Mobile production trucks and OB vans pack an enormous amount of video equipment into a relatively small space.

Cameras, video routers, switchers, multiviewers, monitors, converters, replay systems and transmission equipment may all need to exchange professional SDI video while the truck is being transported from one production to another.

That makes cable selection particularly important.

The best SDI cable for a 3-foot connection inside a densely populated rack may be very different from the best cable for a 150-foot run leaving the truck for a camera position.

Building a reliable mobile production system therefore starts with matching the SDI cable to the signal format, distance and physical installation.

WHY MOBILE PRODUCTION CABLING IS DIFFERENT

A permanent broadcast facility can dedicate significant space to cable trays, equipment rooms and structured wiring.

A production truck has to accomplish many of the same tasks in a much smaller environment.

Cabling may need to pass behind tightly packed racks, through cable-management systems and between equipment with dozens of closely spaced inputs and outputs.

At the same time, external production cables may need to travel much farther from the truck to cameras, stage locations or other production positions.

One cable construction rarely provides the ideal solution for every part of that system.

START WITH THE SDI FORMAT

Before choosing the physical cable, determine the highest SDI data rate the connection needs to carry.

A mobile system may contain a combination of HD-SDI, 3G-SDI, 6G-SDI and 12G-SDI equipment.

For UHD workflows, 12G-SDI allows compatible equipment to transport high-bandwidth video over a single coaxial connection.

Higher SDI data rates place greater demands on the complete transmission path, making cable construction, connectors, termination quality and distance increasingly important.

If the truck is being designed or upgraded for UHD production, using appropriately specified 12G-SDI cable assemblies in key signal paths can also reduce the amount of recabling required during future equipment upgrades.

MINI RG59 FOR DENSE EQUIPMENT RACKS

Space is valuable inside a production truck.

This is where Mini RG59 can provide a major physical advantage.

A smaller-diameter coax reduces the size of cable bundles and makes short connections easier to route behind densely populated equipment.

AV-Cables uses Belden 4855R Mini RG59 for professional 12G-SDI assemblies.

For short equipment interconnects, its compact size can make it particularly useful between:

• Video routers
• Production switchers
• Multiviewers
• Monitors
• Converters
• Patch panels
• Replay equipment

The goal inside the rack is not simply to install the thickest coax possible. It is to use a cable that provides the required SDI performance while keeping the installation manageable.

RG59 FOR THE MIDDLE GROUND

Standard-size RG59 can provide a useful balance between cable diameter and transmission capability.

For 12G-SDI applications, AV-Cables offers assemblies using Belden 4505R RG59.

RG59 can make sense when more transmission capability is desirable but the additional diameter of RG6 is unnecessary or difficult to accommodate.

This makes it another useful tool when designing the different cable zones within a mobile production system.

RG6 FOR LONGER SDI RUNS

As transmission distance increases, attenuation becomes increasingly important.

Larger professional RG6 constructions can provide lower signal loss than smaller coaxial cables, making RG6 particularly useful for longer runs when the specific cable is appropriate for the required SDI format.

AV-Cables offers professional RG6 assemblies including Belden 1694A for appropriate HD, 3G and 6G applications and Belden 4694R for professional 12G-SDI applications.

RG6 requires more routing space, so it may not be the first choice for every short connection inside a crowded rack.

For longer paths, however, the electrical advantage of the larger coax can outweigh the physical-size disadvantage.

USE DIFFERENT CABLES FOR DIFFERENT ZONES

A well-designed truck therefore doesn't have to standardize on one coax size everywhere.

Use the construction that makes sense for each signal path.

BNC, HD-BNC AND DIN 1.0/2.3

Coax size is only one part of mobile production cabling.

The connector must also match the equipment.

Traditional BNC remains extremely common in professional video, but high-density equipment may use smaller connector formats to fit more inputs and outputs into limited panel space.

HD-BNC provides a compact coaxial interface used on selected high-density broadcast equipment.

DIN 1.0/2.3 is another compact coaxial format found on some professional video devices.

BNC, HD-BNC and DIN 1.0/2.3 are different physical connector formats. They are not interchangeable simply because they can all be used in professional 75-ohm video systems.

Always verify the actual equipment connector before ordering an assembly.

SDI SNAKES CAN SIMPLIFY DEPLOYMENT

Mobile production frequently involves several SDI signals traveling between the same two locations.

Running individual coaxial cables works, but deploying and recovering many separate cables can consume time and create unnecessary clutter.

A multi-channel SDI snake cable groups several independent coaxial signal paths into one organized assembly.

That can be useful for:

• Multiple camera feeds
• Monitor positions
• Replay systems
• Fly packs
• Temporary production racks
• Stage-to-production connections

Each SDI channel remains an independent signal path. The snake simply organizes those paths into one deployable cable assembly.

DON'T FORGET BREAKOUT LENGTH

When specifying a multi-channel cable for a truck or fly pack, total cable length isn't the only measurement that matters.

Breakout length determines how far the individual cable legs can reach after leaving the main loom.

Too little breakout can force the trunk into an awkward position. Excessive breakout can create unnecessary loose cable behind equipment.

Consider where the main loom will be secured and where each individual BNC connection needs to reach before specifying the assembly.

LABELING MATTERS IN MOBILE PRODUCTION

When a system contains dozens or hundreds of video connections, troubleshooting becomes much easier when cables and channels can be identified quickly.

Consistent labeling can help technicians determine:

• Signal source
• Destination
• Router input or output
• Camera number
• Snake channel
• Rack location

This becomes especially valuable during setup, equipment changes and troubleshooting under production deadlines.

PROTECT CONNECTORS FROM MECHANICAL STRESS

A production truck moves.

That makes mechanical cable management particularly important.

A coaxial connector should not be expected to support the weight of a large cable bundle.

Provide appropriate strain relief and cable support so movement of the cable does not continually transfer force into equipment connectors.

Also avoid tight bends, crushed coax and routing that forces a connector sideways after it is attached.

MINIMIZE UNNECESSARY ADAPTERS

Adapters can solve an immediate connection problem, but every additional component becomes another connection in the signal path.

If equipment permanently requires BNC on one end and HD-BNC or DIN 1.0/2.3 on the other, a purpose-built cable assembly can provide a cleaner installation than stacking adapters onto a standard BNC cable.

This also reduces physical bulk behind already crowded equipment.

PLAN FOR SERVICEABILITY

Mobile production systems need more than good electrical performance. They need to be maintainable.

When planning the cable system, ask whether a technician can:

• Trace the cable
• Identify both ends
• Disconnect it without disturbing unrelated connections
• Replace it if necessary
• Reach the equipment connector
• Test the signal path

A perfectly functioning cable that cannot be serviced easily can still create problems during a live production.

MOBILE PRODUCTION SDI CABLE CHECKLIST

THE BOTTOM LINE

There is no single SDI cable that is automatically best for every connection in a mobile production truck.

Short, densely packed rack connections may benefit from compact Mini RG59. Standard RG59 can provide a useful middle ground. Longer paths may justify the lower attenuation available from professional RG6 constructions.

High-density equipment may require HD-BNC or DIN 1.0/2.3 instead of traditional BNC, while multi-channel SDI snakes can make repeated deployment considerably more organized.

The most effective approach is to design each signal path around three factors:

SIGNAL FORMAT + DISTANCE + INSTALLATION

BUILDING OR UPGRADING A MOBILE PRODUCTION SYSTEM?

AV-Cables manufactures professional SDI cable assemblies for mobile production, broadcast, live events, studios, fly packs and professional AV systems.

Available configurations include 12G-SDI and 6G-SDI assemblies, BNC, HD-BNC, DIN 1.0/2.3, Mini RG59, RG59, RG6 and custom multi-channel cable assemblies.

AV-Cables assemblies are hand assembled in the USA and individually tested before shipment.

AV-Cables — Professional • Reliable • Connected