7 Deadly Counterfeit Cable Sins for You to Avoid

January 30, 2014 at 10:00 AM

 

 

What scares you more than a faulty, over-rated, counterfeit cable? If you’re like us and work with cables on a daily basis, then you know the answer: nothing.  

 

Shockingly, unscrupulous sellers have found many ways to cut costs on cables, drawing customers in for the low price. But what they don’t tell you is that it comes at a price- sacrificing safety, performance, and network stability.

 

So how do you identify them? Counterfeit cables are bulk cables or cable assemblies sold under false pretenses to undercut legitimate manufacturers.  Usually this means the cable specification does not match the actual product construction. Or it could be that the seller falsely implies that a cable meets a particular performance standard or flammability rating such as Category 5E or CMP/Plenum.  If you get a low bid for your next cable quote, check these factors to make sure you are getting what you are paying for:

 
 
1. Substituting steel or aluminum for pure copper: copper-clad-steel (CCS) or copper-clad-aluminum (CCA) are classic methods of saving on costly copper needed to make cables. Over the length of the cable, however, the signal integrity will drop below the noise and cross-talk levels. There's a good reason the EIA/TIA has not approved CCS or CCA cable for use in high-speed networks…

2. Deceiving Connector construction: This is a two-part deception. For "RJ-45" (8p x 8c) connectors, rejected molded plastic bodies can be re-ground back to pellets, added to new plastic, and then made in new bodies, which can lower the combustion rating for the overall connector. A good tip: check the connector body for foggy or yellowing plastic. Aside from the body, the metal contacts are first coated with nickel then with gold to ensure a good connection. Manufacturers have been skipping the nickel and skimping on the gold, sometimes called gold flash or selective plating. Contacts made this way will eventually corrode and fail to connect when mated.

3. Cable Jacket Material: For those applications that require CMP or CMR flammability rating, the requirement is critical. If it is specified that the cable meets CMP or CMR ratings (per the NEC code) and you get an unusually low bid, ask for proof of the jacket material. A legitimate business will offer a signed Certificate of Conformance (CoC) for the product they sell.

4. Selective Electrical Performance Testing: Some manufacturers will claim their cable or cable assemblies were "Fluke tested", but won't clarify that they only ran the channel test, not the full patch testing. Patch testing is difficult to pass and more expensive, but legitimate manufacturers will do it because it ensures the cable conforms to standards and is worth what they are charging.

5. Misleading Cable Markings: All cables sold in the United States will use a UL "E-file Number" or the manufacturer's name and model number that you can look up on UL's database. The problem is that the marking may conform to UL's standard, but the cable may not. Again, a signed CoC will protect against counterfeits so make sure you get one!

6. Wire Gauge Changes: Often 25 or 26 AWG cables can be mislabeled as 24 AWG. If you require 24 AWG, you should always request a sample cable, cut it open, strip the insulation off of the wires and measure them. Don't trust a manufacturer that claims something they aren't selling; if they are untruthful about the wire gage, what else could they be hiding?

7. The Golden Sample: While it is a good idea to get a sample up front, many manufacturers will make a "golden sample" to be perfect for what you need, sometimes at great expense. When it comes time to manufacture the rest, they scrimp and cheat all they can to deliver under cost. You should always set up a system whereby you QC some of the cables in each shipment-and without the manufacturer's prior knowledge.
 
 
This problem is much more common than you think!
 
L-com found counterfeit cables from both big and small manufacturers, and from both domestic and oversea sources. “Made in the USA” means nothing if the cable is made with poor components in order to offer a cheaper price. If price is your priority, someone can always make a cheaper cable. It doesn’t matter where a cable is made, but how the cable is made.
 
The key is to know that your seller or manufacturer (like us!) is checking cable assemblies, insisting on proving UL compliance, testing their cables, and always meeting standards. At L-com our Ethernet cables are made in our own factory versus in a sub-contractor’s, guaranteeing superior quality every time. 
 

Hot Stuff! Low Smoke Zero Halogen (LSZH) USB Cables

December 3, 2013 at 10:00 AM


Flammability and Toxicity Ratings on Different Cable Types

 

 LSZH USB CableLSZH USB Cable

 

 

What would happen if your cables caught on fire?

 

There's actually much more to consider than the obvious flames and danger. Gasses you can't see and destruction to the inner cable conductors can endanger lives and destroy valuable communications equipment. 

 

To avoid that unknown, here’s a snapshot of USB cable jackets and looking into what yours is made of. Most commercially available cable assemblies have an outer jacket made from polyvinyl chloride, or PVC for short. Another alternative chemical compound that a cable's outer jacket can be made of is called Low Smoke Zero Halogen (LSZH), which reduces the amount of toxic and corrosive gases emitted during combustion.   

 

PVC is a durable, flexible plastic material perfect for most general applications.  If you were to buy a deluxe or premium USB cable, PVC is the type of jacket it would have. Yet for all of its benefits, PVC has some downsides- the biggest of which is the way it burns

 

Once PVC has caught fire it typically burns freely for a long while and releases toxic gasses in the process, including harmful halogens. In a building fire, the danger is that flames can burn along the cable jackets behind a wall and leap from room to room or floor to floor.   In most building fires the toxic gasses are not a big factor since occupants can get outside, and since USB cable is rarely run behind a wall, most manufacturers don't bother making them with non-PVC jackets.

 

But in some instances, a building fire isn’t the only scenario to consider.  Military and aerospace applications add another element to the danger:  people don’t always have outdoor access.  In fact, any application where people are working in close proximity with cable assemblies and cannot easily get ventilation in the event of a fire would require a special jacket material for the cables.

 

USB with LSZH Jackets

 

Though USB is not often run behind a wall and the USB standard is typically only used in peripheral-to-computer applications (including many in military and aerospace environments), having many PVC USB cables can lead to a dangerous situation.  LSZH cables, on the other hand, are self extinguishing. For that reason, L-com has made LSZH USB cables an off-the-shelf product, available for same-day shipping. 

  

 

Standard LSZH USB cables are constructed similarly to the premium line of USB cables: they have 20 AWG power conductors for maximum power transfer, and have 30 micro inches of gold on the contacts to ensure reliable connections through multiple mating cycles. Along with the standard type LSZH cables, L-com also carries a line of its "latching" USB cables with LSZH jackets.  These cables have small latches in the Type A connectors that lock the connector in place.

 

LSZH USB cables with Latches prove to be especially valuable in high-vibration environments such as in a military vehicle or in a device that is meant to be carried over rough terrain. Don’t overlook endangering personnel and valuable communications equipment by using standard PVC USB cables; LSZH USB cables might be better for your application.

 

For more information check out our ratings chart below, or this helpful video on cable flammability tests.

 

USB Flammability Ratings

 

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