How to Wire an Extension Cord for a Generator
Portable generators may produce toxic carbon monoxide fumes, so never use them indoors or in poorly ventilated areas. A sufficient length of extension cord is required to transfer power from a remotely sited generator to the appliances in your home or workshop. Wiring your own extension cord enables you to produce a cord of the right length to meet your specific needs. Constructing a home-made cord may also cost less than purchasing one. Does this Spark an idea?
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Things You'll Need
- Heavy-duty outdoor cord
- Male and female plugs
- Knife
- Electrician's screwdriver
Instructions
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1
Determine the maximum current output from your generator. This should be displayed on a plate attached to the generator and be printed in the manual. The value will be in watts or amps. A cord's thickness determines its ability to safely transmit current, so the cord must be thick enough to cope with the maximum output from your generator.
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2
Assess the circumstances under which you will be using the generator. Cord is manufactured for either indoor or outdoor use. Generators housed outside must use cord designed to withstand the temperatures, dampness, abrasion and UV exposure of an outdoor life.
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3
Select and buy a sufficient length of cord and appropriate male and female plugs. Remove the tops from both plugs and identify the half with a hole through which the cord can be inserted. For each plug, at either end of the cord, push two or three feet of cord through the cord hole. This gives you enough loose cord for you to work on the end of the cord without the plug housing being in your way.
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4
Pull one of the plug housings toward the end of the cord until the tip is level with the furthest plug terminal. Note the position of the cord grip. Cut away the insulating outer covering of the cord from the top of the cable grip to the end of the cord. Cut the internal wires to the correct length to reach the terminals. Do not stretch or bunch up the wires as this may lead to damage and overheating.
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5
Expose the metal at the end of each wire by removing the final quarter of an inch of insulation. If the wires consist of fine filaments, twist them between your fingers to create a stiff rod.
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6
Attach the wires to the plug terminals. Many large appliances have polarized power cords, so generator cords must also use polarized wiring. Connecting the wires to the correct terminals is essential. Attach the "hot" black or red wire to the brass terminal and the "neutral" white wire to the silver terminal. Attach the green or bare grounding wire to the terminal marked with GND.
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Check that the wires connect firmly to the terminals and that there are no pieces of bare wire sticking out beyond the terminals. Secure the cord in the cord grip to prevent it from pulling loose. Replace the housing on each plug and the cord is ready for use.
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Tips & Warnings
Become familiar with your local and national electrical regulations before creating your own generator extension cords. Some areas have specific guidelines and legislation covering the types of cord and plugs you may use.
Always visually examine an extension cord before you use it. If it looks damaged, replace or repair the damaged parts before using it.
Electricity can cause fires, injury and death. If you are uncertain of your skills, consult a qualified electrician or purchase a commercially produced extension cord. Do not undertake "do-it-yourself" electrical projects unless you are competent to do so.
Always use a cord that is rated at least equal to the combined load of the connected appliances. An overloaded cord will become hot and may catch fire.
References
- Photo Credit extension cable image by Gudellaphoto from Fotolia.com
