Conflicting information about barrel jack current capability - Page 1
Forum section: electronics / projects

author: 9291Sam
author_rank: Contributor
timestamp: July 03, 2018, 01:03:17 am
content: I am designing a soldering iron controller (Using a JBC iron). I already have the circuit tested but I ran into a problem.I am trying to figure out how much current I can pass through a DC barrel jack.The component in question is herehttps://lcsc.com/product-detail/DC-Connectors_DC-005-20A_C136744.html.If I was to reference just the title and ignoring the (airquotes) "datasheet" I would think it is rated for 20 amps. But if I look at the "datasheet" it says it is tested for 30V and 500mA.Which one is right? and would it be safe to run 10A through this barrel jack?

author: helius
author_rank: Super Contributor
timestamp: July 03, 2018, 01:11:17 am
content: DC barrel jacks outer contact area is only approx. 1 sq.mm. Can you run 20A though that? absolutely not.

author: NiHaoMike
author_rank: Super Contributor
timestamp: July 03, 2018, 01:45:52 am
content: Depends on the exact connector used. It's pretty common to find them in the 5A range for laptops. For 10A, I suggest using a XT60 or Anderson Powerpole. Overkill but they're cheap.

author: rx8pilot
author_rank: Super Contributor
timestamp: July 03, 2018, 02:29:31 am
content: I have not had any trouble soldering XT60Short and misplld from my mobile......

author: rx8pilot
author_rank: Super Contributor
timestamp: July 03, 2018, 02:39:16 am
content: The high insertion force keeps them compact..... I like them but don't have to mate them often either.Short and misplld from my mobile......

author: 9291Sam
author_rank: Contributor
timestamp: July 03, 2018, 11:42:29 am
content: I never thought about using a XT60 Connector. That would work perfectly.

author: tsman
author_rank: Frequent Contributor
timestamp: July 03, 2018, 01:54:37 pm
content: Quote from: blueskull on July 03, 2018, 01:54:59 amI've only found the unbranded clone XT60 connectors to have issues with high temperatures during soldering. The branded Amass ones I've had zero problems with.

author: cyberfish
author_rank: Regular Contributor
timestamp: July 03, 2018, 02:01:18 pm
content: I had problems with XT60 melting before when I had a lower powered iron. With higher powered one I use now I don't have problems. I do use leaded 63/37 solder, though.

author: Alex Eisenhut
author_rank: Super Contributor
timestamp: July 04, 2018, 02:37:38 am
content: I recommend this jighttps://hobbyking.com/en_us/phenolic-soldering-jig-for-bullet-connectors.htmlfor all your hobby high current connector soldering needs. It won't prevent melting but at least it will hold things in place so they cool in a more useful manner, and let you apply heat quicker so you can get in and out quicker.

author: NiHaoMike
author_rank: Super Contributor
timestamp: July 04, 2018, 03:36:34 am
content: I use a Weller soldering gun for large connections. Not cheap but well worth it. (I hope some company comes out with an inverter soldering gun that's cheaper and lighter, but still powerful and reliable. Low voltage DC operation would also be very handy.)

author: helius
author_rank: Super Contributor
timestamp: July 04, 2018, 03:36:38 am
content: Remember that you can also use resistance soldering on metal contacts. The contact can't be burned as long as the proper dwell time is maintained.Pace and American Beauty make resistance soldering tools.

author: X
author_rank: Regular Contributor
timestamp: July 04, 2018, 05:37:52 am
content: Quote from: 9291Sam on July 03, 2018, 01:03:17 amI have serviced equipment that has run up to 5A through 2.5mm barrel jacks. You can get 10A PSUs that will connect to such a jack too, so presumably there's equipment out there that needs it. I have used 12V 6-8A distributed via an 8-way splitter without incident, so yes it is possible to put a reasonable amount of current through a barrel jack.But this varies depending on the jack. The datasheet you have takes into account the overall handling capacity of the jack, including connecting pins for the PCB or solder terminals. It is usually the connecting pins and the side contact that is the weakest link in these jacks.That being said, I sugest the Anderson Powerpole plugs. As an added bonus they're hermaprhoditic, and they also hold together very well.Edit: Perhaps also look into SAE connectors: