RO 150 EQ plug-it shorting?

[aloechler@comcast.net]

while sanding the 150 started to run slower/faster very strange... almost like someone was pulling the plug out and then putting it back in.

it was securely connected as I have been sanding for hours.

you can see from the pics something is wrong

http://i.imgur.com/eMnpymJ.jpg

http://i.imgur.com/mx4mMa9.jpg

I have had the RO for a couple of years and I have put many hours on it. in the last couple of weeks I have put 40 hours of run time on it for sure.

it lives inside a climate controlled environment so it has never been wet.

EDIT:
I started sanding again with a new cord and it only took about 10 mins to fry another plug-it cord.  so I'm guessing it's something with the prongs on the sander?

that was a quick $80 of plugit cord destruction.  yikes.

 

[jonny round boy]

It can happen sometimes, and I don't know what causes the initial problem (maybe some contamination in the socket?) but you get increased resistance in the connection. This causes heat, which causes charring, which causes a further increase in resistance, which causes more heat, and so it goes. It damages both the cord and the tool socket.

I've had this happen a couple of times now - strange but it always seems to be sanders that it happens to!

As you've discovered, once you have it happen it can very quickly 'infect' other cords, and other tools. The only way to get rid of it is to change the lead and the socket on the tool at the same time.

If your sander is still under warranty, send it in & make sure they change the socket. If you send the cord with it they might swap that too, or you may have to find/buy another (in the UK I *think* the leads are classed as consumables & not covered under warranty; USA might be different).

 

[peter halle]

Throw those cords away. Either you should call Festool to inquire about your situation or you should send it in for repair.  The pins are affected on your sander and it is like a disease.  If you put another cord on and use it will probably damage that cord.  If you use a damaged cord with another tool it stands a great chance of damaging those pins.  And it continues.

Peter

 

[Brice Burrell]

I'll also add that Festool offers a hardwire conversion for the RO150 to replace the Plug-It cord.  If you expect continued hard use of your sander I think the hardwire conversion is a good choice. 

 

[peter halle]

Thank Brice!

 

[aloechler@comcast.net]

I have never had any trouble with my festool stuff but this really sucks.  I love this sander I use it all the time and it has been an awesome workhorse.

sounds like i need to get the hard wire kit and now I'm out $80+ dollars of plug-it cords.

kind of pissed off.

 

[AlexThePalex]

strange but it always seems to be sanders that it happens to!

Sanders are the tools you move around most. All other tools you mostly use in a straight line at a steady pace. But sanders go all over the place, left, right, up, down, turn, and roll over. Their cords take the most stress. 

 

[Kodi Crescent]

This very thing happened to me this weekend.  I was sanding some drywall and the sander started acting funny.  One of the prongs on the plug it connection is burnt and causing an intermittent connection.

Has anyone replaced the connection in the sander handle?  What can I expect if I do it myself?  The tool is out of warranty.  I'll ditch the cord or see about a new end.

 

[jonny round boy]

Has anyone replaced the connection in the sander handle?  What can I expect if I do it myself?  The tool is out of warranty.  I'll ditch the cord or see about a new end.

It's very straightforward. Just undo the screws holding the plastics together (how many and where depends on which sander it is), undo 2 screws holding the socket in place, and disconnect the leads. Reverse the process to fit the new one. No soldering required, they're quick connect terminals. You just need to take note of which way round the wires connect.

 

[aloechler@comcast.net]

http://i.imgur.com/mpDz2yv.png

pretty easy so far... my 150 is from 2010 so it's no longer under warrenty I guess... but I'm going to get the hardwire kit and be done with the plug-it on my sander.

in all honesty I have never much cared for the plug-it deal but it was nice sometimes when switching out tools quickly.  Now that I know it has a long term design flaw... I might consider getting rid of on my most used tools.

 

[Kodi Crescent]

Awesome.  Thanks!

 

[semenza]

strange but it always seems to be sanders that it happens to!

Sanders are the tools you move around most. All other tools you mostly use in a straight line at a steady pace. But sanders go all over the place, left, right, up, down, turn, and roll over. Their cords take the most stress.

Plus it is quite likely that sanders get the most actual run time in hours.

Seth

 

[peter halle]

Of course you are free to do as you wish, but the issue is that the plug it cable might become slightly undone over time.  Especially vulnerable are the tools that are used all the time and the connection isn't tested to be tight like if you were taking the cords or daily to switch to another. 

 

[r cash]

Festools hardwire kit does not inculded the cord so dont throw the cord away.
Ive done this to 3 sanders so far it only takes 10 - 15 min to do .
The Ro 150 is 700w motor has problems with the 18g wire and heat.
Since putting the hardwire on my Ro 150 have noticed less heat build up on the handle.
Have a great day
Rc

 

[aloechler@comcast.net]

do you know what the part # is and can I order it from someplace because festool service never seems to answer their phone?

I have dialed them at least 6 times today and it's either music or a recording telling their biz hours... and it's within their biz hours so...

this is killing me not beging able to use the tool I depend upon the most

thanks

 

[Administrator_JSVN]

Sorry for the trouble. I just called and someone answered on the 3rd ring. So, not sure why the difficulties. Brad, one of our service guys, did say they have been busy today on the phones.

Just curious... what number are you calling? Want to make sure there's not a problem somewhere.

Here are the part numbers.

492780 Kit
450471 Cord
479982 Cap

 

[wow]

The Ro 150 is 700w motor has problems with the 18g wire and heat.

I can't walk out to the shop and check, so I apologize for making someone else do it, but:

Does the RO 150 come with the 18 ga cord or the 16 ga cord? r cash's post makes me think it comes with the 18 ga version.

If it does come with the 18 ga cord, might this problem be (mostly) eliminated if you used a 16 ga cord instead?

 

[jamanjeval]

It can happen sometimes, and I don't know what causes the initial problem (maybe some contamination in the socket?) but you get increased resistance in the connection. This causes heat, which causes charring, which causes a further increase in resistance, which causes more heat, and so it goes. It damages both the cord and the tool socket.

I've had this happen a couple of times now - strange but it always seems to be sanders that it happens to!

As you've discovered, once you have it happen it can very quickly 'infect' other cords, and other tools. The only way to get rid of it is to change the lead and the socket on the tool at the same time.

Just to add a bit to this: The initial problem usually starts either a loose connection (not fully locked and it slips back a little causing less contact area, higher resistance, heat, arcing or a loose crimp during manufacture) or a defect in the metal (loosing the spring action from excessive heat or a small crack from the crimping process causing increased resistance and heat) Once the connection heats up, not only do you get some carbonizing on the connector, the metal looses it's springiness that would normally "wipe" the connection clean.

No matter the root cause, once a connector on the cord starts to go bad it will likely damage the connector in other tools.

These little connectors are often taken for granted, but they are highly engineered precision products. Properly specified during design, proper crimping during manufacture and with proper use, they should be able to last a very long time if not the life of the tool. If anyone is burning these things up regularly, Festool needs to instigate and make some changes.

 

[r cash]

Save your Plug-it hardwire the rotex it will cost less in the long run.
Have a great day
Rc

 

[wow]

The Ro 150 is 700w motor has problems with the 18g wire and heat.

If it does come with the 18 ga cord, might this problem be (mostly) eliminated if you used a 16 ga cord instead?

I was finally able to confirm that the RO150 does indeed come with the 18 ga cord. I will mostly use it with the 16 ga cord that I have attached my DE hose, so we'll see how that goes.