HOME / DC Cable

2020 Buying Guide to DC Cable

2020 Buyer’s Guide to DC Cable

Are you looking forward to custom DC cable plans or coming up with an idea to DIY DC power cable for lighting, solar panels, CCTV camera, consumer electronics, and telecommunications? Check out the 2020 new DC cables buying guide for cable materials structure, electrical cable manufacturer, and electrical cable projector; we’ll offer you the best dc power cables of 2020 with customer service to fit your DIY projects, ideas, files, and plans.

CLICK TO SHOW MORE

1 Difference between DC cable and AC cable

1.1 What is the DC cable?

The DC Cable itself conducts the two sorts of power. It is the divider mole toward the end that is generally extraordinary. On the off chance that the apparatus is intended to run it n AC (mains) power, as most household machines or lights, it has merely an attachment on end. A DC machine, similar to many convenient things, for example, your phones, radios usually have largish connectors toward the future. These connectors convert AC (alternating current) to DC (Direct Current).

 What is the DC cable

1.2 What is the AC cable?

An AC current fundamentally cycles to and fro along the line, sort of an energy motivation, at 60 cycles for each second in the US. Diodes in the connector cut the return cycle off, keeping the current streaming one way-immediate. All batteries are direct current, just like your vehicle. So on the off chance that you have to control an AC thing with a shower or direct current, you need an inverter that uses direct current to make AC through electromechanical methods.

What is the AC cables

1.3 What is the difference between DC cables and AC cables?

The DC cable is used in the rectified DC transmission system. AC cable is often used in the power frequency (domestic 50 Hz) power system.
Power loss during the transmission of the DC cable is small. Power loss during the transmission of the AC cable is Large.
High transmission efficiency and low line loss Low transmission efficiency and high line loss
The DC power cable is positive and negative poles, and the structure is simple.  AC cable is a three-phase four-wire or five-wire system.

2 DC cable type and specification

2.1 What is DC connector?

A DC connector (or Jack connector or a Barrel Connector, for one necessary kind of connector) is an electrical connector for providing direct flow (DC) power. Contrasted with homegrown AC power fittings and attachments, DC connectors have many more standard sorts that are not exchangeable. The measurements and game plan of DC connectors can be picked to forestall the unintentional interconnection of unreliable sources and loads.

What is DC connector

2.1.1 How many types of dc connector plug?

In the gadgets business, there are three generally acknowledged arrangements for DC power connectors: jack, fitting, and repository. A DC power jack is answerable for accepting force and is usually mounted on the PCB or suspension of an electronic gadget. DC power repositories are additionally expected to get power yet are instead found on a force string’s finish. In conclusion, DC power plugs strength gracefully from a force flexibly by associating with a suitable DC power jack or container. [Figure 1] shows these regular arrangements.

[Figure 1]

Outer Sleeve Diameters (mm) Inner Pin Diameters (mm)
2.35 0.50
3.20 0.65
3.30 0.80
3.50 1.00
4.00 1.30
4.30 1.65
4.75 2.00
5.50 2.34
2.50
3.00

types of dc connector plug

2.1.2 What are the DC connector size specifications?

DC PLUG&DC JACK inner diameter tolerance
NO. DC connector size
O.D.*I.D. mm 
PLUG( inner diameter tolerance) JACK( inner diameter tolerance)
1 2.0*0.6 0.6+0.1/-0 0.525+0.005/-0
2 2.35*0.7 0.7+0.1/-0 0.625+0.005/-0
3 2.5*0.7 0.7+0.1/-0 0.625+0.005/-0
4 2.5*0.8
5 3.0*1.1 1.1+0.1/-0 1.025+0.005/-0
6 3.2*0.8 0.8+0.1/-0 0.725+0.005/-0
7 3.5*1.1 1.1+0.1/-0 1.025+0.005/-0
8 3.5*1.5
9 3.5*1.35 1.35+0.1/-0 1.3+0.005/-0
10 3.8*1.35 1.35+0.1/-0 1.3+0.005/-0
11 4.0*1.7  1.7+0.1/-0 1.6+0.05/-0
12 4.75*1.7 1.7+0.1/-0 1.6+0.05/-0
13 5.5*1.0 1.0±0.05 0.95±0.005
14 5.0*2.1 2.1+0.1/-0 2.05+0.005/-0
15 5.5*1.5
16 5.5*2.0
17 5.5*2.1 2.1+0.1/-0 2.05+0.005/-0
18 5.5*2.5 2.5+0.1/-0 2.45+0.005/-0
19 6.0*1.4 1.4±0.05 1.35+/-0.005
20 6.5*3.0 3.0±0.1 2.95+0.005/-0
21 5.5*1.7 1.7+0.1/-0 1.69+0.005/-0

2.1.3 How to calculate the DC connector size?

Ideally, you have the size of the gadgets plug. You can simply check the connectors estimations, there are two estimations for these kinds of connectors, or you can use a Caliper [Figure 05] to measure the connector.

OD – Outer Diameters of the plug.

ID – Inner Diameters of the plug.

A 5 mm OD x 2 mm ID says the external measurement (Outer Diameter) is 5mm, and the inward (Inner Diameter) is 2mm.

How to calculate the DC connector size

2.2 DC cable wire type and specification

2.2.1 What’s type wire use for DC power cable?

When dealing with DC power, the current travels true the whole PVC electrical wire. There are many wires designed for DC power. DC power wires are as follows.

  1. Battery Cable
  2. Fine standard Battery Cable
  3. Marine Battery Cable
  4. Welding Cable
  5. DLO RHH / RHW Cable
  6. Machine tool Wire

All the electrical wires consist of the copper bore and PVC insulation. Using wire type is different according to the environment and process condition.

What is type wire use for DC power cable

2.2.2 What’s wire specification use for DC cables?

NO Cable type

AWG

Normal cross-sectional area

mm2

The min cross-sectional area

mm2

The max direct-current resistance

mΩ/meter

Normal cooper diameter

mm

Average numbers of conductor

strands

1185 cable OD

mm

2468 cable OD

(mm

1 24 0.205 0.201 314.30 0.16 11 1.8*3.6
2 22 0.324 0.318 199.14 0.16 17 1.8*3.6
3 20 0.519 0.509 125.00 0.16 26 3.5 1.8*3.6
4 18 0.823 0.807 78.41 0.16 41 3.5  
5 16 1.31 1.28 48.88 0.16 66 4.0  
Remark The Direct Current cable must meet the min cross-sectional area requirement and the max direct-current resistance.

2.2.3 How to calculate wire size for the DC cable?

How to size wiring for Your System using a universal wire sizing chart could also say dc cable size calculator, a two-step process.

STEP 1: Calculate

VDI = (AMPS x FEET)/(%VOLT DROP x VOLTAGE)

 VDI = Voltage Drop Index (a reference number based on resistance of wire)

FEET = ONE-WAY wiring distance (1 meter = 3.28 feet)

%VOLT DROP = Your choice of acceptable voltage drop (example: use 3 for 3%)

STEP 2: Determine Appropriate Wire Size from Chart Above.

NO Cable type

AWG

Normal cross-sectional area

mm2

The min cross-sectional area

mm2

The max direct-current resistance

mΩ/meter

Normal cooper diameter

mm

Average numbers of conductor

strands

1185 cable OD

mm

2468 cable OD

(mm

1 24 0.205 0.201 314.30 0.16 11 1.8*3.6
2 22 0.324 0.318 199.14 0.16 17 1.8*3.6
3 20 0.519 0.509 125.00 0.16 26 3.5 1.8*3.6
4 18 0.823 0.807 78.41 0.16 41 3.5  
5 16 1.31 1.28 48.88 0.16 66 4.0  
Remark The Direct Current cable must meet the min cross-sectional area requirement and the max direct-current resistance.

3 DC cable applications

3.1 Lighting

Modern lighting frameworks all sudden spike in demand for DC, and the utilization of DC reticulation in LED-based lighting frameworks is getting normal in “savvy” lighting frameworks. Such as low energy lamp, ceiling lamp paneling, street lighting system.

3.2 Automotive accessories

Most car applications use DC. A car battery gives the motor capacity, turning over, lighting, and starting a framework.

3.3 solar panels、battery case

The term solar panel is utilized casually for a photovoltaic (PV) module. Photograph voltaic cells use daylight as a wellspring of energy and produce direct flow power (DC).

3.4 CCTV camera

CCTV link frameworks accompany various devices and segments. Practically the vast majority of CCTV utilize coaxial links and DC power cables for movement.5V dc cable, 12V dc cable, so on.

3.5 Consumer electronics

DC is ordinarily found in most of the extra-low voltage applications and low-voltage applications in Domestic Consumer hardware. Such as Dishwasher, Oven. Fridge, Stove…

3.6 Telecommunications

Phone trade correspondence gear utilizes standard −48 V DC power gracefully. The negative extremity is accomplished by establishing the positive terminal of intensity flexibly framework and the battery bank.

DC cable applications

4 How To Choose A DC Cable Manufacturer?

Custom power cable production is a significant industry, and every facility has an alternate methodology. On the off chance that you need a custom link gathering, it is imperative to do your due determination and locate the correct manufacturer.

  • The custom cable fabricating organization you select ought to be adaptable underway levels.
  • Development is the objective of any business. As your organization develops, you may add items to your setup that require irregular cable congregations.
  • Involvement with your industry is likewise significant. Request the organization’s customer rundown and search for different customers they’ve served in your sector or even your market.
  • They ought to have the option to consider answers for the entirety of your needs.
  • The most significant thing! Search for custom dc cable fabricating is an organization that makes high quality items.

5 How To Complete An Electrical DC Cable Project?

Stage 1: We are listing down the customer’s request. Then we collect the details of cables, pass current, voltage, and necessary information according to the request. Finally, we provide a drawing of the request.

Stage 2: We provide a solution to the customer after confirming the cable stock and connector mold.

Stage 3: After confirming on our side, we discuss with the valued customer and take the final confirmation of the process.   

Stage 4:If we have the mold, then we make the sample. If we haven’t the mold, then we manufacture mold within 20-30 days and make samples.

Stage 5: After making the sample, we send it to the customer to check and confirm. 

DC Cable drawing

6 Is There Any Extra Cost for Custom DC Cable?

No extra charge fee for your custom project. Most of the electrical cables we have stock, and then we also built a lot of different terminals mold. And then, we can handle designing and producing any type of dc cable and are willing to work with small and large MOQs.

From the 2012 year to now, we have served more than 10000+ customers who custom wire harness, power cords as they need. Let us be your partner and remove the stress of sourcing and producing high-quality wires and cables in China.

CLICK TO COLLAPSE