Replace the socket on the sander. 

They haven't updated the plug it cables.  This is an issue with heavily used rotex sanders as far as I know (other sanders don't draw as much power and this doesn't seem to be an issue).  The best bet if you don't want to hardwire is to dedicate one cord to the sander.  If it fails in a few years, at least the issue is isolated and it's easy to replace one socket and cord. 

The vibration and amperage draw subject that connection to more wear that you typically see on other tools.  But, yes, technically correct, it is subject to wear on all tools.  The two tools that are particularly prone are the Rotex and the Vecturo.  On the other tools it's a pretty durable connection. 

There may also be a relation to the number of times the cord has been cycled, as in connected/disconnected to a tool. Much like a wall receptacle that you plug a cord into can fail over time. The pins or blades (depending on the connection style) have a friction fit made snug by spring pressure alone.

Every time you connect or disconnect some of that spring pressure is lost. How, by not always being able to insert or remove the plug exactly in line with the pins/blades. Any off center/angular force will tend to deform the connection, reducing the quality of the connection from an electrical perspective, and increasing resistance which will cause heat that further degrades the connection.

The OP stated that he had one cord that was connected to the boom arm, so I assume that one cord was used for any tool at that work station. So it would see more wear than other cords or the tool because it is plugged/unplugged every time.

Also are there not two versions of the Plug-it cord, one for higher amperage tools?

If the problem was systemic, you'd hear about it on these forums with other sanders with more frequency than the Kapex issues. 

This particular problem pops up once in a while. It's a good ol' regular here.

Personally, I've only used Festool tools for the last 6 years, but never once an issue with the plug it cord I keep at my MFT workstation. 

From what I've read here some people have problems all the time, others never. I think what Bob mentions above is right on the money, the number of connects and disconnects play heavily into it. And the way you use the tools.

For instance, I am sure you and I have very different ways we work with our tools, you work on your MFT, and I've been runing up a ladder all week sanding the edge of a roof with my DTS, ETS125 and Rotex.



Cord and hose taped to my ladder to get 5,50 meter high, and having to change between sanders at height, multiple times. This was a bit of heck week for me, because the condition of the paint was worse than originally anticipated and I decided to use my own ladder for what seemed to be an easy job, instead of renting scaffolding. To my dismay I had to strip it all to bare wood instead of just some light sanding.  

I have worked like this before, with other tools before I got into Festool 11 years ago, and I never had problems with cords. But the Plug-It breaks all the time, one way or the other.

Given that you've had multiple issues with different tools, perhaps the unknown origins of the tools you're refurbing has something to do with it?  And we know an electrical issue can spread like an STD when swapping cords and tools.  So one bad connection can result in many over time if you're not careful.  I'm not discounting your observations, obviously your tools failed you.  But I don't think this a widespread product or design failure on Festool's part which is what you're suggesting.  For my own part, the plug it connection is fantastic.  And one failure in 13 years is perfectly acceptable.  It is a wearable component.

Mostly answered above. It is not the origin of my refurbished tools, it is the number of disconnects and the way of working. I'm out in the field all the time with many different tools. With a total of 17 Festools I think I have to buy 2 or 3 new cords each year. I also have a number of other tools from DeWalt, Elu and Metabo, I never have to replace a cord.

The idea of the Plug-It cord is very nice, it's just not strong enough for rough circumstances out in the field. If you work in the shop all the time, sure, you're going to be fine. But I think it could and should be done better.

I was having weak connection issues with my ETS-EC 150/5 -- no arcing but definitely got the stop-start phenomenon.  Ended up buying a new socket for around $7 and switched it out myself.  Two years on haven't had a repeat of the problems:

 http://festoolownersgroup.com/festool-tool-problems/loose-plug-it-connection-on-ets-ec-1505/

I imagine the process for the RO150 is similar.  It was very simple, even for someone like myself who is not naturally mechanically inclined. 

Quote from: Alex on August 01, 2019, 11:55 AM

I have worked like this before, with other tools before I got into Festool 11 years ago, and I never had problems with cords. But the Plug-It breaks all the time, one way or the other.

I haven't had any Festool Plug-It issues YET...However I've had ZERO issues with Milwaukee's version in over 20 years. They're both insert and quarter turn connectors but the Milwaukee connector is bullet proof. 

Good point, neither of my Milwaukee drills has exhibited this issue and they are both over 20 years. But then again I don't disconnect the cords that often. Actually, they have seen little use the past couple years except for when I have to spin a large diameter bit or hole saws or for extended operation that I know a battery powered drill is not up to the task.

With Festool, you pretty much forced into disconnecting the cord every time you put it in the Systainer.

I am one of those who have yet to have this issue. I am also one that discovered the issue here on the FOG before I started getting heavily vested in Festool. As a result I learned the importance of making sure that the cord is secured/locked properly. I am sure a time will come when either myself or one of my guys will let slip.

The cables have been updated.

That's a total and utter "meh" update.

What they need to update is the connection itself. Not hang something on a tail somewhere in the back. Make the electrical connection more robust. Make the "click" when you twist it tight more pronounced and secure. Make the plastic stronger. Neutrik has so much better connectors.

The design should be renewed from scratch, not a little tweak here and there within a flawed system just the keep it backwards compatible.

Thanks for all the advice guys, I have ordered a new socket to be safe.

I might invest in one of the new plug-it leads for my boom arm but to be honest I hardly ever use my Rotex anymore and I do think that is the only tool that will cause me any problems, I will just take it a bit steadier in future when using it.

Doug

Just to follow up part turned up next day, took 5 mins to fit and all good again, surprised how much tighter the plug-it lead fits now.

Ordered part from Miles Tool and Machinery Centre (am in UK), cost £12.11 including next day delivery.

As soon as you have one tool or cable where the contacts are corroding the damage will start to spread, from sockets to plugs and the other way around. Simply from the resistance going up, leading to heat, eventually arcing. It's basically a STD for Festools, just with no condoms available to mitigate.

So IMHO in case you notice connection issues you should instantly replace the socket on the tool an bin the cable, then carefully examine all other cables and tools that you used recently with the affected PlugIt connectors for signs of corrosion.

That some might have problems while others do not could stem from differences in local humidity, repeated issues likely stem from continuing to use a defective connector (plug or socket). YMMV.

This may not be reasonably applicable to those of you with all, or mostly all Festools.  But I have one Festool, a Domino 700, and many other hand held power tools.  I like the Festool idea of plugging in the vacumn and the power cord but wanted it on my Bosch DEVS 1250 and DeWalt ROS and my DeWalt Track saw.  So I put C14 sockets on these tools - cutting off their power cords to less than a foot long, and then put the female connector on a snipped off cord.  Here is a link to a 10 pack of the connectors for the tool:

https://www.amazon.com/gp/product/B06XTK6R9W/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1

You want a female version for the power cord, there is a locking one for about $8.50.  I also got a couple of long cables with these connectors and use them too. 

I just got my Domino but will snip it's cord soon and wire in one of these C14 connectors.  To some of you that may seem terrible but I don't like the feel of the power cord twisting into the tool connector - I would probably get used to it.  But with a power cord already on my Bosch 5 meter hose, it is just more practical to me to have the one connector on all my tools. 

If I had a Festool that had a power cord that did not want to make contact, I would be very tempted to solder on a stubby cord, however, and use this type of connector rather than pay for the pieces to "fix it right".