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 This is probably not a great idea if you have a static display, or a computerized one in a serial or parallel configuration. However, for our type of setup, this step not only saves us tons of money, but also time, and room as well.
Basically, most people use a standard 3 prong cord to get their power out to the display. Most outdoor lights only use 2 conductors, so each cord has one wasted wire inside. Multiply that by our 136 channels (128 LOR & 8 interactive), and that's a lot of wire not being used. What I do is cut off both ends of the cord leaving about 10 feet of wire on each, and attach 2 conductor cords. I used the male ends in the construction of my panel, and the female ends have enough cord left on to make it into a new shorter one, so there is very little wastage.
The 2 conductor cords I pick up at the dollar store for a buck each. About a quarter the price of Home Depot. Ensure that the cords you buy have one wide plug on each end (this is VERY important). I mark each end with red or black electrical tape so setup and troubleshooting goes relatively quickly.
I take no responsibility for any house that might burn down due to a screw up on your part.
If you do not understand basic electronics or how this works, then you probably shouldn't be trying it.
This is extremely simple and basic, however one little mistake could result in a fire. That being said...
You will need
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1 outdoor 3 conductor cord
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2 outdoor 2 conductor cords
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A soldering iron
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Heat shrink & lighter
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A multi meter
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Colored electrical tape.
Procedure
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Start by cutting the 2 conductor cords in half, and a chunk off each end of the 3 conductor cord. If desired, ensure it's long enough to make a new cord out of it. Put the ends aside.
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Slide a 6 inch piece of 3/8 heat shrink on both ends of the main cord now. Trust me, it really sucks to forget this and have to chop and start all over.
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Strip the ends of all wires, and slide on some small heat shrink on them as you go along. Take the HOT wire from the first small cord (the narrow end on the plug), and solder to the black from the large cord. Heat shrink away.
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Next, take the HOT wire from the second small cord and solder to the ground wire (green). This is going to be the second hot wire.
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Solder the 2 neutrals from the 2 conductor cords together, and then to the neutral (white) of the 3 conductor. Heat shrink that.
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Lastly, cover with the 3/8 heat shrink, and you're done. Repeat at the other end of the cord.
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Test the cord before it's first usage.
IMPORTANT With the multi meter, ensure you have continuity from one end to the other. You should have a dead short (under 1 ohm) from the neutral (wide plug) to all other neutrals, and wide open to both hot's. Also check that you have continuity from each end of each hot, but not to each other. Mark each end of each cord with colored tape to keep them straight when setting up your display. It's that easy. You've just cut in half the amount of extension cords you need.
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Ensure the NEUTRAL on the 2 conductor cords are the wide prong.
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If you are using GFCI'd circuits, the 2 neutrals MUST be on the same circuit, otherwise it will not work correctly. The GFCI measure's current out against current returning, and will trip if they are not within set parameters.
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If you use 16 gauge small cords and add them to a 14 gauge large cord, the new cord becomes 16 gauge. Don't overload it. Because both circuits share the neutral, these cords can handle the COLLECTIVE load of the new cord size. If it is now a 16 gauge cord, the TOTAL of the 2 circuits can now be 10 amps. You can't have 10 on each side.
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Lastly, Do NOT screw up.
As I said, this is quite a simple project, but could have disastrous consequences if done improperly. It's imperative that you do not connect a hot wire straight to ground. If this happens, your breaker should and most likely will trip. However, if it fails to, that wire will be too hot to touch within seconds and quite possibly will result in a fire.
That's about 20 cords done so far. Note the new homemade wooden reel. They hold a few more than the small plastic ones. |
