Otis Singleton
Repairing an electrical cord on an iron can be a tricky task. While some recommend replacing the entire cord, others suggest repairing the damaged section. If you're confident in your ability to repair the cord, it's important to take the necessary precautions, such as deactivating power to the room or circuit and using a fire-safe workbench to protect against burns. There are various methods for repairing the cord, including soldering, twisting the wires together, and using cable connectors or zip ties for a secure connection. However, it's crucial to prioritize safety, as improper repairs can lead to fire hazards or electrical shocks. If you're unsure about the process, it may be best to seek professional help or consider purchasing a new iron.
How to repair an electrical cord on an iron:
| Characteristics | Values |
|---|---|
| When to repair | When the retractable cord is pulled out too far |
| When to replace | When the cord is cut, or when the wires are exposed |
| Tools | Soldering iron, replacement cord, zip ties, wire strippers, razor blade, electrical tape, hair dryer, heat gun, lighter |
| Safety precautions | Deactivate power to the room or circuit, ventilate the workspace, use a fire-safe table or workbench, keep soldering iron in a safe spot |
| Soldering technique | Twist wires together, coat with solder, hold soldering iron at a 45-degree angle, gently melt solder, move iron and solder wire back and forth |
| Testing | Plug into electrical outlet, look for hissing sounds, smoke, or other problems |
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What You'll Learn
Soldering wires together
Soldering is a great way to repair valuable cords when you don't want to buy a new plug or can't find a suitable replacement. It works for all types of cords, but it's often best for single-wire cords with a permanently attached plug. Before you begin, make sure you have a ventilated workspace that is heat-resistant. Choose a spot with a ventilation fan or some windows you can open to let out any smoke from the soldering iron.
To begin the soldering process, strip the wires and wrap them around each other to start the connection. Freshly stripped multi-filament wires need some attention before they will take well to being soldered. First, the filaments of each wire should be twisted together, or pigtailed, to keep them orderly and behave more like a single entity. You can also separate the individual strands and push the wires together so the strands intermesh. Then, twist the strands together to make a solid connection.
Next, melt the solder directly onto the wires to secure them in place. Hold the tip of the solder wire at a 45-degree angle above the exposed wires. Then, raise the heated soldering iron to the wire, holding it at an opposite 45-degree angle. Gently melt the soldering material so it drips onto the exposed wires. Keep moving the solder wire and soldering iron back and forth until the exposed wires are coated in the solder.
Finally, cover and waterproof the exposed wires to seal them. Leave the repair undisturbed so the solder sets properly. If the solder doesn’t have time to cool, it will be too brittle and the wires may come apart. Once the repair has cooled, test the cord by plugging it into an electrical outlet.
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Using a replacement cord
If your iron's electrical cord is damaged, it is recommended to replace the entire cord rather than attempting to repair it. This is because irons can pull a lot of current, and a subpar repair may not be able to handle the current, creating a fire hazard.
You can purchase a replacement cord from a hardware store or an appliance parts shop. Before purchasing, make sure to check the gauge and length of the cord to ensure it is suitable for your iron.
Once you have the replacement cord, follow these steps:
- Unplug the iron and ensure it is turned off and disconnected from the power source.
- If your iron has a screw block terminal, use a screwdriver to unscrew and remove the old cord.
- Inspect the new cord for any labels or instructions. Cord caps have different slots and screws to hold the wires in place, so make sure you match the wires correctly. Typically, the black power wire connects to the orange brass screw, the white neutral wire to the silver screw, and the green ground wire to the green screw. However, wire colours may vary, so check your specific cord.
- Connect the new cord according to the instructions provided with the replacement cord or the iron's manual.
- Once the new cord is connected, carefully inspect the connection to ensure no wires are exposed.
- Plug in the iron and test it to ensure it is functioning properly.
If you are not confident in your ability to replace the cord, it is recommended to seek assistance from a professional or an experienced individual to ensure the repair is done safely and correctly.
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Using electrical tape
Repairing an electrical cord on an iron can be dangerous, and it is recommended to replace the whole cord or get a new iron. However, electrical tape can be used to repair superficial damage to the outer jacket of the cord. Electrical tape is a type of black vinyl that resists electricity, so it can safely wrap up cords as long as there are no exposed metal wires. If there is frayed metal, the cord will likely need to be cut and repaired in a different way.
To repair superficial damage with electrical tape, start by cutting the cord on both sides of the damaged portion using pliers. End-cutting pliers and lineman's pliers are good options for cutting cleanly through electrical cords. Position the pliers past the damaged portion and cut through all the insulation and wiring in one attempt. Then, do the same on the opposite side to completely remove the damaged portion.
Once the damaged portion has been removed, take the edge of the electrical tape and place it over the broken casing. Wrap the tape around the cord a few times to seal the damage. Make sure the tape is well-sealed, and then treat other damaged portions in the same way.
It is important to note that applying electrical tape that is too thick or using too much of it could change the cord's original flexibility and lead to internal damage. Therefore, it is recommended to use suitable electrical tape and apply it properly. Additionally, the depth of any abrasions and cuts cannot be monitored to see if they get worse without removing the tape.
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Using cable connectors
Repairing an electrical cord on an iron can be done using cable connectors. Here is a step-by-step guide on how to do it:
Firstly, ensure you have all the necessary tools. You will need a lead solder, a soldering iron, a wire cutter, and a wire stripper. You should also have a replacement plug with the same rating as the original, and a PVC shrink tube.
Next, cut off the damaged part of the electrical cord. Use the wire cutter to cut away the damaged portion, leaving yourself enough length to work with. Once cut, strip the wires using the wire stripper, exposing the internal wires. Be careful to only cut away the black insulated sheath and not the inner wires.
Now you need to join the wires. Strip the insulation from the ends of the inner wires, ensuring you only expose about half an inch of wire. Twist the copper strands together, matching the colours (black with black, blue with blue, etc.). You can then cover these joints with electrical tape, but for a more secure connection, you should solder the wires together. Heat your soldering iron and touch the tip to the wire until it reaches melting temperature. Apply the lead solder to join the wires firmly.
Once the wires are soldered, slip the PVC shrink tube over the repaired area. Heat the PVC tube gently with a hair dryer or heat gun, moving it back and forth until it shrinks and fits tightly over the soldered joint. If you don't have access to a hair dryer or heat gun, a lighter can be used, but be very careful to avoid burning the tube.
Finally, test your repair by plugging the iron into an electrical outlet. Ensure the outlet is functioning properly, as outlets can wear out over time. If your iron works, you have successfully repaired the electrical cord using cable connectors.
This method provides a safe and secure way to repair an electrical cord on an iron, but always exercise caution when working with electrical appliances.
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Repairing retractable cords
Once the iron is unplugged, visually inspect the cord for any visible damage, such as frayed wires or kinks. Gently pull the cord out completely and allow it to retract, observing any potential jams or resistance. If the cord does not retract smoothly, the retractor mechanism may be the cause of the problem. Lubrication can be effective in addressing a jammed retractor mechanism. It is recommended to use silicone lubricant or sewing machine oil for this purpose.
In some cases, the issue may lie in a worn-out or damaged locking mechanism, insufficient tension in the cord, or debris obstructing the locking mechanism. To address these issues, it may be necessary to open the casing of the iron using a screwdriver to access the cord mechanism. Needle-nose pliers can be useful for handling and untangling cord snags. It is also important to clean the cord and its components with a lint-free cloth and to ensure that the locking mechanism is free of any debris.
If lubrication and basic troubleshooting do not resolve the issue, it may indicate a more complex problem that requires professional repair or replacement of the cord or iron. It is important to consider the cost of repair versus the cost of a new iron, as replacing the entire cord or seeking professional repair services can be expensive.
Additionally, it is worth noting that some retractable cords may not have accessible screws to open the reel, making it challenging to access the internal components for repair. In such cases, it may be more feasible to purchase a new iron, especially if the repair cost exceeds the price of a new one.
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Frequently asked questions
It is generally not recommended to repair an electrical cord on an iron due to the high risk of fire. It is safer and often more cost-effective to replace the entire cord or buy a new iron.
Before beginning any repair work, ensure that the power to the room or circuit is deactivated. Use a fire-safe workbench or a stainless steel/ceramic surface to protect against burns from solder and the soldering iron. Keep the area well-ventilated to dissipate smoke from the soldering process.
First, strip the insulation to expose the inner wires. Twist the wires together and secure them with electrical tape or solder for a more permanent connection. Apply heat-shrink tubing or PVC tubing over the repaired area to provide insulation and protection. Allow the solder to cool completely before testing the cord.
If you are uncomfortable repairing the cord yourself, you can contact a professional repair service or consider purchasing a new iron. Some irons with retractable cords may require special tools or access to repair parts, making it more challenging to fix yourself.
The Bergen Industries Inc PS613163 3-Wire Appliance and Power Tool Cord is a durable and versatile option suitable for indoor and outdoor use. The GE Home Electrical Power Gear 8 Ft Lamp Cord is another reliable choice, offering high-quality construction and an extra-long length for various DIY projects.
