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*[http://www.andersonpower.com/products/pdf/DS-SBFMLYREV01.pdf Anderson Powerpole SB Connector Family data sheet] (PDF file)
*[http://www.andersonpower.com/products/pdf/DS-SBFMLYREV01.pdf Anderson Powerpole SB Connector Family data sheet] (PDF file)


www.appropedia.org/Low_voltage_connection_basics
*http://www.appropedia.org/Low_voltage_connection_basics


[[Category:Electrical power connectors]]
[[Category:Electrical power connectors]]

Revision as of 22:08, 29 January 2007

Connectors for supplying direct current (DC) power are poorly standardized compared to domestic AC power plugs and sockets. DC plug is a common name used for one common type of cylindrical two-conductor plug available in a range of sizes and used to power small pieces of electronic equipment. It is also used to describe some older multi-pin plugs.

Several competing standards exist for DC plugs, and in some cases incompatible plugs will fit together, or can be made to fit, possibly damaging equipment if:

  • the voltage is wrong
  • the polarity is wrong
  • current ratings are exceeded
  • power supply filtering or stability is inadequate for the equipment being powered
  • non-matching connectors are forced together.

Also, confusingly these plugs are occasionally used for AC power supply applications, such as with the Nintendo Entertainment System and SNES video game consoles, which used these for 9 or 10 V AC power (depending on region).

Cylindrical types

Common DC power connectors

Also known as barrel connectors, concentric barrel connectors or tip connectors, small cylindrical connectors come in an enormous variety of sizes.

The intended use of these plugs is on the cable connected to a power supply. The matching jack or socket is then mounted in the equipment to be powered. Some of these jacks contain a normally closed contact, which can be used to disconnect internal batteries whenever the power supply is connected, avoiding the risk of battery leakage or explosion posed by incorrect recharging of the batteries.

Cylindrical plugs generally have an insulated tip constructed to accept insertion of a pin (but note also the internal pin in the larger size EIAJ plugs). The outer body of the plug is one contact, most often but not always the negative side of the supply. A pin mounted in the socket makes contact with a second internal contact. The outer plug contact is often called the sleeve, and the inner the tip, although the tip itself is actually non-conductive.

At least two different national standards exist, EIAJ in Japan and DIN in Germany. As well several conventions have been adopted by specific manufacturers, notably by Sony, to indicate voltage by plug size.

Some manufacturers use opposite polarity standards, and some generic power supplies cater for this by allowing the polarity to be reversed by use of a switch or an unpolarised two-pin plug and socket arrangement. These two-pin plugs seem to be standardized but official specifications are hard to find. The pins are 1.5 mm in diameter, 6 mm long and spaced 4.2 mm apart. (see Egston connector overview, page 6, number 230)

Some power supplies allow the voltage to be switched. Four-way X connectors or six-way star connectors, also known as spider connectors, with multiple plug sizes and types are common on generic power supplies. On others there are arrangements for changing the connector, with from four to nine different connectors available.

A six-way connector on a 'universal' DC power supply, consisting of a 4-way X connector and two individual connectors. The X-connector here provides 3.5 and 2.5 mm jack plugs and two sizes of cylindrical connector

It is quite possible that new sizes will continue to appear and disappear. The most likely reason for a new size is that a particular manufacturer wishes to discourage use of third-party power supplies, either for technical reasons or to promote use of their own products or both. At the same time there is a trend for newer equipment of a particular type to be more tolerant of its power supply than older designs, making previous standards and conventions unnecessary.

Contact ratings vary from unspecified (and probably less than 1 A in practice) up to 5 A ,with 2 A typical. Voltage is again often unspecified, up to 48 V with 12 V typical. The smaller types usually have lower ratings, both for current and voltage.

Generic types

The most common plugs are 5.5 mm in outside diameter (OD) and 9.5 mm in length. Two pin sizes are common in the jacks for this size plug body, 2.1 mm and 2.5 mm, and the plugs should ideally match. Generic plugs are often named for the pin diameter they are designed to take, so these types will be seen described as 2.1 mm DC plugs and 2.5 mm DC plugs respectively. These two sizes are easily confused unless seen together.

Slightly smaller 5.0 mm OD plugs are sometimes used in both 2.1 mm and 2.5 mm pin sizes, as are longer or shorter 5.5 mm OD plugs. All are typically 8 mm to 14 mm in length. There are also 6.5 mm OD plugs taking a 3 mm pin, 3.8 mm OD plugs taking either a 1.35 mm or a 1.05 mm pin, 3.5 mm plugs for a 1.3 mm pin, and many less common sizes.

Use of a plug designed for a larger pin, for example a 2.5 mm pin plug in a 2.1 mm pin jack, may work perfectly depending on the design of the jack, but often the result is an unreliable contact or occasionally no contact at all. A pin that is too large for the plug will not allow insertion of the plug at all. Similarly, a larger plug body (OD) may not fit at all, a smaller one may fit but may not make a reliable contact. Length is less critical than the diameters but is sometimes a consideration, in general a longer plug is no great problem but a shorter one may fail to contact the pin reliably or at all.

After the two common 5.5 mm OD plugs the next most common size is 3.5 mm OD to take a 1.3 mm pin, commonly 9.5 mm in length but both longer and shorter versions also exist. These 3.5 mm OD plugs are normally used for lower voltages and currents.

This list shows all known generic types, and is annotated with the manufacturers each is available from (based on those found in the Mouser and Digi-Key catalogs), since not all make all sizes. It should be further noted that a circular locking detent is present on some of these barrel connectors, and its presence or absence should be a clue in distinguishing very similar sizes. This is not to be confused with the locking DC connectors which use threaded fittings to secure the connection between the plug and jack (see Philmore-Datak catalog page 63).

Some of these sizes always include a high-retention feature, while others feature it only in designs from certain manufacturers. Typically, this is a connical cut-back section of the tip, just behind the insulator that separates the inner from outer contact surfaces.

There are a number of sizes below that appear to be quite similar, and while the tollerances of these connectors is typically indicated as +/- 0.05 or 0.03 mm by the manufacturers, there is still sufficient ambiguity in whether two sizes differing by only 0.05 mm (or where the specification is only to the nearest 10th of a mm) to warrant listing them separately here. Further work should be done to determine the original specification for the size, and then list the similar sizes that are intended to be compatible.

  • 2.40 mm OD × 0.70 mm ID (Egston 212, perhaps rounded-off representation of EIAJ-01 plug)
  • 2.40 mm OD × 0.80 mm ID (Egston 213)
  • 3.00 mm OD × 1.00 mm ID
  • 3.00 mm OD × 1.10 mm ID (Egston 214, Adaptaplug G)
  • 3.40 mm OD × 1.30 mm ID (Adaptaplug H, KOBICONN)
  • 3.40 mm OD × 1.35 mm ID (Egston 218 Medical, 220)
  • 3.40 mm OD × 1.40 mm ID NES/J 135
  • 3.50 mm OD × 1.30 mm ID (Egston 238)
  • 3.50 mm OD × 1.35 mm ID (CUI Inc. P7) (KOBICONN) (Egston 215)
  • 3.60 mm OD × 1.15 mm ID (Egston 216)
  • 3.80 mm OD × 1.10 mm ID (Adaptaplug I, CUI Inc. P9 but with 1.05 mm ID)
  • 3.80 mm OD × 1.30 mm ID (Egston 217)
  • 3.80 mm OD × 1.35 mm ID (CUI Inc. P8)
  • 4.00 mm OD × 1.70 mm ID (EIAJ-02, Adaptaplug B) [1]
  • 4.75 mm OD × 1.70 mm ID (EIAJ-03, Adaptaplug C) [2]
  • 4.80 mm OD × 1.70 mm ID (KOBICONN)
  • 5.00 mm OD × 1.50 mm ID (Adaptaplug J)
  • 5.00 mm OD × 2.00 mm ID (Egston 206, 207, 219)
  • 5.00 mm OD × 2.10 mm ID (Adaptaplug K, CUI Inc. P3)
  • 5.00 mm OD × 2.50 mm ID (Adaptaplug L, CUI Inc. P4)
  • 5.50 mm OD × 1.50 mm ID with 1.80 mm pin (Adaptaplug S)
  • 5.50 mm OD × 2.10 mm ID—2.1 mm DC plug (Adaptaplug M, CUI Inc. P5/P10 locking, KOBICONN) (available in high-retention versions, and threaded collar locking versions)
  • 5.50 mm OD × 2.50 mm ID—2.5 mm DC plug (Adaptaplug N, CUI Inc. P6/P11 locking, KOBICONN, Egston 222)
  • 5.50 mm OD × 2.80 mm ID (Adaptaplug O, used on some Toshiba laptop computers)
  • 5.50 mm OD × 3.30 mm ID with 1.00 mm pin (EIAJ-04, Adaptaplug D)
  • 5.50 mm OD × 3.30 mm ID with 1.00 mm pin (JSBP4--see below)
  • 5.50 mm OD × 3.80 mm ID with 1.80 mm center pin (Adaptaplug P)
  • 6.30 mm OD × 3.00 mm ID (Adaptaplug Q)
  • 6.50 mm OD × 3.00 mm ID
  • 6.50 mm OD × 3.10 mm ID with 1.00 mm center pin (Philmore 285 plug)
  • 6.50 mm OD × 4.10/3.10 mm ID with 1.00 mm center pin (Adaptaplug U, same as Philmore 285?)
  • 6.50 mm OD × 3.40 mm ID with 1.40 mm center pin (JSBP5--see below) [3]
  • 6.50 mm OD × 4.30 mm ID with 1.40 mm center pin (EIAJ-05, Adaptaplug T)
  • 6.90 mm OD × 4.20 mm ID with 0.70 mm center pin (Adaptaplug R)
  • 7.00 mm OD × ?.?? mm ID with 1.00 mm center pin (Philmore 48-412 cable)
  • also [4] (needs careful conversion from inches to mm, and possible matching with existing standard)

Note: KOBICONN was known as DGS Pro Audio prior to May, 2004.

EIAJ standards

EIAJ RC-5320A

Five plug and matching socket or jack designs are defined by the EIAJ standard RC-5320A. Each of these plugs is used with a specified voltage range. Most manufacturers use a yellow insulating material to distinguish these plugs from other similar-looking DC plugs. Japanese manufacturer Hosiden has the most detailed EIAJ DC connector specification document (PDF) for the various jack dimensions.

The outer body of the plug is the negative contact, and the internal contact is positive. The five specified voltage ranges and sizes are:

  • (EIAJ-01) up to 3.15 V, plug diameter 2.35 mm, interior diameter 0.70 mm (CUI Inc. P12) (Philmore 235 plug/205 PC jack) (KOBICONN)
  • (EIAJ-02) 3.15-6.3 V, plug diameter 4.00 mm, interior diameter 1.70 mm (CUI Inc. P13) (Philmore 240 plug/TC240 cord/207 PC jack) (KOBICONN)
  • (EIAJ-03) 6.3-10.5 V, plug diameter 4.75 mm, interior diameter 1.70 mm (CUI Inc. P14) (Philmore 275 plug/TC275 cord/220 PC jack) (KOBICONN)
  • (EIAJ-04) 10.5-13.5 V, plug diameter 5.50 mm, interior diameter 3.30 mm with 1 mm pin (CUI Inc. P15) (Philmore 255 plug)
  • (EIAJ-05) 13.5-18 V, plug diameter 6.50 mm, interior diameter 4.30 mm with 1.4 mm pin (CUI Inc. P16, but 4.4mm ID with 1.37mm pin) (Philmore 265 plug/TC265 cord/214 PC jack)

Unlike most DC plugs, the larger two IEAJ sizes have an internal pin in the plug. The smaller three do not and are similar to the generic plugs in structure. The plug length is 9.5 mm in all cases, and current rating 2 A.

This standard was originally created in 1992 as RC-6705, and updated in 1997, then again in 2005.

EIAJ RC-5321

This is a unique-looking barrel connector, with an outside diameter of 4.75 mm and a protruding pin of 2.5 mm diameter, and the plug is designed for EIAJ voltage classification 2: 3.15 to 6.3 V.

EIAJ RC-5322

According to Hosiden, this is a 12V/24V barrel connector designed for electronic equipment used in cars. The outside diameter is 6.5mm.


DIN 45323 Power Connectors

  • 5.00 mm OD, 2.00 mm ID, 14 mm long?
  • 6.00 mm OD, 1.98 mm ID [5]

JSBP Connectors

Used on some laptop computers, these can be differentiated from standard barrel connectors by the presence of an internal pin and the insulator, which is of a larger diameter than the OD of the barrel.

  • JSBP4: 5.50 mm OD, 3.30 mm ID, 1.00 mm pin: 13.5 V DC @ 2 A (Used on the Microsoft XBOX 360 HD DVD drive, and also reportedly used on some Samsung and Gateway laptop computers)
  • JSBP5: 6.50 mm OD, 4.30 mm ID, 1.40 mm pin: 18.0 V DC @ 2 A (Reportedly used on many Panasonic laptop computers, and some Samsung laptops)

[6] [7]

RadioShack Adaptaplug Conversion Matrix

RadioShack sells adapter plugs that convert from the above-described two-pin non-polarized connector to various DC power plugs. RadioShack, in particular, has assigned a single-letter code to each plug, but has not provided the official name for each plug, nor often their complete specifications on barrel and pin diameter. Here is a complete list:

  • Size A: 2.35mm OD × 0.70mm ID (EIAJ-01 for up to 3.15 V; yellow ring RS #273-1704)
  • Size B: 4.00mm OD × 1.70mm ID (EIAJ-02 for 3.15–6.3 V; yellow ring—RS #273-1705)
  • Size C: 4.75mm OD × 1.70mm ID (EIAJ-03 for 6.3-10.5 V; yellow ring—RS #273-1706)
  • Size D: 5.50mm OD × 3.30mm ID with 1.0mm pin (EIAJ-04 for 10.5-13.5 V; yellow ring RS #273-1707)
  • Size E: 2.50mm (3/32"2.5mm) submini plug (black ring—RS #273-1708)
  • Size F: 3.50mm (1/8"/3.5mm) mini plug (black ring RS #273-1709)
  • Size G: 3.00mm OD × 1.10mm ID (Turquoise ring—RS # 273-1710)
  • Size H: 3.40mm OD × 1.30mm ID (Orange ring RS #273-1711)
  • Size I: 3.80mm OD × 1.10mm ID (Pink ring—RS #273-1712)
  • Size J: 5.00mm OD × 1.50mm ID (Red ring—RS #273-1713)
  • Size K: 5.00mm OD × 2.10mm ID (Purple ring—RS #273-1714)
  • Size L: 5.00mm OD × 2.50mm ID (Dark Green ring—RS #273-1715)
  • Size M: 5.50mm OD × 2.10mm ID (Navy ring—RS #273-1716)
  • Size N: 5.50mm OD × 2.50mm ID (White ring—RS #273-1717)
  • Size O: 5.50mm OD × 2.80mm ID (Brown ring—RS #273-1718)
  • Size P: 5.50mm OD × 3.80mm ID with 1.80 mm pin (no specified color—RS #273-1719)
  • Size Q: 6.30mm OD × 3.00mm ID (Yellow-Green ring—RS #273-1720)
  • Size R: 6.90mm OD × 4.20mm ID with 0.70 mm pin (no specified color—RS #273-1721)
  • Size S: 5.50mm OD × 1.50mm ID with 1.80 mm pin (Gray ring—RS #273-1722)
  • Size T: 6.50mm OD × 4.30mm ID with 1.40 mm pin (EIAJ-05 for 13.5-18.0 V; yellow ring—RS #273-1723)
  • Size U: 6.50mm OD × 4.10mm/3.10mm ID with 1.00mm pin (Light-Yellow ring—RS #273-1724)

Some of these sizes are also available from KOBICONN through Mouser, and from Philmore.

Snap and Lock DC Power Connectors

These connectors look similar to Mini-DIN connectors, but have either 3 or 4 thicker pins and do not mate with any of the Mini-DIN connectors. They can usually be identified by an engraved symbol on the backs of the plug, consisting of two wide arrows pointing in opposite directions, but parallel to each other, or sometimes one wide arrow inside a box, pointing towards the end of the male connector. See [8] for pin configuration.

One manufacturer is KYCON, Inc.

Access Communications Snap and Lock plug information

Mini IEC Connectors

Tamiya Connector

  • Commonly used on radio-control (toy) vehicle battery packs and chargers.
  • [9] shows converter cables for connectors commonly used in the RC community.

Deans Connectors

JST RCY Connector

  • Also known in RC circles as the BEC connector, or the P connector.

Locking Molex Connector

  • Available in 3, 4, and 6 terminal configurations. [10]

Anderson Powerpole connectors

The Anderson Powerpole has been adopted by the amateur radio community as their standard 12-volt DC power connector for everything from radios to accessories. It is a bit more expensive than the older “standards” of the 2-wire trailer plug and Molex connector, but provides a more reliable electrical connection (both mechanically and electrically) and is easier to adapt to a wider range of wire gauges. Powerpole connectors are physically and electrically hermaphroditic, thus avoiding the need to worry about which end is the plug and which the socket, or which end has the correct polarity, as is the case with the physically but not electrically hermaphroditic 2-wire trailer plug.

For use in amateur radio, the community has adopted a standard polarity for assembling the Singlepole connectors, using one red and one black housing, as well as a mnemonic for remembering the arrangement: Red Right—Tongue Top. Before this polarity standard was adopted, some amateur radio groups had chosen the opposite polarity, so it is wise to double-check the polarity before blindly plugging devices together.

Although many sizes of the Powerpoles are available, the size most commonly used is the 15/30/45 amp variety. These sizes all use the same plastic housing, differing only in the metal contact inserted into the housing (selected based on the current need and wire size). Larger Powerpole connectors (the SB/Multipole series) with 2 or 3 contacts in one molded housing are commonly used in various industrial settings, including as a battery connection for some UPS devices, removable truck/Jeep winches, many electric forklifts, and other electric powered vehicles.

For the larger Multipole design, each color is keyed so as to mate only with a like colored connector, and Anderson publishes a list of recommended voltages for each color: [11]

  • 12V: Yellow
  • 18V: Orange
  • 24V: Red
  • 36V: Gray
  • 48V: Blue
  • 72V: Green
  • 80V: Black
  • 96V: Brown
  • 120V: Purple
  • 144V: White

Some manufacturers have ignored this color coding recommendation. One should always test the connection with a voltmeter if unsure. For example, winch manufacturer Warn uses a red housing for its winches, even though they are powered by 12 V DC, not 24 V DC.

The connectors are also starting to be used by Radio Control hobbists.

This connector design was created by Anderson, but the patent on its design has apparently lapsed, and there are be other manufacturers of this connector now, including AMP and Sermos.

Cigar lighter sockets and plugs

The car cigarette lighter is technically called a cigar lighter, since it was originally designed as a lighter for cigars—hence its rather large size (and unheated center barely large enough to light a cigarette).

These sockets were not originally designed to provide DC power, and are not an ideal DC connector for several reasons, notably the fact that three sizes exist (one for 6 V DC and two for 12 V DC) and the mating of the different sized 12 V DC plugs and jacks is problematic. Because of this, and the small gauge wiring sometimes used, they can sometimes provide only unreliable and current-limited power connections.

The polarity for 12V DC sockets is center pin positive (+), outer collar negative (-). Reversed polarity will damage some electronic devices.

Powerlet Connector

Similar in concept to an automotive cigar lighter, the Powerlet is shorter and smaller, and found most frequently on motorcycles (most frequently BMW cycles).

At least one manufacturer sells a plug that combines a cigar lighter plug and a powerlet, in much the same way that combination auto/airplane notebook computer power adapters combine a cigar lighter plug and an Airinc 628/Empower plug. The manufacturer that appears to have the widest selection of Powerlet plugs, sockets, and adapters is Powerlet Products. (They may also be the original OEM designer.)

Other DC connectors

See also power connector.

  • Two different airline seat power connector systems exist—one based on the automotive car cigar(ette) lighter socket, and one designed specifically for airplanes, known as ARNIC 628. Both are called In-Seat Power Supply System, and both are 15VDC systems, not 12 V DC. Commentary on the original debate between the two in-seat power supply system specifications provides good background on the design of the connectors and the power distribution issues on planes. The standard for ARINC 628, Part 2 is intended to be an open standard, i.e. – multiple mfrs, if the economics are attractive. The standard describes a generic part that is originally based on a Hypertronics brand connector. (e.g. - their P/Ns D02PBMRT-0024 or D02PBMRTH-0025.) There should be a reference to a second source for this connector type shown here.
  • Miniature and subminiature jack plugs and even phono plugs are used instead of DC plugs on some equipment, especially in the lower price brackets. Jack plugs typically short circuit while being plugged in. XLR connectors, especially the most readily available XLR3, continue to be used by some manufacturers as power supply plugs despite their being a well-accepted standard for other purposes.
  • Five-pin DIN plugs were used on many early personal computer power supplies. DIN and Mini-DIN plugs of various pin numbers also continue to be used by some manufacturers for power supply purposes.
  • Some plugs with three, four, five or more pins are also called DC plugs. These were common on vacuum tube equipment and continue to be used where several voltages are supplied. On vacuum tube equipment the pins are normally on the equipment side of the join for safety reasons.
  • GlobTek, Inc. has a data page that could be used to further research these and other connectors.
  • There is also the PowerCon locking 3-pole connection system newly introduced to the professional audio market. [12]
  • Old-fashioned DC connectors such as banana plugs and ring lugs should also be mentioned here, to clarify sizes, polarity, and spacing.
  • Some data bus systems like USB or Firewire are designed to provide a limited amount of DC power to external devices.
  • Many cell phones use DC connectors that are unique to the manufacturer. SHENGYIH makes connectors that fit about two dozen brands of cell phones.
  • In the broadcast, film and television industries, the 4 pin XLR connector is the standard for 12v power. The connectors are wired pin 1 negative, pin 4 positive. Often pins 1 and 2, will be negative with 3 and 4 as positive for a higher current rating. Female connectors are used as supply and male connectors are used on loads. Most battery belts and power supplies output 13.2v, but equipment can usually handle a range of 11-18 volts to accommodate battery packs of varying voltages and charging while operating.
  • [13] has a list of laptop DC inlet jacks, by brand, that should be parsed for additional connectors for this page.
  • [14] has a list of many DC input jacks and plugs not yet described here, along with specifications. Includes Molex 2-pole, Microfit 4-pole, and Cinchplug (perhaps Cinch-Jones, or is this an RCA connector?).
  • Winchester Electronics has an interesting snap-on power connector that might be appropriate for this page. [15]
  • Apple Computer introduced the MagSafe DC power connector on the MacBook Pro line of laptop computers.
  • Alden Products makes the Pulse-Lok line of connectors. Some of these may be used for DC. [16]
  • Plastics One offers custom cable and connector manufacturing, primarially targeted at the medical and communications industries. If you find a DC connector not detailed elsewhere, there's a chance they made it. [17]
  • ODU makes specialized industrial-grade connectors. [18]
  • Article on battery-pack connectors. [19]

Summary

Modern equipment is often less sensitive to power supply mismatches than older equipment. However, the only safe courses are to use the manufacturer's recommended power supply, or to determine and match the voltage, polarity, current and filtering required. The fact that the plug does or does not fit the equipment is meaningless unless the equipment and power supply are from the same manufacturer, and unreliable in any case.

Manufacturers and vendors

A common problem is finding an exact replacement PCB mount connector for a broken piece of electronic equipment. This partial list of manufacturers can help.

Manufacturers

Distributors

Many electronics distributors carry a small selection of DC power jacks. A few that deal with small orders and don't require an account include:

Laptop DC power jack replacement

The power jack is one of the most common failure items on a laptop; most laptops will probably require at least one power jack repair in during their useful life. Often the jack only needs to be resoldered but replacement is frequently required. These jacks are usually too weak to stand up to the stresses of moving the laptop while the power cord is connected. There are a number of companies that now specialize in selling replacement jacks for laptops (some also install) at prices of typically $9-$30 for a part that usually costs between $0.50 - $4 from an electronics distributer. Their advantage is that they often know which part is needed for which laptop.

References

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