Production of Long Life Low Noise BNC Cables

Do you want to make the success of your measurement depending on this cable?

Shielding is partially broken, loose contact.

Or this?

This cable looks ok but still has bad contact.

Working with broken cables is very annoying. They can disrupt your measurement or even destroy your sample.

Here i describe my first attempt to make better cables.

Cable Huber Suhner G 03130 HT, avaiable at ETH D-PHYS-Shop: ETH 30232.1

Stick label in the middle of the cable.
(Label: Herma Outdoor, No. 9500)

Shring tubing.

Shrink.

Connector Typ 11_BNC-50-3-36/133_NE
ETH D-PHYS-Shop: 30139.3

Knickschutztuellen Typ
Suhner Typ 78_Z-0-4-4
ETH D-PHYS-Shop: 30396.16

Slide the cable boot and the sleeves over the cable.

Weidmueller Entmantler
Knifes adjusted correctly.
Einsatz Braun

Put in cable.

Orange ring one step forward.
One rotation.
Orange ring one step forward.
One rotation.
...
Open completely.
Take cable out.

Setpoints.
Check the 4.5 mm

Remove the first two rings.

Remove the black coating as shown.
(This step is important. The cable can leak otherwise.)

Remove isolation.

Krimpwerkzeug Tool C2.
Avaiable at ETH D-PHYS-Shop

Clamp the pin with crimping tool fine.
Push the cable into the pin.
Crimp.

Push the cable into the connector completely. The pin has to have the position as shown in the picture.

Sleeve over connector.

Crimp.

Optional: Fix it with a glue-drop.
Without glue, i expect more mechanical stress on the screen, and this is the position where you can get a loose contact after heavy usage.

Glue "UHU Plus 300 Endfest".

Mix the two components well.
Put a drop of fresh miced glue between cable and sleeve.
Fix connector vertikal for 3 hours. Then go on with cable production.

Hint: Put lot of cables an a wall holder, put a drop of glue on the lower connectors.

Drop of glue.

After two hours.

Side the cable boot over the plug.
I made a special tool, you can do it by hand as well.

Test cable with cable_test_2014

Plug in. Bend the cable behind the connectors to test for loose contact. Check the resistance.

Resistance:
G_03130_HT
A inner conductor 0.09 Ω/m
B outher conductor 0.017 Ω/m

Test of isolation with Agilent U1273A. Should show "0.L" (overload), resistance higher than 300 MOhm.

If the black layer was not removed cleanly, the cable can leak.

You can mark the cables with colors.
O-Rings EPDM farbig, Di 7.9 mm Schnur 1.7 mm.

I made a tool to simply slide the rings over the connector.
You can put the o-rings over the cable before crimping the connectors as well.

Final cable.