I've got you beat. I'm also an audio production company and until recently, I was running DMX down my 56-channel audio whip, which is a 200-foot cable terminated with MASS connectors. Break out of that into my stage box, then run up to another 200-feet of XLR microphone cabling to various dimmer packs and other DMX fixtures, but of course, I did the good thing and terminated it with a DMX terminator.
DMX cabling is intended for usage for 110-120 ohms, which is a recommended loading for DATA applications. It has to do with the impedence of the wiring. XLR cabling is designed more for 600-100 ohms. I will guarantee you that you'll hear a difference if you put a mic on a DMX cable, in the concept of "squashy" and "rolled off" especially in the highs. It ain't pretty. Just the fact that both DMX and XLR are shielded twisted pair doesn't make it 100 interchangable.
DMX and XLR cabling both use twisted pair. But what else uses twisted pair? Why, Cat 3, 5, 5e, 6, 6e and other brands of telco cabling, with the exception of most flat 2 and 4 wire modulate telephone cables.
Heck, if you want, you CAN run ethernet over barbed wire. Not that I'd recommend that, but if you can do that(and I HAVE done that, as a test), why not do the same with yor mics and lighting? I mean, look at the time you'd save telling people to stop screwing with your cabling?
You bring up a poin taht I've been trying to make. We have too many cabling standards. This in and of itself is not a bad thing. I mean, look at what we can do with XLR. I've got a 2-pin XLR cable that is some sort of power cable. I have 4-pin XLR cables that I use for power for many of my video devices. I of course mainly use 3-pin for microphones. This is where things get all wierd. From what I hear, DMX was originally using a 5 pin connector, which was silly because DMX only uses TX- and TX- with a shield, so it only needs three wires/pins to operate, which is why DMX is moving to 3-wire cabling: to save money. This is also why 3 to 5 wire DMX converters aren't really that big of a deal, all the money is tied into the connectors anyways.
Let's take a deeper look.
Yes, what you're doing works. Why change? Well, if you're a sound production company, isn't reliability a concern?
Is the color of the cable a concern? Oh please. What, if it's black is all equal? No. there are HUGE differences in audio cabling and it tends to mostly be black too. And yes, I CAN hear it, but it becomes an issue mainly in A-B comparisons. But DMX cabling will say it's for data applications or DMX, where as most microphone cable will say it is for microphones. It says so right on the black outer jacket. It has to, mainly so people don't get confused, especially when they are in a pile of cables and are making cables.
The signal in DMX is streaming, so it has some tolerance in the protocol. It also runs HOTTER than audio, which is also why the impedence is significantly lower. It's a matter of signal optimization. You want to load that cable properly.
Just this year I've converted over to AccuCable for my lighting, and my lighting isn't anything amazing. I've made a 200-foot primary cable, and then 3 25-footers and 6 3-footers. Well, whatever they are, it ate up a 300-foot spool of Accucable. What I've noticed is that things appear ot work faster, be more reliable and more responsive, especially when using MyDMX and my DMX Operator. And yes, that's not a whole lot of DMX cabling. At my last show, I had to integrate some mic cable into my DMX cabling to make it all work. This is an ongoing issue that I am working on and will continue to address for a bit.
Are you going to damage anything by using XLR cabling? No. Well, maybe but if that happens, it's going to be part of a larger catastrophic issue anyways and not due to "operator error or negligence". Worse case is that your stuff won't work as well.
Any production company that I know uses the proper cabling for the job. Or, at least any respectable one. In my sound production company, lighting has become a bigger and bigger issue. It now makes sense to move to the proper cabling. Talking to about 50 lighting companies in the past 4 years, ALL of them are using DMX cabling for their DMX cables, not one of them uses microphone cables. But I guess when you spend a few million bucks on gear, you can afford to spend some money on proper cablng, right? In the end, DMX cabling isn't that much more expensive than mic cabling.
As far as a DMX terminator, this is a data signal. Since we're dealing with an async signal with no clearly defined end, we need a terminator to prevent signal reflection and bring the signal chain to an end. Remember SCSI terminators?
You can make your own DMX terminator by using a male XLR and a 120-ohm 1/4-watt 5% resistor. Should cost you a couple of bucks for 100 resistors and maybe $4 for an XLR connector. I have made 3 of them. Solder the resistor between pins 2 and 3, polarity doesn't matter.
I'm not here to sell you anything. I'm not here to say "Hey, Accucable is your only option". What I am saying is that I've been pleased since moving my DMX off my audio snake and onto dedicated DMX cabling.
Step up to DMX cables. You'll be glad to you did. Worse case is in a pinch you can grab XLR's as needed.
I beleive I have ordered another 300-feet of pre-made Accucable. It is an ADJ product and it appears to be rather rugged and durable.
As far as your state of shock, your manuals all say to use DMX cabling. DMX fixtures, controllers, software, they all say to use DMX cabling. Where is the shock coming from?
Now, go get some DMX cable, build yourself a few DMX terminators. Do it right, your business deserves it, and so do your paying customers.