Choosing The Right Power Cable: Top Tips - Americord

When choosing the correct power cord for household appliances and office devices, people often make costly mistakes by blindly selecting products they think will suit their needs. However, choosing the wrong products can only cause more problems and bring more expenses.

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On the other hand, most people simply go with the longest and cheapest option, which is also wrong. The trick to making an informed decision and intelligent purchase is to know how to choose the suitable power cable for your specific needs.

To do that, you’ll need to inform yourself of the main factors to consider when deciding which extension cord power cord and extension cable to use. There is a wide range of hardware specifications to take into consideration when buying new power cables.

You need to consider why you need power cables. Each device, appliance, and workstation in your home and office requires a matching power cord. With that in mind, let’s get deeper into details regarding power cords to help you make the right decision.

Power cable plugs: Two-prong vs. three-prong

Two of the most common power cable options you’ll find in almost every household and office are two-prong NEMA 1-15 and three-prong NEMA 5-15. Two-prong NEMA 1-15 is the perfect choice for various devices such as TVs, charger cords, lamps, electric fans, and so on.

However, NEMA 1-15 cords aren’t grounded; therefore, they can’t be used for supporting high-powered devices such as microwaves and refrigerators. You’ll need NEMA 5-15 for that. It is a three-prong power cord that comes with a round pin for ground wire use.

Wire gauge

There is a wide selection of wire gauges for household and office extension cables. Which one you choose depends on the application. If you need to support heavy-duty items, you’ll need a thicker gauge cable. Thicker gauge cables allow more power to flow through it and are an excellent option for distances.

There are four standard wire gauge sizes for NEMA 5-15 plugs:

• 10 AWG – 10 AWG power cords are perfect for supporting standard household outlets and electric vehicles, fridges, boats, RVs, and more. The thick 10-gauge wire is an excellent solution for powering devices with lengths up to 10 ft away.
• 12 AWG – perfect for contractors and other similar settings, the 12-gauge extension cords are specially designed for power devices and tools. They enable easy data flow, 100 ft usage, and applications where you need to eliminate any drop in power. 12-gauge is also an excellent solution for situations where accessibility to outlets is minimal.

• 14 AWG – if you need a power cable with the ability to supply a maximum of 15 amps up to 50 ft from a household/office outlet, 14-gauge cords are the right option. They are perfect for powering high-power devices such as power equipment, dehumidifiers, and other devices. Since they are so versatile, they are ideal for both household and office devices.
• 16 AWG – coming with a maximum output of 10-13 amps depending on the length of the cable, 16-gauge cords are more commonly known as the orange extension cables that you can see in almost every office, basement, garage, and similar establishment. This power cord is an excellent option for powering a wide range of household appliances and office devices, including power tools, electric trimmers, and more.

It’s always better to go with a thicker gauge cord than the recommended. Some people prefer thinner gauge wire with a right-angle power cable, but this solution could cause more issues because your devices and appliances do not have enough power to run. If you want to avoid malfunctioning and devices burning out, choose a thicker gauge cable.

Outer jacket

Outer jacket is one of the essential factors when choosing the suitable power cable for your unique needs. For example, if you plan to use a power cord outdoors in colder temperatures, a regular power cord might become much harder to work with due to coldness.

Colder temperatures tend to stiffen up the power cable, making them hard to manage and use. In such situations, power cords with all-weather outer jackets are a much better solution. When choosing a power cord for outdoor use, go with the SJEOW standard for power cables.

SJEOW stands for:

• S – service grade
• J – hard service
• E – thermoplastic elastomer
• O – oil resistant
• W – wet location-rated conductors and sunlight resistant jacket

Now, since you have some basic understanding of important things to know about power cords, let’s move on with the best tips and practices for choosing the correct power cord for your needs, as well as safety tips for working with power cords.

Tips for buying the correct power cord

Here are some points to consider for choosing a suitable cable.

Always buy a longer cable than you need!

Since you can never correctly guess how long a power cord should be for a specific use, it’s always better to buy a longer cable to get some extra room for error. Longer wires are always helpful, more convenient, and safer too.

Of course, you can always connect one cable to another. Still, you risk adding electrical resistance between your device and the outlet that can cause voltage drops, making your devices and power tools run at lower power. Since this can start a fire, melt your cords, and cause other problems, you can avoid all this by simply buying a longer cable.

Choose thicker cords for more power!

In applications where more power is needed, thicker cords always work better. The thicker the wires, the more power the cable can safely carry. This is vital for electrical applications over longer distances.

Any cable should run low-power devices and gear like stereo, battery chargers, and lights. However, if you want to safely run power tools like wet/dry vacs, saws, and drills at peak power, you’ll need a cord for maximum power.

Here is how to choose the correct length and thickness:

• 25 feet – 14 AWG (14/3)
• 50 feet – 12 AWG (12/3)
• 100 feet – 10 AWG (10/3)

Opt for cables that can handle 15 amps!

You can always make sure you have the correct power cord by checking the amperage rating on the packaging. We recommend you go with a 15 A rating. Avoid indoor/outdoor cables rated for 10 A or 13 A.

15 A fuses or breakers are pretty standard in most residential and commercial electrical panels. You can plug in any equipment or tool with a 15 A cable. More importantly, if the cable is pushed beyond its limits, it will cut off the power.

When it comes to contractor cables, anything up to 300 V will do as it meets workplace safety requirements. In terms of residential voltage in the US, 125 V or 130 V will do just fine.

Cold weather cords are generally more flexible!

Some power cables are simply designed to be more flexible and allow for a broader range of applications. The flexibility of use is crucial for applications at lower temperatures.

The more flexible a power cord is, the more usable it is in tight spaces, easier to store correctly, and stretch across your home or workspace. Opt for power cords listing temperatures below freezing as they are generally more flexible to work with.

Stay away from indoor/outdoor cables with multi-outlet ends

Multi-outlet cables, also known as a banana tap, are commonly seen in residential and commercial properties. However, we don’t recommend using them for running work lights and power tools and equipment due to being easy to overload. If you require serious power, we recommend general-purpose cords with one outlet per cord.

Indoor-only cables

The best option is to go with the less robust indoor cords for lower-power gear like wireless speakers, lamps, and chargers. However, most current building codes, including UL, don’t allow the use of extension cables in a permanent installation due to regular wear and tear making them a real fire hazard. Use them for digital devices and appliances that don’t require much power. Keep in mind that indoor cables aren’t weather resistant.

Extension power cables

Let’s quickly cover the three types of extension cords- light-duty, medium-duty, and heavy-duty.

Light-duty power cords

These power cords, designed for light-duty devices, aren’t grounded and come with two plug prongs. You can use them for devices up to 7 amps and other light-duty appliances like clocks, lamps, etc. Recommended cord length:

• 25 feet – 18 AWG
• 50 feet – 16 AWG
• 100 feet – 14 AWG

Medium-duty power cords

Usually grounded, medium-duty cords come with the third wire and can power three plug grounded appliances. You can use them for computers, TVs, and any other similar device that requires up to 10 amps of power.

Recommended cord length:

• 25 feet – 16 AWG
• 50 feet – 14 AWG
• 100 feet – 12 AWG

Heavy-duty power cords

Heavy-duty power cords fit the bill if you need cables that can support 10 to 15 amps of power. These are grounded cables that come with the grounding plug prong and include a third wire. They also have three-slot plugs for powering grounded appliance cables. These cords are perfect for heating appliances and power tools.

Recommended length:

• 25 feet – 14 AWG
• 50 feet – 12 AWG
• 100 feet – 10 AWG

If you’re looking for the best power cables for outdoor purposes that can also resist moisture, look for the cords with a built-in ground-fault circuit-interrupter (GFCI) protection that prevents shock hazards.

Quick safety tips

Taking precautions while working with power cables is extremely important. Since we cannot stress this enough, here are a few quick tips to keep you safe:

• If you’re not using a power cord at the moment, make sure it’s unplugged. Cords are nothing more than a temporary electric solution and should be treated as such.
• When using a power cord indoors or outdoors, make sure you use the correct power cord. Using indoor-rated cords for outdoor use could result in various issues, including getting injured, fire hazards, and more.
• Avoid connecting multiple extension cords by plugging one cord into another, as this could result in a power overload.
• Do not cover power and extension cords with rugs, carpets, or any other similar item. Covering power cords could result in overheating, which can turn a power cord into a fire hazard.
• If an extension cannot fit into a power socket, do not force it in.
• When you plug a cable in, always ensure it is fully plugged into the socket.

Reasons why power cords are dangerous

When you look at a power cord, you can see that it’s nothing more than a bundle of insulated electrical wires. While there’s nothing suspicious about that, the problem is that the electrical current flowing through those wires generates a lot of heat that can quickly turn a simple power cord into a real hazard.

If a power cord overheats, it can melt the plastic insulation and cause fires, short circuits, and more. In most situations, you’ll just power a device or an appliance by plugging it directly into a power outlet using its factory cable.

However, in situations where you don’t have a proper factory cord sized appropriately for the electrical current load and demand, you’ll need to work with what you have. If you exceed the safe load capacity, the consequences could be disastrous. In such cases, always take help from an expert.

Conclusion

We sincerely hope this guide helps you choose the suitable power cable for your commercial and residential needs. Even though it may sound a bit complicated initially, it’s isn’t that hard to get into it once you know what to look for. Keep these tips in consideration when buying power cables, and don’t forget to stay safe while working with power and extension cables.

If you don’t have anyone around who’s an expert in this field, it’s best to consult an electrician when you are tampering with electricity for the first time. So, be well prepared, and there should be no worries.

Cabling and wiring perform a range of amazing tricks in industrial assemblies. From powering motors to controlling instrumentation to communicating with other machines, they’re the secret to success in many projects.

Because industrial applications have so many unique considerations, the cable vendor often has to correct the purchaser on the best type for them. Even the project engineer(s) sometimes needs a nudge in the right direction if they’re not a wiring whiz.

To spec the right type of electrical wire and cable for your industrial project, learn the seven key categories you may run into.

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(Related Resource: Wire & Cable Selection Guide)

7 Types of Electrical Wires and Cables

There are almost more ways to categorize wires and cables than you can count. Let’s stick with these common terms, as they might most affect the outcome of your project:

• Single-conductor
• Multiconductor
• Twisted pair
• Ethernet
• Coaxial
• Fiber-optic
• Ribbon
  
  

Single-Conductor Cables

A single-conductor (or single-core) cable is just that – a flexible wire with one metal conductor in the middle and insulation surrounding it.

The name, however, is kind of a technicality. Yes, single-conductor cables can exist as a lone wire for grounding or the positive leg of a low-voltage system. However, it’s common to bundle several of them into a more complex cable harness. Each wire within the assembly may carry a unique electrical signal.

Using single conductor wires reduces the bulkiness of the assembly. The installer can fan out bundles, making routing easier in tight spaces. The lack of an outer jacketing layer further increases their flexibility because they can bend at tighter radii.

That slimmer design comes at a performance cost. Single-conductor industrial cables have limited abrasion resistance and high susceptibility to electrical noise (unless you add shielding). While single-conductor wires work well in prototyping and development, a multiconductor cable is the safer option in environments with mechanical hazards and potential cross talk.

UL (Underwriters Laboratories) rates a huge range of wires for industrial use. Popular UL-approved single-conductor wires include:

• UL
• UL
• UL

All three are usable in temperatures up to 105°C at voltages of 300V+.

Multiconductor Cables

A multiconductor (multicore) cable is a single product that combines more than one wire – anywhere from two to 60. The manufacturer twists, wraps, or otherwise binds the strands together. 

Compared to their single-conductor cousins, multiconductor cables have many advantages for industrial users:

• Higher mechanical strength
• Easier to bend
• Assembled cabling is neater & more space-efficient

One example of their convenience is that several “legs” can be grouped into a main “trunk.” For instance, an appliance cable could bundle two main power wires and two low-voltage wires into a single, UL -friendly package.

Customizability is the name of the game for multiconductors – you can tweak the exact type and placement of shielding to satisfy design requirements. The gauge and cable lay are also configurable for the number of circuits you need. Because the cable contains multiple strands, there’s a limit to the thickness of each wire. 

Popular UL-listed multiconductor cables include:

• UL
• UL
• UL
  
  

Twisted Pair Cables

Twisted pair cabling is a type of wire bundle that performs a special feat: It makes electromagnetic interference (EMI) disappear. The mastermind behind twisted pair cables is none other than Alexander Graham Bell.

EMI is one of the biggest obstacles to cable performance, often stemming from cross talk between neighboring components or radiation from unshielded cables. Twisted pair cables cancel out these external sources.

Common applications include:

• Telecommunications
• Sound engineering
• Theaters
• Data centers

Commercial-grade twisted pair cables come in solid or stranded construction. It’s also possible to shield the cable for additional noise protection. In custom multiconductor cables, you can personalize the gauge and shielding for each twisted pair in the assembly.

Ethernet Cables

You may know this type as cat, category, network, or LAN cabling.

Industrial cat cables are just like commercial-grade versions in terms of data rate. Where industrial Ethernet cables differ from commercial and residential options is the inclusion of extended temperature switches and rugged connectors for heavy-duty jobs.

Applications for Ethernet cables include:

• Computers
• Network devices (modems, routers, services, & switches)
• Automated machinery

They can be solid or stranded construction. Stranded is usually the choice when you plan to expose the cable to frequent bending and twisting (i.e. a robotic arm on a production line).

Cat5 vs. Cat6 Cables

If you’re looking for industrial-grade Ethernet cables, you’re probably looking for either Category 5e, 6, or 6A. The category refers to the generation of unshielded, twisted pair (UTP) cables to which it belongs.

Coaxial Cables

Coaxial cables get their name from their physical design: a signal-carrying channel surrounded by a concentric channel along the same axis.

These cables are fantastic in industrial settings for high-frequency applications. They provide excellent shielding and signal integrity for transmitting:

• Data
• Video
• Audio

Coaxial cables are capable of low-loss transmission of electrical signals. This makes them logical choices for:

• Cable TV
• Broadband internet
• Radio transmitters & receivers

The construction of a coaxial cable starts with a familiar format: The innermost channel is typically a copper wire, surrounded by insulation. The outer channel acts as a ground, usually copper mesh. A second insulation layer surrounds the outer and inner channels. 

Shields are usually copper, but you can add silver plating for extra conductivity or switch to aluminum foil to save money in low-risk applications. The conductor is typically solid copper, but you can also try stranded copper (for extra bend resistance) or copper-plated steel (for more strength).

Common types and uses of coaxial cable include:

• DS3 – Telecommunications & networking applications, providing high-speed data transmission over long distances
• DS4/NA – Long-distance fiber carrying of broadcast radio & television, as well as central offices
• RG11 – For special and long-distance signal transmission in TV & camera applications. Poor flexibility for tight-fit applications
• RG59 – Legacy solution for TV, video, & other A/V technology requiring a 75-ohm cable. Good for short- and medium-length connections
• RG6 – An evolution of the RG59, it has a thicker conductor and frequency bandwidth. Often sold with F-pin connectors

You can also increase the number of conductors to change the functionality.

Triaxial cables have a third conductor and an additional shield for protection. Quadraxial cables feature two cables on the same axis and two twisted together, offering noise suppression in applications below 50 MHz. Finally, twinaxial cables are similar to coaxial cables, but feature two conductors twisted together as a low-cost solution for short-range, high-speed differential signaling.

Fiber-Optic Cables

Fiber-optic cables use light signals to transmit data over long distances at ultra-high speeds. Almost universally, they offer higher working temperatures than other cable types. 

Fiber-optic options are ideal for industrial applications that require high bandwidth and immunity to electromagnetic interference. Today’s engineers are figuring out more and more ways to use them:

• Military
• Datacom
• Transportation
• Oil, gas, & mining

Fiber-optics are gaining popularity for reasons go beyond speed and distance:

• Low weight
• Flexibility
• Can print & precut them for layouts with multiple breakout points
  
  

Ribbon Cables

A ribbon (aka flat or multiplanar) cable is a series of single-conductor wires with high fiber density. They’re connected side-by-side, giving the illusion of a ribbon. However, it has yet another name – zip-wire – because it’s possible to separate the conductors from the ribbon. Unlike other types of electrical cables, the wires don’t go inside a single jacket; they instead receive their own insulation.

It might sound like hocus-pocus, but the unique design of ribbon cables is beneficial in several ways:

• Saves space
• Less time to prep & install
• Signal integrity

The organized layout simplifies cable management, reducing the risk of tangling and misidentification. Their noise-resistance qualities make them suitable for transmitting sensitive signals over long distances without compromising data accuracy.

Like with any cable type, there are drawbacks to ribbon cables:

• Only bends along its longitudinal axis
• Jacketing can be brittle
  
  

How Do You Source an Industrial Cable?

Once you know which industrial cable type you need, the next step is matching your application to a specific material and product. Some categories of cables serve dedicated purposes:

Depending on your application, the top traits to seek in a cable are:

• Temperature rating – response to heat, cold, & fire
• Electrical reliability – affected by gauge, length, & shielding
• Mechanical strength – crush & cut-through resistance
• Mechanical flexibility – usability in tight spaces without snapping
• Corrosion resistance – ability to withstand moisture & chemicals

The cable’s jacketing and insulation material are the biggest overall factor in these properties.

More Education on Electrical Cable & Wire

Knowing each type of electrical cable and wire is about more than turning you into a walking encyclopedia. It’s about guaranteeing performance, safety, and a long service life for your specific industrial application. 

From heavy appliances to medical electronics, multiconductor cables are often the starting point for industrial builds. But there’s more we didn’t even have space to cover – armored cables, thermocouple cables, and more. Keep your cable wizardry sharp by checking out (and bookmarking) our full resource center:

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