Plug It Adapters on Tools Failing

[pdlandgang]

Over the last few weeks I have had the male plug it adapter on my ETS 150/3 fail and now the one on my TS55 is starting to fail.  I know it is this part.  Any other tools works fine with the cord and if I switch cords the problem still occurs.  I swapped the part on the 150 and will need to do so on my 55.  They are 6-7 years old and get pretty good use.  They are not abused, but they do get used.

Does/has anyone else had similar problems with their tools or am I not doing something correct.  The part in cheap (S&H cost more than the part), so I am not complaining.  They have been great, reliable tools.  Just wondering if this is common after a certain time period.

Thanks.

 

[AlexThePalex]

Yes, this is very common, the plug-it system and its cords fail constantly. I myself just had to buy a new cord & tool receptacle for the umpteenth time, and they're not cheap.

These plugs and it's receptacles just aren't sturdy enough for prolonged use.

 

[Peter_C]

pdlandgang, do you unplug the cords for every use?

Alex, how are you using the connectors?

Just curious as mine are pretty hard to turn, but for the most part I never unplug my tools at the plug-it connection. The amount of torque required to remove and replace the ends just seems like a failure is eminent.

 

[RustE]

I'm curious.  Is this a mechanical failure of the plastic parts?  Is this a loss of contact between the metal conductors?

 

[AlexThePalex]

Alex, how are you using the connectors?

I sort of take the plug and stick it into the socket, that's how I use them.

Just curious as mine are pretty hard to turn, but for the most part I never unplug my tools at the plug-it connection. The amount of torque required to remove and replace the ends just seems like a failure is eminent.

Never had the problem that they're hard to turn. A brand new cord maybe on a brand new tool. Once they're a bit used they get pretty sloppy. In fact the last one I replaced would come loose by the vibrations of the sander. Then at one moment I notice this smell of burning plastic, the plug came so loose it wouldn't make proper contact anymore, which led to arcing between the contacts and the melting of the surrounding plastic.

Another failure that happens often is a broken copper wire inside the cable, due to bending of the cord during use. This happens with all tools from all brands, but with other brands you just cut away the broken part and reattach the slighty shorter cord. But with Festool's plug-it cord you have to replace the entire cord because everything is molded on.

 

[RustE]

Alex, are you a tradesman using these tools daily or a few times per week?  I'm just wondering if a hobbyist like me will encounter the same problems.

 

[AlexThePalex]

Alex, are you a tradesman using these tools daily or a few times per week?  I'm just wondering if a hobbyist like me will encounter the same problems.

I'm a hobbyist, but with a pretty big network of friends and family I am probably using my tools more often than the hobbyist who only works on his own stuff.

 

[semenza]

Its a matter of disconnect frequency , usage , and time.  But at some point , which could be many , many years, you will probably need to replace one. It was about five years before I had to replace on the TS55 which was my most frequently used tool with lots of disconnecting.

It is suggested that you replace the cord and the tool socket. And check your other tool sockets for any signs of damage or wear. As for whatever reason the problem seems to be able to migrate. This has been pretty well discussed on FOG.

Also on the newer connections , at least in the USA, the amount of torque / force required to twist them fully into place can be quite high. 

Seth

 

[Holmz]

The plugit cost twice as much, or more, then a Nuetrik TrueOne, and they work 1/2 as well. But it is part of a system, looks good, and generates more revenue.

In the same scheme of wishing all tools had a common rail (like the Bosch/Mafell) in an ISO sense...
Almost all of mine, save the Domino700 I am selling, have the Nuetrik on them.

 

[pdlandgang]

The sander and saw are my most used tools, so I will just call and order the part.  I will also replace the cord to be safe in case there has been any arcing to mess that part up as well.

 

[peter halle]

But just remember that IF there was any damage to the cord and that its internal contacts were damaged AND that cord was used on another tool THEN the other tool should be examined for damage to the connector on the tool.

Peter

 

[pdlandgang]

Thanks Peter.  I will check the other machines as well.

 

[rljatl]

Will something like this help prevent failure?

Permatex 22058 Dielectric Tune-Up Grease