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Preparing the plug and flex
1. Open up the new plug by undoing the screw on its base between the rectangular pins. Inside there will be three terminals, a fuse in a holder and a clamp for securing the flex.
2. Many new plugs have a template showing precisely how much sheath and conductor insulation to trim. If yours doesn’t have this you can measure the lengths as you go.
3. Use a pair of side cutters to cut the outer sheath of the end of the flex.
4. Peel this back and remove the excess with the side cutters.
5. Hold the sheathed section next to the flex clamp and separate the conductors. Mark the length required for each conductor – allowing for the actual connection. Cut the conductors to length.
6. Using a pair of wire strippers, trim the insulation of each conductor back by about 5mm or as detailed on the template.
7. Twist together the individual filaments of each conductor making them easier to connect.
Connect the wires to the plug
8. Connect the brown conductor to the terminal marked L or live.
9. Connect the blue conductor to the terminal marked N or neutral.
10. If you are fitting a plug to an appliance requiring an earth, you will have a green and yellow conductor, which should be connected to the terminal marked with an earth symbol or labelled Earth.
Double insulated appliances
11. If you are fitting a plug to a double insulated appliance (labelled with the double insulated symbol), you should not have an earth conductor in your flex.
Securing the flex
12. Fit the sheathed section of flex into the clamp (screw type or push fit).This secures the flex and reduces the risk of the wires being pulled out of their terminals.
Fitting the fuse in the plug
13. Check what rating of fuse is in the carrier. Most new plugs are supplied with 13 amp fuses. However, depending on the recommended fuse rating for your appliance, you may need to change this. Always use the fuse recommended in the instructions or detailed on the appliance. If no details are given, use a 3 amp fuse for appliances up to 720 Watts, and a 13 amp for appliances from 720 Watts to 3000 Watts.
14. Double check all your connections. Replace the cover and fasten with the retaining screw.