Installing SmartPlug on R25

Todd: I have to be wrong I agree... after talking with founder of the SmartPlug, Ken Smith.... it's a gray cell issue no doubt.

[Edit] Just checked the boat and boat's receptacle is male with the 3 pins sticking out. Sorry for any confusion.

As an aside, Ken Smith said they are starting manufacturing adapters that will mate two SmartPlug cord sets together and also another one to mate with a standard Marinco cord set. This product should be available in 4 to 6 months time. Nice... 🙂
 
Point of information. There have been photos posted showing melted plugs and such. What I found interesting on my boat was when I installed my galvanic isolator. Part of the installation requires connecting the ground wire to the isolator. I removed the shore power connector to do this. What I had discovered was that the guts of the connector had melted and the wires even fused to the terminals. This was a condition not evident from the exterior. I called Fusion to get a replacement part and they sent me a new connector free of charge (I did not expect that!), which I installed, but it has bothered me since that this had happened. I have now ordered the smart plug from Defender and will be replacing my shore power connector as soon as possible.
On another note, Jim Favors from Kismet mentioned the change in West Marine’s match price policy and he is spot on. Before ordering from Defender I went to West Marine to get a Smart Plug and they would not match the Defender Price. Their new policy is to match any brick and mortar store within a 50 mile radius of their store. It will be interesting to see how things shake out. As great as the internet is the impact on brick and mortar retail has been a fatal blow in some cases.
Mike Rizzo
 
Mike:

I found the same WM price matching policy to be the same in my Seattle area as well.

I also installed a Galvanic Isolator on our R-25 last year and had to remove the backside cover on the boat's shore power receptacle. For me, I saw no such melting as you described thank goodness. I wonder if the initial connections had not been tightened down securely which would cause resistance arcing and heat buildup.

As an aside, when chatting with the SmartPlug founder Ken Smith yesterday he told me that the traditional Marinco 30 amp cord set product was really only good for 24 amps. If this is a fact then drawing more than 24 amps might lead to overheating in some part of the cord set & receptacle.

I also checked on eBay for the SmartPlug product and did not find any auctions. All SmartPlug components were advertised at a set minimum price which really was in no contention with Defender's Sale pricing providing a 10% discount.

I just hope Defender has enough SmartPlug stock to handle the run on that product over the 4-day sale.... 😱 :roll: If not, some of us will have to wait for a later delivery. I assume we all will know on Monday or shortly after if our orders shipped out.
 
knotflying":38e8a1zw said:
On another note, Jim Favors from Kismet mentioned the change in West Marine’s match price policy and he is spot on. Before ordering from Defender I went to West Marine to get a Smart Plug and they would not match the Defender Price. Their new policy is to match any brick and mortar store within a 50 mile radius of their store. It will be interesting to see how things shake out. As great as the internet is the impact on brick and mortar retail has been a fatal blow in some cases.
Mike Rizzo

West Marine has many stores in handy (IE close to marinas) areas. They feel and rightly so that they have a captive clientele. Not many other Marine Supply stores have as many locations as West Marine. We are lucky that in Anacortes there is Marine Supply and Hardware that has a great stock. I bought Polyform fenders from them at over 50% less than at West Marine. I would not even price shop. http://www.marinesupplyandhardware.com/ They have been in business forever and if you are ever in the area they are worth a trip by just to browse.
 
I second Herb's advice about visiting the Anacortes Marine Supply shop he mentioned. It a great shop to browse for things new and old/used. As we attend the Anacortes street fair each year I always use that opportunity to visit this shop.
 
Just got an e-mail from Defender that my Smart Plug has shipped. Not too bad considering all the orders that must have been placed during their sale.
 
knotflying":vf7x2663 said:
Just got an e-mail from Defender that my Smart Plug has shipped. Not too bad considering all the orders that must have been placed during their sale.

Yep -- same here. My Defender Sale's order delivers to my doorstep April 1st. :lol: ...and my yellow CordPro CP-XL Cord Organizer I purchased on eBay arrives today. 🙂

I assume that because the SmartPlug is non-standard and quite likely represents a very small fraction of the cord sets being used in the boating world, that it is less likely to be stolen by thieves... but really dunno... the shiny boat side receptacle may just be too much for them to resist... time will tell. 😉 :roll: I would be most upset if returning to the boat and find the boat side connector has been snipped off... :cry: :twisted:
 
I'm one day later than you guys with arrival on the 2nd. Now figuring out when I can do the 800 mile drive back to Washington to install the goodies. Bass Pro shop is shipping an external VHF radio speaker also. That was from a gift card I had to use up.
 
This image was posted on a local marina's facebook page with a plea to marina clients to regularly check their shore power connections and cords. The Smart plug keeps lookin' better and better . . .

Gini

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Just received my SmartPlug and after seeing that pic 😱 from Gini, the weekend can't get here fast enough so I can switch the plugs out! 😉
 
Yesterday I went to check on my boat after a couple of days and found that the AC circuits were dead and the red "Reverse Polarity" light was engaged. After a short investigation, I found that the shore power cable had been knocked slightly loose or worked itself loose at the utilities stand on the dock. I plugged it back in securely and everything went back to normal.

Please chime in, but it seems to me that the Blue Seas panel is sensing the increased resistance and shutting off the power if it detects a problem. If the circuit is open, there is no power flowing and no opportunity for a "thermal incident" as described, and shown very graphically in the pictures in the previous posts. Correct me if I'm wrong, but doesn't this feature that we already have on our boats provide similar safety to the thermal sensor in the Smart Plug?
 
Rich,
I think a couple of things may have happened and I am only speculating here. First, the shore power device we have is not thermally protected. You may have gotten the reverse polarity reading because one of the legs was not connected and the system was not getting an equal return current. Not sure why the breaker went off, but if the current was coming in and there was no return current the breaker could have gotten hot and tripped off. If I use my Honda 2000 generator I get the reverse polarity reading, but the breaker does not trip. The reason for the reverse polarity with the Honda is how the voltage cycles out of the generator, which is different than you standard cycles, hence the reverse polarity reading, but this is not a dangerous issue. If you read back on this thread I had melted guts in my shore power. The breakers are set to trip if they exceed the amperage going through them and this happens because there is a heat mechanism that makes it trip. All of the wires on that circuit will get hot as well, but the device trips before they melt and cause a fire. However, the shore power connection is susceptible to overheating if the connection is poor and creates resistance at the connection. The circuit breaker thinks everything is fine because the heat is not at the breaker, but at the shore power connection. The load will continue to be fed through the circuit, the breaker will not trip and then a fire can result at the shore power connection. If the power was supplying a motor of some sort the reduced current could blow out the motor.
I hope this helps.
Mike Rizzo
 
Hi Rich,

It sounds like the neutral connection in the shore plug opened when the connector was loose. The hot and ground must have still been connected. With the neutral open at the shore side the boat side would have risen to approximately full AC voltage by feeding through the loads on your boat. The reverse polarity light is connected between the neutral and ground and lights when a miswire causes the neutral to be the 120VAC hot circuit. Look at the following:

http://www.bluesea.com/articles/90

You can see if the neutral is open at the shore connection the boat side neutral will rise to nearly full AC voltage and light the reverse polarity indicator.

You should look at the prongs on your shore side of the cable, if it had a partial connection before it opened completely it may have heated causing damage. There is no automatic shutdown on the boat side except for an overload tripping a breaker as Mike described.

Howard
 
Received my SmartPlug on Monday and installed it today. It took me less than 1 hour. No issues were encountered and the install instructions were spot on. I also now get to use my new CordPro XL to keep things tidy on the dock.

This SmartPlug is a quality made piece of equipment. It's very sturdy and can is for me a one-handed operation for connecting/diconnecting the cord set end to/from the boat.

I talked with the SmartPlug Tech person at their Seattle headquarters just to go over things before I started and they said if I found any issues with the product they would replace it promptly and if any questions arose over the years they wanted me to report them to them. Nice customer service.

I noted that the complete SmartPlug cord set has just the blue lit LED at the boat side end so there's not a lid cam nub for the lid to engage. The individual boat side connecter that I also purchased that splices onto the end of the traditional Marinco cord set does not have the blue LED but does have the protruding nub for the lid cam to engage. The SmartPlug Tech person said the reason for this is that the complete SmartPlug cord set having the blue LED provides no room inside the connector to allow for the protruding nub. Not an issue IMO, but it did satisfy me I did not have an older cord set model set to me by Defender. 🙂

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Hey, I like that Cord Pro. How long have you had it? Does it work well? Does it automatically retract the cord? How long a Cord will it hold? Too much coffee!
 
I caught the Defender.com sale and ordered a Smart Plug and cord for installation on our to-be-built Ranger 27. It arrived yesterday. I took both out of the packaging and hooked the boatside connector into the plug. It was a very tight fit -- a bit too tight, almost. I had to kind of work the plug back and forth a bit to get it to seat fully, and similarly had to work the plug a bit back and forth to get it off. I realized at the time that, without the plug installed, my leverage is different than it will be once the plug is permanently installed on the boat. Still, to be in the safe side, I shot an email off to Smart Plug last night to ask them about it.

I had a phone call by 8:15 this morning, and a follow up email when they didn't reach me. I called the tech rep back, got him right away, and had a great conversation. Both in the email and in person, he explained that the fit is by design very positive and can seem a bit tight when first installed. He also said it will be a bit more difficult to make the attachment when the plug isn't installed -- because there is less leverage holding it in your hand. But most importantly, he immediately offered to send me a replacement 50' power cord now if I want, and assured me that, at any point during the 7 year warranty, if I'm unhappy with it for any reason, they will make it right.

So, two points: first, if you find the fit on your new Smart Plug a bit tight, give it a little "break in" time; second, this is a great company and if you need their support on anything, you will get it. And you will get it for at least the next 7 years after you buy it. Impressive.

Gini
 
Regarding that Cord Pro - do not use it with any length of electric cord wound inside... that was a popular item at RV gatherings we have attended in the past, and there is talk that there is heat build-up if the cable is left wound up inside that Cord Pro.
 
knotflying":16arsl7b said:
Hey, I like that Cord Pro. How long have you had it? Does it work well? Does it automatically retract the cord? How long a Cord will it hold? Too much coffee!

I had only just purchased the CordPro XL... to go along with my SmartPlug purchase. It works very well for me. It does NOT automatically retract. The inside of the CordPro XL is split in such a way that 25' will wind up into one side and the other 25' winds up into the other side. You insert one end of the cord set into a hole of a very strong plastic divider inside the CordPro and then pull the cord set through until 25' has been pulled. You then wind 25' in one side of the CordPro and the other 25' is wound into the other side. Both sides can be easily unwound to the desired length. This then leaves no ugly looking mess of cable cord laying around on the dock.

The question of heat build up inside the CordPro XL if some of the cord set is left inside has been brought up here and elsewhere. I talked with the SmartPlug Tech help about this and the person said he saw no real issue with this, but to monitor things. If I encountered any real heat issues or found that only a fraction of the 30 amps can be drawn because of this I was to call back and discuss it with SmartPlug. Typically, in my case. I suspect only some 5 to 8 feet of each 25' remains in the CordPro XL when at my dock. My research tells me that if the 50' were to be fully coiled up then only some 15 amps could be safely drawn to avoid too much heat generation in the coiled wire cable. It is something to be aware of.

The CordPro XL can accommodate only 50' of a 30 amp cord set.

Note also, to thread the cord set through the inner plastic divider sheaf do so before installing a lock ring on the dock side end, otherwise you will not be able to thread it through the plastic divider sheaf. I found this out the hard way. 😳

It is true that once the boat side receptacle has been installed then inserting the SmartPlug connector into the receptacle is much much easier than doing so before installing the receptacle... as mentioned by another member, there's a lot more leverage when things have been installed. I also called SmartPlug Tech help about this before starting my installation and I was told the same story, and in addition was told if after doing the installation the connection was found to be to stiff and hard to insert and remove the connector they would send a replacement.

I had also bought the SmartPlug female connector to use on my old Marinco 30 amp cord set. To be honest, it was a real bugger installing it, even though I followed the instructions carefully.

1. When the instructions say to apply some washing soap liquid make sure you apply a liberal amount. On my first attempt I found I could not push and slide the cut off Marinco cord end into the SmartPlug connector and it got stuck half way in and would not budge. I had to pull it back out and add tons of the soap liquid. This did the trick and the cord end slid smoothly and easily into the SmartPlug connector. Also the clever white tubular adapter that's provided to help with this does not go over the outer casing of the Marinco cord end. Not a big issue but kind of concerned me at first as the SmartPlug website video shows that it does.

2. The included instructions say to trim back the Marinco outer covering by 1.25", yet the online SmartPlug video says this should be 1.5". IMO it needs to be at least 1.75" as working the three heavy gauge wires into their clamping holes is a real struggle otherwise. IMO you need more length than 1" of sheafed wire to facilitate the bending and proper alignment for each of the 5/8" of exposed twisted wire to be inserted into their correct clamping holes.

3. Even though I correctly twisted the 5/8-inch bare wire ends (black, white and green wires of the Marinco cord) and inserted them into the clamping slots/holes and then tightening the clamps as much as I could, I found unless they were well and truly clamped (and I mean well and truly) the wires could with a slight tug come back out. My advice, if you have not already done this, is to really tighten those wire clamps down good and strong until your wrist hurts... and then give each one the wiggle and pull test to ensure they will not come back out.

4. Once all the three wires had been secured properly now the task is to get the unit back into the connector housing. It can only go in one way due to the asymmetric nature of the cover dimensions. Doing this requires some care as the plastic wire retention legs need to be folded in against the wires. As the unit is slid back into the cover these three plastic wire retention legs must line up with curved recesses in the base of the cover. This alignment is kind of automatic but if slightly out of alignment the unit cannot be push all the way in. This presents two problems; a) the plastic wire retention legs do not do their job correctly and b) the unit will not slide fully in and will therefore not slide into the boat side SmartPlug receptacle fully causing the two spring clips to not engage nor will the lid will engage when lowered onto the connector. I made this mistake and had to disassemble the whole thing to ensure the plastic wire retainer legs were positioned correctly.

It must have taken me two hours to install the SmartPlug boat side connector onto my Marinco cord set, and was harder than I expected it to be. I also speared myself with my sharp knife at one point 😳 and blood spurted out all over the dinette table. Blood can be very sticky when it starts to dry... :roll: Now that's done I have a backup cord set. 🙂
 
Today I spoke with Ken Smith at SmartPlug in Seattle. Ken is the company founder. I gave him my feedback on installing the SmartPlug connector on my old Marinco cable. He was extremely appreciative of my comments.

The issue of the wire clamps not holding very well is something they are re-designing and understood my concern. They had originally used standard industry flat plate clamps. The new design will use a stainless set screw and a much better clamping device to avoid the issue I raised. This re-design is already underway and the new connector will be released in about 90 days.

The issue where the printed instructions say trim back 1.25" vs. the online video indicating 1.5" was noted and the printed instructions will be updated to state 1.5". I had mentioned IMO it should be more like 1.75". We discussed this and Ken said the three plastic legs for restraining/holding the cable inside the cover are supposed to bite into the outer surface of the Marinco cable and by pushing the adapter into the cover the plastic legs should fold up. However, Ken could see that this could be an issue with the plastic legs not really doing what they were designed to do plus it could lead to the adapter not seating all the way in as I had experienced. Ken went onto saying the three plastic leg design is being re-worked to avoid this situation and will likely be some form of an easy clamp solution to provide cable strain relief.

One last feedback item I made with tongue in cheek was for the SmartPlug cord set to glow at nighttime as a safety measure to avoid people tripping on the cable.... :lol: Ken did not dismiss the idea and said the new cables are being made up and designed at this time and he would pass the idea along to the cable manufacturer.

As I mentioned above, the new connector is being re-designed and is well underway and will be available in about 90-days time. Ken was so happy with my feedback he took my name/address/phone#, and said he will be sending me the newly designed connector in 90 days and would appreciate feedback on installing it. Way to go Ken..... 😀
 
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