BF30 Smart Plug: Installation Instructions

Tools Needed

• #2 Phillips Screwdriver
• Wire Cutters
• Utility Knife
• Liquid Soap
• Rag or Paper Towels

Materials Included

Step 1

Cut female cord-end from your existing 30A/125V Cord-set. Inspect copper wires for corrosion, and cut back more cord if necessary to reach bright copper.

Step 2

Measure 1.25” back from freshly cut cord end and use marker to indicate cut. Lightly score the outer jacket with a utility knife and be sure not to cut any inner wires. Remove only the 1.25” segment of outer jacket exposing the inner wires and the fibrous cord filler. Cut away all strands of filler.

Step 3

Measure and cut .5” of inner wire jacket from each of the individual color coded conductors.

NOTE:Inspect all freshly exposed copper for corrosion. If corrosion is present, re-cut entire cord several inches back or until you find bright copper. Then repeat steps 1-3. Set aside and continue to step 4.

Step 4

Separate the gasket, connector face and the 3 screws from each other by removing connector face from connector body. Squeeze levers and pull them apart. Set connector face assembly aside.

Step 5

Compress flexible cord seal and force into rear of plug body as shown. Look inside plug body and inspect for proper cord seal fit. The seal should be fully expanded and free from folds or kinks. Set assembly aside.

Step 6

Use the cone shaped cord-install tool and cover the end of the prepared cord as shown apply liquid soap liberally on cord install tool and 12” of cord.

Step 7

Push lubricated cord with cord-install tool through cord seal and connector body from REAR as shown. Continue pushing cord until 6-8” of cord has moved past the front of the connector body. Remove install tool.

Step 8

For ease of alignment, use pliers and slightly bend the ends of the conductor wires as shown. Next, use the provided hex key and loosen the set screws in the front connector assembly to allow plenty of clearance for the insertions of the copper strands into the inlet holes.

Step 9

Simultaneously align and insert the individual wires into their corresponding color-coded inlets as shown. Push all wires in as far as they will go. Make sure all copper wiring is fully captured within the rear of the metal capture. Visually inspect through the clear plastic inlets that there are no stray copper strands. Use the hex key and tighten all screws to 20-25lbs/in.

• Green Inlet-Green Wire(Ground) 
• Black Inlet-Black Wire (Hot) (L1)
• White Inlet-White Wire (Neutral)

Step 10

Close cable clamp arms around cable jacket as shown (1) and make sure a minimum of ¼ inch of cable jacket extends beyond the jaws of the cable clamps (2). Insert (2) #6x1.25” screws (included) and pinch cable clamps around cable to hold them steady.

Step 11

Use Phillips #2 screwdriver and tighten screws evenly about 1 turn each while alternating from one screw to the other until cable is sufficiently captured. Do not exceed 14lbs/ in torque specification. Do not over tighten screws into cable clamp swing arm. A small gap as shown is acceptable, and should be even on both sides. About a 0.125” or ⅛” gap is correct. No gap may occur for smaller diameter cords.

Step 12

Hold cord seal and connector body in one hand as shown (1) and carefully pull cord with other hand backwards until it begins to enter connector body only. CAUTION!! Do not pull components completely together. Carefully push components together as shown (2) until assemblies are fully seated. Wipe clean any excess soap.

Step 13

Locate and install (3) #6x1” screws (included) into corresponding inlet holes as shown. Use Philip’s #2 and carefully screw components together by hand only. Do not over tighten. Max torque is: 14-20 lbs/in.

Step 14

Remove adhesive backing from seal and slip over the plug face as shown. Use blunt tool and continue pushing seal into assembly until it seats and adheres fully. Check for any deformation of seal and adjust to fit.