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DC power jack design decision: 2.1mm ID or 2.5mm ID?????

Former Member

Hello there!

We are designing a family of consumer devices that will require an input DC power barrel connector on our PCB.  It will be for +12vdc of various power levels.  We will be able to purchase "off the shelf" UL-listed wall warts depending on the application.  My question is, as I design our PCB to work with a PCB mount DC barrel jack, which is more common?  2.1mm ID or 2.5mm ID for DC power jacks with 5.5mm OD???  So far it looks like they both are "standards".  So, which do I design for if I want to be most forward compatible?  Does one of the options work with both plug types, but not vice-versa?

 

Switchcraft 2.1mm ID, 5.5mm OD $1.61 @ qty=1k

http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=SC1330-ND

 

CUI 2.1mm ID, 5.5mm OD $0.19 @ qty=1k

http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=CP-102A-ND

 

CUI 2.5mm ID, 5.5mm OD $0.19 @ qty=1k

http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=CP-202B-ND

 

Thank you for any suggestions!!.... changing after we make several thousand will be much more difficult!

Respectfully,
Steve  French
814.584.1220.office
814.730.0003.cell
 
President, Volt  Vision
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  • 0

    The 2.1mm-vs-2.5mm dilemma strikes me as kind of a blood type scenario. Where some people can give blood to anybody, others can receive from anybody:

     

    A 2.1mm receptacle:

    • Will be able to have both types of plugs plug into it.
    • Although some 2.5mm plugs have very springy inner contacts (so that they can make a solid contact with a 2.1mm pin), others do not, and, hence, can lose contact if the plug gets wiggled. But, at the very least, if all you have is a 2.5mm plug, you can get your device powered... but you may have to ensure that it doesn't get bumped or moved. Probably the choice when you prefer user-friendliness over solid reliability.

     

    A 2.5mm receptacle:

    • Will not be able to receive a 2.1mm plug. This removes all doubt about which type of connector the user needs. They can only plug in the "correct" size. This could force your user to forestall using your device for a day or two as they shop for the proper power supply.

     

    But your question was about which one was more common/standard. I try to make a habit of trying a 2.1mm plug on every new coaxial-powered device I get, to find out for sure. Lately, it seems like everything I use has a 2.1mm pin on the receptacle.

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  • 0

    The 2.1mm-vs-2.5mm dilemma strikes me as kind of a blood type scenario. Where some people can give blood to anybody, others can receive from anybody:

     

    A 2.1mm receptacle:

    • Will be able to have both types of plugs plug into it.
    • Although some 2.5mm plugs have very springy inner contacts (so that they can make a solid contact with a 2.1mm pin), others do not, and, hence, can lose contact if the plug gets wiggled. But, at the very least, if all you have is a 2.5mm plug, you can get your device powered... but you may have to ensure that it doesn't get bumped or moved. Probably the choice when you prefer user-friendliness over solid reliability.

     

    A 2.5mm receptacle:

    • Will not be able to receive a 2.1mm plug. This removes all doubt about which type of connector the user needs. They can only plug in the "correct" size. This could force your user to forestall using your device for a day or two as they shop for the proper power supply.

     

    But your question was about which one was more common/standard. I try to make a habit of trying a 2.1mm plug on every new coaxial-powered device I get, to find out for sure. Lately, it seems like everything I use has a 2.1mm pin on the receptacle.

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