How to Wire 230V Extension Cords
- 1). Review the conditions under which you intend to use the cord. Establish the length, maximum current it will carry, and the types of plugs needed to connect it to the receptacle and your appliances. The National Electrical Code states that all extension cords must have polarized wiring. Refer to your local and/or national regulations, or check out the Consumer Product Safety Commission safety suggestions for extension cords.
- 2). Select, and then purchase, the right type of cord for your circumstances.
For example:
A 16-gauge cord is safe to use for loads up to 10 amps over a cord no longer than 100 feet;
A 14-gauge cord is safe to use for loads up to 15 amps over a cord no longer than 50 feet;
A 12-gauge cord is safe to use for loads up to 15 amps over a cord no longer than 100 feet, and will safely power most domestic power tools. - 3). Disassemble the new female and male plugs. With each plug, take the half containing the cord hole and pass sufficient cord through it for you to comfortably work on the cord without the housing getting in your way.
- 4). Remove approximately 2 inches of the outer insulating sleeve at each end of the cord. Cut carefully to avoid damaging the insulation on the internal wires. Cut each of the wires to the length required to reach the plug terminals. Strip the insulation from the last 1/4 inch of each wire to expose the metal core. If you are using braided wire, twist together the small filaments to stiffen the end of each wire.
- 5). Attach the bare wires to the correct terminals. The white "neutral" wire goes to the silver-colored terminal. The black "hot" wire connects to the brass terminal, and the grounding wire, which may be bare or covered in green insulation, connects to the GND, or green terminal. Tighten each terminal screw, check the wires are firmly attached, then trim away any excess wire protruding beyond the terminals.
- 6). Checks that the wires are not kinked, trapped or under strain, then fasten the cord clamp over the cord. Ensure that the clamp rests on an insulated section of cord, not the exposed inner wires.
- 7). Test the cable to ensure that all the connections are correct. Using a continuity meter, or a digital multimeter to measure continuity, attach the probes to the "hot" terminals in the male and female plugs. A "beep" or a zero reading on the scale indicates a correctly polarized connection. Repeat between the two neutral terminals and then the two grounding terminals. If you see a high reading or hear no beeping, double-check the polarity of your cord connections. When all three tests confirm that the wires are correctly connected, re-assemble the plug covers. Your extension cord is ready for use.
