Built to order · 40 assemblies
DC Plug and Barrel Power Cables
DC power leads built around 5.5 × 2.1 mm and 5.5 × 2.5 mm barrel plugs, plus 4017, 3513, XT60 and Anderson options, with USB-C PD up to 240 W and fused multi-way splitters. Gauge, jacket, fuse rating and plug polarity are set per order.
- Barrel plug
- 5521 · 5525 · 4017 · 3513
- High current
- XT60 · XT90-S · SB50
- USB-C PD
- Up to 240 W (PD 3.1 EPR)
- Wire gauge
- 24 – 14 AWG
- Jacket
- PVC · silicone · braided
- Protection
- Inline fuse · low-voltage cutoff
- Sealing
- IP67 on request
- Length
- 0.2 m – 5 m
Specification table
DC leads are where a small specification error becomes a field failure: the wrong barrel size, reversed polarity or a conductor too thin for the run length. We build to the plug dimension you name, state the polarity on every drawing, and size the conductor against the current and the distance.
| Parameter | Standard build | Available on request |
|---|---|---|
| Barrel plug | 5.5 x 2.1 mm, 5.5 x 2.5 mm, 4.0 x 1.7 mm, 3.5 x 1.35 mm | Any barrel size or straight plug to a sample |
| Polarity | Center-positive unless stated otherwise | Center-negative, documented on the drawing and the label |
| Wire gauge | 24 to 14 AWG stranded copper | 12 AWG for high current leads |
| Current | Sized from the load current and the run length | Derating curves supplied with the quote |
| Jacket | PVC (general purpose), silicone (high temperature) | Braided sleeve, coil cord, direct burial compounds |
| Protection | Inline fuse holder | Low-voltage cutoff modules, reverse polarity protection |
| Sealing | IP67 assemblies for outdoor equipment | Overmolded strain relief with a sealing grommet |
| Length | 0.2 m to 5 m as standard | Any length; voltage drop checked before quoting |
| Termination | Barrel plug to stripped and tinned leads | Second connector, spade terminals, ferrules |
| Compliance | RoHS and REACH materials | UL styles and ampacity documentation |
Barrel dimensions follow IEC 60130; conductor ampacity is worked to the installation rules in NFPA 70 where North American installations require it.
Typical applications
- Security cameras and access control Outdoor runs where the lead has to seal at the camera housing.
- LED lighting and signage Constant-voltage feeds with the right barrel plug and current rating.
- Solar and battery packs Higher current leads with XT60, XT90-S or SB50 hardware.
- Medical and lab devices Documented materials and repeatable lot-to-lot consistency.
- Point-of-sale and kiosks Short harnesses with labeled branch lengths.
Related reading
- Voltage Drop and AmpacitySizing conductors from real resistance instead of a rule of thumb, for both DC and long runs.
- PVC vs PUR vs TPEOil, abrasion, cold-flex and cost compared side by side so the choice survives the washdown.
- How to Prepare a Custom Cable Assembly RFQThe fields a supplier needs before quoting: interface, length, environment, quantity and drawing.
Questions buyers ask
How do I pick the right conductor size?
Start from load current, then check voltage drop over the actual run length. A 2 m lead at low current is a different problem from a 5 m lead carrying most of its rating. Our voltage drop and ampacity guide walks through the arithmetic with real conductor tables.
What happens if I order the wrong polarity?
The equipment usually does not survive it. We mark every drawing center-positive or center-negative and ask you to confirm before production; assemblies can also be labeled at the plug end.
Can you supply USB-C power instead of a barrel plug?
Yes. For anything above 60 W we build to USB Power Delivery with an E-marked cable, quoted against the power level the device negotiates rather than by gauge alone.
Have one built to your drawing
Send the connector part numbers, lengths and environment. We review manufacturability in writing before any tooling spend, and we tell you up front what we cannot do.