PORT & CABLE / FIELD GUIDES / 02 / DC BARREL IDENTIFICATION
Three named Tensility examples show why nominal outside diameter and bore do not settle exposed barrel length. Values are drawing-specific, not a fit gauge.
Each PDF includes two pages: the chart, then source notes and a reused visual. Downloads work in the native site and full offline preview. Evidence dates remain unchanged.
01 / KEEP THE LIMIT BESIDE THE ANSWER
| Label / exact scope | What the evidence establishes | What to check next |
|---|---|---|
| 10-02319 assemblyTensility / right-angle plug example | 5.5 × 2.1 mm nominal diameters; exposed barrel 10 ± 0.50 mm. Do not infer: The component-table 23 mm length is not the exposed mating length. | Use the exposed-length dimension in drawing 10-02319. |
| 55-00051 plugTensility / named component | 5.5 × 2.1 mm nominal diameters; exposed barrel 12 ± 0.5 mm. Do not infer: The same diameter label as 10-02319 does not make the lengths equal. | Match the equipment-required insertion length as well as both diameters. |
| 55-00050 plugTensility / named component | 5.5 × 2.5 mm nominal diameters; exposed barrel labelled 12 mm. Do not infer: This length is not universal for 5525 plugs; polarity is not established. | Read the complete device connector and approved supply requirements. |
Tensility / right-angle plug example
Tensility / named component
Tensility / named component
02 / SEE THE DISTINCTION
(private workspace)Tensility 55-00051
cable-plug · Side exterior and isolated end-view inset
physical-study · not to scale · technical/rights reviews pending. Qualitative exterior only; not to scale. No pin numbering, device wiring, fabrication tolerance or mating approval.
Inspect this exact view and carry its context → (private workspace)
(private workspace)Tensility 55-00050
cable-plug · Side exterior and isolated end-view inset
physical-study · not to scale · technical/rights reviews pending. Qualitative exterior only; not to scale. No pin numbering, device wiring, fabrication tolerance or mating approval.
Inspect this exact view and carry its context → (private workspace)03 / THE EVIDENCE STAYS ATTACHED
Compiled 2026-10-11 from inherited observations. A compilation date is not a new source inspection. Expand a row for its original claims, dates and source locators.
Example scope: Tensility / right-angle plug example
Tensility drawing 10-02319 specifies a right-angle 5.5 × 2.1 mm plug example using component 50-00540 and overmold 24-00190.
This assembly only; appearance does not identify an unknown barrel.
Original claim verification: 2026-10-11. Status: source_checked. No independent hardware approval.
Drawing 10-02319 dimensions the exposed barrel at 10 ± 0.50 mm; the component-table length of 23 mm is not that exposed mating length.
Drawing-specific distinction; no dimension is approved for fabrication.
Original claim verification: 2026-10-11. Status: source_checked. No independent hardware approval.
S473 · Tensility — 10-02319 cable assembly drawing
Sheet 1 of 1: side elevation and end view of 50-00540 plug with 24-00190 overmold; component table and exposed barrel dimension. · Source record checked 2026-10-11
Example scope: Tensility / named component
Tensility drawing 55-00051 shows a 5.5 x 2.1 mm plug with an exposed barrel length of 12 +/- 0.5 mm.
A separate example from the earlier 10-02319 assembly. Matching nominal diameters do not make their documented exposed lengths equal.
Original claim verification: 2026-10-11. Status: source_checked. No independent hardware approval.
S485 · Tensility — 55-00051 DC plug drawing, revision A
Sheet 1: assembled/end views; 5.5 outer / 2.1 bore / 12 +/- 0.5 exposed length. PDF text encoding is corrupted; visual source was inspected. · Source record checked 2026-10-11
Example scope: Tensility / named component
Tensility drawing 55-00050 identifies an assembly-type DC plug with a 5.5 mm outside diameter and 2.5 mm bore.
Nominal identification using this exact product drawing; not a universal replacement specification.
Original claim verification: 2026-10-11. Status: source_checked. No independent hardware approval.
The assembled view of Tensility 55-00050 labels its exposed barrel length as 12 mm.
Do not apply this length to every connector sold as 5.5 x 2.5 mm.
Original claim verification: 2026-10-11. Status: source_checked. No independent hardware approval.
Tensility 55-00050 shows the connector, inner sleeve and outer sleeve as separate assembly components.
A connector component is not a power supply or an established wired polarity; no assembly instructions are provided here.
Original claim verification: 2026-10-11. Status: source_checked. No independent hardware approval.
S484 · Tensility — 55-00050 DC plug drawing, revision A6
Sheet 1: assembled view, 5.5 outer / 2.5 bore / 12 barrel labels and component breakdown. PDF screenshot inspected. · Source record checked 2026-10-11
