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In Reply to: RE: Xfinity X1 CATV box DC umbilical project posted by Sondek on September 19, 2016 at 12:57:35
A good bulk-length commercial interconnect cable to build a longer-length 5 foot DIY DC umbilical (with an acceptable 1.42% voltage drop for a 12V DC 1.67A load) would be the DH Labs BL-1 (not to be confused with the Connex BL-Ag) featuring 20 AWG silver plated stranded copper conductors with FEP Teflon dielectric and foil shield with drain wire. While it's not a solid core pure silver cable, it's well-respected for low-current DC umbilical applications according to Darren Hovsepian of DH Audio, and the 5.5mm outer diameter of the BL-1 is slim enough to terminate with a Switchcraft DC plug.
Follow Ups:
Duster,
Thanks a bunch for the recco. I think I have a new project.
Best
Make sure to cut-back both the exposed foil shield and the drain wire all the way to the end of the cable jacket at the load end of the cable (the component end of the DC umbilical) so the foil shield and drain wire are no longer at risk of accidentally touching the DC plug contacts. The drain wire should be soldered to the ground contact of the DC plug only at the source end of the cable (the power supply end of the DC umbilical).
BTW, now is the time to buy a Switchcraft DC plug, since Arrow Electronics is offering free shipping during the month of September. Make sure to know the size of the DC plug that is required for your specific application, since there are two different sizes to choose from: 2.1mm ID or 2.5mm ID. A typical 2.1mm ID DC plug is the Switchcraft 762 that I posted a link to, but a 2.5mm ID version is also available from Arrow Electronics.
See link to the 2.1mm ID version:
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