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.
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