Non standard DC connector size adapter - Page 1
Forum section: electronics / projects

author: Alex30
author_rank: Regular Contributor
timestamp: January 21, 2015, 12:40:55 pm
content: So I picked up another laptop adapter hoping to use it for some projects and looked at the pictures and the plug seemed to be a standard DC connector size, only to find that it wasn't when it arrived. The adapter I picked up is a 608428-001 HP 19V 4.74A.The DC connector has on OD of 7.4mm and an ID of 5mm and a length of about 12mm. Is there any adapter that anyone knows of that would fit this size to adapt to a more standard DC barrel size? Or has anyone attempted to replace the plug on an adapter like this successfully?The reason I ask the last question is that the last adapter I thought I could simply replace the plug on, used ridiculously high gauge wire in an internal sheath surrounded by the ground wire in a fashion I have only seen being used as shielding, which was really odd and made trying to solder on a standard DC plug impossible. That one was a toshiba PA3237U-1ACA 15V 8A adapter for your interest.Cheers

author: Monkeh
author_rank: Super Contributor
timestamp: January 21, 2015, 01:01:39 pm
content: Have a quick google, those adapters are standard.The coaxial style cable is quite normal for laptop power leads, it allows for a round and flexible cable without wasting space with extra insulation. it is, however, a bit of a pain to terminate..

author: Alex30
author_rank: Regular Contributor
timestamp: January 21, 2015, 01:07:53 pm
content: Quote from: Monkeh on January 21, 2015, 01:01:39 pmOh... You're right, I feel a bit silly now haha. Just don't normally see that size and I ass-u-me-ed.Quote from: Monkeh on January 21, 2015, 01:01:39 pmReally? Do you have any tips?Also while we're on the subject, the only way to open these things is with a dremmel tool or something isn't it? Is there any difficulty encountered after that normally?

author: Monkeh
author_rank: Super Contributor
timestamp: January 21, 2015, 01:11:22 pm
content: Quote from: Alex30 on January 21, 2015, 01:07:53 pmUse the largest (and best quality) DC jack you can. Don't try and pass either conductor through the silly little holes, get it cut to exactly the right length, tinned, and solder it flat up against the tab. Make sure the strain relief is good and no solder wicks up into it.Better yet, get some pluggable terminal blocks. You can get plugs for them which have a tab for a cable tie to provide strain relief.QuoteMakes a horrible mess and won't seal up again. Put them in a vice and squeeze opposite corners to crack the joints, or tap it with the handle of a screwdriver like a maniac to crack them. Either way expect to do a lot of gentle prying and risk badly breaking the case.

author: Alex30
author_rank: Regular Contributor
timestamp: January 21, 2015, 01:28:23 pm
content: Just to show you how large the gauge is I have attached a picture shown next to a standard 5mm connector. The wire won't even fit into the seat. Do larger connector sizes have larger seats? Or should I say large enough to fit this?Quote from: Monkeh on January 21, 2015, 01:11:22 pmThanks I will give that a try if I can't get a connector to solder on properly. Then I can just replace the cableEditThe internal live wire is about 3.2mm

author: Monkeh
author_rank: Super Contributor
timestamp: January 22, 2015, 10:14:44 am
content: That is quite immense, but itisan 8A supply. Asking a bit much of a little barrel connector.I recommend using a more appropriate method of termination for such a supply.

author: Alex30
author_rank: Regular Contributor
timestamp: January 22, 2015, 10:31:30 am
content: Quote from: Monkeh on January 22, 2015, 10:14:44 amYou're probably right. This coax is just a pain though, I will have to do some research. Thanks for the help!