Bespoke and custom cable services
Product variations
We can change every variable on basic mainsleads to make them custom cables, e.g. different length, colour, cross-sectional area, fuse (in UK plug); different plugs one end and different connectors the other. We will also advise which combinations are or are not recommended e.g., approvals, cost, ampacity, temperature, mechanical strength etc, to come to the best solution.
Audiophile plugs and custom cables
Our rewireable plugs and connectors can have their contacts plated with precious metals to decrease electrical resistance, to improve sound quality in audiophile settings, e.g. gold, silver and rhodium plating. Cables can be oversized to also reduce resistance, using the largest that will physically fit, for added benefits.
Shielded cable is a common requirement to limit interference, preventing the mains cable acting as an aerial; fitting ferrite beads or cores to suppress high frequency noise is another solution.
We can also supply earth cable for grounding each piece of equipment independent of the mains, e.g. clean earth systems. Braided cable or braided sheaths are also possible for aesthetic reasons.
Custom cables: processing
We can alter any lead to your requirements – these include the following:
- Cutting the cable to different lengths
- Stripping back the outer cable jacket insulation
- Different length live, neutral and earth insulation inner cores
- Adding loose and moulded grommets and strain reliefs
- Applying insulated and uninsulated crimp terminals (M-series rings, bootlace ferrules, male and female push-on/fast-on 4.8mm and 6.3mm spade terminals)
- Hand-wiring rewirable plugs, sockets, terminals, and IEC connectors.
Packing and packaging versatility
We offer a full range of individually tailored packing solutions. These include having power leads individually hanked, in polythene bags, or with labels on the box, bag, or powercord. As this is labour-intensive, it is usually best done at the manufacturing stage to minimise handling processes and benefit from automation and lower manpower costs. We can break box quantities for smaller orders, and if required also pack different items or specified quantities in different boxes and ship on different dates. Larger orders can be palletised, and if necessary weight-limited or packed on pallets of specific dimensions.
Plugs and sockets for film use
We are regularly asked to consult on the use of plugs and sockets in set dressing for film use, on both geographical suitability and historical accuracy. This is mostly cinema, occasionally television, and once theatre: “it’s a play set in 1920’s Italy and unplugging a lamp is critical to the plot”. Sometimes it can be an interesting and edifying challenge.
An important distinction must be made if the plugs and sockets are required to work, with the plug assembled onto the equipment cable, and the socket wired up to the mains. These must be electrically safe, respecting voltage and current ratings, and carry the relevant approvals.
The other option is plugs and sockets for purely decorative use, which will carry no current (it may be wise to render them 100% harmless by e.g. removing contacts). This becomes increasingly the case the older the setting, as standards change, and genuine, accurate examples become rare. This allows for more flexibility and historic pieces can be sourced without having to maintain traceability, ‘aged’ or modified from modern parts, or entirely reproduced by 3D printing from photos. A second, hidden, connection can be added to power the equipment if so required.
Get in touch now for a swift, competitive quotation, call us on 01264 353489 or click here to contact us
Non-standard adaptors
We can supply outside usual requirements to make fully custom cables, such as intra-series IEC adaptors with different current ratings, e.g. 10 Amp C14 to 2.5 Amp C7, 10 Amp C14 to 16 Amp C19 leads; or temperature ratings, e.g. 70°C C14 to 120°C C15 leads found in data centres. We do recomend staying within the current ratings on these prducts, unless there is a compelling operational need.
We also supply short inter-series adaptor leads for PAT testing and evaluation of equipment to be exported, e.g. UK plug to a IEC60309 ‘Commando’ socket, or European Schuko plug to 6-way Australian extension lead, or Swiss plug to single Italian socket.
Hospital grade
Some countries have special requirements, higher specifications, and tighter tolerances for medical power cables; we can supply hospital-grade plugs and leads for all of these countries (click on individual links for more information):
The UK does not have specific requirements for medical settings, but some possible requirements are a red plug on white cable, or alternatively, high-visibility orange, or polyurethane cable which is water and fluid resistant
Cabling
In addition to standard pvc, we also supply rubber and neoprene custom cables for resistance to mechanical wear, Low Smoke Zero Halogen (LS0H) to limit the dangers of smoke inhalation in the event of fire, shielded cord to reduce electromagnetic interference, armoured cable for serious protection and heat-resistant cables for high temperature environments.
Whilst Europe and most of the world uses Harmonised cable, we additionally provide the correct, discrete, cables for North American, Japanese/Taiwanese, Australian, Indian, and Chinese standards, along with some multi-approved cables that cover most of these.
Coiling
We can offer two-core, three-core and multi-core ‘curly’ (spiral or retractible) custom cables on request in both PVC (polyvinyl chloride) and PU (polyurethane), and occasionally rubber also. These are possible either on their own or with moulded or rewireable plugs and connectors fitted. These are often used on movable equipment, e.g. hotel hairdryers, electric lifts, and industrial cutters. In addition to the normal mains cable spec, for these we need the following lengths: open (extended), closed, and tails (un-coiled cable at each end).
Get in touch now for a swift, competitive quotation, call us on 01264 353489 or click here to contact us
Specials
There is no Minimum Order Value (MOV), and no Minimum Order Quantity (MOQ) on stock items. However, custom cables requiring a special production run may have a MOQ of varying quantity depending on how non-standard the product is.
These parts can be manufactured to our customers’ drawings on request. Morvan offers stock-holding facilities at no extra charge, whereby we store customers’ special stock in our warehouse ready for next day delivery, guaranteeing leadtime and spreading the cost over the duration of the order. Our technical team may also be able to recommend a similar or equivalent product from stock.
We can also supply high (or higher) quality equivalent parts to many own-brand manufacturers at a fraction of the price. Please contact us with your requirements and we can offer different options.
North America
On top of the standard domestic 125 Volt 15 Amp 2 pin and 3 pin USA plugs and sockets, we can also supply almost the full spectrum of NEMA 2 pole, 3 pole and 4 pole straight blade and locking plug and socket variations, including 3-phase and more obsolete types. Generally these are 15A, 20A, 30A, 50A, and 60A current ratings; 125V, 250V, 277V single phase and 3-phase Wye (Y) and Delta (Δ). As rewireable plugs these can be assembled onto an existing cable to make American custom cables to fit the required socket outlet. Our North American page for more details.
Head Office
Morvan Trading Ltd,
Westover Farm,
Goodworth Clatford,
Andover, Hampshire,
SP11 7LF