Same DUT, Different Measurements with Different Hookup Wires

[brandock]

Hoping someone can explain this to me.

I created a breakout for my CurrentRanger (attached) with a USB micro female receptacle on one side, and USB A female on the other. GND is connected to GND. VIN and VOUT are not connected to each other. Instead they are broken out by plated holes where I can connect my CurrentRanger to the source and the load. (I went for a little fun and tried to make the breakout actually look like it is being broken.)

OSHPark sent me three copies, as they do.

To copy 1 I soldered IC test clips and attached the LPL Shop banana plugs. https://lowpowerlab.com/shop/product/183

To copy 2 I soldered female headers and attached Dupont male-male connectors, with the other ends clipping into the green thumb terminals.

I measured the current used by one of my projects. With setup 1 (banana plugs) I was reading (if memory serves) 50-60 mA. With setup 2 (Dupont wire) I was reading (if memory serves) about 32 mA.

Question: is this a known thing that the hookup to the DUT can make such a difference in the readings? Or is something else going on that I should look into in my setup?

[Felix]

You're probably seeing the effects of voltage drop over weaker wiring and more loose connections that act as higher resistance.
So then by the time the CR sees this voltage has already dropped a bit over all those interconnects.

[spairo]

- This is my usb to usb board design.
- I will test the connections after assembly