A power cord is something that most people don't think about unless something goes wrong. And when something goes wrong, it usually goes wrong in a hurry. Things like frayed wires, overheated jackets, loose connections, and blown circuits are not just bad breaks. They are the direct result of preventable mistakes, mistakes that have been building over time.
Besides, the unfortunate part is that most power cord failures seem to follow a very predictable pattern. A small number of mistakes seems to cause most power cord failures, regardless of where they occur. A power cord is overloaded, misused in the environment, or ignored when the initial signs of failure occur. All of these situations are completely preventable, however.
This is why the best way to prevent power cord failures is to learn what causes them in the first place. Here are nine of the most common issues, along with exactly what you can do to prevent each one.
1. Overloading the Cord
Every power cord has an amperage rating, and the quickest way to create a potential hazard is to exceed it. If you plug in more devices than the cord is rated for, it will overheat and exceed its amperage rating. The heat will build up inside the cord's jacket, eventually deteriorating it from the inside out.
The solution is quite simple. Just check the rating on the cord itself and add up the total load of all the devices plugged into the cord. If the total load exceeds the cord's rating, split the load between two cords. A 12-gauge cord has a maximum rating of 20 amps. A 16-gauge cord has a maximum rating of 13 amps. The most critical factor in avoiding electrical hazards is matching the cord to the actual load.
2. Using the Wrong Gauge for the Job
A gauge is an instrument for measuring the amount of current that can safely be passed through a cord. Many people tend to use any cord at hand without ascertaining if it is adequate for the task. Using a thin 16-gauge cord to power an appliance with high draw is like running water through a straw.
Here is a quick guide to gauge selection:
16 AWG is adequate for lamps, chargers, and small devices up to 13 amps
14 AWG is adequate for power tools, fans, and medium devices up to 15 amps
12 AWG is adequate for heavy-duty tools, cord length, and devices up to 20 amps.
3. Daisy-Chaining Extension Cords
One of the most common and dangerous practices in both homes and work environments involves using one extension cord to plug another. The more extension cords used in the daisy chain, the more resistance they cause. Also, the more resistance they cause, the more heat they tend to produce.
OSHA has already prohibited the practice in the construction industry. The same practice should be prohibited in all other industries. If your extension cord does not reach the power source, then get only one long extension cord.
4. Running Cords Under Rugs or Carpets
Hiding a power cord under a rug or carpet may seem like a tidy solution, but it poses a major fire hazard. The cords can get hot when in use, and covering them prevents them from cooling down. Also, the heat damages the insulator over time, and it can even catch fire.
Therefore, the solution is to run the cords along the baseboards, use cable organizers designed for wall mounting, or use a flat cord designed for flat mounting. The common factor here is that we're not covering the cords, and hence, there is always somewhere for the heat to go.
5. Pulling the Cord Instead of the Plug
Removing a cord from the wall by pulling the wire rather than the plug will, over time, damage the connection between the wire and the plug. This is not necessarily something that can be seen from the outside. On the inside of the plug, the wires will loosen or fray, creating a resistive connection that heats up whenever the cord is carrying electricity.
Always remove the plug by holding the plug body. It takes an extra second and adds years to one's life.
6. Storing Cords in Tight Coils
Winding a power cord into a very tight coil and leaving it that way stresses the internal wire over time. The copper conductors inside the cord are flexible but not indestructible. Repeated tight bending at the same spot causes microfractures in the wire, which eventually break conductors and create resistance hotspots.
Store cords in loose, wide loops rather than tight coils. The over-under coiling method, where you alternate the direction of each loop, keeps the cord from developing memory and makes it easier to unwind without kinks.
7. Using Indoor Cords Outdoors
An indoor power cord used outdoors would be exposed to moisture, UV radiation, and temperature extremes for which it was not originally rated. The insulation on an indoor power cord would degrade rapidly under such conditions, exposing the bare wire.
Outdoor-rated cords would be marked with the letter "W" on the cord jacket and use insulation compounds rated for outdoor exposure.
8. Ignoring Physical Damage
A cracked jacket, a bent plug, or a section of the cord that feels unusually warm to the touch after use indicates that something has gone wrong inside the cord. People tape over the damage and go on using the cord. This is a mistake and a dangerous practice.
If the insulation on a cord has been physically damaged, the conductors inside the cord will be exposed. Touching the conductors will give a shock. Arcing off the conductors will cause a fire. Inspect your cords frequently, especially in high-traffic areas where they are likely to be physically abused.
9. Using Non-Certified Cords
Not all cords on the market are safe for use within the US. These cords have wire sizes that are too small, insulation that is too poor, and plug components that lose their ability to maintain consistent contact as they are used. The price difference between a safe and an unsafe cord may be small, but the safety difference is enormous.
Check for UL or ETL on all cords you buy. This means that the product has been tested for safety by a third-party lab.
Final Thoughts
Power cord problems rarely happen overnight. They occur over time as a result of repeated behavior that is harmless in the short term but can have long-term consequences. Overloading, incorrect gauge selection, daisy chaining, physical damage, and incorrect application of the power cord are the primary causes of power cord failure.
The best news is that each of these issues is entirely avoidable. One can begin by choosing the right power cord for the task, inspecting power cords regularly, and purchasing certified power cords from manufacturers who support their standards. Check Americord's entire range of power cords to find the right one for any application, designed to meet the safety standards required by your setup.