Stage Lighting Cable: What Every Lighting Tech Should Know Before the Show
Introduction
You’re currently in the process of putting up a concert stage. The rig has already been hung, and all the lighting fixtures have been mounted in their proper locations when you receive a cable from someone that is the wrong one. This ultimately delays the show for a few minutes. This may seem like a small issue, but it happens much more often than people want to acknowledge.
Deciding what type of stage lighting cable you will use for your live event is not glamorous but is essential to the success of your event. Using the wrong cable would result in either signal loss, tripped circuit breakers, or even worse — your rig dying halfway through your show. On the other hand, if you use the correct cable, it should fade into the background, allowing everything else to perform as intended.
This article examines the different types of cables used in Stage Lighting Cable, their function, and how to choose the best ones for your application. Defining a Professional Grade Stage Light Cable There are many different grade lengths of cables used in the production industry. The design and function of any cable will vary between the various types.
One of several important considerations will be the material of the conductor. For professional Stage Lighting Cable, a high-quality cable will usually be made from oxygen-free copper (OFC) which provides excellent conductivity at long distances and low voltage; it also remains supple when used in colder environments and especially during the 5 am load-in times.
The jacket of a touring cable endures a lot of physical abuse such as being run over, improperly coiled by a tired crew, and being dragged across concrete floors so these cables require a thicker, flexible PVC or rubber jacket to prolong the cable's life span. A touring cable jacket usually outlasts the connector because connectors such as Neutrik and Amphenol come with a locking mechanism and built-in strain relief so cutting corners on connectors is not an option.
Accuracy of impedance: When it comes to DMX and data lines, impedance is much more important than most people think. A cable rated 110 ohms but actually measuring 120 ohms will cause communication problems, including flickering fixtures, communication errors, and intermittent loss of data.
DMX Cable: The Backbone of Lighting Control
DMX512 is the protocol used to control dimmers, moving lights, LED fixtures and other Stage Lighting Cable over a DMX cable. The DMX cable is technically known as a shielded and balanced data cable with a 110 ohm impedance rating.
Many individuals utilize a standard microphone cable (XLR) to connect to DMX devices, even though this cable type was intended only for audio. There are times when this method of connection will work; however, this microphone cable was manufactured with an impedance level of approximately 75 ohms, which is not compatible with the impedance level that is required by DMX devices. On short runs, you may not detect any issues; however, on long runs or if you utilize complex light rigs, you will see differences in how your DMX system has dropout problems and inconsistently operate.
When obtaining materials from a provider of DMX cable, ask for the impedance rating (ohm) and also inquire about the type of shielding (see examples above). Foil shielded and 100% foil shielded Belden twist pairs with drain wires are an industry standard in professional environments.
3-Pin vs. 5-Pin DMX
They both send identical signals. The original standard was based upon the five-pin connector and included two additional pins for a second data-transport universe (though in practice, this was seldom adopted). Over time, as XLR connectors became less expensive and more accessible, the use of three-pin DMX grew more prevalent.
3 pin connectors are commonly used in modern fixtures; however, most rental facilities carry adaptors as well. If you are purchasing cable for a permanent installation, it is worth checking what type of connection the fixtures and consoles use before making an order.
Socapex Cable: Power Distribution for Large Rigs
If DMX handles control, Socapex handles power — specifically, multi-circuit power distribution for dimmers and fixtures.
A Socapex cable usually transports six separate circuits through one heavy-duty, multiple pin connector. Each circuit consists of its own hot, neutral and ground, all together as a bundle. Instead of having to connect six separate power cables from a dimmer rack to a Stage Lighting Cable bar you only have to run one Socapex and then you can use a breakout (also known as a fanout or spider) at the fixture to separate the circuits.
This matters a lot in large venues and touring setups. Fewer cables in the air means cleaner rigging, faster load-in, and less weight on the truss. On a big rig, that adds up quickly.
Six 20-amp circuits are carried by a standard 19-pin Socapex connector, and they typically use conductors that have a cross-section area of size 2.5mm² (12 AWG). Be sure to check for the rated amperage matches the dimmer output and the load of the fixture; do not simply assume that all 19-pin Socapex connectors will work with any application.
Factors to Consider When Purchasing a Socapex Cable - Conductor Size: Most theatrical and concert uses call for a 2.5mm² conductor size - Cable Jacket Flexibility: When using the cable for touring applications where the cable will be constantly coiled and uncoiled, look for rubber jacket/cover options.
-Pin retention for connectors: A well-made & reliable pin contact on your 19 pin connectors will prevent arcing when it’s under load (If you have lower quality connectors they will arc). -Length options for stage cable: The commonly used lengths for stage cable are 5m, 10m, or 15m. There are many stage cable manufacturers that can also create custom lengths specifically for your permanent installation.
Audio Snake Cables: More than Just for Audio Departments Although audio snake cables (also known as multi core cables) are commonly recognised to be for just sound departments they frequently make an appearance within Stage Lighting Cable as well.
Some touring installations employ audio snake cables for carrying video syncs or intercoms as well as low-voltage control cabling along with the Audio channel cabling. Multi-channel approaches (4 to 24 pairs) make these cables practical for use where multiple signals must be transported in a single jacket.
To keep from picking up radio signals, a good-quality audio snake cable should have their wires grouped in pairs with some sort of shielding applied to each wire. Cables themselves should be made with strong enough jackets that can withstand repeated physical abuse, but should not be so stiff that they cannot be easily coiled for transport. Stage Lighting Cable designers frequently utilize audio snake cables to connect their intercom and headset systems to controls located at FOH, dimmers, and behind-stage areas during tech rehearsals and performances.
Sourcing from a Stage Cable Manufacturer
The majority of equipment rental companies cannot afford to purchase cheap cables from general suppliers. When a cable breaks during a live performance, the cost of fixing it (or repairing your reputation) is greater than your original savings on the product.
By working with a stage cable manufacturer, you can be involved directly in how they manufacture your order; this gives you more control over your product. You can specify the size of the conductors, the material for the outer jacket, the type of connectors, and the length of the cabling. This allows rental companies who are building a new inventory or rebuilding an existing inventory to specify cables that fit the actual stage rig they intend to use instead of something that has been sitting on the shelf.
Questions To Ask A Manufacturer Before Placing Your Order: – Are they measuring impedance on DMX cables prior to shipment? – Which manufacturer's connectors do they use? Can they supply me with one? – What is the minimum order quantity for custom lengths?
- Do they have CE or TUV certified cable for the European Union (EU) Market? A good manufacturer should respond with assurance to these questions. If they hesitate to provide an answer, then you should find another manufacturer. --- ## Cable Management for the Stage: A Few Practical Considerations
Even the best cables fail faster if they're stored and handled poorly.
Cabling method for coiling - Always use the Over/Under for any cables that will be coiled regularly. This prevents internal twisting, which stresses the conductors over time. It only takes one week to develop a habit through consistent practice. They can provide your cables with longer service life due to this habit.
Connector protection — Socapex and DMX connectors should be protected during transit. A simple zip-lock bag or a purpose-built connector cap keeps moisture and debris out of the pins.
Marking — During a load, proper marking of all connectors will also drastically reduce time by eliminating confusion related to line connections between the two ends of the cable(s). The most commonly used method for marking is either heat shrink labels or gaffers tape at the connector end of each run.
Checking equipment prior to any production should always be on the pre-rigging checklist. Having a basic DMX tester and continuity checker for power cables at your disposal will make searching for a defective cable in your warehouse much easier than climbing up 40 feet to locate one with limited time left until your production begins.
End of Talk The Correctly set up stage lighting cables will determine whether or not a live production runs smoothly. When show crews exhibit a good understanding of the differences between DMX ("digital multiplex") and microphone (or other) cable types, how Socapex connectors work and proper specifications for the termination of various types of stage cable can help ensure that shows run without interruptions.
If you are looking to create a larger inventory of cable or you need a custom run of cable for a specific installation, companies like Tourycable provide cable manufacturing services for events and stages, including DMX, Socapex, Audio Snake Cables and Multi Pin Assemblies as well.
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