Powercords - How to make the right connection

For example, a standard moulded UK plug can require a variety of combinations of fuse ratings and colours. Then there is the choice of which cable to use with it, before finally deciding which end preparation is suitable for your end product. Not always as simple as it sounds.

In addition there is the key issue of safety. Powercords are safety critical items, defective cords can lead to product recalls and liability issues - it is not wise to cut corners. When procuring powercords it is essential to find a manufacturer or supplier that can supply cords that are approved by the appropriate regulatory body, such as either ASTA or BSI for the UK. This ensures that the cord you are using is safe and fit for purpose.


Plugs

It is important to find a supplier that holds the correct approval for the country that you are supplying to. In recent years new plug types and approvals have been introduced in Israel, Brazil and lately Saudi Arabia. There have been reports of goods being stopped at borders for unapproved product and cases of cords having to be replaced on finished appliances because they do not match the new standards.

Some plugs look the same but can require different approvals for different countries, South African plugs are the same shape and size as an Indian plugs, but both countries have different approval bodies. It is important if supplying to Japan that you are using a Japanese approved cord not a North American one, when both are virtually the same.

The range of cords that are required to supply products globally is extensive. If you are seeking to buy cords for a number of countries it may prove cheaper in total to buy from a single source that can service the full global requirement. Most manufacturers are unlikely to service what they see as small volume business on “exotic cords”


Cables and Connectors

When any cord is approved by a regulatory authority, they will be approved the plug with a particular cable size and type. There are a wide number of cables which can be approved with each plug, so there is value in finding the manufacturer or supplier that has a full range of cable approvals for the plug type required. Some manufacturers may not hold approval for their cords with a full range of cables. Securing sources for cords with rubber cable can be a problem for some buyers as not all manufacturers will hold the appropriate approval.

For countries that use the CSA/NEMA standards of North America there is a large range of potential plug and cable combinations. So if you are looking to source cords on an international basis it is important to find that the manufacturer is not only approved for the correct plug for that country, but that they are able to supply it with the cable that is required.

Once the correct plug and cable type have been selected, it is then a case of what is required at the other end? Some customers will have a requirement for an IEC connector which can fit into an appropriate IEC inlet, a detachable cord. For example on most desktop PCs the cord is fitted with a C13 connector that fits into the inlet on the PC, but can be removed as and when required.

Not all powercord manufacturers are approved to offer a full range of IEC connectors. So it is important to find one that can supply an approved version of the plug, cable and connector that you need.

Alternately the requirement maybe for a hardwired connection to an appliance, in which case it is important to find a supplier that can offer what might be needed in terms of end termination. Some cords may require special crimping or tin dipping as well as housings.
Lengths of conductors may vary. There may even be a requirement to mould a strain relief on the end of the cable to enable it to fit into the housing of the finished product.
This is the field of customised terminations. If you have a very specific requirement it is highly unlikely that a supplier or manufacturer can provide it from stock. In such cases it is important to identify a source that can provide such a custom solution. There may be a need to debate which terminals or housings may be required. To work together to decide how tooling might be paid for. Such solutions are not likely to be off the shelf.

In many cases this will require discussions with factories on the other side of the world, where common language and time difference may be a big problem. In such cases there is value in working with a local UK office that can facilitate these discussions and minimise the delay in getting samples and finished cords to you.


So if you are able to find a supplier that can give you an approved cord with the right cable and termination are you home and dry? Almost, but don’t be caught out by regulations.

New regulations regarding hazardous substances and electrical and electronic waste raised new challenges for power cord manufacturers and suppliers in the last five years.
It is important to find a supplier that complies with the following regulation.

RoHS

The RoHS Directive and the UK RoHS regulations came into force on 1 July 2006. It is a European Union Directive for specified products placed on the internal market of the European Union.
The RoHS directive aims to restrict certain dangerous substances commonly used in electronic and electronic equipment. Power cords and their components are tested for the presence of certain substances including Lead , Cadmium and Mercury.


WEEE: Waste Electrical and Electronic Equipment
The Waste Electrical and Electronic Equipment (WEEE) Directive aims to reduce the amount of WEEE being produced and encourages everyone to reuse, recycle and recover it


The WEEE Directive came into force in January 2007 and aims to both reduce the amount of WEEE being produced and encourage everyone to reuse, recycle and recover it. The Directive also aims to improve the environmental performance of businesses that manufacture, supply, use, recycle and recover electrical and electronic equipment.

Since then it is a requirement that all cords are supplied in compliance with these regulations. Many manufacturers now comply but it is worth checking that they can supply the appropriate documentation that shows their product complies.


In summary if you are looking to buy powercords it is important to find a supplier that is

• Fully approved by safety authorities for the appropriate country
• Has a full range of plugs with suitable cable, connectors and termination options
• Has the ability to provide customised solutions

For UK based buyers there is one other question-how quickly can I get the cords?
During the last 10 years the volume production of powercords has gradually shifted from the UK and Europe to China. The trend is not exclusive as some local manufacturers remain. The challenge for those companies has been to match the lower manufacturing costs enjoyed by China factories.

If you are looking to buy hundreds of thousands of cords there may be a case to deal direct with China factories. However there are distributors such as YEG Cabcon who are able to offer a full range of product sourced from China. Thereby taking away the costs involved in managing the supply line of product and being prepared to support customers by holding stocks of custom made cords too. Issues such as the cost of letters of credit, the effort of trying to deal with Chinese factories are removed.