DIY USB 2.0 Type A Male to Female cable extension for Charging and Data 2~3A

[Kiriakos GR]

I have a project ahead,  I have a USB 2.0 to TTL converter, this is used for communication with a electronic circuit this using an Micro controller.

Minimum micro controller requirements for DC current this is 64mA.
Maximum micro controller requirements for DC current this is 270mA.

USB 2.0 to TTL converter, this has requirements for DC current at 16~20mA

USB 2.0 to TTL converter, this accepts power due USB 2.0 Type A  Male to Female cable extension.
Power output at 5V,  this is delivered due standard USB 2.0 port over a PC system  / Motherboard.

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My new challenge, this is of how to make my own USB 2.0 Type A cable extension.
This having the minimum possible of 1% voltage drop specification under load.

According to electrical education, we are looking for best results, and minimum wires resistance according to Ohms law.
Exact and accurate Ohms law calculation this is not that helpful in this application.

Such a project this requires special hardware parts :
As first we need USB 2.0 Type A connectors, them designed to handle 2A continues, and these maxing out at 3A.
Such high power USB connectors they have also a different specification regarding matting force.
For example a regular USB 2.0 Type A connector, this is designed for Data and 1A Max.

The second special hardware part this is the ideal cable which this support Charging and Data 2~3A
Another of high importance priority, this is keeping low entire project costs.

While the reason that we go DIY, this is because we do not trust the specification of generic products, which are everywhere available.

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With allot of hunting of my own,  I did discover that at the communist Ali Express, they are widely available these USB 2.0  A type powerful connectors (2~3A).
The source of these connectors, the factory,  this named as USBR ( Shenzhen USBR Precision Hardware Electronics Co., Ltd. ).
https://www.typeconnector.com/Products/1.html


And regarding the cable, NEDIS a European distributor of Chinese products,  they have a product since 2018,  this is a 5m long USB 2.0 Type A to Mini USB, assembled cable.
Product code this is CCGL60300BK50, they are four types of assembled cables with the same code.
This 5m cable it is made by two pairs,  28 AWG for Data, and 20 AWG for power.   
20 AWG this is almost three times more powerful than 24 AWG.

https://nedis.com/en-us/product/cables-and-adapters/computer-and-network/usb-cables/550784956/usb-cable-usb-20-usb-a-male-usb-mini-b-5-pin-male-480-mbps-nickel-plated-500-m-round-pvc-black-label 
 
CCGL60300BK50 products packaging its so poorly documented, and 98% of the marketplace this is also unaware of actual electrical specifications.
NEDIS did also another mistake, and there is no specification markings over the cable.

I did succeed finding (so to buy) stock of this cable, at my own town, at a small computer parts store,  retail price 4,94 € with VAT.   

( Alternatively CCGL60300BK30  3m , this is made of  28/22 AWG)
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This project starts for me at a minimum cost of  €2,86 EUR to AliExpress with VAT. 10 Pairs of USB connectors
plus
€4,94  with VAT. for the cable.
SUM of €7,8

My planning is the assembly of three DIY cable extensions (for now).
And with the spare seven pairs of connectors, I will deal with any future needs.

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Next to follow, will be confirmation by actual electrical measurements.

At first, I did use two unbranded 28/24AWG cables, 2m long its one.
My electrical measurements they show weird numbers.
Manufacturer A, this cable cut to length at 1m, this shown Identical results with Manufacturer B cable this be at twice the length at 2m.
At another test, a third 28/24AWG from Manufacturer C, this found to have non-copper shield this not accepting soldering.

With so many fake communication cables, and cheating at inner product assembly,  my trust this is permanently broken to advertised specifications.
I hope for NEDIS, this to be here an exception, they did the opposite,  they did poor advertising of their own product this having decent specifications on paper. 

[Andrew-88]

New electrical adventure ahead   

At 2005 ~ 2015, lots of unbranded imports of communication cables they found their path at the Greek market.

From the other hand, all product of NEDIS they come under CE certificates, these be signed at European soil.
Your chances of getting the best results, they appear increased so far.

[Kiriakos GR]

At this unboxing presentation, you will see weird photographs.

My cable received within a nylon bag, Nedis packaging, and I moved all labels over a carton box, for safe storage. 

The actual cable, this had a serial number bracelet, which I carefully removed and save it as souvenir.
According information received by Nedis (few weeks ago), the expansion of first row of numbers this corresponds to production date.
01-01-2021

I did also confirm, that actual cable does not have printed specifications markings, as you can see due my photographs, we have Nedis marketing information alone.
OD diameter this fluctuates from 4.50mm up to 4.80mm .. 

Over the nylon bag label, there is the text: Made in China ©2008 specifications are subject to change....
This is actually a declaration, that cable specifications they have be customized according to importer request at the factory.
   
Nedis never changed since 2018 this custom product design, while technical documentation this were renewed at 2023, and this update was about document appearance.

Now feel free to enjoy my collection of photographs and or pack of souvenir.
I am not going to use entire cable length at once, my DIY storage solution will assist several purposes.

 

[Kiriakos GR]

Gentlemen and Kids.
The treasure its not 100% fake. 

We have tinned copper at the wires / pairs.
20 AWG insulation diameter 1.26 mm
Total strands diameter 0.88 mm
Copper strands: 7 x 0.29 mm 


28AWG insulation diameter  0.78 mm
Total strands diameter 0.23 mm
Copper strands 7 x 0.12 mm

Cable braid Aluminum or other = Does not accept solder. 
But I can fight back this poor choice, by adding a crimping ferrules on top.
Then it can be soldered at a USB connector.

Westerns always remember There is not a chance, a Chinese to not cheat somewhere at the manufacturing stage.

First conclusion, the cable it does meet named specifications.
Build quality this is average,  cable braid its light-weight and probably aluminum, this is a bad recipe regarding rolling it at small diameter, and or stretching it.
Nedis cables for Smartphone charging does not have the best reputation, they are negative reviews in Greece, they fail under extended periods of rolling and stretching.

CCGL60300BK50 Wires insulation this is very sensitive to soldering iron temperature.

[overvolt]

I do understand the problem, bulk cable comes in spools of 100m as minimum.
There is one type available at international distributors CSUSB-100 ( 28/20AWG).

Nedis?  This is another one of the many, Chinese super market. 
I am glad, that you did succeed  to make something useful, by using this low end cable.
Its obvious, Nedis tinned copper is not easy to be soldered either, you did your best at soldering, its not your fault.

When you will receive these USB 2.0 connectors, check the female one, of how strong it is the matting force, and let us know.   

[Kiriakos GR]

I did run allot of tests, and for many hours,  and this cable it is truly a disappointment.

I also have one cable 28/24 AWG this outperforms the Nedis cable by 100mV higher voltage output, under 230mA load.
Both cables are cut to length of 1.6m.

I can not measure the damned benefit by using  this Chinese 20 AWG.

I got triggered to find the roots of the better performing cable, and this is made in Taiwan.
Copartner Tech Corp.
https://www.copartner.com.tw/en/product/copperwire

About the poorly performing Nedis cable, this has be made by recycled copper of poor conductivity.
There is no other explanation.

My new USB connectors, they expected to arrive in three weeks time.
I am not going to delete the references about the Nedis cable, I will leave them as Customer Beware Note.