Why I HATE the "plug-it" cord!

[tbellemare]

I like the color-coding idea.

Another solution is to always use the high-current cord.

Tom

 

[nickao]

I think the plug it cord is a great addition to the more modern Festool's. The Rotex though is more prone to problems due to the higher current draw. You really need to make sure the connectors are properly mated or you can burn out the plug.

What I really like about the system is it forces me to unplug the tool before replacing the blades.Back in the old days I used to be lazy with the Bosch jigsaw and wouldn't bother unplugging it.

As Frank mentioned it would be nice if Festool designed all tools with one cord in mind rather then having two different style connectors. Another option would be too color code the plug it cord and connector on the back of the tool to help identify which tool gets which cord.

Dan Clermont

I suspect Festool saves(or makes) money with the two cord system. The wiring is probably cheaper for the smaller amperage draw cords so they save on costs there and then they are able to sell more cords while simultaneously claiming safety, by making a two cord system. Pretty slick.

If you start changing over just try to make everything with the higher amp cords, it is what I am in the process of doing.

 

[Frank Pellow]

...
As Frank mentioned it would be nice if Festool designed all tools with one cord in mind rather then having two different style connectors. Another option would be too color code the plug it cord and connector on the back of the tool to help identify which tool gets which cord.

Dan Clermont

Dan, have now done exactly that with my plug it cords and tools that use them.  I'm really surprised that Festool did not think of doing this.

 

[nickao]

I like the one cord idea a lot.

 

[vajper]

In Sweden we only have one type of Festool cords. Guess that is because we have 230VAC outlets and even the high power tools only requires at maximum 1.5mm^2 area. Probably they even go for a lower area because it is a limited, known cable length.

 

[slb]

I suspect Festool saves(or makes) money with the two cord system. The wiring is probably cheaper for the smaller amperage draw cords so they save on costs there and then they are able to sell more cords while simultaneously claiming safety, by making a two cord system. Pretty slick.

If you start changing over just try to make everything with the higher amp cords, it is what I am in the process of doing.

Given the high price of Festools, I really doubt that the cost difference is a significant factor.  I think more likely it is just a case of overengineering.  I too would be happy if they put the heavier plug-it on all the tools.

Steve

 

[FestoolMike]

Programmergeek,

Thanks for the link of the Gorilla braided shield.  What size of shrink tubing did you fit on the ends of the run?  Also, would you recommend the same size sheathing on the larger Festool 37mm hose?

I think this is a great solution.  I will run both styles of cord under the sheath and then color code the ends as well as the connection at the tool.  Use some sort of Velcro to keep the cord not in use out of the way.

Thanks for your post!

 

[tbellemare]

The larger cord fits where the smaller one does so you really only need the large one.

Tom

 

[FestoolMike]

The larger cord fits where the smaller one does so you really only need the large one.

Tom

I see, I am new to these tools.  Now that I think about it, you are correct. 

I was getting so frustrated with the cord as I invariably had the "wrong" cord.  I didn't stop to compare them and fished the correct one out of the appropriate systainer.

 

[Martin Johnson]

As with all things Festool, there is a practical and logical reason for the three cord configurations:

1) The smallest cord is designed to work with lower amp machines like sanders...While you can use the larger plug-it cord with the smaller machine...the reverse is not true.  Using the smaller cord (more flexible) also offers the greatest flexibility when working with the tool.  Imagine trying to sand with a 12 gauge extension cord  (not very flexible).  You would end up fighting with the cord instead of focusing on the task at hand.

2) The larger cord is required for the higher amp consumption machines...UL approval requires it.  This is why you can not use the smaller cord with these machines.  It's the same reason the CTs come with the 20amp pigtail...

3) Non-Plug it cords are for machines that pull so much power that the plug it solution would not be practical....CT, OF2200 or Kapex running at maximum capacity as an example. 

I personally love the system, as it allows me to work without a lot of cords plugged into outlets, as well as not having to plug/unplug machines into my CT every time I change tools.

:

 

[tbellemare]

I think FestoolMike is making a cord/hose one-piece assembly. The relative stiffness of the higher-current cord won't be an issue in that situation.

Tom

 

[Frank Pellow]

The larger cord fits where the smaller one does so you really only need the large one.

Tom

Right you are.  I should have been able to figure that out  :-[ 

Now, if only I had taken the larger cord with me in the situation I described in reply #36 in this thread, I would not have had to resort to the use of a Makita saw.

 

[nickao]

I think FestoolMike is making a cord/hose one-piece assembly. The relative stiffness of the higher-current cord won't be an issue in that situation.

Tom

I will purchase one if for sale. I am having trouble getting the one Festool sells from across the pond.

 

[mwhafner]

Nick,

You can use Techflex to create your own - http://www.techflex.com/prod_PTN.asp.

I have used this or similar products for years in the electronics field, and would be great for this application. 

 

[nickao]

Yep I have the tech flex stuff. I have the yellow sock over the hose with two cords and shrink wrap at the ends. I have this on two boom arms. I wanted the Festool version for something else and to try it out.

By the time I use a festool AS hose and buy the sock and shrink wrap and it was a pain to get it just right, it cost as much or more than the Festool ready made.

 

[mwhafner]

it cost as much or more than the Festool ready made.

I bet you are right.  It has been a few years since I bought any, but the flex and the shrink wrap are both fairly expensive.

How does it work on the boom arms?  I have thought about trying the flex, but am still working out how I am going to setup my workflow.  When I am working in the shop, I switch between the 27mm and 36mm hose too often for it to be practical.

 

[EcoFurniture]

As with all things Festool, there is a practical and logical reason for the three cord configurations:

1) The smallest cord is designed to work with lower amp machines like sanders...While you can use the larger plug-it cord with the smaller machine...the reverse is not true.  Using the smaller cord (more flexible) also offers the greatest flexibility when working with the tool.  Imagine trying to sand with a 12 gauge extension cord  (not very flexible).  You would end up fighting with the cord instead of focusing on the task at hand.

2) The larger cord is required for the higher amp consumption machines...UL approval requires it.  This is why you can not use the smaller cord with these machines.  It's the same reason the CTs come with the 20amp pigtail...

3) Non-Plug it cords are for machines that pull so much power that the plug it solution would not be practical....CT, OF2200 or Kapex running at maximum capacity as an example. 

I personally love the system, as it allows me to work without a lot of cords plugged into outlets, as well as not having to plug/unplug machines into my CT every time I change tools.

:

Martin,
Thanks for the info!
Maybe you can help me on this:
As you mentioned we can use the higher amp, plug it cord on all Festool. So this morning I hooked up the TS55 cord up to my ETS 125, worked great! I then took the OF1400 power cord and connected it with my TS55 --nothing! Both plug it cords have the same specifications written on them... The cord in question works just fine when hooked up to the router. Any idea? Is there anything else you can tell us?

Thanks in advance!

Andreas

 

[nickao]

it cost as much or more than the Festool ready made.

I bet you are right.  It has been a few years since I bought any, but the flex and the shrink wrap are both fairly expensive.

How does it work on the boom arms?  I have thought about trying the flex, but am still working out how I am going to setup my workflow.  When I am working in the shop, I switch between the 27mm and 36mm hose too often for it to be practical.

I am lucky enough to have one of each size hose always set up, one on each boom arm.  I have two hoses and 4 different extensions. The DeWalt routers use a quick plug set up so I have those with the Festool cords on each arm.

Yeah even just that shrink wrap is really expensive!

 

[nickao]

As with all things Festool, there is a practical and logical reason for the three cord configurations:

1) The smallest cord is designed to work with lower amp machines like sanders...While you can use the larger plug-it cord with the smaller machine...the reverse is not true.  Using the smaller cord (more flexible) also offers the greatest flexibility when working with the tool.  Imagine trying to sand with a 12 gauge extension cord  (not very flexible).  You would end up fighting with the cord instead of focusing on the task at hand.

2) The larger cord is required for the higher amp consumption machines...UL approval requires it.  This is why you can not use the smaller cord with these machines.  It's the same reason the CTs come with the 20amp pigtail...

3) Non-Plug it cords are for machines that pull so much power that the plug it solution would not be practical....CT, OF2200 or Kapex running at maximum capacity as an example. 

I personally love the system, as it allows me to work without a lot of cords plugged into outlets, as well as not having to plug/unplug machines into my CT every time I change tools.

:

Martin,
Thanks for the info!
Maybe you can help me on this:
As you mentioned we can use the higher amp, plug it cord on all Festool. So this morning I hooked up the TS55 cord up to my ETS 125, worked great! I then took the OF1400 power cord and connected it with my TS55 --nothing! Both plug it cords have the same specifications written on them... The cord in question works just fine when hooked up to the router. Any idea? Is there anything else you can tell us?

Thanks in advance!

Andreas

The cord I use on my TS75 fits all my tools.

 

[tbellemare]

The photos below show two PlugIt cords and two receptacles.

This is the high-current cord. It is 16 Ga. SJO cord.

[attachthumb=#1]

This is the low-current cord. It is 18 Ga. SJO cord. Notice that it also has an extra protuberance that the cord above doesn't.

[attachthumb=#2]

This is the low-current receptacle (on a Domino). Notice that it has a keyway that corresponds to the protuberance above.

[attachthumb=#3]

This is the high-current receptacle (on a TS 55). Notice the extra keyway is missing.

[attachthumb=#4]

That key and keyway is what keeps the low-current cord from being plugged in to a tool that draws too much current for it. The high-current cord, however can be plugged into the low-current receptacles.

The OF 1400 cord and the TS 55 cord are the same, both are high-current cords.

Tom