Electronics > Beginners
Assemble a cable with NEMA L5 connectors. Reliable?
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aurmer:
I am working with a stage lighting vendor. Today we had issues with losing power to a group of lights. Turns out the power cable leading to the lights was poorly terminated with a store bought plug. By the time we got to it, the male and female connectors were melted together.

I spoke with the vendor who had done the install, and he laughed it off saying, "That happens all the time with these connectors".  |O

So, I came here to check in with some experienced folks before I give in to impulse and find another vendor. My gut tells me not to trust him with any more installations.
Would you say that a skilled individual can consistently assemble reliable cables?
Or is it your experience that no matter how skilled you are, some of these will come loose?
Bratster:
If the connector is rated for the current that you were pushing through it, then that vendors an idiot saying this happens all the time and I would stop using him.

It is not hard at all to properly install a power connector on a cable. As long as you're not overloading it there should never be problems.

Now if this is a cable that is constantly plugged/ unplugged then the female side can wear out and not provide the same force on the contacts which will lead to heating and a bad time.



Sent from my Moto x4 using Tapatalk

ikrase:
IMO, kinda need some info on the particular failure mode. What melted?
aurmer:
Here are some details on this installation.

There are 4 theater lights on one breaker. (spec sheet says 750W maximum... 4.8A typical @ 120V) spec sheet link
This circuit is on a 20A breaker.
3wire 12AWG cable.
There are two cables along this run. The cables are joined by a L5-20 plug and receptacle.
It was this L5-20 which failed. The failure appears to be a poor connection between a wire and the connector. Images attached.

This connection is in the ceiling. It isn't touched, pulled, or stressed unless we go up in the lift to modify the installation.

EDIT: The spec sheet does say that typical half-cycle inrush current is 10.3A. They are all turned on at the same time, so that is a potential of 41A inrush. I don't know if this could be an issue on our circuit. It has been fine for about a year until this failure.
mleyden:
Worth a read:

http://www.pbase.com/mainecruising/installing_a_smart_plug
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