Otis Singleton
Electrical cord plugs may wear out or become damaged over time, and changing them is a quick fix that can be done at home. This is a useful skill to have, as it can extend the life of appliances and save you money. The process is relatively simple and can be done with a few tools, but it's important to be cautious when working with electricity. The steps include examining the cord, cutting the wire, stripping the insulation, attaching the wires to the new plug, and securing the connection. It's important to match the plug style and voltage rating to the cord and ensure that the wires are connected correctly to avoid electrical hazards.
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What You'll Learn
Safety precautions
Before attempting to change an electrical cord plug, it is important to take the necessary safety precautions to ensure you do not harm yourself or damage the appliance. Here are some detailed safety guidelines to follow:
- Unplug the Device: Always unplug the device from the power source before attempting any repairs or replacements. If the plug is damaged and still plugged in, turn off the power at the breaker before unplugging it. This is crucial to prevent any electrical shocks or short circuits.
- Wear Protective Gear: When working with electrical components, it is important to wear protective gear to safeguard against potential hazards. Wear thick gloves to protect your hands from sharp edges and to prevent any direct contact with electrical components. Additionally, consider eye protection to shield your eyes from any debris or sparks.
- Use Appropriate Tools: Only use tools specifically designed for electrical work, such as wire cutters, wire strippers, and screwdrivers. Avoid using scissors or any other non-specialized tools for cutting wires, as they may damage the cord or provide an uneven cut. A clean and precise cut is essential to ensure a safe and secure connection.
- Work on a Flat Surface: Always work on a flat and stable surface to minimize the risk of accidents. Place the cord or appliance on a flat workbench or table to ensure it remains steady while you work. This helps prevent slips or mishandling that could lead to injury or further damage to the appliance.
- Identify the Correct Plug Type: Different appliances use different types of plugs, such as polarized or non-polarized plugs. Identify the correct plug type for your appliance by examining the prongs and electrical information printed on the plug. Ensure you purchase the same style of plug for replacement to maintain compatibility and safety.
- Inspect the Cord: Before making any changes, carefully inspect the cord for any damage or wear and tear. If there is significant damage close to the plug, it may be advisable to replace the entire cord rather than just the plug. A damaged cord can pose a fire hazard, especially in the case of older cloth-covered wires where insulation may have deteriorated.
- Disconnect with Caution: When disconnecting the old plug, proceed with caution. Remove any screws holding the plug together and carefully separate the wires. Ensure you know which wires are which (live, neutral, earth) and take note of their orientation to facilitate correct reassembly. If the cord is connected to screws inside the plug, unscrew them carefully to release the cord.
- Be Mindful of Insulation: When stripping away insulation from the wires, be mindful of how much you remove. Do not cut back too far, as the inner wires should not be exposed when you install the new plug. If you cut too much, trim the wires accordingly. Proper insulation is crucial for safety and to prevent short circuits.
- Secure Connections: When attaching the wires to the new plug, ensure secure connections. Form the ends of the wires into U-shapes or hooks, and then attach them to the corresponding terminals in the plug. Tighten the connections by winding the wire ends clockwise around the screws and then fully tightening the screws. This ensures the wires remain securely in place.
- Test in a Controlled Manner: After reassembling the plug and appliance, test the connection in a controlled manner. Plug the appliance back into a power outlet, but before turning on the power, double-check that all connections are secure and that there are no exposed wires. Then, turn on the power to test if the appliance is functioning properly.
By following these safety precautions, you can help ensure that you replace an electrical cord plug safely and effectively.
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Assessing damage
Before attempting to repair or replace an electrical cord plug, it is crucial to thoroughly assess the damage to ensure your safety and the effectiveness of the repair. Here are some detailed steps to guide you through the assessment process:
Unplug the Device: Always start by unplugging the device from the power outlet. If the plug is still connected to a power source, turn off the power at the breaker before proceeding. This is an essential safety precaution to avoid any risk of electrical shock.
Inspect the Cord: Carefully examine the entire length of the cord for any visible signs of damage. Look for fraying wire insulation, burn marks, cracks, discolouration, melting, or other physical deformities. Even minor fraying or cracks can indicate potential issues. Remember, some damage might not be immediately visible, so feel along the cord with your fingers to detect any irregularities that could suggest internal damage. A soft, sticky, or bumpy texture can indicate degradation or internal cord issues.
Check the Plug: Assess the plug for any signs of damage. Bent, damaged, or loose prongs are a safety concern and may need to be replaced. Check if the ground prong is visible and undamaged. Ensure that the prongs match the slots on the outlet to prevent electrical arcing. If the plug is polarised, it will have two prongs of different widths, guaranteeing correct insertion and enhancing safety.
Identify Exposed Wires: Exposed wires are a significant hazard and must be addressed promptly. They can lead to electrical shock or short circuits. If you spot any exposed wires, carefully cut away the damaged sections using the appropriate tools, such as wire cutters or insulated pliers.
Assess Cord Integrity: Evaluate the overall integrity of the wire insulation to guarantee electrical safety. Modern cords are coated with PVC, which provides excellent insulation and abrasion resistance. However, this insulation can be compromised by vacuum cleaners, being walked over, or excessive use. If the insulation is damaged, it can lead to live wires being exposed, increasing the risk of electrical shock or electrocution.
Remember, if you are unsure about the damage or how to proceed with repairs, it is always best to consult a professional electrician. They can provide expert advice and ensure that your electrical cord and plug are safe to use.
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Choosing a replacement plug
When choosing a replacement plug, there are a few things to keep in mind. Firstly, it is important to buy the same style of plug that you are replacing. Check that the replacement plug will accommodate the shape of your cord, as some cords are round while others are flat. Make sure the plug matches the voltage rating and amperage of the wire. The number should be printed on both the old and new plugs, so just ensure they match. Do not replace a three-prong plug with a two-prong plug or vice versa.
If you are replacing the plug for a high-frequency device, such as a facial device, a simple new plug connector should suffice. For other appliances, you can opt for an Eaton or Hubbell 5-15 cap as a replacement plug. If your generator has an L5-20 receptacle, a cap for that would be a suitable replacement.
If you are unsure about the specific replacement plug you need, it is always best to seek advice from a professional electrician or a hardware store specialist. They can guide you in choosing the right plug for your specific appliance and ensure that you have the correct tools and knowledge to perform the replacement safely.
Additionally, when dealing with vintage appliances, it is important to exercise caution. Antiques and vintage appliances often have fabric-covered power cords, and it may be advisable to replace the entire cord instead of just the plug. The insulation in old cloth wiring can deteriorate over time, increasing the risk of a fire hazard. Asbestos was also used as an insulator in appliances made prior to the 1980s, so cutting into a cloth cord to remove the plug can release asbestos fibres into the air. In such cases, it is recommended to consult a professional for safe replacement.
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Stripping and cutting wires
First, examine the cord closely to assess the damage. If the cord itself is frayed or has exposed wiring, you may need to replace the entire cord. If the damage is limited to the plug or is close to it, you may only need to replace the plug and cut the cord at the damaged spot.
Now, let's get into the wire stripping and cutting process:
- Cutting the Wire Below the Plug: Using a wire cutter, cut the wire about 1/4 inch (0.64 cm) below the base of the old plug. This step is necessary to detach the old plug. Ensure you use the right tool for a clean cut and avoid damaging the cord.
- Removing the Old Plug: If your cord has a removable plug, you can remove the screws holding the plug together and open it up. You may also need to unscrew any connections inside the plug to free the cord.
- Stripping the Wire Jacket: Use a wire stripper to expose the inner wires. Wrap the wire stripper around the cord about 3/4 inch (1.9 cm) from the end and squeeze and rotate it to cut through the outer housing. Then, slide off the jacket to reveal the wires underneath. Be careful not to cut too far back, as you don't want the inner wires exposed when installing the new plug. If you don't have a wire stripper, you can carefully use a utility knife or razor blade instead.
- Exposing and Preparing the Inner Wires: Depending on your cord type, you will have two or three inner wires. These wires have different colour jackets that indicate their function: green for the ground wire, white for the neutral wire, and black for the hot wire. Strip off about 1/2 to 3/4 inch of insulation from each inner wire, being careful not to cut any strands. Then, bend the copper portion of each wire into a U-shape or a hook. This hook shape will make attaching the wires to the new plug easier and more secure.
- Attaching the Wires to the New Plug: Loosen the terminal screws inside the new plug to make room for the wires. Tuck each wire into the corresponding terminal: the green wire into the green screw (ground), the white wire into the silver screw (neutral), and the black wire into the brass screw (hot). Ensure that the wires are securely attached by wrapping the wire ends around the screws in a clockwise direction and then tightening the screws.
Remember to always prioritise safety when working with electrical components. Ensure your appliance is unplugged, and if you're dealing with vintage appliances or cloth-covered cords, be cautious of potential hazards like asbestos.
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Attaching the new plug
Next, cut the wire just below the base of the plug, using a wire cutter. Take care not to use scissors or any other tool that is not designed for cutting wires, as you need to get a clean cut to avoid damaging the cord. Once the old plug is removed, strip off about 1-1/2 inches of the outer covering using wire strippers. Be careful not to cut the wire while removing the outer covering. Cut away the interior cloth insulation, leaving only the black and white wires exposed. If your cord has a yellow insert, push it out of the centre of the plug by inserting a screwdriver through the cord end and pushing up.
Now, it's time to prepare the wires for attachment to the new plug. Bend the copper portion of each wire into a U-shape or a hook, as this will make attaching them to the new plug easier and more secure. Strip off about 3/4 inch of insulation from each wire, being careful not to cut too far back. The wires shouldn't be visible when you install the new plug, so if you cut too far, trim the ends of the wires accordingly.
Finally, attach the wires to the new plug. The black wire should be attached to the brass blade or screw, while the white wire should go to the silver blade or screw. Loosen each screw enough to wrap the hooked wire end around it, then wind the free end of the wire clockwise around the screw and tighten it. Ensure that the wires are securely attached and that they correspond to the correct terminals. The green screw is for the ground wire, the silver screw is for the neutral wire, and the brass screw is for the hot wire.
With these steps, you can safely attach a new plug to your electrical cord.
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Frequently asked questions
Always unplug the appliance from the electrical socket before attempting to replace the plug. If you have a vintage appliance with a fabric-covered power cord, it is best to replace the whole cord instead of just the plug as old cloth wiring can deteriorate over time and become a fire hazard.
You will need a wire cutter, wire stripper, utility knife or razor blade, and a screwdriver. You should also wear gloves and work on a flat surface.
You should buy the same style of plug that you are replacing, ensuring that it can accommodate the shape of your cord (some cords are round, some are flat). You should also check that the plug matches the voltage rating and amperage of the wire.
