USB cable with solderable wire - Page 1
Forum section: electronics / repair

author: Ogitek
author_rank: Regular Contributor
timestamp: January 09, 2024, 01:45:10 am
content: If you will cut a USB cable in half. The wiring are so thin or not solid enough to be soldered. What kinds of wiring is this?How do you find USB cable with wiring that is solid enough to be soldered?

author: BlownUpCapacitor
author_rank: Frequent Contributor
timestamp: January 09, 2024, 02:57:45 am
content: If the conductors are thin, It's likely just because it's a cheap cable.The wire is called stranded wire. It is also of high gauge because it's cheap.To find a USB cable with thicker conductors, you buy a higher quality cable.

author: wraper
author_rank: Unknown
timestamp: January 09, 2024, 03:08:54 am
content: If you have problem soldering it, it's problem with you, not the cable. Data wires normally should be 28 AWG.

author: pickle9000
author_rank: Super Contributor
timestamp: January 09, 2024, 05:35:54 am
content: Some wire is woven with plastic. That allows it to be much thinner and flexible, not to mention cheap.Try exposing the wire as best you can, quickly heat up with an open flame, blow it out if it catches on fire. Apply flux and dragthe end through some molten solder on your iron. You should see a small 1mm section tinned. Cut up to that and awayyou go.

author: wraper
author_rank: Unknown
timestamp: January 09, 2024, 02:48:46 pm
content: Quote from: pickle9000 on January 09, 2024, 05:35:54 amThis is high speed data cable, not earphone cable.

author: Ian.M
author_rank: Super Contributor
timestamp: January 09, 2024, 03:03:01 pm
content: OTOH it could be fake CCA wire. A flame test would detect that.

author: xrunner
author_rank: Super Contributor
timestamp: January 09, 2024, 03:10:42 pm
content: Quote from: Ogitek on January 09, 2024, 01:45:10 amIf it's the same tiny wire I've run into before, it might seem like it doesn't take solder. I've repaired a friends earphones which had the tiny earbuds, it was hard to do.The point is that tiny wire that's used has a coating on it sort of like enamel wire does, which insulates it. But it's not an enamel coating. It won't take solder unless you "burn" off the insulating material. You must leave the iron on it till that coating melts off, and then it's ready to be soldered.I don't know if this is the trouble you are having or not though. I may be describing the same thing as this -Quote from: pickle9000 on January 09, 2024, 05:35:54 am

author: voltsandjolts
author_rank: Unknown
timestamp: January 09, 2024, 04:47:54 pm
content: Consider not cutting the cable, and instead plug the cable to a connector on breakout board.Lots of breakout board options available on eBay etc.Example micro usb breakout:

author: Jwillis
author_rank: Super Contributor
timestamp: January 09, 2024, 09:31:17 pm
content: Just a side note word of advice. Don't buy those cheap USB cables sold at checkouts. They aren't worth dog snot. They won't last a couple hours charging a cell phone before they burn up. The wire is thinner than a Gnats pubic hair. Leave them in proverbial junk bin they are displayed.

author: Ogitek
author_rank: Regular Contributor
timestamp: January 11, 2024, 09:02:58 am
content: USB 2.0 uses 28 gauge AWG wire.I found out the LEMO crimps can only accept gauge 26 to 22. The 28 is too small for it so it can slip when crimping. The 32 to 28 gauge crimps are not carried by any suppliers.So where can I find a USB 2.0 with 26 gauge wires (instead of the normal 28 gauge)? Are there milspec USB 2.0 cable with 26 - 22 gauge wires inside?I found out USB 3.0 cable has 26 gauge wires but it has 9 wires inside instead of just 4 wires. Getting 9-wire USB 3.0 cable with only 4 connecting to the LEMO connection can mess things up.

author: wraper
author_rank: Unknown
timestamp: January 11, 2024, 10:18:48 am
content: Quote from: Ogitek on January 11, 2024, 09:02:58 amThere is a simple hack for that. You strip insulation from a longer piece of wire, and fold it back and forth several times until you have required conductor thickness. For example if you have 28AWG wire but need 26AWG for crimp, you fold it just once.

author: Ogitek
author_rank: Regular Contributor
timestamp: January 11, 2024, 11:20:39 am
content: Quote from: wraper on January 11, 2024, 10:18:48 amHave you or anyone actually tried that with a Lemo crimp? Also without any Lemo crimping tools. Can I just use long nose pliers to crimp them? It's just one cable I need.

author: wraper
author_rank: Unknown
timestamp: January 11, 2024, 12:02:02 pm
content: Quote from: Ogitek on January 11, 2024, 11:20:39 amI've done this with many different connectors with no issues. As of not having crimping tool. I guess you could try crimper for small ferrules but YMMV.

author: Ogitek
author_rank: Regular Contributor
timestamp: January 11, 2024, 12:29:34 pm
content: What is more difficult to solder?1. a new wire into a new USB male head2. a LEMO connector3. a 0603 SMD resistor/capacitor?My only experience is soldering DC jack like this. I can't imagine how to avoid the 4 pins from sharing one blob of solder. I tried soldering a 0603 SMD resistor but destroyed the PCB. Is soldering a Lemo as difficult as soldering a 0603? About the crimp. If it is not attached to the plastic connector securely. It can eject back when plugging in the equipment, isn't it.

author: wraper
author_rank: Unknown
timestamp: January 11, 2024, 12:51:48 pm
content: Quote from: Ogitek on January 11, 2024, 12:29:34 pmIt's not even soldered, just wire covered in solder blob that is not attached to connector terminals at all.

author: wraper
author_rank: Unknown
timestamp: January 11, 2024, 12:54:20 pm
content: Quote from: Ogitek on January 11, 2024, 12:29:34 pmContacts are held by two barbs that have nothing to do with crimpable part.

author: xrunner
author_rank: Super Contributor
timestamp: January 11, 2024, 12:54:48 pm
content: Quote from: wraper on January 11, 2024, 12:51:48 pmI agree, that is a poor solder job. Looks like you need more flux ...

author: wraper
author_rank: Unknown
timestamp: January 11, 2024, 12:56:49 pm
content: Looks like connector terminals were heavily oxidized and no surface cleaning was done.

author: Ogitek
author_rank: Regular Contributor
timestamp: January 11, 2024, 01:26:39 pm
content: I have never used flux before in soldering. And I don't want to do it first time with a LEMO.Ok. Who can help me solder a USB cable to the LEMO? The following is the pin configuration:I plan to use this LEMO connector at Ebay. You can order it so it ships directly to you. Then please choose the best USB cable. Will you use shielded cable? Of course before anything else. I'll pay you in paypal or amazon gift certificate. The finished product will be shipped to New York pickup at your place via UPS (you book it so your address is kept hidden (you can use fictitious "from" address)).https://www.ebay.com/itm/185704165011?epid=1918294288&hash=item2b3cd4ae93:g:HqgAAOSwcxFjoC~~&amdata=enc%3AAQAIAAAAwJacea6RlePBSif3FvqANJSeChrPB%2FpAPzQ%2BeDDoVBaL1dnUFb8y3zUkkHcKVJAQr0Ww7kQQhB6zUWWH9wmlKn5P5zUDcIUt9lVKgRp0Knq99GM6G5bpM%2Bj%2FGWEXIRf9UBxVH5uKM4yJFpiVgzaaWrFIhp7JCSJchGDnGUK%2B6YeEPSCAvFTUPB1nTj62qNGE95inwHc1nmTcnuOaqdRjR74sQ4fheg7VPKDFSqfMG3tFD7v525PAm4OeN%2B1J9fkfZQ%3D%3D%7Ctkp%3ABk9SR9rgxYmfYw

author: xrunner
author_rank: Super Contributor
timestamp: January 11, 2024, 01:38:54 pm
content: Quote from: Ogitek on January 11, 2024, 01:26:39 pmYes you have. It's inside the electronic solder you are using (rosin core solder) ... unless ... you aren't using solder for electronics (rosin core solder).Please tell us you are using rosin core electronics solder.Adding more flux is NOT going to be a problem. I think you need to perfect your soldering skills before you go into any more projects. But what do I know I've only been doing this for over half a century.

author: Ogitek
author_rank: Regular Contributor
timestamp: January 11, 2024, 01:44:44 pm
content: Quote from: xrunner on January 11, 2024, 01:38:54 pm100% of electronic solder has flux inside now? The soldering lead is made in china, very cheap.The LEMO connector doesn't have to be FGG.0B.304.CLAD52Z... it can use CLAD42 for example, and doesn't have to have the Z (strain relief) at end. Does any USB cable have diameter of 4mm instead of 5mm?

author: Ogitek
author_rank: Regular Contributor
timestamp: January 11, 2024, 02:29:20 pm
content: Doesn't anyone of your do electronic service/repair for a living? Please pm me. I need your service in soldering the USB-LEMO cable.

author: Ogitek
author_rank: Regular Contributor
timestamp: January 11, 2024, 10:40:20 pm
content: I've come up with a natural solution that doesn't require me to solder the connector. There is this Eonvic FFG.0B to USB cable suggested to me earlier but I didn't get it because the keying is wrong (FGG instead of FGC and I don't want to saw the key to avoid wrong rotation). But after learning more about them and acquiring a set of used FGC shell that is obsolete now. I will just try to replace the shell of the Eonvic with that of the FGC. Does anyone know the pin configuration of the "PD Movie". What's a PD Movie? If the pins don't match. Then I have to cut the cable in half and rewire all the 4 wires, at the cost of lost of any shield (if there is).https://www.amazon.com/gp/product/B06XKV73C1/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&th=1What other USB to 4 pin LEMO do you know besides it, which I can acquire and reconfigure?

author: MathWizard
author_rank: Super Contributor
timestamp: January 11, 2024, 10:59:00 pm
content: 1 thing I don't like about fixing USB cables, is when they have powder on the wires. I've had wires that seemed sticky, and had dust/powder on them. The powder would be for helping them flex.

author: Ogitek
author_rank: Regular Contributor
timestamp: January 12, 2024, 12:40:27 am
content: After more searching. I realized the original PD Movie USB-LEMO cable made by Ikan has really original LEMO connector but no stock. The Eonvic only uses china LEMO clone. I have 2 china LEMO connector clones coming from Aliexpress anyway. I don't know how mixing china internal part in an original used FGC shell will do. And not to mention rewiring all the wires in the USB, which has powder? If I indeed rewire them. I can just connect the shielding by touching them without soldering?Ok. What is the worst thing that can happen if the pins touch each other and data lines were shorted to positive or ground. Are all USB 2.0 protected from shorting, or are there USB ports that don't have any protection at all?

author: tooki
author_rank: Super Contributor
timestamp: January 13, 2024, 08:19:33 am
content: Quote from: Ogitek on January 11, 2024, 11:20:39 amNo, you can’t crimp them with long nose pliers. Forget that. You’d be better off soldering into the crimp contacts if you had to.Quote from: Ogitek on January 11, 2024, 01:44:44 pmYes, it always does, and this isn’t some new thing, it’s how it's been for nearly a century. Soldering does not work without flux, it is an absolutely mandatory part of the soldering process.* So solder manufacturers started including it long ago, as the flux core. Your solder wire is basically a tube of solder filled with flux. When you heat it, the flux melts first and flows just ahead of the metal, allowing the metal to wet properly. The performance of solder wire depends highly on both the quality of the metal (correct alloy, absence of contaminants) and the quality and suitability of the flux. (A gentle flux will be fine for brand new, untarnished components, but for soldering older, more tarnished parts, a more aggressive flux is needed.)Quote from: Ogitek on January 11, 2024, 01:44:44 pmDon’t fuck around with cheap Chinese solder. The quality of that stuff is all over the place: you might get a pack that’s decent, you might get one that is horrible. I think it’s a false economy to buy cheap solder, since it may result in you ruining expensive parts because the solder doesn’t want to flow properly, so you keep heating…Given that a large 1lb/500g spool of quality solder can be had for around $40 and will last you for years and years and years as a hobbyist, the cost per project is negligible. (Not to mention that you can buy smaller packages of top-brand solder.)*let me preempt any pedants by stating that I know it is possible to solder without flux using very specialized equipment and processes. But ordinary soldering using ordinary equipment in ordinary air environments requires flux.

author: tooki
author_rank: Super Contributor
timestamp: January 13, 2024, 08:20:09 am
content: Quote from: Ogitek on January 11, 2024, 02:29:20 pmSure, but it’s unlikely to be cheaper than just buying the right cable.

author: tooki
author_rank: Super Contributor
timestamp: January 13, 2024, 08:21:19 am
content: Quote from: MathWizard on January 11, 2024, 10:59:00 pmLots of cables have talc in them to help flex. Almost all mains cords are like that.