How to install the SmartPlug 30 Amp Shore Power Connector
http://smartplug.com/install_30a_plug.html[5/9/2012 9:04:25 AM]
Install instructions for 30 Amp shore power connector (BF30)
Tools Required for Installation
Cutting/Wire Stripping Pliers
#2 Phillips Head Screwdriver
Flathead Screwdriver
Measuring tape
Liquid soap
Silicone adhesive (optional)
Watch the installation video now!
Warning!
*To prevent electrocution, disconnect shore power cord on both ends before beginning!
*Failure to comply with the following instructions could result in an electrical failure/fire or personal injury.
* Strip the outer insulation back NO MORE than 1.5".
If cut too far back, the Connector's inner strain relief jaws won't be able
to adequately secure the cord. (From Step 3)
Installation instructions
1. With cord disconnected from both the *dock and *boat, cut off the female plug from the existing cord.
2. Back out the screws (3) from the face of the SmartPlug assembly and set aside for reinstallation. Squeeze side levers and pull on plug face to
pull out internal connection from plug housing. Images 1 & 2
3. Strip back no more than 1 ½” of the exterior wire insulation. Be careful not to cut the insulation of the three internal wires. Images 3 & 4
4. Slide rubber cord gasket into the rear of the plug housing making sure the cord gasket “pops” into place. For additional waterproofing, apply thin
film of silicone adhesive between cord gasket and plug housing. Images 5 & 6
5. Placing the larger end of the supplied installation tool over the three wires, apply liberal coating of liquid soap to the installation tool and the first
3 inches of the cord. Image 7
6. Starting with the small end of the cord gasket, work the gasket/housing assembly onto the cord making sure there is sufficient length to wire the
rest of the plug. See Images 8 & 9
7. Strip back 1/2” of insulation from each of the three wires. Make sure the wire is in good condition, a clean and bright copper color.
8. Twist bare copper wires into a tight and straight formation. Insert the bare wires into the corresponding color-coded terminals on back of plug
face. Insert wire until insulation butts up against the plastic of the internal connection. Tighten the wire terminal screw clamps after each wire is
inserted. Make certain there is no insulation inside the terminal clamp. Images 10 & 11
9. Grab the cord gasket and work the gasket/housing assembly until the plug face sits within the housing. Image 12
10. Reinstall screws (3) and tighten with moderate torque to fully seat the SmartPlug assembly together. Image 13
11. Peel the paper off the neoprene ring seal and carefully slide it down into the recess on the face. Use a small blunt object to push it down the
rest of the way. Once the seal is seated in the recess, plug it into the inlet and the seal will be permanently set. Images 14 & 15
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