How to chose the right dc plug for charger...

Hello everyone, I'm currently trying to choose the right DC power plug for my charger. The charger is meant for a 12S Li-ion battery pack max V of 50.4v and 3amps. Link to the charger below...

https://www.aliexpress.com/item/4001050596003.html?spm=a2g0o.cart.0.0.756d3c00EHTyFm&mp=1

I'm trying to go with the option of DC 5.5x2.1 but I've been finding out that the plug is only rated for 12v and 0.5 amps.
My question is, is it safe to use the DC 5.5x2.1 dc power plug?
Should I re-solder the xt60 connector instead as a power plug?
If so does wire gauge matter for the xt60 connector?

I'm not that knowledgeable about the types of power plugs so any other information or links to the type of plugs available would be great!
Thank you!

I know one can get those 5.5x2.1 barrels connector rated up to at least 1 amp.

But in my opinion the XT60 is the better choice. The problem with XT60 is that no one makes a XT60 Female (with sockets) panel connector. There are adapters on Ebay but I just use a stub cable instead.

LewTwo said:

I know one can get those 5.5x2.1 barrels connector rated up to at least 1 amp.

But in my opinion the XT60 is the better choice. The problem with XT60 is that no one makes a XT60 Female (with sockets) panel connector. There are adapters on Ebay but I just use a stub cable instead.

Click to expand...

I think the problem it, if the female is panel mounted, it either has to stick out for the male to plug in, or it has to be recessed and have gap around the perimeter to make room for the male plug.

https://www.thingiverse.com/thing:3530615

On the other hand, it also adds another thing to the list of reasons for getting a 3D printer :wink:

If it's a pre-built battery, I'd use whatever connector was on the battery. I plug 2A and 3A chargers into the barrel connectors all the time, and the battery plastic case apparently conducts enough heat away from the connector. They probably use sockets rated for 3A too.

n the other hand, I've got some batteries that are XT60 for charging and for those, I bought some molded 5.5mm sockets and wired them to male XT60 plugs. The barrel socket does get noticeably warm on 3A, not too bad on 2A. WIre gets warm too, probably too thin.

3 Amps is next to nothing. You don’t really need connectors, just twist the wires together.

Seriously, any kind of connectors will do, preferably matching the wire size to crimp, but not so important with solder.

Snip the DC connector off and install Powerpoles, XT60/90, 4/5/6/7/8mm bullet connectors

I found andeson powerpoles quite good for charger connections. But others would do equally well, xtc, or larger RC bullets.

Crimping the powerpoles is fussy, but once I learned how, it worked quicker than soldering the other types for me.

dogman dan said:

Crimping the powerpoles is fussy, but once I learned how, it worked quicker than soldering the other types for me.

Click to expand...

XT60 connectors can be a true challenge to solder ...
especially with 10 or 12 AWG fine stranded conductors I use to carry power to the controllers.
The 18 or 20 AWG used for chargers are fairly easy by comparison.

Now ALL of my power/charger connections are XT60 ...
makes it easy to swap batteries from one system to another.

Which ever connector one chooses to use, consistency is next to godliness

Thank you everyone for all the information! I will update you guys with the plugs when they come in! I have a 3d printer I'm using to create a housing for my electric longboard so I'll let you guys know!

E-HP said:

LewTwo said:

I know one can get those 5.5x2.1 barrels connector rated up to at least 1 amp.

But in my opinion the XT60 is the better choice. The problem with XT60 is that no one makes a XT60 Female (with sockets) panel connector. There are adapters on Ebay but I just use a stub cable instead.

Click to expand...

I think the problem it, if the female is panel mounted, it either has to stick out for the male to plug in, or it has to be recessed and have gap around the perimeter to make room for the male plug.

https://www.thingiverse.com/thing:3530615

On the other hand, it also adds another thing to the list of reasons for getting a 3D printer :wink:

Click to expand...

Thats so smart! That design looks really clean!

docw009 said:

If it's a pre-built battery, I'd use whatever connector was on the battery. I plug 2A and 3A chargers into the barrel connectors all the time, and the battery plastic case apparently conducts enough heat away from the connector. They probably use sockets rated for 3A too.

n the other hand, I've got some batteries that are XT60 for charging and for those, I bought some molded 5.5mm sockets and wired them to male XT60 plugs. The barrel socket does get noticeably warm on 3A, not too bad on 2A. WIre gets warm too, probably too thin.

Click to expand...

I agree. I figured the plastic surrounding is enough to dissipate heat for 3amps max. I think im leaning towards xt60 connectors for sure tho.

E-HP said:

On the other hand, it also adds another thing to the list of reasons for getting a 3D printer :wink:

Click to expand...

3D printer? .... more excuses ???
I Made Bicycle From 3D Pen (and it works!)
https://youtu.be/cc36NVlqa7A

Using inexpensive 3D prints to make carbon fiber bicycle frames
https://youtu.be/noxZ6gUiL0k

Bamboo Bicycle with Carbon 3d Printed lugs
https://youtu.be/XcnFSZhhUgY

Mini Town Bicycle
This is actually an entire series of videos that goes for design, through fabrication of a bicycle. Some 3D printed parts are used for various jigs and frame construction fixtures.
https://youtu.be/oY-b_FXTD_U

Kona with 3d printed mid drive walk-around
https://youtu.be/UBgo6NMlMOc