Wiring a plug is a fairly straightforward task, but it does require due care and attention in order to be completed successfully - and safely.

What you need

  • A plug with appropriate fuse
  • A screwdriver
  • Something to cut the wires to the required length. You can use a wire cutter, or simply a sharp pair of scissors.

The process
  1. Remove the plug cover

Unscrew the cover by loosening the cord grip/flex clamp screw, and take out the other.

  1. Take out the fuse

Carefully remove the fuse. You may need a screwdriver to do this. Loosen the terminal screws.

  1. Insert the flex in the plug

Place the flex in the plug, then cut the wires so they go past the terminals by about 1/2inch (13mm). You may need to cut off some of the plastic sheath.

Where the wires go
  • Green/yellow wire to the earth terminal - top of the plug
  • Blue wire to neutral terminal - left of the plug
  • Brown wire to live terminal - right of the plug

Note that some appliances have a two-core flex with live and neutral only: these double-insulated appliances do not require an earth.

  1. Strip away insulation

Strip away the plastic sheath so that enough wire is exposed to fit to the terminals. Expose about 1/4 inch for screw-hole terminals and 1/2 inch for clamp terminals. Be sure you don’t damage or cut the wire strands. Twist together the strands of exposed wire.

  1. Fit cable clamp and tighten screws

Fit the cable clamp over the end of the outer flex/sheath. Connect each wire to the applicable terminal and tighten screws. Be certain there are no stray wire strands.

Some wires may be very thin. In this case you can fold the wires over before connecting them to the terminals.

For clamp terminals, wrap the wire around the pillar in a clockwise direction, then tighten the screw.

  1. Make your last checks
  • Ensure the wires are connected to the right terminals - see image
  • Be sure there are no errant wires
  • Ensure the flex clamp secures the outer sheath, rather than the thinner wires. The wires may well come loose if you do not do this.
  • Ensure all screws are tight
  • Attach the right fuse for the appliance. Read the manual if you are unsure what amp fuse to fit
  • Replace the cover and secure

Older plugs

If you are rewiring an older appliance, the wire colours may be different. In this case, the green should connect to the earth, the red to live and the black to neutral.

Safety first

It goes without saying that the plug should not be in a power outlet when the re-wiring is undertaken.

Do not insert the re-wired plug into a power outlet until all checks have been completed and the cover is securely screwed on.

 

 

startrescue.co.uk always recommend seeking the services of a professional tradesperson If you're not entirely comfortable carrying out repairs or maintenance by yourself.