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Ask an Expert Forum DC power jack design decision: 2.1mm ID or 2.5mm ID?????
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  • jack
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DC power jack design decision: 2.1mm ID or 2.5mm ID?????

Former Member
Former Member over 15 years ago

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
www.voltvision.com
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Top Replies

  • Andrew J
    Andrew J over 4 years ago in reply to Gough Lui +1
    Yep, more choice in PCB mount but not that many. I wanted a 3-pin, panel mount one that would give me more flexibility in positioning a PCB inside a case and given I already have a 2.1mm 15V wall wart…
  • Gough Lui
    Gough Lui over 4 years ago in reply to Andrew J +1
    I'm sure it will be fine, as long as you're not connecting/disconnecting under load too frequently - the arcs could damage the contacts and increase the contact resistance before the connector reaches…
Parents
  • dougw
    0 dougw over 11 years ago

    Using the smaller pin on the target device allows both sizes of wall wart connector to be used in a pinch. The bigger pin can only be used with the proper mate.

    The bigger pin seems a bit sturdier and should have higher retention force.

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  • Former Member
    0 Former Member over 9 years ago in reply to dougw

    Be a bit careful with that idea.  I have come across many 2.1mm sockets that don't connect well with the 2.5mm plug.  The 2.1mm pin doesn't always contact the 2.5mm hole properly.  You wouldn't think it possible, but it's bitten me lots of times.

    Here is the solution, a dual 21./2.5 socket:

    http://au.element14.com/webapp/wcs/stores/servlet/Search?catalogId=15001&langId=43&storeId=10184&categoryName=All%20Categories&selectedCategoryId=&gs=true&st=FC681465

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  • Former Member
    0 Former Member over 9 years ago in reply to dougw

    Be a bit careful with that idea.  I have come across many 2.1mm sockets that don't connect well with the 2.5mm plug.  The 2.1mm pin doesn't always contact the 2.5mm hole properly.  You wouldn't think it possible, but it's bitten me lots of times.

    Here is the solution, a dual 21./2.5 socket:

    http://au.element14.com/webapp/wcs/stores/servlet/Search?catalogId=15001&langId=43&storeId=10184&categoryName=All%20Categories&selectedCategoryId=&gs=true&st=FC681465

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