Audio over cat6a cable?

My podcast-partner in crime, the mighty Hugh Waters asked me how often I run audio signals over twisted-pair data cable in media facility builds. Has has a customer who is eager to do it this way.

I’ve done it a few times and it’s fine with a few considerations.

1. Earthing is still important and since IT people have no idea about proper grounding it can be an issue. If it’s a cat6a install in a TV facility done by me I’d have no worries, but the average IT install might have issues. But as four twisted pairs with individual screens cat6a is ideal for audio. It’s the other parts of the facility I’d worry about,
2. RJ45s don’t have the same DC/LF performance as a good old B-gauge (or Bantam) connector; if the circuits are going to be patched often I’d be wary – mechanically they aren’t great next to traditional audio connectors, 
3. From a wiring perspective; how do you nicely terminate into XLRs from a piece of cat6a?
4. Track shuffling is hard,
5. AES – just fine. Cat6a has an impedance of ~100Ω per pair, ideal for twisted-pair AES. Same observations as 1, 2 & 3.

There you go. I did work at one facility where the engineer had got obsessed with structured cabling and did everything he could over cat6 – analogue video (via baluns), audio, RS422 etc. He liked the idea that you could patch an offline i/o with two RJ45s (stereo i/o on one and video i/o and remote on the other). It didn’t work well and I put in proper cabling and patching after a year.

Sometimes convenience blinds you to fitness for purpose.

Earth Leakage - in water!

I recently bought an Agilent U1191A clamp-meter. This is a piece of test equipment that can measure current flowing in a conductor without having to break the circuit (how you would if all you had was a digital multimeter). The jaws physically couple around the conductor in question and by induction you can measure the electrical current flowing in the conductor. 

Clamp meters have moved on somewhat since I last had to buy one (a Fluke; sometime in the late nineties). This one is a pretty competent DVM as well as being able to sample and hold min, max and average values across all setting. For most days it could definitely do double duty against my Amprobe 37XR multimeter - EXCEPT the Agilent doesn't have non-contact voltage detection (the Amprobe does!). Anyhow - how do you get four and a half digits of resolution across multiple ranges on a brand-name test set for less than a hundred quid? Engineers today, don't know they're born...!

Today I was called to a customer's site where they have three canal-barges, each with two or three edit rooms on board. In the bilges of each boat there is room for little half-height equipment cabinet where they have the shared-storage chassis, network switches etc. They've been suffering an unusual number of equipment failures (motherboards dieing etc) and since they also seem to have RCDs tripping out as a regular feature my first thought was earth leakage.

Here is a picture of the electrical termination point for each boat - two 32A feeders go into the hull, one for the pumps and one for the mains distribution board. The cables are permanently suspended in the water (and have been for many years!) and the ones I inspected had clearly been submerged for so long there has been lots of water ingress into the rubber jacket of the cables. One felt almost ready to crumble in my hands.

Insulation has both electrical resistance and capacitance – and it conducts current through both paths. Given the high resistance of insulation, very little current should actually leak. But -- if the insulation is old or damaged, the resistance is lower and substantial current may flow. Additionally, longer conductors have a higher capacitance, causing more leakage current. Attaching the clamp meter to the incoming earth bond (pre-the consumer unit) measured a massive 100mA of leakage current. This not only risks the equipment being fed off this supply - there is an imbalance between the live and neutral cores and Class-1 equipment is often upset by this, and power supplies can pass this residual current to the earth-plane on PCBs.

More worryingly you've also compromised the safety action of any RCD (Residual Current Devices) in the feed. 

So - my advice was; replace those 32A feeders with marine-grade power cable as soon as possible.

Three phase electrical supplies and technical earth

I had a customer ask a question yesterday about why single phase in a machine room is considered a good thing and why technical earths need to be unified. Here's what I wrote; it's not a complete chapter & verse but it's a good excuse to put in a link to the episode of the Engineer's Bench that Hugh & I did in 2012.

He's confusing the phase that his various supplies are on with the "best practise" requirement of a unified technical earth. Twenty years ago the 16th Edition of the IEE regs forbade powering bays next to each other with different phases. There is more than 400v of difference between the mains phases and so it was thought that having that much potential difference within reach of each other was more dangerous than should be allowed; hence the practise of powering the machine room off a single phase.

However, the other consideration is that the power company charges you 3 x your most heavily used phase. So, if you're averaging 100A on the red (your machine room maybe?) but only 10A on the blue & yellow phases you'll be paying for 300A of current whilst only using 120A - if you don't "balance the phases" your electricity can (worst case) cost you three time per KW/h than it should. So, what with the improvement in RCDs and the cost issue the 3rd revision of the 16th Edition (and it's carried into the 17th) allows for mixed phase supplies in machine rooms. Looking up section 514 all that is required is labelling;

"6.1 Labels to be Provided The following durable labels are to be securely fixed on or adjacent to equipment installed in final circuits. (i) Unexpected presence of nominal voltage (U or Uo) exceeding 230 V Where the nominal voltage (U or Uo) exceeds 230 V, e.g. 400 V phase-to-phase, and it would not normally be expected to be so high, a warning label stating the maximum voltage present shall be provided where it can be seen before gaining access to live parts. (ii) Nominal voltage exceeding 230 volts (U or Uo) between simultaneously accessible equipment For simultaneously accessible equipment with terminals or other fixed live parts having a nominal voltage (U or Uo) exceeding 230 volts between them, e.g. 400 V phase-to-phase, a warning label shall be provided where it can be seen before gaining access to live parts."

On the subject of a technical earth - it's an entirely different consideration to mains phases but best practice is that you run all your tech feeds - bays and edit desks etc, back to the same earth bus-bar in the MCR. This is then run to the incoming feed supply. It's not good to try and tie it to the domestic "cooking" earth somewhere upstream of the incoming supply. The attached PDF is what we spec to customers' electricians.  It’s worth pointing out that getting the earth’s wrong is not unsafe; you can have volts of difference between two earths and they still both work as effective safety earths, but a hundred mV of earth differential between and edit suite and MCR will be a problem – the HD/SDi signal is only a volt big after all and zero level analogue audio is 775mV.

I did a podcast on the subject; http://youtu.be/rL1ZiciXRBg

Chassis vs Signal earth on RS422 remotes

Grounding is essential to reliable operation of any RS422 connections. It is also the most overlooked and least understood. The easiest way to ground your RS422 equipment is to simply use "Earth" ground as your return path. Although easy this may not be the best method for grounding your application, because current leaking from equipment, electro-static discharge (ESD), and lightning all drive current through this path which results in high noise content. The reason for this increased noise level is due to the fact that "Earth" ground presents a relatively high resistance. RS422 is designed to operate normally with a ground potential difference of +/- 12 Volts. During normal operations this is typically not a problem, however during fault conditions or lightning strikes even within ½ mile the ground potential difference can reach hundreds and in some cases thousands of volts. This will most likely result in damage or failure of one or more devices on the RS422 router.

In TV facilities I most often come across three methods of earthing;

1. No earth - assume that the mains return is good (all equipment is class-1 and bolted into it's bay and that signal and chassis earths will be close)
2. Use pins 1 and/or 9 on the 9-pin D-type to couple the chassis earths together; please, don't get me started about intentionally connecting mains earths between different areas! Do you like dealing with induced hum between different areas or buildings?!
3. The best way; using pins 4 & 6 - the signal screens (it's what they're there for).

The job I'm finishing at the moment had a problem with Digital Rapids workstation which wouldn't run through the RS422 router although patching around the router worked - the PC could control a VTR. My first port of call was to test the cabling/router patch by sticking an old Sony RM450 edit controller at the back of the Rapids and pretend the RM450 was the workstation - all good; VTR control and timecode return worked fine (so Tx and Rx doing their things). 

So my first thought was to measure the impedance between the signal ground on the router and the mains earth - high Z so no return patch for the RS422 via the router if it was relying on the mains earth (scenarios 1 & 2 above) and since the router is optically isolated on it's data inputs I wasn't surprised. That is the way it should be done.

Now then; most PCs that are running video apps and have to control a piece of broadcast kit use an RS232 port with an external RS232-422 adaptor. These essentially just balance the Tx and Rx pins and there are several models. None of them (in my experience) actually use a pair of rep coils to properly balance rather they use a pair of op amps in a differential input configuration. This is fine but doesn't have the noise immunity that you get with coils (common mode rejection). What it does mean is that all of the noise immunity of the circuit comes from the electrostatic shielding of the earth and so you better get it right!

I cracked open the cheap'n'cheerful '232-422 adaptors supplied with the rapids and they had the screen connected to the shield of the 9-pin on the RS422 side (so relying on scenario 1 above). Moving that to pins 4 & 6 (scenario 3) fixed the problem. 

As an aside the Adenda "Rosetta Stone" adaptors that Avid supply do the right thing!