Molly Ayala
Electrical cords wear out over time and can be damaged by pets, family members, or accidents. Replacing them can be expensive, but it is possible to fix them yourself for a fraction of the price. However, it is important to exercise caution when repairing electrical cords, as incorrect repairs can introduce an electrical hazard with the risk of fire, electrocution, or even death. This introduction will cover the steps to replace a damaged electrical cord safely and successfully.
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What You'll Learn
Identify the type of plug and cord
Before you replace a bad electric cord, it is important to identify the type of plug and cord you are dealing with. There are several different types of electrical outlets and plugs used worldwide. In the United States, for example, the standard voltage is 110-120V, and there are three major types of replacement plugs: self-connecting, terminal screw, and three-prong.
The first step is to determine the number of prongs on the plug. The most common types are two-prong and three-prong plugs. Polarized plugs, which have one wider prong, are safer than non-polarized plugs because they prevent reversed polarity and an open circuit. If you are dealing with an antique or vintage appliance, it is likely to have a fabric-covered power cord, and it is recommended to replace the entire cord rather than just the plug due to the risk of asbestos exposure.
Another important consideration is the voltage and amperage of the cord and plug. The ratings should be printed on the plugs, and it is important to ensure that the new plug matches these specifications. For example, do not replace a three-prong plug with a two-prong plug or vice versa. If you are replacing a polarized plug, make sure that the new plug is also polarized.
Additionally, different types of cords and plugs may have varying wire colours. The standard colours are black for the power wire, white for the neutral wire, and green for the ground wire. However, in some regions, such as Europe, the power wire may be brown or black, the neutral wire may be blue, and the ground wire may be yellow or green.
Finally, when identifying the type of plug and cord, consider the overall condition of the cord. If the cord is frayed or has exposed wiring, it is recommended to replace the entire cord rather than just the plug to ensure safety and avoid the risk of electrical shock.
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Unplug the device and cut off the damaged area
Before you begin any work on the electric cord, it is important to unplug the device. If the plug is damaged and still plugged into an outlet, turn off the power at the breaker before unplugging. This is a crucial safety step.
Once the device is safely unplugged, you can begin to assess the damage to the cord. If the cord is frayed or has exposed wiring, it is best to replace the entire electrical cord. If the damage is confined to a small area, you can simply cut off the affected section of the cord. Use electrical scissors, wire cutters, or sharp shears to cleanly cut the cord, removing the damaged portion. Ensure you cut off enough of the cord so that the remaining section is smooth and undamaged.
If the damage is close to the plug, you may need to cut off the plug itself. If you are dealing with a polarized plug, be sure to mark the side with the wider prong with tape before cutting. After cutting off the damaged area, you will be left with a slightly shorter cord, but this is necessary to ensure safety.
At this stage, you have successfully unplugged the device and cut off the damaged area of the cord. Now, you can proceed to the next steps of repairing or replacing the cord and plug.
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Strip the wires and match the colours
Stripping wires is a crucial step in repairing or replacing an electrical cord. It involves removing the insulation from the wires to expose the conductive copper strands. This process is typically done using wire strippers, which offer more precision than a utility knife or razor blade.
To begin stripping, measure about 3/4 inch (1.9 cm) from the cut end of each wire. Use wire strippers to break through the casing, then slide off the cut insulation to reveal the copper wires. These wires will be slightly smaller in diameter than the cord itself. If you are working with stranded wires, twist these strands together before proceeding.
Now, it's time to match the colours of the wires. The wires inside an electrical cord typically consist of a black or red "hot" wire, a white or grey "neutral" wire, and a green, green with yellow stripes, or bare "ground" wire. The colour coding may vary depending on your location; for example, in Europe, the "hot" wire is often brown or black, while the "neutral" wire is blue.
When splicing the wires together, ensure that the colours match. For instance, connect the black wire with the black wire and the blue wire with the blue wire. Twist the copper strands together for a secure connection. You can then cover the spliced area with electrical tape or heat shrink tubing to insulate and protect the connection.
Additionally, if you're working with a plug, you'll need to connect the wires to the correct terminals. The "hot" wire typically connects to the brass-coloured screw, the "neutral" wire to the silver-coloured screw, and the "ground" wire to the green screw. However, the screw colours may vary, so always refer to the plug's labels or markings.
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Splice the wires together
Before splicing the wires together, ensure that you have cut off the damaged portion of the cord. If the damage is close to the plug, you may be able to salvage the wire by cutting the cord at the damaged spot.
To splice the wires together, first, strip about 1.9 cm of the black sheathing to expose the two inner wires with their colour-coded insulation. Then, cut away the wires' insulation by about 1.25-1.9 cm from both ends. You should see a blue wire and a black wire. Cut one of the inner wires about 1.25 cm shorter than the other. Next, strip 1.25 cm from both wires. Now, on the other end, cut 1.25 cm off the opposite wire. For example, if you cut 1.25 cm off the red wire on the first end, cut 1.25 cm off the white wire on the second end. Bend each wire into a U shape and hook the mating wires together. Twist the wires together tightly, being careful not to leave any ends sticking out that could puncture the insulation. Make sure the wire colours match or that you match the ridge side with the smooth side.
After splicing, cover the repaired area with a PVC shrink tube and shrink it with a heat gun. You can also use electrical tape, but this is not recommended as the only method of insulation.
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Fit a new plug
Before you begin, ensure that the plug and cord match in terms of voltage rating and amperage, and the number of prongs. Do not replace a three-prong plug with a two-prong plug or vice versa.
If the cord is frayed or has exposed wiring, it is best to replace the entire electrical cord. If the damage is close to the plug, you may only need to cut the cord at the damaged spot and replace the plug.
If you are only replacing the plug, start by unplugging the device. If the plug is damaged but still plugged in, turn off the power at the breaker before unplugging. Then, using electrical scissors, wire cutters, or sharp shears, cut the plug off the end of the power cord. If there is damage to the cord close to the plug, trim those parts off, too. The cord should be smooth and undamaged until the end.
Next, open the new plug housing. You will likely need a Phillips-head or flat-head screwdriver for this. Unscrew the plug cover or plug jacket and set the screws aside. Depending on the replacement plug, the screws will be near the prongs or on the side of the plastic plug cover.
Finally, insert the cord into the new plug housing. Ensure that the wires are connected to the correct spots. The cord cap should have labels showing where each wire fits, such as "black" and "white", which correspond to the wires inside the electrical cord. If the cap doesn't have labels, the black power wire connects to the orange brass screw, the white neutral wire connects to the silver screw, and the green ground wire connects to the green screw.
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Frequently asked questions
Before replacing an electric cord, it is important to unplug the device and turn off the power at the breaker.
If the cord is frayed or has exposed wiring, it is best to replace the entire cord. If the damage is close to the plug, you may only need to replace the plug. For vintage appliances with fabric-covered cords, it is recommended to replace the entire cord.
First, cut off the damaged portion of the cord. Then, strip the wires and splice them together, ensuring that the wire colours match. Cover the repaired area with a PVC shrink tube and shrink it with a heat gun. Finally, plug in your repaired cord to test that it works.
