What about diagnosing, testing, and preventing possible faulty Plug-it issues?

JCB

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May 4, 2024
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Recently My LS-130 had low, pulsing cavitation action. I was able to get it to perform better with a different plug-it but it seemed like it had a similar problem with strain on the cord A third seemed to have no apparent issue.  The first cord was dedicated to the extractor hose so it made sence it might be worn and faulty; it also had a toasted look on one of the socket terminals.  The other cord had no where near as much use and was mildly discolored on one side; it was howerver off my OS 400 and Its been in some challenging situations, so again could be the cord.  But then the thir, a unused plug it is now having problems! 

I may have seen this already; my RO125 actually melted down after cavitating and when I got it back it back from festool the first time I went to use it, it was acting faulty with multiple cords. I believe I tested it with no problem but when it had the persistent fluctuation in Power I sent it back to festool and they sent it right back saying normal function. And then it worked fine for me too, using the same plug it cords! 

Then, recently I was about to box the RO125 up after ~20 hrs of use when my LS-130 clued me in my plugit might be the culpret.  I tested it with the unused plug-it and it seemed fine which was more evidence my cord or cords were the problem.  But now I thin the LS-130 has incfected the new cord and I am about to change the socket on the tool but Id like to understtand whats going on. 

I tested all of my cords for continuity and they all registered about the same. Also I tried cleaning up all the connections which usually fixes odd electrical mysteries. 

I dont want to just throw money away buying parts if it is unnecessary or worse, doesent fix the problems.  So who can describe whats going on with the plug-it mystery? How to know weather to replace the cord or the tool socket or both and which tools how often? Et cetera.  Is there a diagnostic strategy to find the fault before it gets worse, to prevent or anticiapate a fault?  IF there is a fault, where is the fault and what is the official recomendation? 

One more thing.  I used a product called DEox-it on my connections and I am wondeing if this was a bad idea somehow.  I assumed it was fine , I also would assume its fine to use synthetic dialectic grease or OXguard on the recepticle connectors as well.  Any thoughts on this?

I have enjoyed my festools very much.  They have proved to allow for more precise work and are fairly durable but electrically they are tempermental.  I have sent my TS-55 in twice, for problems involving sparks, heat and melted plastic, et cetera; and I use it infrequently.  Maybe long custs to demo strata of wood flooring with the stock blade was too hard for it even though the dust control aspect made sence.  Perhaps the Panther rip tooth blade I used for ganged up 3/4" melamine was wrong too.  I stopped my cut but finished them individually because the saw seemed strained and it fried next time, on soft pine and 1/4 ply.  Now, its the Rotex and my LS-130, or plugits, or both, or neither.  Please, any feedback is appreciated!
 
Continuity testing without load doesnt tell anything really.

Cords usually break near one of the ends and you can hear it on the machine when you jiggle the end.

I have never sprayed anything on the contacts.

The one broken plug it cord I have seen was used with a sander, often without hose attached. Using with 3.5m hose and 4m cord prevents pulling on the cord.
 
[member=81795]JCB[/member] Welcome to the forum.  Sorry that your first post was about an issue.  I'll let others talk about the testing, etc. but here is one thing that has been advised here since the beginning:  If you are exoeriencing issues with a cord and especially if you notice darkened terminals on either the tool or the cord or both, if you then try another cord it is likely that that cord will also become compromised and the "disease" can spread to cords and other tools.  Best to address the issue on the cord and the tool.

Peter
 
JCB said:
I tested all of my cords for continuity and they all registered about the same. Also I tried cleaning up all the connections which usually fixes odd electrical mysteries. 

--snip--

One more thing.  I used a product called DEox-it on my connections and I am wondeing if this was a bad idea somehow.  I assumed it was fine , I also would assume it's fine to use synthetic dialectic grease or OXguard on the recepticle connectors as well.  Any thoughts on this?

Unless your area of use is outdoors or you have a very damp ares where you store your tools there is no benefit to using those products. In point of fact using them on the metal areas will reduce the ability of those to conduct electricity. The kinds of areas where dialectic grease is useful is in the rubber boots of spark plugs to seal water out of the area above the ceramic insulator.
It should never be used on the metal areas that conduct the current.

"Dielectric grease is a simple compound of oil and silica filler that’s very hydrophobic and is excellent at sealing out moisture and preventing corrosion. It is an electrical insulator or dielectric, and while a popular material for batteries, power outlets, light bulbs and spark plugs, its use is often misunderstood. The trick with using a dielectric grease is knowing where to apply it to seal the electrical contacts from moisture ingress and prevent arcing while not impeding current flow."
View attachment 1
https://mgchemicals.com/blog/dielectric-grease-on-spark-plugs/#:~:text=Dielectric%20grease%20is%20a%20simple,its%20use%20is%20often%20misunderstood.

In short if you have been using it on the pins and sockets of the connectors you have been doing yourself a disservice and creating your problems.

I have a single plugit cable attached to my dust extractor hose that is the only cable I have used for 15+ years with about 12 different tools and hundreds of make and break connections. I have never needed to swap it out for any of the other 11 cables that are in as new condition.

TLDR using any grease or lubricant on the connectors has caused your problems.
They should be clean and dry, free of dust and grease.
 

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Yes, I use my tools outdoors and I live in a very damp environment. This is why I have considered using greese for electrical connections, and I had an electrician recommend using oxguard on connections in exterior junction boxes. The labeling says it enhances and protects the connection.

I have not greased any of my plugits but I am considering it as a precaution since I very clearly have a problem that is well documented. I will say my vectouro and ro 125 have been worked very hard and the plugits have taken a lot of strain and I am not surprised if that has damaged them. Also, the ls130 is used less than the orbital sanders but the direction of movement affects the cord management. My hose likes to come off the ls130, I imagine the plug-it gets the same strain.

I used a product called deoxit, it’s a very expensive cleaning oil that says it cleans an enhances, I just tried it yesterday when I was working on this problem. I can’t see how it would hurt but it definitely did not seem to help!

I believe the new socket will do the trick but I am wondering if the “used once” plugit cord is now somehow wrecked. It doesn’t look burned and it seems to have continuity with the new socket but it smells a bit like hot plastic and I washed a bunch of soot out.

If you like, I could take some of your spare plugits off your hands! 😉
 
JCB said:
Yes, I use my tools outdoors and I live in a very damp environment. This is why I have considered using greese for electrical connections, and I had an electrician recommend using oxguard on connections in exterior junction boxes. The labeling says it enhances and protects the connection.

If you have a connection that is not designed to be made and broken, but like the terminal of a breaker is a one and done deal then the dialectic grease (it is not greese) can protect that from corrosion. However on a plug they is designed to be connected and disconnected it is a very poor idea as it can only make the connection worse

JCB said:
If you like, I could take some of your spare plugits off your hands! 😉

Well if you use the best in service plug design  View attachment 1 and care to travel to UdonThani province we can discuss that idea
 

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I do essentially the same thing, but with 2 cables, because of 2 extractors. I have kept those Plug-its in place on each of them since they were new. There are days where I swap tools/connections dozens of times. I do "inspect" them occasionally, just to be aware, but it has never been a problem.
I don't know that they were intended to deal with that many in a day, but it has never been cautioned against either. Nearly 6 years on one and 4 on the other.
 
I let a buddy borrow my RO150. He didn’t have the cord completely locked in and kept using it even after he was smelling something burning. It actually caught fire.  I couldn’t believe Festool repaired it under warranty but very happy they did. 2009ish.  Still have that Rotex and it works great. 

If any cord is suspect toss it out and get a new one.  Not worth the risk.
 
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