BORMANN PRO BPP3500 Variable Cordless Angle Grinder User Manual

PRO BPP3500 Variable Cordless Angle Grinder
User Manual

www.bormanntools.com

BPP3500 Variable Cordless Angle Grinder

**: Parts indicated by this symbol may not be parts of this product version and may not be included along with the product.

Technical Data

• The manufacturer reserves the right to make minor changes to product design and technical specifications without prior notice unless these changes significantly affect the performance and safety of the products. The parts described / illustrated in the pages of the manual that you hold in your hands may also concern other models of the manufacturer’s product line with similar features and may not be included in the product you just acquired.
• Please note that our equipment has not been designed for use in commercial, trade or industrial applications. Our warranty will be voided if the machine is used in commercial, trade or industrial businesses or for equivalent purposes.
• To ensure the safety and reliability of the product and the warranty validity, all repair, inspection, repair or replacement work, including maintenance and special adjustments, must only be carried out by technicians of the authorized service department of the manufacturer.

General Safety Rules

WARNING I READ AND UNDERSTAND ALL INSTRUCTIONS.
Failure to follow all instructions listed below, may result in electric shock, fire and /or serious personal injury.
Work area

1. Keep work area clean and well lit. Cluttered and dark areas invite accidents.
2. Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.
3. Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control.

Electrical Safety

1. Do not abuse the cord. Never use the cord to carry the tool. Keep cord away from heat, oil, sharp edges, or moving parts. Replace damaged cords immediately. Damaged cords may create a fire. (The following applies only to tools with a separate battery pack)
2. A battery operated tool with integral batteries or a separate battery pack must be recharged only with the specified charger for the battery. A charger that may be suitable for one type of battery may create a risk of fire when used with another battery.

Personal Safety

1. Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury.
2. Dress properly. Do not wear loose clothing or jewellery. Contain long hair. Keep your hair, clothing, and gloves away from moving parts. Loose clothes, jewellery, or ‘bng hair can be caught in moving parts.
3. Avoid accidental starting. Be sure switch is in the locked or off position before inserting batter pack. Carrying tools with your finger on the switch invites accidents.
4. Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enable better control of the tool in unexpected situations
5. Use safety equipment. Always wear eye protection, Dust mask, non-skid safety shoes, hard hat, or hearing protection must be used for appropriate conditions.

Power tool use and care

1. Use clamps or other practical ways to secure and support.the work piece to a stable platform. Holding the work piece by hand or against your body is unstable and may lead to loss of Control.
2. Do not force tool. Use the correct tool for your application. The correct tool will do the job better and safer at the rate for which it is designed.
3. Do not use tool if switch does not turn it on of off. A tool that cannot controlled with the switch is dangerous and must be repaired.
4. Store idle tools out of reach of children and other untrained persons. Tools are clangorous in the hands of untrained users
5. Maintain tools with care. Keep cutting tools sharp and clean. Properly maintained tools with sharp cutting edge are less likely to bind and are easier to control.
6. Check for misalignment or binding of moving parts, breakage of parts, and any other condition that may affect the tool’s operation. If damaged, have the tool serviced before using .Many accidents are caused by poorly maintained tools.
7. Use only accessories that are supplied with your model. Other accessories that may not be suitable for this tool and may create a risk of injury when used.

Recommended and Proper Use

This hand held power tool uses abrasive disks to grind metals or masonry. It is intended for domestic and light commercial use only. Any other application is considered misuse. This power product is supplied without batteries or charger. This power tool should only be operated combined with the recommended by the manufacturer genuine Bormann battery and charger.
Specific Safety Rules
Have this tool repaired by a qualified person. This tool is designed to conform to the relevant international and local standards. As such, it should be maintained and repaired by someone qualified, using only original parts supplied by the manufacturer – This will ensure the tool remains safe to use. – Check that speed marked on the wheel is equal to or greater than the rated speed of the grinder.
– Ensure that the wheel dimensions are compatible with the grinder.
– Abrasive wheels must be stored and handled with care in accordance with manufacturer’s instructions.
– Inspect the grinding wheel before use. Do not use chipped, cracked or otherwise defective products.
– Ensure that mounted wheels and points are fitted in accordance with the manufacturer’s instructions.
– Ensure that the abrasive product is correctly mounted and tightened before use.
• Run the tool at no-load for 30 seconds in a safe position.
• Stop immediately if there is considerable vibration or if other defects are detected. If this condition occurs, check the machine to determine the cause.
– Never use the angle grinder without the safety guard.
– Do not use separate reducing bushings or adapters to adapt large hole abrasive wheels.
– Check that the work piece is properly supported.
– Do not use cutting wheel for side grinding.
– Ensure that sparks resulting from use do not create a hazard e.g. do not hit persons, to ignite flammable substances.
– Always use eye and ear protection.
– Personal protective equipment such as dust mask, gloves, helmet and apron should be worn.
– The wheel continues to rotate after the tool is switched off.
Warning! Prior to mounting an abrasive wheel ensure the expiry date has not exceeded rendering it potentially hazardous. Secure work. Use clamps or a vice to hold the work. It is safer than using your hands and it frees both hands to operate the tool.
Stay alert. Watch what you are doing. Use Gammon sense. Do not operate tool when you are tired.
Wear proper clothing. Do not wear Bose clothing, neck-ties or jewellery (ring, wristwatches etc.) to catch in moving parts.
Non-slip footwear is recommended. Wear protective covering to contain long hair.
Roll long sleeves above the elbow. Use safety goggles (Head protection). Wear goggles approved to the relevant standards at all times. Normal spectacles only have impact resistant lenses, they are NOT safety glasses. Also, use face or dust mask if application is dusty and ear protectors during all operations.
Sound levels. Some types of machines may have high sound levels when working. In such cases ear protection must be worn. Vibration levels. Hand held power tools produce different vibration levels. You should always refer to the specifications and the relevant Health and Safety guidelines.
Dust extraction. If your tool is fitted with a dust extraction facility, always ensure that it is connected and being used with a dust extractor. Vacuum cleaners can be used if suitable for the material being extracted. Check damaged parts. Before use, any blade guard or other part that is daittaged should be carefully checked to determine that it will operate properly and perform its intended function. Check for alignment of moving parts, free running of moving parts, breakage of parts, mounting and any other coitions that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced by anathematized service center unless otherwise indicated in this instruction manual. Have defective switches replaced by an authenticated service centre. Do not use the tool if the switch does not turn it on and off.
Have your tool repaired by a qualified person. Use of this electric tool importance with the relevant safety requirements. Repairs should only be carried out by qualified persons using original spare p.t.s, otherwise this may result in considerable danger to the user.
Safety Recommendations For The Correct Use Of Abrasive Products
General. Bonded abrasive products are breakable and shall therefore be handled with utmost care. The use of damaged or improperly mounted or used abrasive products is dangerous and can cause serious injuries.
Delivery, handling and storage. Abrasive products must be handled and transported with care. Abrasive products must be stored in such a manner that they are not subjected to mechanical damaged and harmful environmental influences. Selection of the abrasive product. Information on the label or the abrasive product stating restrictions of use, safety indications or any other instructions must be followed. In case of doubt concerning the selection of abrasive products, the user shall request information from the manufacturer or supplier.
Visual inspection and ring test. Abrasive products must be subjected to a visual inspection as received before mounting. In addition, a ring test shall be executed for vitrified wheels with D>80mm. Damaged abrasive products shall be destroyed. Mounting before starting and information for grinding. The mounting of abrasive products shall be carried out according to the instructions provided by both the wheel and the machine manufacturer. Mounting of abrasive products must be carried out by a qualified trained person. After initial mounting, the wheel must be test run for a reasonable time – the specified maximum operating speed of the wheel shall not be exceeded.

Main Description

1. On / Off Switch
2. Rear hand grip
3. Spindle lock button
4. Locking Flange
5. 20V Li-ion Battery Pack “(Sold Separately)
6. Auxiliary handle
7.  Safety Guard

Basic Operation

Auxiliary Handle (Fig 4.)
For reasons of safety, when working with this type of electric power tool, the operator must always use the auxiliary handle (6).
– Screw the handle clockwise, into one of the three threaded apertures best suited to the application and user comfort.
Warning! This machine must never be operated (cutting off/grinding processes) without the correct guard placed correctly and operating fully.
Fitting The Guard (Fig.5-6)
The guard supplied is designed for grinding only, it is not intended to be used for cutting operations. If you intend to perform cutting operations with this machine, you need to purchase the additional cutting guard, which has a more enclosed design to contain any fragments if the cutting disc fails.
– Position the guard onto the grinder collar with the quick release lever in the open position.
-Rotate the guard until it is in the correct position and then close the quick release lever to lock the guard.
Warning! Never attempt to operate this machine without the guard securely fitted and correctly positioned.
With the exception of wire cup brushes etc. which negate the guards effectiveness.
Fitting/Replacing Accessories (Sold Separately) (Fig.7-9)
Warning! Prior to mounting an abrasive wheel ensure the expiry date has not expired, rendering it potentially hazardous.
Warning! Selection of the correct accessory, suitable for the intended application is vital. Seek guidance if uncertain of selection.
Warning! The rated (no load) revolutions per minute of the tool must not exceed the speed capacity of the accessory. Please refer to the accessory manufacturers instructions for information.
Visual Inspection:
– Prior to fitting, abrasive/super-abrasive wheels shall be subject to a visual inspection.
Inspection: – Each time after mounting, the abrasive/super-abrasive wheel shall be test run for a reasonable time.
– The specified maximum operating speed of the wheel shall not be exceeded.
– Damaged abrasives shall be destroyed.
– Always wear approved safety goggles.
Important information B,C,D (Fig.6):
– For cutting applications, and to comply to current legislation, it is necessary to replace the “grinding” guard supplied with this machine with a “cutting” guard.
– Press and hold the spindle lock button (3). – Loosen the locking flange (4) anti-clockwise using the pin spanner (8) supplied.
– The spindle may rotate slightly before the spindle lock fully engages.
– Remove the locking flange only.
– Clean the flanges and spindle prior to fitting any accessory.
• If the rear flange (4.1) is removed for cleaning, ensure it locates correctly on the spindle flats when refitting and does not spin freely.
– When fitting the appropriate accessory please refer to (FIG.7 for specific details on the locking flange correct orientation as applicable. Securely tighten the locking flange clockwise using the pin spanner while holding down the spindle lock (4).
Note: When using wire cup brushes the locking flange is not required due to the design of the brushes. When fitted check the accessory is correct and, importantly fully secure on the spindle.
Warning! Never press the spindle lock button (4) while the spindle is in motion.
On/Off Switch (Fig.10)
– Push the switch (1) forward to start the grinder.
– Push the switch further forwards and down to lock it in the ‘ON’ position.
– To stop the grinder, release the switch by pushing down on the back of the switch (1).
Note: To prevent accidental starting in a situation of power failure to the grinder, the ‘ON/OFF’ switch G) is fitted with a protective device that prevents the angle grinder from starting up automatically when the power is re-established. In this case, and with the power re-established, release the switch to the ‘OFF’ position, then switch to ‘ON’ as normal.
Warning! Do not set the machine down until the spindle has completely stopped.
Note: During use, keep clothing out of the line of any sparks formed. Sparks from metal grinding can set fire to many types of clothing in a short time. The risk is less if your outer clothing is made of wool, or flame retardant treated cotton. Dust A correctly fitted dust mask, suitable for the activity and in accordance to the relevant standard, must be worn.
Grinding (Fig.11)
When performing grinding operations maintain an angle of approximately 30° between the work surface and the disc face. Only use abrasives specifically designed for this task.
Cutting
Warning
– Cutting operations should only be attempted with the “cutting” guard fitted to this grinder.
– This guard must be fitted for your safety.
– When performing cutting-off operations do not incline the machine as this can lead to the abrasive wheel becoming jammed, damaged or excessively and abnormally worn.
– Only use abrasives specifically designed for this task. As the abrasive disk wears during use, its diameter reduces. This reduces the peripheral speed and the machine’s efficiency. This results in increased load on the grinding machine which if continued will damage the motor. Ensure that the diameter of the wheel is within 25% of its original size.
Important: Excessive pressure on the machine does not result in a higher abrasive efficiency. Excessive pressure increases wear and tear on the accessory and will damage the angle grinder which is not covered under the guarantee.
Battery Pack Charging (Fig.1-2)
Warning: Use only the genuine charger, for charging the batteries, supplied separately by the manufacturer. Only Bormann designated battery packs and chargers can be used in conjunction with this product. Use of any other third party battery packs/chargers with this product is considered misuse and will invalidate the produces warranty.
Once connected to the mains supply recharging of the battery pack can be left generally unsupervised requiring minimal attention. Complex circuit construction monitors the battery pack condition adjusting the recharge current to suit. When the recharge cycle is complete and to maintain the full capacity a low output current will continue as required.
Warning!
Check the condition of the charger and battery prior to each charge. If there is any sign of damage then do not commence charging, seek advice from an authorised supplier.
To charge the battery pack (5) , it must first be removed from the tool.
To release the battery pack:
Press the battery pack release button (5.1) and gently slide the battery pack off (Fig.1).
Plug the battery charger unit (9) into a 230V/AC 13amp socket.
The green LED (9.1) will stay it to show the charger has power.
Slide the battery pack into place ensuring the battery terminals and the charger terminals make a good connection Fig.2.
After a few seconds delay the red LED (9.2) will light to show the battery pack is being charged and the green LED will turn off.
Warning!

• Ensure battery pack is connected correctly (Fig.2). Sliding the battery pack on incorrectly may cause damage to the battery/ charger.
• When the battery pack is fully charged, the green LED (9.1) will light on.

Warning!

• If the indicator lights fail to illuminate during the charging cycle, the charger from the power supply socket outlet and replace the battery pack.

Completing the charging cycle:
Disconnect battery charger from the power supply. Caution: Do not pull the plug out of the power supply by pulling on the cord

• Make sure to grasp the plug when removing from power supply to avoid damaging the cord. Remove the battery pack from the battery charger.
• Supporting the battery charger with hand, pull out the battery pack from the battery charger

Caution: When the battery charger has been continuously used, the battery charger will be hot. Once the charging has been completed, give 15 minutes rest until the next charge. If the battery pack is charged when it is warm due to battery use or exposure to sunlight, the battery pack will not be recharged. In such a case, let the battery pack cool before charge. If the red indicator flickers rapidly at 0.2 – second intervals, check for and take out any foreign objects in the charger’s battery slot. If there are no foreign objects, it is probable that the battery pack or charger is malfunctioning. Now battery/charger to normalise and try again. If a fault remains after trying this then contact an authorised supplier.
Battery charging status (Fig.3)
To display the amount of charge left in the battery pack press the charge level indicator button 5.2
Battery Pack Efficiency And Charging Advice
Recharge the battery packs before they become completely exhausted
When you feel that the power of the tool becomes weaker, stop using the tool and recharge the battery packs. If you continue to use the tool and exhaust the electric current, the battery pack may become damaged.
Avoid recharging at high temperatures. A rechargeable battery pack will be hot immediately after use. If such a battery pack is recharged immediately after use, its internal chemical substance will deteriorate, and the battery life will be shortened. Leave the battery pack and recharge it after it has cooled for a while.
The battery pack should only be used and/or charged when battery pack temperature is between 5°C and 30°C.
The battery pack needs to be warmed-up or cooled down in order to prevent damage to the batteries internal components.
Note: Failure to warm up or cool down a battery pack could result in serious damage to tie battery, charger and user.

Main Description Maintenance and Troubleshooting

Maintenance
Regular inspection and cleaning reduces the necessity for maintenance operations and will keep your tool in good working condition.
The motor must be correctly ventilated during tool operation. Avoid blocking the air inlets and vacuum the ventilation slots regularly.

Troubleshooting

2.Battery faulty or damaged.
3.Blown fuse in charger plug.| 1.Re-charge battery.
2.Replace battery.
3.Replace fuse.
Motor runs, but slowly/ losing power.| 1.Battery no charge.
2.Battery faulty or damaged.| 1.Re-charge battery.
2.Replace battery.
Machine vibrates.| 1.Wheel damaged or out of balance.
2.Wheel loose.| 1.Replace wheel.
2.Stop machine immediately – When stopped, refit accessory.
Wheel will not cut/grind.| Incorrect disc fitted.| Fit correct disc for material/application.
Important: Please note, all repairs/service should be carried out by a qualified person.

Handling and Storage

Care must be taken when handling this product.
Dropping this power tool could have an effect on its accuracy and could also result in personal injury. This product is not a toy and must be respected.
Environmental conditions can have a detrimental effect on this product if neglected. Exposure to damp air can gradually corrode components.
If the product is unprotected from dust and debris, components will become clogged.
If not cleaned and maintained correctly or regularly the machine will not perform at its best.

Disposal

At the end of the machine’s working life or when it can no longer be repaired, ensure that it is disposed of according to national regulations.
— Contact your local authority for details of collection schemes in your area.
In all circumstances:

• DO not dispose Of power tools with domestic waste.
• DO not incinerate.
• Do not dispose of WEEE as unsorted municipal waste.

Warning!

• Do not put battery pack in fire or mutilate; cells may burst or release toxic materials.
• Do not short circuit cells, may cause burns.
• The battery pack must be removed from the appliance before it is scrapped.
• The battery pack is to be disposed of safely.
• Do not mutilate batteries; corrosive electrolyte will be released.
• Do not dispose of batteries or cells in a charged condition.

Expired batteries must be recycled/disposed of in accordance with the appropriate regulation or legislation. They should be returned to your local warranty agent/stockist.

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