Blastrac BMG-444 User manual

Original Instructions
OPERATING INSTRUCTIONS BMG-444
VERSION 1.0

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Inspection comments
Recurring inspections / maintenance log
*Competent person
Date / Hour counter
Findings
Repairs / Cleaning
Test
on
By*
Inspection before initial operation on: __________________________________________
By: __________________________________________
Date of initial operation: __________________________________________
Serial number & Year of manufacture: __________________________ _____________

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Table of contents
Inspection comments 2
1. Introduction 4
2. Machine description 4
3. Safety Rules 6
3.1 Work area safety 6
3.2 Electrical safety 6
3.3 Personal safety 7
3.4 Machine safety 7
3.5 Maintenance safety 7
3.6 Dust collector safety 8
3.7 Grinding safety 8
3.8 Transport safety 9
3.9 Signs on the machine 10
4. Initial operation 11
4.1 Checkpoints of electrical safety 11
4.2 Checkpoints of machine safety 11
4.3 Manual moving of the machine 12
4.4 Adjust the steering height 13
4.5 DIAMAG Grinding tools 15
4.6 Hardness graph and colour code 17
4.7 Before start-up 18
4.8 Wheel height 18
5. Operating 19
5.1 Switch on the machine 19
5.2 Switch off the machine 19
5.3 Speed control version 20
5.4 Operating during grinding 21
5.5 Wet grinding 21
5.6 Dismount the BMG-444 22
6. Maintenance 23
6.1 Frequency inverter (Speed Control version) 24
6.2 Most Common Fault codes 25
6.3 Replacing the upper belt 27
6.4 Tensioning the lower belt 28
6.5 Replacing the lower belt 29
7. Troubleshooting 30
8. Technical data 31
8.1 Extension cables 32
8.2 Dimensions of the BMG 444 33
Contact

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1. Introduction
Before use, operators must be provided with information, instruction and training for the use of the machine
and the substances for which it is to be used, including the safe method of removal and disposal of the
material collected. All persons who are working with or maintaining this machine must read the manual
carefully and understand it fully. In case you sell the unit, hand it on to the next owner.
Keep this manual always with the machine, to enable it to be referred to at any time.
Any other work not covered by this operating manual must not be carried out. Always use common sense
when working with machines.
This machine is designed for industrial use by professionals. Only authorized and trained personnel may
operate this machine. This machine is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience and knowledge. Blastrac BV offers a course on
the use of the machine in order to make the operating and maintenance personnel familiar with all elements of
the machine.
2. Machine description
The BMG-444 is an electrical driven planetary grinding machine. This is a three headed machine for levelling,
grinding and polishing of floors. The 3 planetary rotating discs are Ø155 mm. It can be used for dry and wet
applications.
The BMG-444 can be used on almost any floor to plane, to make ready for coatings, or to remove coatings or
glue residues or to expose aggregate. The machine may not be used without an adequate dust extraction
system. A specially designed Blastrac dust collection system ensures dust-free operation of the machine and
clean air at the workspace. This machine may not be used on wood.
1
Steering handle
6
Drive mechanism
2
Water hose connection
7
Fill up block
3
Diamond plate holders
8
Motor
4
Brush for floating shroud
9
Main Handle
5
Floating shroud
10
Switch box

5
Control box
BMG-444
Standard version
BMG-444
Speed Control version (SC)
A
Stop button (RED)
B
Start button (GREEN)
C
Speed regulator
D
Switch for clockwise and counter clock wise grinding

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3. Safety Rules
Warning!
Read all safety warnings and all instructions. Failure to follow the warnings and
instructions may result in electric shock, fire, explosions and / or serious injuries.
Only authorized and trained personnel may operate this machine. This machine is not
intended for use by persons (including children) with reduced physical, sensory or mental
capabilities, or lack of experience and knowledge.
It is the responsibility of the user to analyse the surface to be treated. The surface may not contain any
substances which could pose a fire-, explosion- or health risk when treated. The user should make a risk
assessment on the basis of the information obtained about the surface to be treated and take proper
precautions for the work to be performed.
In case of any inappropriate usage, improper operation or repair, the producer shall be exempt from liability.
3.1 Work area safety
a) Do not use the machine in rain, damp or wet locations.
b) Avoid dangerous environments: do not work in the presence of explosive atmospheres, in the presence of
flammable liquids, gases or dust. Remove materials or debris that may be ignited by sparks.
c) In some cases sparks could be created by grinding.
d) The surface to be treated must be swept, make sure to remove all stones, screws etc..
Any stones, screws, bolts, pieces of wire etc. could cause serious damage if it gets inside the machine!
e) Make sure there is enough ambient light on the work area. Cluttered or dark areas invite accidents.
f) Do not use on wood.
g) Keep children and bystanders away while operating the machine. They are likely not to foresee the
potential dangers of the machine. Distractions could cause you to lose control of the machine.
h) Persons who are not operating the machine must not be permitted to stay in the surrounding area of at
least 5 meter from the machine.
i) Never use the machine when the surface is not clear and if there is a risk of stumbling or tripping.
j) Make sure that there are no cables or hoses in the driving direction of the machine.
k) Make sure that there is nothing standing or situated on the surface to be treated.
l) Make sure the machine can travel over all inequalities on the surface, small inequalities like weld seams or
floor joints are no barriers for the machine.
m) Never stay in the rain with the machine
n) Check if there are any obstacles that can snag the cables when the machine is moving.
o) Remove reinforcing steel or other objects protruding from the surface in order to prevent damage to the
compounds or diamond discs.
p) Secure the work area around the machine in public areas providing an adequate safety distance from the
machine. Use a red and white safety chain and danger sign to enclose the work area.
q) Warning!
Make sure that the surface to be treated does not contain dangerous materials such as:
- combustible or explosive dusts or substances.
- carcinogenic or pathogenic substances.
In these cases, additional safety measures should be used. Always mind the local safety
requirements. Contact your dealer for additional options.
3.2 Electrical safety
a) Use only extension cables for extending the main cable that are sized and marked in accordance with the
overall power consumption of the machine. Do not use damaged extension cables.
b) Electrical cables must be rolled entirely off of the reels.
c) Any damage to the electric cables and/or electrical components is not permitted.
d) The voltage on the identification plate must comply with the power supply.
e) Use an electrical power supply connection with earth connection and earth leakage circuit breaker.
f) The circuit breaker of the power supply must have a ‘’D’’ characteristic. Circuit breakers with a “C” or “B”
characteristic can give problems when switching the motor on.
g) Keep the machine original; The machine is always equipped with an earthed connection, do not
change this and always use earthed cables with an earthed plug.
h) Inspect and test the electrical components regularly. The electrical components have to satisfy with the
requirements set out in the harmonised norm EN60204-1.

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i) Always call a skilled electrician or your distributor when you have questions about the safety of the
electrical components.
j) Work on electrical equipment or operating materials may only be undertaken by a skilled electrician or by
trained persons under the guidance and supervision of a skilled electrician as well as in accordance with
the electrical engineering regulations.
k) Always use tools that are insulated against voltages.
l) Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the machine. Keep cord
away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of
electric shock.
m) Be careful with water on the treated surface. Electrical cables must not come into contact with water.
n) During a long standstill of the machine, pull out the main plug and cover it with plastic foil.
o) If the machine is to be operated using power from a generator, the generator must be operated in
accordance with the current legal regulations and directives in force. (this applies to the protective earth
conductor in particular) in order to ensure that all safety devices are functioning and to eliminate possible
damage to electrical components.
3.3 Personal safety
a) Always wear Personal Protective Equipment while working with the machine.
-Dust mask class FFP3 or higher
-Ear protection
-Safety glasses with lateral protection
-Protecting gloves
-Safety shoes
b) Dress properly. Do not wear loose clothing or jewellery. Keep your hair, clothing and gloves away from
moving parts.
c) Stay alert, watch what you are doing and use common sense when operating the machine.
d) Always seek professional medical attention immediately in case of injury.
e) All persons surrounding the machine should wear Personal Protective Equipment.
3.4 Machine safety general
a) Safety functions and operating functions must work correct.
b) No loose bolts and nuts permitted.
c) Never operate machine without the guards and/or safety devices in place.
d) Never change anything on the safety devices on the machine!
e) The machine, specially the handle grips must be free of fats/oils and has to be dry.
f) If the length of the brushes is, due to wear, less than 5mm or they are extremely deformed, the brushes
have to be replaced. Check the Service Manual for the order numbers.
g) All repair work has to be done by qualified Blastrac personnel, this guarantees a safe and reliable
machine.
h) Always use original Blastrac spare parts, grinding discs, grinding wings and polishing pads. This
will ensure the best performance. Only original parts meet the factory specifications and quality.
Otherwise Blastrac BV cannot guarantee the safety of the machine.
The part numbers can be found in the Service Manual.
i) If safety-critical changes occur to the machine or its working method, the machine must be shut down
immediately! The cause of the fault must be established, and rectified.
j) In the event of operational malfunctions the machine must be shut down immediately and secured!
k) Do not use the unit when it is damaged.
l) Do not open or remove protective guards while driving gears are running.
m) Do not stand on the machine. Do not add extra weight on the machine.
n) Do not place anything on the grinding motor. Make sure that the motor has enough airflow to cool.
3.5 Maintenance safety
a) Pull out the main plug before starting inspections and repairing on the machine. Press the Emergency
shutdown button.
b) Wait for standstill of all drives before any inspections, adjustments and/or maintenance work is started.
c) Block the machine in stable position before doing any maintenance work.
d) Failures due to inadequate or incorrect maintenance may generate very high repair costs and long
standstill periods of the machine. Regular maintenance therefore is imperative.
e) Operational safety and service life of the machine depends, among other things, on proper maintenance.
f) Prevent premature wear by keeping the machine as dust free as possible. Clean the machine for this
reason regularly with a dust collector and non-aggressive materials, especially the upper drive. Never use
a high pressure water cleaner to clean the machine.

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g) It is advisable to stock all spare parts or wear parts that cannot be supplied quickly. As a rule, production
standstill periods are more expensive than the cost for the corresponding spare part.
h) Do not use any aggressive cleaning materials! Use lint-free cleaning cloths!
i) For the electrical parts, use a tool that is insulated against voltages.
j) The suitable precautions include decontamination before disassembling the machine, adequate filtered
ventilation of the exhaust air from the room in which it is disassembled, cleaning of the maintenance area
and suitable personal protection equipment.
3.6 Dust collector safety
a) Always use a Blastrac dust cleaner to ensure a dust-free operation of the machine and clean air at the
workspace. Also the airflow helps to cool the machine and prevents overheating.
b) Read the operating instructions of the dust collector before using it.
c) The dust container/bag of the dustcollector must be emptied regularly. Comply with the local waste
treatment regulations considering the removed material.
d) The dust hose must be connected properly with a hose clamp and industrial tape.
e) The dust hose must be undamaged and free of obstructions.
f) Always switch on the dust collector first!
3.7 Grinding safety
a) The machine contains rotating parts, which are protected with a sliding cover. Always leave the diamond
disc on the floor while the motor is turning.
b) The rubbers inside the flex disc can become worn out with use, because of this there can be higher
vibrations than normal. Check for this reason the rubbers inside the flex disc for deformation and damage
before every use.
c) Do not let the machine rest on the diamond disc or coupling when it is not in use, this will cause
deformation to the rubbers inside the flex disc.
d) Make sure the brush seals are in good condition, this to avoid dust.
e) Make sure the diamond disc is not damaged or worn out.
f) Always pull out the main plug before u start changing the wings or disks.
g) When mounting or removing a diamond disc or wing; lay down the machine so it is lying on the metal
support. Make sure the machine will not fall back down. A second person can hold the handle down to
make sure it will not fall back down.
h) For changing the disks/wings u should wear Personal Protective Equipment like a dust mask, safety
goggles, gloves, protective shoes, and close fitting protective clothing.
Use the vacuum cleaner to prevent excessive dust.
i) Caution! The grinding disks/ wings will heat up during grinding, don’t risk getting burned, always wear
protective gloves when handling them.
j) The machine contains rotating parts; because of this never pull the machine backwards with a
turning motor.
k) Be careful with the machine and pull or let down the machine slowly, big shocks can damage the electrical
parts.
l) Make sure the floating shroud is in transport mode when you transport the machine.
m) Clean the brush-sealing directly after wet grinding. It will be very hard to clean the brush-sealing when
the dust-water mixture has dried up and hardened.
n) Be careful, the workfloor can get slippery when grinding wet.
o) Keep all electrical cables and connections away from water.
3.8 Transport safety
a) Be aware of your surroundings and machine operating level. Do not side hill, do not run on steep incline,
this could cause machine to tip over.
b) The weight of the BMG-444 is between 120 and 128 kg, depending on the version. Use a crane or lift
when transporting the machine, use the lifting eyes of the machine.
c) Before every use check the lifting eyes/lugs and welds for: deformation, damages, cracks, corrosion and
wear.
d) Only lift the machine as shown in the picture below.
e) When lifting the machine from the ground, always use the lowest lifting speed. The cables must first be
tensioned at this speed; they must not be slack when the machine is lifted from the ground.

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f) During hoisting make sure to be at a safe distance from the machine with the most optimal view on the
machine and working environment.
g) Never stand directly below the machine.
h) When transporting the machine do so in such a manner that damage due to the effects of the use of force
or incorrect loading and unloading is avoided.
i) The lifting eyes can also be used to fasten the machine on a pallet or during transport.
j) Always drive backwards when driving up to a ramp or grade, and forwards when driving of the ramp.
k) Chock wheels for transport and keep control handle in neutral position.
l) Don’t leave the machine unsecured on jobsites.
m) Park the machine always on a flat horizontal and levelled surface.
n) Make sure the floating shroud is in transport mode when you transport the machine.
o) Make sure the electrical cable and dust hose are disconnected.
p) Store the cleaned and dry machine in a humid free room. Protect the electrical motor from moisture, heat
dust and shocks.
q) Never use the machine for lifting or transporting persons or items.
It is not allowed to lift the machine without appropriate appliances as a lift or crane.
Make sure the floating shroud is in transport mode when you transport the machine.

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3.9 Signs on the machine
The following stickers are placed on the machine. Meanings of these symbols are:
Type plate:
EU Declaration of Conformity:
Wear a dust mask class FFP3 or
higher.
Hearing protection is obliged.
Safety glasses with lateral protection
are obliged.
CE-mark on this machine.
Wear protecting gloves.
Safety shoes obliged.
Consult the manual before operating
the machine.
Name, address and CE mark.
The machine type.
The net weight of the machine in kilogram.
The year of manufacture.
The serial number of the machine.
Email address, Website, Telephone & fax number.
! Danger Hazardous voltage in motor
even when solid state controller is OFF.
Disconnect main power before servicing
motor, controller or associated wiring.
Warning! Hot surface.

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4. Initial operation
Before using the machine it is important to inspect the machine.
It is not permitted to use the machine if the safety is not checked according to the checkpoints described
below.
Before switching on the machine make sure that no-one can be endangered when the machine starts up!
4.1 Checkpoints of electrical safety
Use only extension cables for extending the main cable that are sized and marked in accordance with
the overall power consumption of the machine.
Electrical cables must be fully unwound of them reels.
No damage is permitted for electrical cables.
Use an electrical power supply connection with earth connecting.
The main switch of the machine should be put to ‘Off’ before connecting to the power supply. (Only if
there is a main switch present on the electrobox.)
Make sure the power supply is in accordance with the machine specifications.
If the machine is to be operated using power from a generator, the generator must be operated in
accordance with the current legal regulations and directives in force. (this applies to the protective
earth conductor in particular) in order to ensure that all safety devices are functioning and to eliminate
possible damage to electrical components.
4.2 Checkpoints of machine safety
Safety functions and operating functions must work correct.
Check the diamond wings for damages and/or wear.
The rubbers inside the flex disc should not be deformed or damaged.
The tools you are about to use under the machine (discs/wings/pads/etc.)may not be damaged.
Check all screws and other fasteners for tightness. No loose bolts and/or nuts are permitted.
Check the electrical components, cables and connections for wear and/or damages.
Dust hose connection must be reliable: use hose clamps and industrial tape.
Dust hoses must be undamaged and free of obstructions
Make sure that the dust bin/ big bag and Longopac is empty and connected properly.

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4.3 Manual moving of the machine
To move the machine, first lock the floating shroud. After locking the floating shroud, press down the
handgrips of the machine until the front part rises from the ground. It can now be pushed around on its
wheels.
The machine should only be moved around when the dust hose and power supply cable are disconnected.
WARNING! Always make sure all rotating parts have come to a complete standstill before moving around the
machine.
Be careful! Make sure nobodies feet get under the wheels. Wear appropriate safety shoes when you drive the
machine to or from the work area.
Locking the floating shroud for transporting the BMG 444.
-There are sleeves on both sides to lock the floating shroud.
Step 1. Lift up the floating shroud.
Step 2. Turn the floating shroud
counterclock wise. And it will slide in the
sleeves. Now the floating shroud is
locked. To unlock the floating shroud,
Procede the process backwards.

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4.4 Adjust the steering height

14
Adjust the steering handle

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4.5 DIAMAG Grinding tools
The Diamag Slidemag system does not require any tools to insert or remove the grinding wings from the
adapter plates. Diamag grinding tools are designed to be mounted on all our triple disc grinders. Fast inserting
and removing of the diamond tools has never been so easy. There is a safety lock with an interlocking system
and a magnet, it is easy to insert the tool into its seat so that you are ready to grind!
Contact your Blastrac distributor for more information or check WWW.DIAMAG.EU
Changing the wings
Warning! Always wear Personal Protective Equipment!
The dust can be hazardous to the health! Wear a dustmask!
The wings can get hot! Don’t risk burning your hands! Wear protective gloves!
Make sure all moving parts of the machine have come to a complete standstill before changing the wings.
Pull out the mains plug before you start
Always wear gloves and a dust mask of at least class FFP3
Use the vacuum cleaner in order to work as dust free as possible
Tilt the machine back and lay down the machine so it is laying on the metal support(Green arrow).
Make sure the machine will not fall back down. A second person can hold the handle down to make
sure the machine will not fall back down.

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Mounting the slide wings
Read chapter 3 Safety Rules and wear personal protective equipment.
Make sure the machine is disconnected from the power supply.
Lay down the machine so it is lying on the metal support. Make sure the machine will not fall back
down. A second person can hold the handle down, to make sure the machine will not fall back down.
Slide the slide wings in to the adapter slide plate.
Removing the slide wings
Read chapter 3 Safety Rules and wear personal protective equipment.
Make sure the machine is disconnected from the power supply.
Lay down the machine so it is lying on the metal support. Make sure the machine will not fall back
down. A second person can hold the handle down, to make sure the machine will not fall back down.

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4.6 Hardness graph and colour code
Blastrac has designed a full range of diamond products, which provides the opportunity to treat any floor and
specific application. The identification of the correct diamond tool is fundamental in the grinding process, in
order to optimize efficiency, speed and intervention costs.
A simple rule is that a hard surface needs a soft bond segment and a soft surface requires a hard
bond segment, to optimize an efficient wear of the diamond tool.
Hardness graph
Concrete hardness varies according to several factors: the mixture, the aggregates and the time spent since
the pouring. To determine concrete hardness, you can use a sclerometer (to measure floor hardness) or carry
out a scratch resistance test (MoHs scale). Once you know the hardness of your floor, you can select the
correct tools.
Colour code
Blastrac has created a unique colour code system specially designed so you know which tool to use ,
depending on the hardness of the surface.
Contact our experts at Blastrac for the correct application of the different tools and their
corresponding working speeds.
WHAT TYPE OF FLOOR
The concrete test hammer or
sclerometer is used to
measure the hardness of the
floor.
REFER TO HARDNESS CHART
The value is given in
MegaPascal (MPa). With this
measurement, you can then
select the ideal tool for your
job.
CHOOSE THE RIGHT TOOL
Depending on the hardness
of your floor, select the best
tool for the job from a wide
range of diamond tools.
START GRINDING
Blastrac machines are easy
to operate.
Just plug and grind!

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4.7 Before start-up
Before start-up, the operating personnel must be familiar with the safety regulations given in this manual.
Put the grinding machine and the dust collector on to the surface to be processed.
Fit the appropriate diamond grinding wings that are required for this particular process. Please read
Chapter 4.6 of this manual.
Connect the machine and the dust collector to the electricity supply point, these electric supply points
should be protected and equipped with an earth connection and earth leakage circuit breaker. In case
of doubt ask the local safety officer.
Check the dust hose for damages and obstructions. Make sure the dust bin of the dust collector unit is
empty. Observe the local regulations regarding waste disposal.
Connect the grinding machine and the dust collector unit with the flexible dust hose. Use hose clamps
at the connections.
Before grinding, clean the surface to be treated. There should not be any trash, stones, cloths, or oil
on the surface.
Remove all objects from the surface that can damage the machine. Remove reinforcing steel or other
objects protruding from the surface in order to prevent damage to the machine, the seals or diamond
wings.
4.8 Wheel height
The wheels of the BMG-444 can be set at different heights for different applications.
On the frame there are marks to indicate for what application the hole is used.
-“G” for Grinding & Polishing pads (upper holes).
-“B” for Bush hammering. (lower holes).

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5. Operating
During operating the BMG-444, the following additional safety instructions must be followed closely.
5.1 Switch on the machine
Connect the dust hose to the machine and turn on the dust collector before switching on the machine.
Connect the power supply to the machine (1).
Stand behind the machine and hold the handle(2) tight.
Push down the handle of the machine (2) so that the Grinding heads are off the ground.
To start the machine, push the green button on the electrical box.
Check the direction of rotation of the 400 volt version. The machine must turn counter clockwise. (the
fan of the motor is turning clockwise if the motor turns counter clockwise).
Let down the machine till the diamond wings hit the floor.
Start grinding.
5.2 Switch off the machine
Push the red button on the electrical box.
Wait until the machine stops rotating before laying down the machine on the metal support.
Pull out the power supply.
Shut down the dust collector.
Start and Stop Buttons

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5.3 Speed control version
The machine is also available in a speed control version. All the points during operating machine are similar to
the standard version. The difference is in control panel which give option to change the speed of grinding
heads.
Switch on the machine
Connect the dust hose to the machine and turn on the dust collector before switching on the machine.
Stand behind the machine and hold the handle (5) tight.
Be sure that the emergency switch (1) is turned up.
Turn the speed regulation button (3) counter clockwise so the machine will turn as slow as possible.
Turn the Left/Right button (4) to one of the positions.
To start the machine, push the green Start button (2).
Raise if necessary the speed of the machine with the speed regulation button (3)
Switch off the machine

Push the red (emergency) button (1) on the electrical box.
Wait until the machine stops rotating before laying down the machine on the metal support.
Pull out the power supply.
Shut down the dust collector.