Having trouble with your Festool power tool? Well, we're here to help you. Before posting to the forum, give us a chance to diagnose and resolve your issue. In the U.S. and Canada, call us toll-free at 888-337-8600 on Monday-Friday between 8a-5p EST or contact us via email at service@festoolusa.com. For other countries, please visit http://www.festool.com for contact information for your local Festool service department.

Author Topic: power cords burning out  (Read 7270 times)

0 Members and 1 Guest are viewing this topic.

power cords burning out
« on: April 18, 2013, 05:49 PM »
85397-0 We have a number of Festool ETS 150 RO sanders in the shop and have used them with no problem for years. Now, I am getting shorted power cords on these. Any thoughts as to why this may be happening? See attached immage.

Festool USA does not pre-approve the contents of this website nor endorse the application or use of any Festool product in any way other than in the manner described in the Festool Instruction Manual. To reduce the risk of serious injury and/or damage to your Festool product, always read, understand and follow all warnings and instructions in your Festool product's Instruction Manual. Although Festool strives for accuracy in the website material, the website may contain inaccuracies. Festool makes no representations about the accuracy, reliability, completeness or timeliness of the material on this website or about the results to be obtained from using the website. Festool and its affiliates cannot be responsible for improper postings or your reliance on the website's material. Your use of any material contained on this website is entirely at your own risk. The content contained on this site is provided for informational purposes only and does not constitute professional advice.


Offline Bikeboy80

  • Posts: 467
    • Drumm Design Remodel
Re: power cords burning out
« Reply #1 on: April 18, 2013, 05:51 PM »
Not fully connected causing an arc?
The Green Koolaid sure is sweet...

Kapex w/crown stops, Domino DF 500 Set, Syslites, PS300, RTS400, RO150, OF1010 w/LR32 Kit, TS75, 75" + (2) 55" rails, RO90, ETS125, RAS, Custom abrasive systainer, CTmini, CT36AC w/blastgates, PLANEX w/harness, TI15, T12+3 set, MFT/3 cross cut, Universal Cleaning set, Turbo Suction Brush, 12 drawer Sortainer, Extra Systainers with job specific tool collections

Drumm Design Remodel

Offline Peter Halle

  • Global Moderator
  • *
  • Posts: 12385
  • Remington Steele - My Third Boy
Re: power cords burning out
« Reply #2 on: April 18, 2013, 06:05 PM »
Burned cords are like a virus.  You should contact Festool service.  If you have one cord that has an issue due to whatever reason, it can cause damage to the tool Plug-it connection.  Then if a new cord is added then it will happen again.  Move a damaged cord to a good tool and there is the risk that that tool will have its connections damaged.

Peter

Offline Brice Burrell

  • Posts: 7392
Re: power cords burning out
« Reply #3 on: April 18, 2013, 07:02 PM »
Welcome to the forum.  Sorry it is under these circumstances.  Peter is right, this can trash several tools if you aren't careful.  Festool has a hard wire conversion for the RO150.  That might be a good idea if you use your sanders hard.  Give Festool a call.  

Offline SRSemenza

  • Global Moderator
  • *
  • Posts: 9656
  • Finger Lakes Region, NY State , USA
Re: power cords burning out
« Reply #4 on: April 18, 2013, 08:21 PM »
What they said, and it seems that  length of time they have been used matters.  Had this happen on my TS55 with the one cord that gets the most use. I luckily notice that something wasn't right.  Sort of happened all of a sudden.  Realized the problem from posts here on FOG and caught it before I spread it to other tools.


Seth
« Last Edit: April 18, 2013, 08:29 PM by SRSemenza »

Offline jashawk

  • Posts: 3
Re: power cords burning out
« Reply #5 on: March 10, 2016, 04:29 PM »
Yes I have had this problem multiple times. I agree that it seems to transfer from one tool to the next if switching cords.

Offline mrB

  • Posts: 892
Re: power cords burning out
« Reply #6 on: March 10, 2016, 07:47 PM »
This is very interesting, and a good thing to know about!

So does this issue stem from the power cord only, or can a tool that has been affected by a dodgy cord transfer the issue to another cord as well?  Does that question make sense?
there's nothing like the right tool for the job

Offline Brice Burrell

  • Posts: 7392
Re: power cords burning out
« Reply #7 on: March 10, 2016, 08:57 PM »
This is very interesting, and a good thing to know about!

So does this issue stem from the power cord only, or can a tool that has been affected by a dodgy cord transfer the issue to another cord as well?  Does that question make sense?

The answer is yes, this problem can go from tool to cord and cord to tool.

Offline RobBob

  • Posts: 1378
Re: power cords burning out
« Reply #8 on: March 10, 2016, 09:17 PM »
I am regretting going down the Festool path more and more.  This problem and the Kapex issues have been going on for ages.  So now I have to constantly worry and be vigilant about this issue and hope that I catch it in time.  Festool is making a big mistake by letting these problems fester and never provide a solution.  Why can't I just use and enjoy my tools? 

Offline Holmz

  • Posts: 4010
Re: power cords burning out
« Reply #9 on: March 10, 2016, 10:01 PM »
I am regretting going down the Festool path more and more.  This problem and the Kapex issues have been going on for ages.  So now I have to constantly worry and be vigilant about this issue and hope that I catch it in time.  Festool is making a big mistake by letting these problems fester and never provide a solution.  Why can't I just use and enjoy my tools?

Enjoy the tools.
If they break then fix or sell them.
If you do not get joy, then move them on.

Offline Cheese

  • Posts: 8720
Re: power cords burning out
« Reply #10 on: March 10, 2016, 11:13 PM »
I am regretting going down the Festool path more and more.  This problem and the Kapex issues have been going on for ages.  So now I have to constantly worry and be vigilant about this issue and hope that I catch it in time.  Festool is making a big mistake by letting these problems fester and never provide a solution.  Why can't I just use and enjoy my tools? 

Who say's you can't just use your tools?
This is just a hobby and should be enjoyable. If you need to treat this as a money making task, then so be it, and retain the tools you trust, and sell the tools that cause you angst.

If this is just a hobby...please see the above comment... [big grin]

Offline mwahaha

  • Posts: 110
Re: power cords burning out
« Reply #11 on: March 11, 2016, 02:23 AM »
I am regretting going down the Festool path more and more.  This problem and the Kapex issues have been going on for ages.  So now I have to constantly worry and be vigilant about this issue and hope that I catch it in time.  Festool is making a big mistake by letting these problems fester and never provide a solution.  Why can't I just use and enjoy my tools?

Why don't you try a Disston? they never have any electrical problems.
Makin' chips since ages ago

Offline Festoolfootstool

  • Posts: 2076
  • The trouble with Bob is its all about Bob
Re: power cords burning out
« Reply #12 on: March 11, 2016, 04:15 AM »
I am regretting going down the Festool path more and more.  This problem and the Kapex issues have been going on for ages.  So now I have to constantly worry and be vigilant about this issue and hope that I catch it in time.  Festool is making a big mistake by letting these problems fester and never provide a solution.  Why can't I just use and enjoy my tools?

All tools that are used regularly need maintaining, the power lead would be a part of this, As zxcv says use them if they break fix them. look at power leads as part of a maintenance regime.
the plugit lead is a useful addition.
however do worry if you own a kapex
If the milk turns out to be sour, I ain't the kind of **** to drink it.......

Why do Festool accessories only have a two month guarantee here in the UK ?

Offline Untidy Shop

  • Posts: 2746
Re: power cords burning out
« Reply #13 on: March 11, 2016, 06:51 AM »
Simple, every time, just before I 'plug it', I look at both the tool and the lead. So far so good, even for the twelve year old.
If you don't like Signatures, just go to Look and Layout and tick No Signatures.

“The test of the machine is the satisfaction it gives you. There isn't any other test. If the machine produces tranquility it's right. If it disturbs you it's wrong until either the machine or your mind is changed.”
― Robert M. Pirsig, Zen and the Art of Motorcycle Maintenance: An Inquiry Into Values

Re: power cords burning out
« Reply #14 on: March 11, 2016, 03:21 PM »
This is a normal problem.  We chose to hardwire all our tools.  (Festool has provided this solution, they aren't ignoring it).  Its better than melting the connections with worn cords. 8)

Offline JD2720

  • Posts: 1217
Re: power cords burning out
« Reply #15 on: March 11, 2016, 03:36 PM »
This is very interesting, and a good thing to know about!

So does this issue stem from the power cord only, or can a tool that has been affected by a dodgy cord transfer the issue to another cord as well?  Does that question make sense?

This is caused by plugging & unplugging the cords. The same thing happens to extension cords. The more the cords are plugged & unplugged the quicker the ends where out.   

Offline Holmz

  • Posts: 4010
Re: power cords burning out
« Reply #16 on: March 11, 2016, 03:50 PM »
This is very interesting, and a good thing to know about!

So does this issue stem from the power cord only, or can a tool that has been affected by a dodgy cord transfer the issue to another cord as well?  Does that question make sense?

This is caused by plugging & unplugging the cords. The same thing happens to extension cords. The more the cords are plugged & unplugged the quicker the ends where out.

These cords are not as good as Neutrik TrueOne PowerCon.
Ideally all tools would have those.

Offline Alex

  • Posts: 7547
Re: power cords burning out
« Reply #17 on: March 11, 2016, 03:50 PM »
I never experienced burning of the plug it cord, but they do fail way too often. Mostly the wire inside breaks on the tool side because of twisting.

Same happens with power tools of other brands, but with those you simply cut away the broken part and reattach the slightly shorter cord. Not possible with Festool of course, because everything is molded on.

And of course they discontinued the replacement plug. Which was way too expensive already anyway at €16.

Now, a fix that's FREE on other brands' tools, cost €26 for a completely new Festool cord. I'm getting sick of this.   

Offline mwahaha

  • Posts: 110
Re: power cords burning out
« Reply #18 on: March 12, 2016, 04:12 AM »
Mostly the wire inside breaks on the tool side because of twisting.   

This can be reduced by leaving the cord loose when packing away tools, not winding the cord around the tool tightly.

The Bosch multi tool has a neat little ball joint swivel at the base of the cord to allow the cord a LOT of flexibility where it meets the tool. It will be interesting to see how long it hold up compared to other tools. The Fein supercut comes with the best cord i have seen on a power tool, its very rubbery and flexible, it took about 7 years of torture before it gave out, and that's with the old case where you have no option but to squash the cord up tight.
Makin' chips since ages ago

Offline Alex

  • Posts: 7547
Re: power cords burning out
« Reply #19 on: March 12, 2016, 04:42 AM »
Mostly the wire inside breaks on the tool side because of twisting.   

This can be reduced by leaving the cord loose when packing away tools, not winding the cord around the tool tightly.

I don't wind the cords anyway.

Offline DB10

  • Posts: 911
Re: power cords burning out
« Reply #20 on: March 12, 2016, 04:45 AM »
I was also impressed with the Fein Multimaster lead, long and very rubbery, but it failed after 10 months. The cord was never wrapped tight just loosely coiled and sat at the top of the systainer. Tooltechnic fixed it under warranty but the new cord that they attached is far less rubbery and a lot shorter.

Offline jobsworth

  • Posts: 6723
  • Festool Baby.....
Re: power cords burning out
« Reply #21 on: March 13, 2016, 03:54 AM »
I had that problem with my RO 150. Thats why I took it to festool service. Though my cords didn't look that bad. I had a burn mark on the right hand pin of on the cord.

Though I use the cords on other tools with no issues the 150 would shut off. Until I fooled with it and it would turn back on then repeat.

So if this happens, festool service is your friend. Mines is a US model and festool UK took care of it no worries. They did include a new 110V power cable with the service. Ill get it tomorrow.

I hope its a US cord. If not well It will be a give away at my BBQ this summer.

Offline Untidy Shop

  • Posts: 2746
Re: power cords burning out - is it ROTEX Sanders?
« Reply #22 on: March 16, 2016, 10:38 PM »
Renovating cutting boards today. Too hot and windy outside at C31/F88 and good opportunity to work in cool A/C of the Untidy Shop and keep Ms Untidy Happy.  [big grin]

Are ROTEX Sanders the common thread in Plug It Failure?

One of the recommended ways to hold a RO150/125 is with the right hand at the end if the barrell. Today I noticed at one point that my thumb was applying some leteral preasure on the Plug It. So then I moved my hand a little forward to prevent this. [See Images].

I have not had Plug It failure and regularly check tools and cords. But I was left thinking that one cause of Plug It failure may be from some users interpretation of this holding method for RO Sanders.

And if the leads are shared . . . . .? 'PlugIt Virus'.  [eek]

« Last Edit: March 17, 2016, 05:12 AM by Untidy Shop »
If you don't like Signatures, just go to Look and Layout and tick No Signatures.

“The test of the machine is the satisfaction it gives you. There isn't any other test. If the machine produces tranquility it's right. If it disturbs you it's wrong until either the machine or your mind is changed.”
― Robert M. Pirsig, Zen and the Art of Motorcycle Maintenance: An Inquiry Into Values

Offline Nigel

  • Posts: 641
Re: power cords burning out
« Reply #23 on: March 17, 2016, 03:57 AM »
Mine went on Rotex 150. Maybe the weight and sander movement.

Offline Hunter A Keller

  • Posts: 1
Re: power cords burning out
« Reply #24 on: April 05, 2021, 06:32 PM »
This is a normal problem.  We chose to hardwire all our tools.  (Festool has provided this solution, they aren't ignoring it).  Its better than melting the connections with worn cords. 8)

Realize I am resurrecting an older thread, but this just happened to me this weekend and I had to finish a relatively small 8"x36"x48" oak shadow box with my 'disposable' RO sander. I've had this Festool ETS 150/5 EQ-Plus for many years, probably 13 years or more. Way out of warranty, but I thought I took really good care of it. A couple large custom kitchen cabinet installations - which is why I chose it, but after that mostly smaller projects and some drywall work, but always used it with dust collection. So I was sanding away and suddenly I could feel heat in my hand and while I was figuring WTF, smoke started pouring out where the cord connected to the sander. Even after I let go of the trigger, so a  quick yank of the cord (Was attached to an extension cord, but a decent one). Anyway, the butt connector of the tool is relatively melted, probably FUBAR, and the cord end is decisively shot. I took the sander apart and thought about hard wiring it myself - the cord, with the exception of the sander end is in awesome shape. Anyway, if there is a reasonable solution before I DIY and heavily tape the end (haven't gotten a hold of Festool Service/Parts yet) I would greatly appreciate the feedback. I'm new here to this forum, my Google-Fu led me here, but I've been a member of SawMillCreek for many years now, same user name as here.
-Hunter

Edit: Much of that damage came after removing the cord, but after review I'm going to need both internal and external parts or just straight hardwire it. Guess I didn't maintain it as well as I thought. They aren't exactly giving these things away. Live and learn...
« Last Edit: April 05, 2021, 06:43 PM by Hunter A Keller »