Why I HATE the "plug-it" cord!

[EcoFurniture]

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

Tom

Hi Tom,

Thanks for the explanation! You are saying the the OF1400 cord should work with the TS55... Well, mine doesn't. I even tried to use my second Ct MINI to find out if the problem is somewhere else. But I got the same results... I'm confused.

 

[tbellemare]

I'll go try mine to make sure I'm not halucinating. I'll be right back...

It works. Try plugging yours directly into a wall outlet. It might be the CT.

Tom

 

[score0matic]

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.

I Do not think the "more flexible" feature in any way covers the PIA of not having a single universal plug it cord. We are not trying to imagine using a 12 ga extension cord but are arguing purchasing  16 ga cords to replace the (in the view of many of these posts) the deficient 18 ga cords that make Festool use Slower, Harder and Frustrating.  I must then conclude that in this area Festool is using an impractical and flawed logic. 

One cord for the Plug it tools is the best choice

Craig

 

[nickao]

I never notice any difference in the flexibility of the electrical cord because you have the vac hose to contend with anyhow. No matter how much more flexible the cord is the vac hose is the factor determining flexibility of movement. One cord for all is the way to go and the way I work. The reason for multiple cords is the same idea for any business, money.

I know many businesses say they are in business to make great tools or help the consumer, but any company is really in business to make money, period. Multiple cords must make them more money one way or another or at least they perceive that it will, otherwise why go through the hassle of the multiple cords. From a manufacturing point of view it must be simpler to offer one cord for everything, for them and the consumer. 

For something that is to work together as a system one cord makes much more sense because two or more cords is neither Faster, Easier nor Smarter.  I think the multiple cords probably makes them more money faster easier and smarter, but that's about it.

I have a drawer full of brand new Festool cords for the lighter duty tools if someone wants to purchase them.

 

[KorDes]

I dont see what all the fuss is about, I have one plug it cord in my CT33 and its my Domino cord. Works fine with my OF2000 to my LS130 and all my other Festool tools.

 

[Canucker]

Wow.. I just posted about this.. I just got a QF-1400 and thought that cord thing might be the dumbest thing I had ever seen.. lol..

So all this irritation is about having an 18ga or 16ga cord ?? ... I could see if it was an 18 ga. or an 8 ga. cord.. I didnt even know they where a different guage until I read this..

 

[dirtydeeds]

first

to my knowledge there WERE at one stage, a couple of versions of the plug it "tool end" connection

aparantly it was something to do with the cable cross section

however over a period of 6 years i have never come across the problem and i have a rake of festool gear

second

festool have changed the type of plastic from which they make the plug it "tool end" connection

it is also a tighter fit especially in the first months 

 

[JeromeM]

first

to my knowledge there WERE at one stage, a couple of versions of the plug it "tool end" connection

aparantly it was something to do with the cable cross section

however over a period of 6 years i have never come across the problem and i have a rake of festool gear

I think you will find that 240v cables are all the same. It is probable that the 110v cables are different depending on power consumption.

 

[monkeyswithhammers]

Hey, I bet I'm not the only knucklehead to find myself on-site with the ts75 and only the smaller gauge wire.  I know this is wrong in so many ways but I just cut that little nub off the wire that prevents you from using it for the higher amp tools.  But I agree with others for what we are paying they should ditch the thinner wire.

On a positive note.  I usually cut the wires on all my other power tools short and replace the plug.  I also don't allow my apprentice to place any tools on the bench while he is working if they are plugged in.  I've damaged too many machines tripping over the wire only to hear the tool crash to the floor and break. (Punctuated with !@#$%).  Being able to unplug the tool at the machine and leave it on the bench is much more convenient than looking for where it plugs into the extension cord.

 

[summerwind]

i have another problem with this cord and it may or maynot be the cord......Festool has refused to warranty the issue as well without even seeing the tool.
the RO150 has been in use for 2 years now, and just recently had the cord replaced as the wire exiting the twist housing wwent south and basically had a broken wire from using it so much.
the new cord was attached (i never remove my Plug-it cords from any of my Festools) 3 months ago and was very much twisted on as required.
for some reason though i was getting burts of speed that was not there before. the machine was getting hot and the "plug-it" cord was getting real hot. i kept checking to be sure it was connected (twisted on) properly and confirmed that was not the isse with the intemittance.
it finally burned off one side of the plug.
having to finish my job though left me with no choice but to take the cord off my Festool jigsaw and use it.
10 more minutes of sanding finished my job, but the cord was becoming toasted...............the cord was twisted on as tightly as humanly possible, so what gives?

the word from our local rep here in Fresno, Ca is that it is a known issue when the cord is not twisted on all the way and is therefore a user error...........sounds more like a design problem that Festool is sweeping under the carpet.
so like i said, the cord(s) have been attached properly, but i can not at this time use my RO150...................instead i have to rely on my backup which is the one i bought 5 years ago where i have to use an allen wrench to change pads.

 

[summerwind]

one more thing, the rep in our area of Fresno, Ca did tell my install manager that i could buy Festoll's "hard wire kit" to remedy this issue........so if i should do that and there is a fire related to this issue, is Festool ready for this kind of liability?

 

[wnagle]

Summerwind,

Did you call Festool customer service?  I bet you could send it to them to check out.  Then you would find out if there is a problem with your saw or a problem with the way you are twisting the cord on.

I would call Festool customer service.  If its Festools problem they will fix it for free.  If it's your problem they will fix it for a charge.

 

[score0matic]

It would seem that the issue is in the plug it female end on the tool rather than the cord. I would follow Wayne's advice and check w/ customer service.

Craig

 

[Brice Burrell]

Summerwind, the plug-it cords can be very hard to twist a full 1/4 turn to make the correct connection when they are new. Your comment "twisted on as tightly as humanly possible" doesn't mean you it was on correctly. Your ability to twist the cord may be much different than mine. Your comments about your plug-it cords staying on your tools also makes me believe that you may have never attached the plug-it cord correctly when the tool and cord were new when the cord is at it's most difficult time to install. It may have come lose at some point as well. I'm not saying your at fault necessarily, some plug-it cords can be so hard to turn you truly believe it won't go any farther without breaking. They will turn the full 1/4 to lock correctly but it can be hard to do.

This isn't a problem Festool is trying to sweep under the rug. The manual clearly states the plug-it cord must be twisted a full quarter turn to be properly connected. Be sure to read your manual folks there is some good info in there.

 

[Brice Burrell]

It would seem that the issue is in the plug it female end on the tool rather than the cord. I would follow Wayne's advice and check w/ customer service.

Craig

Yes, there likely is. When the plug-it isn't attached correctly it arcs and burns out both the cord and the tool end of the connection. I too would strongly recommend you call Festool's service dept. and have them fix your Rotex.

 

[tbellemare]

Another complication that arises is that after a cord has been damaged due to the arcing Brice described, if it is used on another tool, the problem can metastasize to that tool also.

Tom

 

[summerwind]

Summerwind, the plug-it cords can be very hard to twist a full 1/4 turn to make the correct connection when they are new. Your comment "twisted on as tightly as humanly possible" doesn't mean you it was on correctly. Your ability to twist the cord may be much different than mine. Your comments about your plug-it cords staying on your tools also makes me believe that you may have never attached the plug-it cord correctly when the tool and cord were new when the cord is at it's most difficult time to install. It may have come lose at some point as well. I'm not saying your at fault necessarily, some plug-it cords can be so hard to turn you truly believe it won't go any farther without breaking. They will turn the full 1/4 to lock correctly but it can be hard to do.

This isn't a problem Festool is trying to sweep under the rug. The manual clearly states the plug-it cord must be twisted a full quarter turn to be properly connected. Be sure to read your manual folks there is some good info in there.

Bruce,
i have been in the trades since 1974............have been a millman for nearly 75% of that time. i am currently in solid surfacing as it pays 3 times as much.
i am fully able to read and understand mechanical aspects of tools and their operation and requirments.
the plug-it cords have been fully locked.........one thing for sure is that when you look at the cam locking area on the cord is you will easily be able to identify with how much turn is needed to fully lock the cord, so there is no need to point out that i have not fully locked the cord. the tools i own were delivered to me without the cords attached, so i am the only one who has attached the cords.
the problem is that the RO150 is burning up these cords now.
2 pairs to be exact, and both were FULLY LOCKED into posistion.
this is a design flaw to start with, but right now it is a tool issue. anytime an AC powered machine starts pulling enough amps through a cord to burn it is a defect, or something has gone wrong internally.

if you'd like to identify with my skills as a craftsman/mechanic......please read through my current scale project here,

http://www.rcuniverse.com/forum/m_8507751/tm.htm

i'm not a beginner at any of this.

 

[summerwind]

Another complication that arises is that after a cord has been damaged due to the arcing Brice described, if it is used on another tool, the problem can metastasize to that tool also.

Tom

i have installed 2 brand new Plug-It cords to this sander.............both were twist locked fully...........both have been cooked on the same peg.

but since my rep says a hard wire kit will fix this issue, i ask, the burning that has been seen on these 2 cords is obvious, and if hard wired, should that burn or cause a fire, will Festool take care of it?

why is the RO150 the only one i read about that has an issue?

 

[tbellemare]

That indicates that the outlet on the sander is the culprit.

You should call Festool service at 800-554-8741 during business hours. They should be able to take care of you. They are very helpful and friendly.

Tom

 

[Brice Burrell]

SW, your experience in the trades isn't in question here. You described your problem and I'm telling you what likely caused the problem. This isn't a new issue and it's not only happened to RO150 sanders, almost all of the time it is a user problem. I've put my Festool tools through years of daily professional use without my plug-it cords coming lose on their own. Only one time did a plug-it cord come lose, it was because I didn't attached it correctly. You said you're no beginner, that's fine but what makes you think only a beginner would make this mistake? It can happen to anyone at anytime.

i have installed 2 brand new Plug-It cords to this sander.............both were twist locked fully...........both have been cooked on the same peg.

I'm not sure I understand what happened to your first plug-it cord that caused you to replace it but maybe there was damage to the Rotex's side of the connection at that time. With a burned the pin on the Rotex the first replacement cord burned up and so did the second one because of the Rotex's damaged pin/connection. In other words, it didn't matter if the cords were installed correctly or not it was going to burn up. This is probably why you feel like you aren't at fault.