VARO POWERPLUS POWX0680 User manual

POWX0680 EN
Copyright © 2012 VARO P a g e | 1 www.varo.com
1APPLIANCE .....................................................................................3
2DESCRIPTION (FIG.1).....................................................................3
3PACKAGE CONTENT LIST.............................................................3
4SYMBOLS........................................................................................3
5GENERAL POWER TOOL SAFETY WARNINGS ..........................4
5.1 Work area ................................................................................................................4
5.2 Electrical safety.......................................................................................................4
5.3 Personal safety .......................................................................................................4
5.4 Power tool use and care.........................................................................................5
5.5 Service.....................................................................................................................5
6ADDITIONAL SAFETY INSTRUCTIONS ........................................5
7ASSEMBLY......................................................................................6
7.1 Removal of the saw blades.....................................................................................6
7.2 Fixing saw blades ...................................................................................................6
8OPERATION.....................................................................................6
8.1 Switching ON/OFF...................................................................................................6
8.2 Feed speed..............................................................................................................6
8.3 Instruction for cutting various cross sectional materials.....................................6
8.4 Lubricant instructions ............................................................................................7
8.5 Dust extraction........................................................................................................8
9CLEANING AND MAINTENANCE...................................................8
9.1 Cleaning...................................................................................................................8
9.2 Checking and replacing the carbon brushes ........................................................8
10 TECHNICAL DATA..........................................................................9
11 NOISE...............................................................................................9
12 SERVICE DEPARTMENT................................................................9
13 STORAGE ........................................................................................9
14 TROUBLESHOOTING .....................................................................9
15 WARRANTY...................................................................................10
16 ENVIRONMENT .............................................................................10

POWX0680 EN
Copyright © 2012 VARO P a g e | 2 www.varo.com
17 DECLARATION OF CONFORMITY ..............................................11

POWX0680 EN
Copyright © 2012 VARO P a g e | 3 www.varo.com
DUAL SAW 1050W
POWX0680
1 APPLIANCE
This item is designed to saw all material without changing the saw blades. It makes smoother,
cleaner cuts with less vibration and kickback then any other single blade saw.
It is not designed for commercial use.
WARNING! Read this manual and general safety instructions carefully
before using the appliance, for your own safety. Your power tool should
only be passed on together with these instructions.
2 DESCRIPTION (FIG.1)
1. ON/OFF switch
2. Auxiliary handle
3. Dust extraction outlet
4. Protection cover
5. Wax stick
6. Saw blades
3 PACKAGE CONTENT LIST
Remove all packing materials
Remove remaining packaging and transit supports (if existing)
Check the completeness of the packing content
Check the appliance, the power cord, the power plug and all accessories for transportation
damages.
Keep the packaging materials as far as possible till the end of the warranty period.
Dispose it into your local waste disposal system afterwards.
WARNING Packing materials are no toys! Children must not play with
plastic bags! Danger of suffocation!
1 x dual saw
2 x Tungsten universal saw blades (assembled)
10 x wax stick
1 x auxiliary handle
1 x wrench
1 x manual
When parts are missing or damaged, please contact your dealer.
4 SYMBOLS
In this manual and/or on the machine the following symbols are used:
Denotes risk of personal
injury or damage to the tool.
Read manual before use.
In accordance with essential
safety standards of applicable
European directives.
Class II - The machine is double
insulated; earth wire is therefore
not necessary.

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Wear noise protection.
Wear a mask In dusty conditions.
Wear eye protection.
Wear gloves.
5 GENERAL POWER TOOL SAFETY WARNINGS
Read all safety warnings and all instructions. Failure to follow all warnings and instructions
may result in electric shock, fire and/or serious injury. Save all warnings and instructions for
future reference. The term "power tool" in the warnings refers to your mains operated (corded)
power tool or battery operated (cordless) power tool.
5.1 Work area
Keep work area clean and well lit. Cluttered and dark areas invite accidents.
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.
Keep children and bystanders away while operating a power tool. Distractions can cause
you to lose control.
5.2 Electrical safety
Always check that the power supply corresponds to the voltage on the
rating plate.
Power tool plugs must match the outlet. Never modify the plug in any way. Do not use
any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching
outlets will reduce risk of electric shock.
Avoid body contact with earthed or grounded surfaces such as pipes, radiators, ranges
and refrigerators. There is an increased risk of electric shock if your body is earthed or
grounded.
Do not expose power tools to rain or wet conditions. Water entering a power tool will
increase the risk of electric shock.
Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power
tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled
cords increase the risk of electric shock.
When operating a power tool outdoors, use an extension cord suitable for outdoor use.
Use of a cord suitable for outdoor use reduces the risk of electric shock.
If operating a power tool in a damp location is unavoidable, use a residual current device
(RCD) protected supply. Use of an RCD reduces the risk of electric shock.
5.3 Personal safety
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.
Use safety equipment. Always wear eye protection. Safety equipment such as dust mask,
non-skid safety shoes, hard hat, or hearing protection used whenever conditions require
will reduce personal injuries.

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Avoid accidental starting. Ensure the switch is in the off position before plugging in.
Carrying power tools with your finger on the switch or plugging in power tools that have
the switch on invites accidents.
Remove any adjusting key or wrench before turning the power tool on. A wrench or a key
left attached to a rotating part of the power tool may result in personal injury.
Do not overreach. Keep proper footing and balance at all times. This enables better
control of the power tool in unexpected situations.
Dress properly. Do not wear loose clothing or jewellery. Keep your hair, clothing and
gloves away from moving parts. Loose clothes, jewellery or long hair can be caught in
moving parts.
If devices are provided for the connection of dust extraction and collection facilities,
ensure these are connected and properly used. Use of these devices can reduce dust
related hazards.
5.4 Power tool use and care
Do not force the power tool. Use the correct power tool for your application. The correct
power tool will do the job better and safer at the rate for which it was designed.
Do not use the power tool if the switch does not turn it on and off. Any power tool that
cannot be controlled with the switch is dangerous and must be repaired.
Disconnect the plug from the power source before making any adjustments, changing
accessories, or storing power tools. Such preventive safety measures reduce the risk of
starting the power tool accidentally.
Store idle power tools out of the reach of children and do not allow persons unfamiliar with
the power tool or these instructions to operate the power tool. Power tools are dangerous
in the hands of untrained users.
Maintain power tools. Check for misalignment or sticking of moving parts, breakage of
parts and any other condition that may affect the power tool’s operation. If damaged, have
the power tool repaired before use. Many accidents are caused by poorly maintained
power tools.
Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting
edges are less likely to stick and are easier to control.
Use the power tool, accessories and tool bits etc., in accordance with these instructions
and in the manner intended for the particular type of power tool, taking into account the
working conditions and the work to be performed. Use of the power tool for operations
different from intended could lead to a hazardous situation.
5.5 Service
Have your power tool serviced by a qualified repair person using only identical
replacement parts. This will ensure that the safety of the power tool is maintained.
6 ADDITIONAL SAFETY INSTRUCTIONS
Always keep one hand on the auxiliary handle and the other on the motor housing.
Keep your body positioned to either side of the saw blade, but not in line with the saw
blade.
Do not reach under the material being cut.
Do not attempt to remove cut material when the blade is running.
Never clamp or tie the lower guard into the open position.
Do not use any abrasive wheels.
The lower guard should be retracted manually only for making special cuts such as
‘pocket cuts’ and ‘compound cuts’.
Never hold the piece being cut in your hands or across your leg.
Never attempt to operate saw with only one blade. Kickback will occur and send the saw
towards you resulting in serious enjury.

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7 ASSEMBLY
7.1 Removal of the saw blades
Unplug the saw and allow blades to cool.
Lock one of the driver flange with the help of spindle lock on the gear housing.
Unscrew lock nut by rotation in counter clock wise direction.
Open lower guard.
Lift up and remove blade B.
Lift up and remove blade A.
7.2 Fixing saw blades
Lay the saw down with the lock nut pointing upwards and open the lower guard.
Place blade A (with the big bore) onto the flange with the text clearly visible.
Place blade B (with the small bore)onto the flange with the text easily visible.
Tighten the lock nut.
Carefully turn blades with your hands to be sure they easily turn in opposite directions.
The saw blades can’t be used in two directions!
8 OPERATION
8.1 Switching ON/OFF
To turn on the machine, push the ON/OFF switch in the ON position.
To turn the machine off, push the ON/OFF switch into the OFF position.
8.2 Feed speed
Feed speed is how quickly you push the saw blades through the material being cut. The
correct feed speed is totally determined by the hardness and the thickness of the material
being cut.
If the feed speed is too slow the blades will only press down the material rather then cutting it.
The blade edges glide an wear down the material, what causes a poor cut and will cause
excessive wear on the blades.
If the feed speed is too fast there is a definitive risk that the cut might split. The splinter will get
bigger and bigger and eventually break risking serious personal injury.
If the feed speed is too high there is risk that the cut might split and the splintering opening’s
volume will not be sufficient to divert all shaving. The result is poor cut with significant
discharge on the lower side of the material.
8.3 Instruction for cutting various cross sectional materials
Flat stirp:
Move blades in a 90° angle across the piece.
Aluminium / copper:
Apply lubrication sticks.

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Square tube:
Move blades in diagonal.
U profile:
Move blades in diagonal.
Round tube:
Move blades through the piece making sure
they come out in a 90° angle.
Thin sheet material:
Slide blades through the sheet.
8.4 Lubricant instructions
To become a longer blade life time, lubrication of the blades is necessary, especially when
cutting aluminum, copper, stainless steel and cast iron:
Place the wax stick into the foreseen hole.
Turn the feeder wheel to lubricate the blades.

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Copyright © 2012 VARO P a g e | 8 www.varo.com
Proper dosage is required.
8.5 Dust extraction
Attach a vacuum cleaner to the dust extraction outlet.
Ask your vacuum distributor for the correct connection piece if it isn’t included.
9 CLEANING AND MAINTENANCE
Attention! Before performing any work on the equipment, pull the power
plug.
9.1 Cleaning
Keep the ventilation slots of the machine clean to prevent overheating of the engine.
Regularly clean the machine housing with a soft cloth, preferably after each use.
Keep the ventilation slots free from dust and dirt.
If the dirt does not come off use a soft cloth moistened with soapy water.
Never use solvents such as petrol, alcohol, ammonia water, etc. These
solvents may damage the plastic parts.
9.2 Checking and replacing the carbon brushes
The carbon brushes must be checked on a regular basis.
In case of wear, replace both carbon brushes at the same time.
Mount the carbon brush holders.
After mounting new carbon brushes, let the machine run at no load for 15 minutes.
Use only the correct type of carbon brushes.

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10 TECHNICAL DATA
Rated voltage
230-240V
Rated frequency
50Hz
Power
1050W
No –load speed
5500 min-1
Max. cutting depth
30mm
Saw blade diameter
125mm
Teeth
32T
Protection class
Double insulated
Rated operation
Continuous operation
11 NOISE
Noise values measured according to relevant standard. (K=3)
Acoustic pressure level LpA
98 dB(A)
Acoustic power level LwA
112 dB(A)
ATTENTION! The sound power level may exceed 85 dB(A), in this case
individual hearing protection shall be worn.
aw (Vibration)
Max. 2.8 m/s²
K = 1,5 m/s²
12 SERVICE DEPARTMENT
Damaged switches must be replaced by a qualified technician.
If the connecting cable (or mains plug) is damaged, it must be replaced by a particular
connecting cable which is available from our service department. Replacement of the
connecting cable must only be carried out by our service department (see last page) or by
a qualified person (qualified electrician).
13 STORAGE
Thoroughly clean the whole machine and its accessories.
Store it out of the reach of children, in a stable and secure position, in a cool and dry
place, avoid too high and too low temperatures.
Protect it from exposure to direct sunlight. Keep it in the dark, if possible.
Don’t keep it in plastic bags to avoid humidity build-up.
14 TROUBLESHOOTING
Problem
Cause
Solution
Very high spark generation
1. Damaged teeth
2. Feed speed is too slow
3. Blunt teeth
1. Replace blades
2. Increase feed speed
3. Replace blades
A lot of wear in sections
1. Feed speed is too fast
2. Damaged teeth
3. Blunt teeth
4. Not cutting parallel or
perpendicular to work
surface
1. Reduce the feed speed
2. Replace blades
3. Replace blades
4. Hold saw parallel to
work surface
Blades are breaking
1. Damaged teeth
2. Feed speed is too fast
3. Blunt teeth
1. Replace blades
2. Reduce feed speed
3. Replace baldes

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4. Blades have buckled
5. Blades have burned out
4. Replace blades
5. Replace blades
15 WARRANTY
This product is warranted for a 36-months period effective from the date of purchase by
the first user.
This warranty covers all material or production flaws. It does not include defective parts
subject to normal wear & tear such as bearings, brushes, cables, and plugs, or
accessories such as drills, drill bits, saw blades, etc. ; damage or defects resulting from
maltreatment, accidents or alterations; nor the cost of transportation.
This warranty covers all material or production flaws, excluding batteries, chargers,
defective parts subject to normal wear and tear such as, in particular, bearings, brushes,
cables, plugs… Accessories such as drills, drill bits, saw blades etc. also do not fall under
this warranty.
Damage and/or defects resulting from inappropriate use also do not fall under the
warranty provisions.
We also disclaim all liability for any bodily injury resulting from inappropriate use of the
tool.
Repairs may only be carried out by an authorised customer service centre for Powerplus
tools.
You can always obtain more information at the number 00 32 3 292 92 90.
Any transportation costs shall always be borne by the customer, unless agreed otherwise
in writing.
At the same time, no claim can be made on the warranty if the damage of the device is the
result of negligent maintenance or overload.
Definitely excluded from the warranty is damage resulting from fluid permeation, excessive
dust penetration, intentional damage (on purpose or by gross carelessness), inappropriate
usage (use for purposes for which the device is not suitable), incompetent usage (e.g. not
following the instructions given in the manual), inexpert assembly, lightning strike,
erroneus net voltage. This list is not exhaustive.
Acceptance of claims under warranty can never lead to the prolongation of the warranty
period nor commencement of a new warranty period in case of a device replacement.
Devices or parts which are replaced under the warranty therefore remain the property of
Varo NV.
We reserve the right to reject a claim whenever the purchase cannot be verified or when it
is clear that the product has not been properly maintained. (Clean ventilation slots, carbon
brushes serviced regularly, etc.).
Your purchase receipt must be kept as proof of date of purchase.
Your appliance must be returned undismantled to your dealer in an acceptably clean state,
(in its original blow-moulded case if applicable to the unit), accompanied by proof of
purchase.
16 ENVIRONMENT
Should your appliance need replacement after extended use, do not discard it
with the household rubbish but dispose of it in an environmentally safe way.
Waste produced by electrical machine items should not be handled like normal
household rubbish. Please recycle where recycle facilities exist. Check with your
Local Authority or retailer for recycling advice.

POWX0680 EN
Copyright © 2012 VARO P a g e | 11 www.varo.com
17 DECLARATION OF CONFORMITY
VARO N.V. - Joseph Van Instraat 9 - BE2500 Lier - BELGIUM, declares that,
product: Dual saw
trade mark: Powerplus
model: POWX0680
is in conformity with the essential requirements and other relevant provisions of the applicable
European Directives, based on the application of European harmonized standards. Any
unauthorized modification of the apparatus voids this declaration.
European Directives, and their amending directives:
2004/108/EC
2006/42/EC
European harmonized standards, and their amendments:
EN60745-1: 2009
EN60745-2-5: 2010
EN55014-1: 2006
EN55014-2: 1997
EN61000-3-2: 2006
EN61000-3-3: 2008
The undersigned acts on behalf and under the power of attorney of the company
management,
Philippe Vankerkhove
Certification Manager
Date: 18/06/2012