Flame Rating Tests for Power Cords. Feel the Burn

Ensuring your power cord meets fire prevention requirements for a device is a safety measure you cannot ignore. In a previous blog discussing test procedures, we mentioned multiple tests that power cords must undergo before being approved by safety agencies. To refresh your memory, some of the tests we talked about were:

ul94-testing

  • Grounding test
  • Continuity test
  • Hi-pot test
  • Polarity test
  • Insulation test
  • Pull-test

This post will cover another important test: flame rating, or flame resistance.

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Selecting the Right High Voltage Cords

high voltage

High-voltage cables are found in virtually all environments, powering high-intensity equipment safely and securely. From households and consumer uses to industrial machinery, these cords ensure electrical safety while providing reliable power to strong equipment. There are many styles of high-voltage electrical cords, each designed for distinct uses and to fulfill specific demands. Understanding the various types of cables will help you make the best selection for your needs.

If you need to operate powerful electrical equipment, a high-voltage cable is the solution for you. Read below to learn more about high-voltage power cords, or find answers to any questions by contacting Quail Electronics, Inc. today.

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The Importance of Ground Pins on Plugs

ground pin

2-pronged and 3-pronged plugs are among the most common plug styles for consumer use, with an obvious difference being the number of prongs per plug. Both plug styles have two flat, rectangular pins; however, a 3-prong plug features an additional prong. This prong, known as the “ground pin,” is easily identifiable by its rounded, cylindrical shape. It is critical in promoting electrical safety and protecting devices and operators.

Read below to learn about the importance of grounded plugs, their contribution to safety, and reasons to avoid cutting the ground pin. Contact Quail Electronics, Inc. with any questions or for more information about ground pins.

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Office Safety Tips for Power Cords and Power Strips

office heroPromoting electrical safety in the office is underrated yet highly necessary. Office spaces commonly use many electronics and require many power strips, power cords, and high amounts of electricity to power devices. It can be easy to be lulled into a false sense of security around electronics. However, there are still risks involved, especially in offices using many devices at once. These office safety tips for hazard prevention and safe handling are designed to protect your office and employees.

Quail Electronics, Inc. encourages safe electronic practices through education and information. Contact us today with any questions, and our team will happily assist you. Continue reading Office Safety Tips for Power Cords and Power Strips

Choosing Between Molded Power Cords & Mechanical Power Cords

Molded Power Cord

When deciding on a power cord, common considerations include plug and connector styles, cord length, and voltage. However, another important factor is determining whether you need a molded or a mechanical power cord. Here, we discuss the differences between these types of power cords, their benefits, and how to choose the best style for your needs.

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Understanding Electrical Wire Colors & Wire Color Codes

black wiresWhen handling electrical wires and power cables, it’s crucial to understand and differentiate between color codes. The color of a wire indicates its properties and where it’s safe for use, meaning making the wrong decisions or connections can prove extremely dangerous or even fatal. Before you start working with the internal wiring of power cords, make sure you can confidently identify the role of each wire.

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Do You Have Melting Power Cords?

melting cord

With proper care and use, power cords are excellent and reliable solutions for powering a range of electronic devices. However, it is essential to understand the potential risks that come with transporting electricity. One such risk is melting power cords. While power cables may experience melting for a variety of reasons, proper education and safety practices will prevent melting or additional hazards.

Keep reading to learn more about the factors that may lead to melting power cables, as well as safety and prevention methods. Contact Quail Electronics, Inc. for more information, and our team will happily assist you with any questions.

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Power Supply Voltage Drops: The Basics

If you’re noticing decreased efficiency in your electronic systems and equipment, they may be experiencing what’s known as voltage drop. While power supply voltage drops can be damaging, understanding the basics and how to combat them can help you prevent future harm and protect your equipment. Keep reading to make sure you understand what a voltage drop is, common causes, and how to reduce the risk of voltage drops.

What is a Voltage Drop?

A supply voltage drop describes how the energy of a power supply decreases as the electrical current flows through passive elements in an electrical circuit. The potential for voltage drop increases with the length of the circuit. The further the electricity travels from the power supply, the higher the risk of voltage drop, resulting in weaker currents and decreased power.

Excessive voltage drop can be damaging and may lead to disruptions, inefficient electrical systems, and even mechanical harm. These issues can negatively impact your electrical equipment, potentially resulting in higher operating costs and decreased productivity. Understanding some of the most common sources of voltage drops can help you better prepare for and prevent damage to your electrical systems.

Common Causes of Supply Voltage Drop

  • Length of the power cable
  • Cable gauge size
  • Using AC power over DC power
  • Amount of current at the power supply
  • Power line resistance

How to Measure Voltage Drop

While small amounts of voltage drop are expected―especially for lengthy electrical circuits―monitoring for excessive voltage drop can help protect your equipment and prevent harm.

Ohm’s law describes a formula to calculate the proportional relationship between voltage, current, and resistance. The formula to calculate voltage drop is:

V = I x R

Where V represents voltage, I represents current, and R represents resistance. For further assistance in calculating voltage drop, contact a team member at Quail Electronics, Inc.

Minimize Voltage Drop in Your Power Supply

You can use various techniques to compensate for the effect of voltage drop on long circuits or where voltage levels must be accurately maintained.

  • Appropriate Wire Size: The most important factor in avoiding excessive voltage drop is selecting the correct wire size. Choose a wire gauge appropriate for the distance and current you require to best reduce resistance in your system.
  • Increase Conductor Size: One of the simplest ways to reduce voltage drop is to increase the diameter of the conductor between the source and the load, lowering the overall resistance.
  • Routine Inspection: Regularly examining your power cables and electrical systems will help you quickly identify any significant voltage drop. Make any necessary repairs as fast as possible to avoid lasting damage or costly maintenance.
  • Specialized Power Supply Design: Custom-made power cords and connectors can help you easily balance power loads and regulate voltage levels for improved performance.
  • High Voltage Power Cables: Using high-voltage power cords increases the amount of voltage flowing through a circuit and minimizes the amount of current. Higher voltage levels result in decreased voltage drop.

Learn more about global voltage standards with our helpful International Voltage and Frequency Guide.

Contact Quail Electronics, Inc. Today with Any Questions

With over 30 years of industry experience, Quail Electronics, Inc. is a leading expert in all things electronic. We offer competitive pricing, convenient same-day shipping, and minimal order requirements to get you precisely what you need for your applications. Our trained specialists can answer any questions and help you choose the best types of power cords for your requirements.

For more information about supply voltage drop and how to protect your electrical equipment, contact Quail Electronics, Inc. today, and our team will assist you with any questions.

Your Best Guide to IEC 60309 Plugs

IEC 60309 plugs (International Electrotechnical Commission) are internationally certified for industrial purposes. The 60309 specification identifies these plugs as compatible with high voltages and high-powered connections. However, these industrial plugs are often referred to under a different name, making shopping for them more difficult than it needs to be.

Read below to learn more about IEC 60309 plugs and how they can best serve your applications.

What Are IEC 60309 Pin and Sleeve Plugs?

Also known as pin and sleeve plugs, IEC 60309 plugs feature male “pins” for plugging into corresponding sockets and are surrounded by a female “sleeve” for protection and safety. Often, the sleeve is made from impact-resistant plastic to reduce the risk of electrical shock and promote safe handling. The male and female pin and sleeve design reinforces electrical connections and makes them ideal for industrial high-voltage applications.

IEC power adapters are designed to accept IEC 60309 plugs and safely power various industrial applications. These plugs are compatible with IEC power cords and universal power strips.

Commando Plugs vs IEC 60309 Plugs

If you’re in the market for IEC 60309 plugs, you may be searching for them under the popular brand name Commando. When IEC 60309 plugs began gaining worldwide popularity for industrial and high-voltage uses, various countries began adopting it and slightly changing the name for their own standards or colloquial terminology.

Just like how the Kleenex brand name took over facial tissues and the Xerox brand name took over copiers, the MK Commando brand took over IEC 60309 plugs. However, when searching for an industrial plug, the correct term is still the IEC 60309.

Benefits of IEC 60309 Pin and Sleeve Plugs

IEC 60309 plugs are known for their extreme strength and durability. Built to handle high voltage levels and extreme amperages, these plugs can reliably power large machinery in various industries. Additionally, these plugs can continue to provide power with complete safety even when submerged underwater. IEC 60309 plugs have an IP rating guaranteeing their ability to withstand water and foreign objects, protecting them from dirt and dust.

Applications

IEC 60309 pin and sleeve plugs can be used for a wide range of industrial applications, including but not limited to:

  • Cameras & Video Displays
  • Communications & Laboratory Machinery
  • Computing Equipment
  • Cooking Units
  • Data Servers
  • Industrial Lighting & Machinery

Quail Electronics, Inc. is Your Leading Supplier of IEC 60309 Plugs

With over 30 years of experience, Quail Electronics, Inc. is your trusted source of standard and custom power cords for a variety of applications. We proudly offer competitive pricing, no minimum order requirements, and same-day shipping on all in-stock products. Contact us to get started on your order today!

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Different Wire Termination Styles for Power Cords

Wire termination refers to the end style of a power cord. The way a cable is terminated affects its applications and determines how it can be used.

In this blog, we talk about the different ways to terminate a power cord, various wire termination methods, and types of electrical terminals for creating new cable connections.

Types of Power Cable Ends

The end of a power cable determines the available wire termination methods for that specific application. The most common cord end styles for power cables are:

  • Standard Ends
  • Stripped Ends
  • Custom Ends

For standard power cords, both ends can be plugged in or unplugged, and the cord is ready to use. All internal wires are hidden, meaning wire termination is contained in the plug or connector. However, for stripped and custom power cable ends, there are different ways to terminate a cord’s exposed wires.

Wire Termination Methods for Stripped End Power Cords

Stripped end power cords feature exposed wiring, where the insulation has been removed or “stripped” away from one end of the power cord. Also referred to as removed outer jacket cords or ROJ cords, the wire termination methods for these cords are permanent and result in reliable results.

Crimped Wire Termination

Crimped wire termination is named for the crimping tool required. A contact or terminal is “crimped” to the stripped wire, forming a permanent attachment. Crimp termination is the most common type of wire termination and forms a mechanically strong, reliable connection between the power cord and the attached terminal.

Soldering Wire Termination

Soldering wire termination is often used for direct hard-wiring applications. The stripped wires are treated with Flux and the desired contact or terminal is soldered directly to the exposed wires. Soldered wire termination is often used for simple applications or when a wire is too small for crimping tools.

Terminals for Stripped & Custom Cable Termination

Stripped and custom-end power cables use electrical terminals to create new ends for connections. Available in insulated styles, terminals come in a range of connection options:

  • Ring Terminals: Used to ground a wire in a device.
  • Locking Ring Terminals: Offer a more secure connection for grounding wires.
  • Fork/Spade Terminals: Allows for fast wire connections.
  • Quick Disconnect Terminals: Used when wires require fast disconnection.
  • Flag Terminals: A left-angle version of quick disconnect terminals.

When selecting a terminal, ensure the sizing matches your wire gauge.

Quail Electronics, Inc. is Your Expert in Power Cords & Electronic Supplies

Got questions? With over 30 years of experience and a team of knowledgeable experts, we can answer any question and assist you with any inquiries. With competitive pricing, convenient same-day shipping, and minimal order requirements, we supply you with precisely what you need. Contact us with any questions or to get started on your order today.

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