide range of compatible plug-in connector components designed to work seamlessly together.
- The female connector typically accommodates the field wiring and features options such as screw or spring clamp types. It is designed with locking structures for secure mating and easy maintenance.
- The male header is soldered onto the PCB and aligned precisely to the corresponding female socket. Variants include straight, angled, and flange-mounted options, suitable for different layout and installation needs.
Part2. How to Choose the Right Pluggable Terminal Block for Your Application
Selecting the correct pluggable terminal block is essential for ensuring electrical safety, system stability, and long-term maintenance efficiency. Here are the key factors to consider during your selection process:
1. Electrical Requirements
Start by evaluating the voltage and current specifications of your circuit. Choose terminal blocks that meet or exceed these requirements to avoid overheating or voltage breakdown.
- Low-voltage signal systems → 3.5mm pitch, compact design
- Power circuits → 5.0mm / 5.08mm pitch with higher current ratings (up to 16A or more)
- Look for certified ratings: UL, CE, RoHS compliance
2. Pitch and Pole Count
The pitch (distance between pins) determines the compactness of your layout. Choose based on your PCB spacing and wiring density:
|
Application Type |
Recommended Pitch |
|
Compact control modules |
3.5 mm |
|
Power interfaces / PLC IO |
5.0 – 5.08 mm |
|
High-density signal wiring |
2.5 – 3.5 mm |
Select the appropriate number of poles (positions) according to your required connections. AOSI offers up to 24-pole options to meet modular wiring needs.
3. Mounting Configuration
Choose the header and socket structure based on mechanical layout:
- 180° vertical – standard top-down plug-in
- 90° right-angle – for edge-mount PCBs or side-entry installations
- With/without flange – depending on whether locking or panel fixation is needed
- SMD or THT headers – depending on your PCB assembly method
4. Wiring Type and Connection Method
Consider the type of wire used and how often it will be connected/disconnected:
|
Connection Method |
Best For |
Features |
|
Screw clamp |
Power wiring, thick wires |
Strong, time-tested |
|
Spring clamp |
Vibration-prone or quick install |
Tool-free, fast wiring |
|
Push-in type |
Maintenance-friendly environments |
Simple, operator-safe |
AOSI offers multiple wiring options across its plug-in series to suit both field wiring and PCB applications.
🌟 Why Choose AOSI for Your Terminal Block Needs?
With over a decade of experience in the terminal block industry, AOSI Electronics is a trusted OEM/ODM manufacturer committed to delivering high-quality, cost-effective interconnect solutions. Our in-house production, strict quality control, and fast turnaround enable us to serve customers across industrial automation, power control, and smart building sectors.
✅ Certified quality – UL, CE, RoHS-compliant products
✅ Flexible customization – pitch, color, packaging, and branding options
✅ Global logistics – rapid shipping with stable lead times
✅ Professional support – free samples, technical guidance, and cross-brand compatibility advice
Part3. 🔥 2025 New Launches: Pluggable Terminal Block Innovations
As industrial automation, smart control systems, and compact PCBs evolve, the demand for modular, space-saving, and efficient terminal blocks continues to grow. In response, AOSI Electronics proudly presents its 2025 lineup of next-generation pluggable terminal blocks—engineered for performance, flexibility, and future-ready applications.
🌟 What’s New in 2025?
(1) Ultra-Narrow Pitch Designs (≤3.5 mm)
Ideal for miniaturized control modules and signal boards where every millimeter counts.
Model Number: FS1.5-XX-500-24
Plastic material: PA66 UL94V-0
Pitch： 2.5mm
Certification: UL,CE,ROSH,CQC,TUV
Wire range: Can be 26-20 AWG
Max soldering: 250℃~±10℃/5Sec
Pole: 2-12P
(2) Multi-Function Plug-In Modules
Integrated options such as LED indicators, dual-row layouts, and test points to support smart control systems.
Model Number: FS1.5-XX-500-24
Plastic material: PA66 UL94V-0
Pitch： 3.5mm
Certification: UL,CE,ROSH,CQC,TUV
Wire range: Can be 28-16AWG
Max soldering: 250℃~±10℃/5Sec
Pole: 2-12P
(3) Upgraded Locking Mechanisms for High-Vibration Environments
Enhanced mating security ensures stable connections for railways, robotics, and renewable energy equipment.
Model Number: FS1.5-XX-500-24
Plastic material: PA66 UL94V-0
Pitch： 3.5mm
Certification: UL,CE,ROSH,CQC,TUV
Wire range: Can be 28-16AWG
Max soldering: 250℃~±10℃/5Sec
Pole: 2-12P
Built for the Demands of Modern Industry
PLC panels, building automation systems, power distribution units, LED lighting modules, telecom stations, and factory automation networks.
Explore New Products »
Frequently Asked Questions
1. What is the difference between a pluggable terminal block and a fixed terminal block?
2. Which wire sizes are supported by AOSI pluggable terminal blocks?
3. How do I select the correct pitch for a pluggable terminal block?
4. Are AOSI pluggable connectors compatible with Phoenix Contact or WAGO?
5. Can I get customized terminal blocks with my company logo or color?
Conculsion
With our 2025 product launches, you can access the latest innovations in wiring technology—backed by expert support, fast shipping, and tailored OEM services.
👉 Ready to upgrade your terminal block solution?
Contact AOSI for samples, datasheets, or technical consultation.
