Cable that fits Barrel Jacket plug? - Page 1
Forum section: electronics / beginners

author: ElectricPower
author_rank: Frequent Contributor
timestamp: December 13, 2019, 04:29:25 am
content: My question is possibly simple, but i just wonder how big cable that fits in an standard 5.5x2.1/5.5x2.5 barrel jacket plug or "DC connector". I want to invest in ome silicone wires, but i want to know the total size of input hole back on the barrel jacket before i buy cables.I'm going to order som barrel jacket plugs from Aliexpress and some slicone wires, but need to know how big cable that fits without destroying the plug.Thanks

author: Brumby
author_rank: Unknown
timestamp: December 13, 2019, 05:01:13 am
content: I know this isn't going to be an answer you would have hoped for - but it depends on the plug.There are "plugs" and there areplugsand there arePLUGS.

author: ElectricPower
author_rank: Frequent Contributor
timestamp: December 13, 2019, 05:22:40 am
content: I mean plug like these:https://www.aliexpress.com/item/32949784101.html?spm=a2g0o.cart.0.0.70843c00noInS5&mp=1

author: jhpadjustable
author_rank: Frequent Contributor
timestamp: December 13, 2019, 06:04:21 am
content: Quote from: ElectricPower on December 13, 2019, 05:22:40 amOh, mate, those arepLuGs, no data available.I just stuck some calipers in the strain relief end of some 5.5mmPlugSI happened to have in stock and the diameter appears to be 4.9mm. They're stretchy so you may be able to work some thicker leads in. If you like, you could just cut the strain relief off and fashion your own out of Sugru, among many other options.

author: Brumby
author_rank: Unknown
timestamp: December 13, 2019, 06:07:12 am
content: My answer remains unchanged. There is still a lot that can vary within connectors that would appear the same in a photo - and that is assuming the photo provided is of the exact same item that you will receive.You need to have them in front of you to make definitive statements. Either that or full specifications - that you can trust.

author: ElectricPower
author_rank: Frequent Contributor
timestamp: December 13, 2019, 06:19:35 am
content: Quote from: jhpadjustable on December 13, 2019, 06:04:21 amThanks alot!I can therfore asume that two 16awg silicon wires can be pressed inn there. If not, i just fins a walkaround.

author: tooki
author_rank: Super Contributor
timestamp: December 13, 2019, 02:00:12 pm
content: I doubt you could fit 2x16ga silicone into that without modification.. Why? Because silicone insulation (especially on test lead wire) is thicker than other insulation types. 16ga silicone test lead wire has a total diameter of 3-4mm.

author: jfiresto
author_rank: Frequent Contributor
timestamp: December 13, 2019, 03:27:06 pm
content: Quote from: ElectricPower on December 13, 2019, 06:19:35 amLaying them against the metal is very likely all you will be able to do. If my experience yesterday with a Japanese-made, inline, 5.5/2.1mm, Lumberg 10487, female DC power socket is anything to go by, there isno absolutely wayyou can feed 16AWG wires through the conductor wiring holes. I had enough fun threading in a 28AWG wire.

author: JackJones
author_rank: Regular Contributor
timestamp: December 13, 2019, 03:45:23 pm
content: I've got a set of the ones you linked (at least looks identical) and Ijustmanaged to squeeze two wires of the 16 AWG silicone wire I have through. The opening is about 5 mm in diameter.They're not the greatest quality though, if you're investing in some nice silicone wire might as well buy nicer quality plugs as well.Edit: I might add that the wire I have at hand is not proper test lead wire, just some random silicone wire from Ali/etc. The wire diameter is 3mm, the opening is a bit flexible.

author: ElectricPower
author_rank: Frequent Contributor
timestamp: December 13, 2019, 06:23:19 pm
content: I have seen some youtube videos and it looks like 18awg silicone cable is 2.2mm thick. That means 4.4mm for two wires. 16 awg is 3mm, and i espect 6mm total going to be tight yes...

author: mariush
author_rank: Super Contributor
timestamp: December 13, 2019, 08:14:26 pm
content: Why do you keep looking around in various places and guess?Just go at distributors of electronic components and electronic related things and get some actual data.For example, Digikey has a VERY GOOD filtering mechanism.Go to barrel jack connectors, filter by the ones with 5.5mm OD (outer diameter) and 2.1 / 2.5 mm ID (inner diameter):2.1/5.5 (28 plugs) :https://www.digikey.com/products/en/connectors-interconnects/barrel-power-connectors/435?k=&pkeyword=&sv=0&pv28=387800&sf=1&FV=-8%7C435%2C1954%7C124090&quantity=&ColumnSort=0&page=1&pageSize=252.5/5.5 (26 plugs) :https://www.digikey.com/products/en/connectors-interconnects/barrel-power-connectors/435?k=&pkeyword=&sv=0&pv1952=9405&sf=0&FV=28%7C387800%2C1954%7C130727%2C-8%7C435&quantity=&ColumnSort=0&page=1&pageSize=25All you have to do is open the datasheet for random connectors from the results (pretty much every result has datasheet) and look at the schematic to get the diameter.Here's a random example... you see it says 4mm +/- 0.5mm (0.157") :https://www.cuidevices.com/product/resource/pp3-002b.pdfNow you can look at cables ... there's almost 21K single wire cables on Digikey:https://www.digikey.com/products/en/cables-wires/single-conductor-cables-hook-up-wire/474You can filter by gauge.Here's AWG18 :https://www.digikey.com/short/p194qjYou can look at "Jacket (insulation) diameter", that will tell you the overall diameter of the cable. "Jacket (insulation) thickness" will tell you the thickness of the insulation.You can see you have wires as thin as 1.3mm and as thick as 6.73mm.You can then further filter by insulation material and see silicone cables how thick they are :https://www.digikey.com/short/p194jm- as you can see they're anywhere from 1.98mm to 6.12mmEither way, assume the majority of awg18 cable is gonna be under 2.3mm but it's unlikely they're gonna be 2mm or less... as the diameter of the hole is 4mm, you're not gonna fit two in the connector.Also, you may be better off buying pre-made cables.Here's 2.1/5.5:https://www.digikey.com/products/en/cable-assemblies/barrel-power-cables/464?FV=28%7C125172%2C-8%7C464&quantity=50&ColumnSort=1000011&page=1&pageSize=25Here's 2.5/5.5:https://www.digikey.com/products/en/cable-assemblies/barrel-power-cables/464?k=&pkeyword=&sv=0&pv28=131840&sf=0&FV=-8%7C464&quantity=50&ColumnSort=1000011&page=1&pageSize=25

author: admiralk
author_rank: Regular Contributor
timestamp: December 13, 2019, 08:46:29 pm
content: Quote from: mariush on December 13, 2019, 08:14:26 pmAnd here is a random one that says 6.6mm.http://www.switchcraft.com/Documents/NPB_583_-_sealed_power_plug_&_jack100315_edit7_30_2012.pdfHere is one that is adjustable.https://media.digikey.com/pdf/Data%20Sheets/Tensility/55-00096_50_51_Assem_Instr.pdfSince he already has the wire, it might be a better idea to find a plug that will accommodate the wire. What is really fun is matching multiple plug types; RCA, Mini XLR, etc. with the same wire.

author: tooki
author_rank: Super Contributor
timestamp: December 14, 2019, 07:42:07 pm
content: Quote from: ElectricPower on December 13, 2019, 06:23:19 pmThere isn’t one thickness per gauge. It varies by cable type. Silicone wire varies wildly in overall thickness even within a given gauge. For example, Pomona (Fluke) makes18ga silicone test lead wirewhich is 3.6mm thick.You really need to just a) stop operating on assumptions and guesses, and b) do as mariush said and start doing your own research on actual parts you want to use.