A short history of cable design
Telegraph signals combine elements of both analogue and digital electronics, and the first practical binary code electromagnetic telegraphs used two wires, connected broadly as we would wire an analogue audio circuit today. However during 1835-6, Carl Steinheil in Munich successfully showed that he could almost halve the landline costs by employing a single wire with ground return. Despite the vast distances of the terrestrial US telegraph systems (which were trans national by the 1860's), little was known about the electrical characteristics of these landlines, except for the importance of insulators. However, when undersea cables became involved, it was obvious that what we now know as 'bandwidth', was lacking.
Early cable designers failed to analyse this effect correctly. Famously, E.O.W. Whitehouse believed that with enough voltage, any cable could be successfully driven. This theory resulted in predictably nasty results on the first transatlantic cable.
By the 1890s, the choice of unbalanced landline operation was called into question for two major reasons. Firstly, unusual interference and landline characteristic changes on the long submarine cables, were guessed to be unknown effects of atmospheric electricity and the geomagnetic field. Interestingly, these mysterious effects motivated many of the early polar expeditions. Secondly, the emerging urban electric power distribution systems, along with traction (rail and tram) systems, all shared earth return circuits with the telegraphs and telephones. This led to the first proper use of twisted pairs, or for long distance telephones, four-wire circuits. Adding loading coils to these long circuits, formed a low-pass filter with peaking characteristics. This could flatten the electrical speech band response so that unamplified telephone calls could be made at distances up to 1000 km. By the 1920's, vacuum tube 'repeater' amplifiers enabled trans US calls to be made on these landline cables.
Analogue cables for high quality audio - best practice requirements
'Professional' audio uses twisted conductor two or four wire screened cables. The four conductor cables are used exactly as for two conductors using parallel connection of opposite pairs. The advantage of this four conductor 'star-quad' cable comes simply from the symmetrical electrical geometry that gives a better impedance balance between the two signal paths.
In either regime, each of the cable pairs can be seen as a fixed 'lumped' capacitance or inductance depending on the receiving load. Typical transmission line impedances are 30 to 70 ohms. As a result, the impedance (as 'seen' by the transmitting end) of two 10km open-ended cables, where the only difference between the two cables is the gauge size of the wires, if plotted against the signal frequency, will differ in the following way.
Since this produces a resistive characteristic, the two resulting curves will not start in the same place. However, as they get closer to the characteristic impedance, they get closer and closer together. If they have the same capacitance and inductance, they will eventually have the same value of impedance. Analogue audio cables are therefore normally driven from a low source impedance (50/100 ohms typically) with a high load impedance at the far end (10k ohm typically). There will be series copper losses and parallel dielectric loss. But signal losses across the baseband audio frequency range should certainly not exceed 1dB on a 100 metre run whatever the construction.
Balanced operation of transmission lines for high quality audio
Despite popular belief, a balanced signal is not necessary for noise rejection. As long as the two circuit impedances are balanced (including the cable), noise will couple equally into the two wires and be rejected by a differential amplifier, regardless of the signal that is present on them.
There are some benefits to driving the line fully differentially, though. The electromagnetic field around a differential line is ideally zero, which reduces crosstalk into adjacent cables. Also, for the same maximum signal level, the output from the differential drivers is twice as much, effectively improving the signal to noise ratio by 6dB.
Screening
Most audio cables are screened, and this keeps out the higher radio frequencies, and enables phantom power to be carried. However, telephone lines have always run over vast distances unscreened, and the BBC ran hundreds of metres of unscreened paper insulated cable successfully around Broadcasting House.
Because of the large dynamic signal range that can be expected on analogue audio cables, physical constructional characteristics such as balance, screening and noise induction (especially with flexing) become important. The different types of screening aim at different applications, and below is a list of the types normally met:
Serve or spiral shields can be made to be ultra-flexible. However, serve shields can open up when flexed, which compromises shield effectiveness. A spiral of wire obviously affects the inductance of the shield. Therefore spiral shields are rare in video and are usually used for audio only. There is a double spiral serve, also known as a 'Reussen' shield. This configurations 'shorts out' the inductive effect of a signal spiral, but the shield can still open up when flexed. The ultra-flexibility of these cables is a key.
Braid shields are formed by spinning wires or groups of wires around a core. and braiding is the most expensive single step of cable manufacturing. Single braid coverage of up to 95% can be realized. Double braid coverage can be up to 98% coverage. Since braids always have 'holes' where the wires cross, 100% coverage is not possible with braid. Braid shields are most effective at frequencies from 1,000Hz to 50MHz. For these frequencies, the low resistance of a braid gives good coverage. Below 1,000Hz there is no standard braid material which is effective. The wavelengths are so long, and the low frequency energy so pronounced, that the only effective shielding is solid steel conduit. And, even at 60Hz, steel conduit gives only 27dB of noise reduction! At frequencies above 50MHz, braid becomes 'wavelength dependant' where the holes look larger and larger as the wavelength gets smaller and smaller. The effective coverage of a braid gets worse and worse, especially compared to a foil shield, which has no holes.
French braid shields are a combination of serve and braid. A French braid consists of two serves braided along one axis. This gives cables excellent flexibility and excellent RF performance. This may be partly because the braiding 'shorts out' the inductive effect of serve shields and 'shorts out' the RF noise too. Maximum coverage of a French braid is 98%.
Foil shields are the easiest and cheapest to apply and they actually consist of two layers, a metal layer and a polyester substrate. Since foil shields lack the mass and low resistance of a braid shields, the exhibit poor to average low-frequency performance. However, after 50MHz, foil shields have excellent high frequency coverage. Since foil is a continuous sheet of metal, coverage can be 100%.
Combination shields consist of foil and braid combined. Occasionally there can be more than one layer of each. Because of this, combination shields are the most
expensive of all. But they also give the best broadband coverage, since it contains a braid for low frequencies and a foil for high frequencies.
The difference between broadcast coax cables, which often contain foil and braid in digital applications, and CATV/broadband cable is that CATV cables use low coverage braid (sometimes as low as 40%). The reason is that these cables only operate above 50MHz. At those frequencies, braid shields are ineffective and it is actually the foil shield that is doing all the noise reduction. The braid shield is there just to give the connector something to connect to.