Operation Instructions TBi BRG-2-VD - Rev 1.01 - e

Installation and Original operating instructions
Automatic torch cleaning station
TBi BRG-2-VD
Special version with externally controlled spraying
TBi Industries GmbH

Ruhberg 14
35463 Fernwald-Steinbach
Tel. +49 6404 9171-0
Fax +49 6404 9171-58
info@tbi-industries.com
www.tbi-industries.com
 2017 TBi Industries GmbH Rev. 1.01 / 01.2017 NR. DOKP44507A

Operating Instructions TBi BRG-2-VD special version TBi Industries GmbH
Table of contents
1 Important basic information ...........................................................................................................................29
1.1 Safety instructions ................................................................................................................................29
1.2 Symbols and Signal words ...................................................................................................................30
1.3 Conditions of intended use ...................................................................................................................30
1.3.1 Field of use, Transport and Storage ................................................................................................30
1.3.2 Scope of delivery .............................................................................................................................30
1.3.3 Disposal and Recycling....................................................................................................................30
1.4 Incorporation into a machine ................................................................................................................31
1.5 Warranty ...............................................................................................................................................31
2 Product description, Technical data ..............................................................................................................32
2.1 Field of application and product description .........................................................................................32
2.2 Functional description ..........................................................................................................................32
2.3 Specifications .......................................................................................................................................32
2.3.1 Model overview and comparison of functions ..................................................................................32
2.3.2 Technical specifications ...................................................................................................................33
2.4 Setup BRG-2-VD ..................................................................................................................................34
3 Prepare product for use .................................................................................................................................35
3.1 Transport and Storage .........................................................................................................................35
3.2 Installation ............................................................................................................................................35
3.3 Installing the station..............................................................................................................................35
3.4 Installation of the waste bowl ...............................................................................................................36
3.5 Connection to the compressed air supply ............................................................................................36
3.6 Electrical connection to the robot control .............................................................................................37
3.6.1 Configuration of the connector (X1, X2) ..........................................................................................38
3.7 Programming the robot control .............................................................................................................39
3.7.1 Flowchart..........................................................................................................................................39
3.8 Setting up the station............................................................................................................................40
3.8.1 Preparing the station for further setup steps....................................................................................40
3.8.2 Replacing the reamer.......................................................................................................................41
3.8.3 Determining the correct torch position for cleaning .........................................................................42
3.8.4 Setting the cleaning position of the reamer .....................................................................................43
3.8.5 Aligning the spray nozzles and setting the anti-spatter fluid dosage ...............................................44
3.8.6 Concluding the setup activities ........................................................................................................44
3.8.7 Readying the station for operation ...................................................................................................45
4 Operation .......................................................................................................................................................45
4.1 Normal operation: Switching on the device ..........................................................................................45
4.2 What to do in case of faults or maintenance ........................................................................................46
4.3 TCP reference point .............................................................................................................................46
5 Service and maintenance ..............................................................................................................................47
5.1 Recommended accessories .................................................................................................................47
6 Spare and wear parts ....................................................................................................................................48
6.1 Reamers ...............................................................................................................................................48
7 Information regarding the decommissioning of the unit.................................................................................49
7.1.1 Uninstalling the product ...................................................................................................................49
7.1.2 Transport and Storage .....................................................................................................................49
7.1.3 Disposal and Recycling....................................................................................................................49
8 Troubleshooting .............................................................................................................................................49
9 Appendix ........................................................................................................................................................51
page 28 / 51 Subject to change without notice.  2017 TBi Industries GmbH

1 Important basic information

1.1 Safety instructions
Danger!
In order to prevent serious personal injuries and/or damage to your installation and
equipment the information and statements given in these operating instructions must be
observed. All personnel operating machines fitted with the product or doing work on the
product itself must have read these operating instructions thoroughly before starting and
must follow the given indications at all times.
1. The device is a partly completed machine with regard to the machinery directive 2006/42/EC. The
partly completed machine must not be put into service until the final machinery into which it is to be
incorporated has been declared in conformity with the provisions of this directive.
2. An automatic cleaning device comprises a variety of potential hazards for humans and the
environment. The product must only be used by trained personnel, this also applies to
commissioning and maintenance. Therefore all safety regulations in these operating instructions
and robot control must be followed.
3. The accident prevention regulations as well as in-house and national safety-related provisions must
be strictly observed.
4. The TBi BRG-2 torch cleaning station may only be used within the scope of its technical data and
with the specifically provided TBi components in connection with a welding robot. The torch
cleaning station may only be used for mechanised torches. It has not been approved for cleaning
manual torches.
5. The device may only be operated in a shielded area, which cannot be accessed by personnel
during operation. Suitable electrical interlock circuits are to be provided by the operator of the
installation.
6. The station must be anchored in the robot’s operating range with 4 bolts prior to start-up. Risk of
the station overturning!
7. The compressed air supply must be interrupted prior to any work on the TBi BRG-2, such as
installation and repair work, and the input line to the station must be vented. There is the risk of
injury from the unintentional start-up of the station.
8. In the event of installation and repair work in the robot’s operating range it must be ensured that the
entire system has been shut down and has been secured against unintentional operation, e.g. as a
result of an operating error. All the protective measures must remain in place for the length of stay
in the hazard zone. If this is disregarded, there is a risk of fatal injuries from the robot. When
working on the TBi BRG-2, there is a risk of fatal electrical shock, injuries from pneumatically
moved parts and burning and stabbing injuries from the wire. There is also a risk of the destruction
of other system parts as a result of a short-circuit.
9. All electrical wires and hoses must be protected against damage. The condition of the station must
be inspected by an expert on a regular basis. Damage must be properly repaired prior to further
operation.
10. In normal operation, the device sprays the anti-spatter fluid with which it has been filled. Usually
this agent contains high levels of oil or water. Depending on how the device is installed, it is
possible for this agent to get on the floor, thereby creating a considerable risk of slipping and injury
to persons. The operator of the system must carry out a safety analysis and take appropriate
precautions prior to commissioning. Legal issues regarding the protection of the environment and
of employees’ health in relation to aerosols and skin contact must also be observed.
11. Independent system modifications are not permitted.
12. Additional extensions may only be attached with the manufacturer’s express written consent.
Subject to change without notice.  2017 TBi Industries GmbH page 29 / 51

1.2 Symbols and Signal words
Symbol Signal word Distinction
Danger! Indicates immediate danger that could cause serious or even fatal
injury.
Warning! Indicates a possible hazardous situation that could cause serious or

even fatal injury.
Caution! Indicates a possible dangerous situation that could cause light or

minor injuries.
Notice:, Indicates a potentially dangerous situation that could cause

Important notice! material damage.
1.3 Conditions of intended use

1.3.1 Field of use, Transport and Storage
1. The product is only intended for commercial and industrial use by qualified experts. The manufacturer
accepts no liability for accidents and damage as a result of improper use of the product.
2. The automatic torch cleaning station TBi BRG-2-VD is solely designed to clean robot and automated
welding torches within the scope of its technical data.
3. The products reflect the latest state of technology and are reliable, if they are assembled, operated and
maintained by trained personnel. The installation, operating and maintenance provisions specified in these
instructions must be followed.
4. Dry and oil-free air must be used for the compressed air supply. Only the releasing agent recommended by
the manufacturer may be used for the spray device; no guarantee is provided for the system’s chemical
resistance to other products. TBi recommends an environmentally friendly operation with the lowest
possible quantity of releasing agent.
5. The product must be protected against humidity and moisture during transport, storage and operation.
6. The product is designed for use at ambient temperatures between + 5° and + 50° C. Special measures
may need to be taken outside of these limits.
1.3.2 Scope of delivery

 Installation and Original operating instructions
 TBi BRG-2 (without reamer)
1.3.3 Disposal and Recycling

 Please do not dispose of this unit with household waste.
 Please respect the local regulations regarding disposal of this unit.

1.4 Incorporation into a machine

The TBi BRG-2 is a partly completed machine with regard to the European machinery directive 2006/42/EC.
To achieve the necessary safety for people, the unit must be incorporated into a superordinate machinery,
which provides the missing safety equipment. During normal operation, it must be prevented that people are
present in the immediate vicinity of the unit while it is operational. The main risk results from the possibility,
that the device is unintentionally and automatically activated via the external controller without direct action of
a person present in the danger area. As the unit will be placed inside the working area of an industrial robot,
this robot also represents a risk for any person entering the area. The operator of the installation must define
and implement necessary protection measures.
The risk analysis showed the following requirements:
Measure Requirement
Provide a monitored barrier around the The barrier must securely prevent access to the
installation preventing access for people. danger areas (pneumatic clamping cylinder for
gas nozzle, reamer, movement range of the
pneumatic motor and the space up to approx.
1 m from the spray nozzles).
When the barrier is opened, automatically Required Performance level
disconnect compressed air supply of the unit and PLr according to DIN EN ISO 13849: d
depressurize the supply line.
When the barrier is opened, automatically Required Performance level

disconnect the control signal connection to the PLr according to DIN EN ISO 13849: b
unit.
The partly completed machine must not be put into service until the final machinery into which it is to be
incorporated has been declared in conformity with the provisions of the directive 2006/42/EC.
1.5 Warranty
Before delivery, our products are carefully checked. We guarantee, that each product is free from defects of
material and workmanship at the time of delivery and is functioning according to its intended use.
TBi Industries GmbH provides warranty on defects of material and workmanship according to legal
requirements. Wearing parts are exempt from this warranty.
The warranty does not cover any damages or functional deficiencies resulting from
 overloading, abusing or non-intended use of the product

 collisions or accidents
 non compliance with indications stated in these operating instructions
 improper installation or assembly
 insufficient maintenance
 modifying the product from its original state
 chemical influences
 normal wear and tear during proper operation.
TBi Industries assumes no liability other than for replacement or repair of faulty parts.

2 Product description, Technical data

2.1 Field of application and product description
The automatic torch cleaning station TBi BRG-2 is solely designed to clean robot and automated welding
torches in connection with automated welding systems, such as welding robots. The TBi BRG-2 is controlled
by the robot control. Status signals are provided by the station.
The station can remove welding spatter and similar impurities from the torch head and the gas nozzle using a
rotation reamer. The areas that can be cleaned depend on the torch type and the reamer used.
The TBi BRG-2-VD has an integrated spraying device that allows the torch head to be sprayed with anti-
spatter fluid after cleaning. This reduces the reattachment of welding spatter.
A TCP reference point is provided on the housing of all stations.
Benefits of the TBi BRG-2-VD
 Automated cleaning process, no manual cleaning by the operator
 Short cleaning time and resulting high system availability
 Also cleans spatter that is difficult to remove
 Prevents pollution-related quality deviations of the weld
2.2 Functional description

The torch’s gas nozzle is fastened in the cleaning station and then cleaned.
Milling technology is used in the cleaning process. Precisely designed reamers are available for different robot
torches. These are available separately from the station. The appropriate reamer is selected depending on the
torch type or gas nozzle and contact tip (see section 6.1). The correct reamer is required in order to ensure an
optimal cleaning result. The reamer enters the gas nozzle and simultaneously encloses the contact tip during
the cleaning process. This process removes weld spatter from the gap between the gas nozzle and the
contact tip.
The fully automatic cleaning program commences after the start signal is provided. The spraying of the torch
head can be electrically activated as needed.
2.3 Specifications
2.3.1 Model overview and comparison of functions

2.3.2 Technical specifications
Compressed air supply Dry and oil-free compressed air 6 bar / 87 psi
Required air quantity Approx. 10 litres per second
Ambient temperature Storage: -10° to +50° C (14° to 122° F)
Operation: +5° to +50° C (41° to 122° F)
Program sequence Pneumatic

Supply voltage BRG-2-VD U = 24 V DC, I max= 0.15 A
Cleaning cycle time Approx. 4-5 sec.
Emission sound pressure level LEQ ≤ 70dB(A)
Releasing agent supply BRG–2-VD 500 ml
Anti-spatter liquid dosage Infinitely adjustable
Weight Approx. 14 Kg (without foot)
Signal input:
“Start cleaning” Electric; U = 24 V DC, I max= 0.105 A
(output signal from the robot control)
“spraying” Electric; U = 24 V DC, I max= 0.105 A
(output signal from the robot control)
Signal output:
“Clamping cylinder open” U = 24 V DC, I max= 0.1 A, current limiter must be
provided at the installation site
(Clamping cylinder open and reamer in downward
(status signal to the robot control)
position)
Monitoring “reamer in upper position” U = 24 V DC, I max= 0.1 A, current limiter must be
provided at the installation site
(status signal to the robot control)
Important notice!
Please check the technical data applicable to your device before commissioning. This can
be found on the rating plate fitted to the device. Please have the units serial number ready
in case of any queries.

2.4 Setup BRG-2-VD
Item Description Function / Options

1 Clamping cylinder To automatically clamp the gas nozzle (torch)
2 Gas nozzle locking rail Counter-support for the gas nozzle
2a, b Locking, setting screws To set the gas nozzle locking rail
3 TCP reference point Reference point for TCP (Tool Center Point) measurement
(with bolted cover)
4 Pneumatic motor Drive for the reamer
5 Reamer Must match the torch (see section 6.1)
6 Bracket for the pneumatic Pneumatic motor height adjustment
motor
7 Compressed air supply port Compressed air supply for the station, screw connection G1/4”
8 Cover
X1, X2 4 pol connector socket Interface for the robot control
9 Pivot foot (accessory) Optional stand for BRG-2
top fig. Base plate With four anchoring options for the pivot foot
10 Waste bowl Removable container for spatter and removed welding wire
11 Spraying unit BRG-2-VD Spraying unit with Venturi nozzle
11e “Storage” container Storage container for anti-spatter fluid
11g Spray nozzle Sprays the anti-spatter fluid
11h Cover For spray nozzle and reamer
11j Anti-spatter fluid dosage Spray quantity regulation for anti-spatter fluid

3 Prepare product for use
Danger!
Before commencing the installation activities in the robot’s operating range, make sure that
all the necessary protective measures have been taken to ensure your personal safety and
that they remain in place for the duration of the activities.
The regulations in the “Safety instructions” chapter must be followed!
3.1 Transport and Storage

Please observe the following points during transport and storage:
 The device must always be stored and transported in an upright position.
 To avoid any dangers by toppling over of the unit during transport and storage, it is recommend to
leave the unit in its original packaging material.
 Protect the device from humidity.
 The specifications for the surrounding conditions must be respected.
3.2 Installation
Please observe the following points during installation:
 Carefully remove the packaging material. To avoid any dangers of the unit toppling over, only
place the unit on stable ground.
 Make sure that all components of the unit are present. (see sections 1.3.2, 2.4)
 To determine a suitable location for placing the unit, please see section 3.3.
 For further preparations to operate the unit, please observe the instructions of all other sections.
3.3 Installing the station

The following points must be complied with when selecting an installation area:
 The station may only be placed in a shielded area of a robot cell.
 The station must be positioned so that it is protected against humidity and moisture.
 The station must be firmly anchored at the desired location prior to start-up. Only use the 4 screw holes
in the station’s base plate for this purpose.
The pivot foot available as an accessory is suitable for floor mounting. The foot must be anchored to the
floor using four appropriate screws, as prescribed. The station may then be bolted to the foot.
 The station must be placed in the robot’s operating range so that the robot arm can slide the torch, or its
gas nozzle, vertically into the station.
 It is recommended that all sides of the station are accessible for maintenance purposes.

3.4 Installation of the waste bowl

Please follow these steps to install the removable waste bowl included with the unit:
1. Position the mounting bracket (10a) for the waste bowl under the base of the unit. The waste bowl (10)
must be located beneath the reamer motor.
2. Then attach the unit and the mounting bracket with the supplied 4 cylinder screws (13) and washers
(13a) with a stable mounting surface, e.g. the stand available as accessory
Important notice!
You must use an adequate screw
locking method, e.g. the supplied
tooth lock washer (13b) in
conjunction with the base
hex nuts (13c).
mounting surface
3.5 Connection to the compressed air supply
1. Connect the 6 bar compressed air supply using the screw connection G1/4” (7).
2. We recommend connecting a maintenance unit with adjustable outlet pressure upstream of the
station, max. flow-rate approx. 1,000 l/min, with water separator / oil separator

3.6 Electrical connection to the robot control

The station must have an electrical connection to the primary process control, generally a robot control.
Please follow these steps :
1. Wire a suitable cable with connector (4-pin) according to the wiring diagram.
(See section 3.6.1 for X1, X2)
2. Then connect the plugs to the sockets (X1, X2) and secure with locking ring.
(Please ensure correct allocation!)
Important notice!
Please follow the electrical configuration of the following section „Configuration of the
connector (X1, X2)”.

3.6.1 Configuration of the connector (X1, X2)
Connector X1:
Pin 1 not connected
Pin 2 Input signal “spraying”
Start signal for the Spraying unit VD, +24 V DC, max. 0.105 A
Pin 3: 0V DC (common for all signals)
Pin 4: Input signal “start cleaning”
Start signal for the cleaning cycle, +24 V DC, max. 0.105 A
Connector X2:
Pin 1: Supply voltage for BRG-2, +24 V DC, max. 0.15 A
Pin 2: Signal output: “reamer in upper position”:
Monitoring signal for correct cleaning process, +24 V DC, max. 0.15 A
Pin 3: 0V DC (common for all signals)
Pin 4: Signal output “clamping cylinder open”
Signal is active (+24 V DC, max. 0.1 A) if the reamer in downward position and
clamping cylinder is open.
See section 5.1 Recommended accessories

3.7 Programming the robot control

We recommend programming the program sequence for the cleaning cycle and the wire cutting in a separate
robot control programming element. Pay attention to the sequence described below. The wire can be cut
before or after cleaning.
Torch cleaning and spraying process
1. Query whether the output signal “Clamping cylinder open” is active (X2, Pin 4:+24 V must be applied)
2. Move the torch to the cleaning position
3. Issue the “Start cleaning” command to BRG-2 from the robot control (X1, Pin 4: +24 V signal)
4. The station starts the cleaning process:
5. The gas nozzle is clamped and the “Clamping cylinder open” signal becomes inactive (X2, Pin 4: 0V)
6. The duration of the cleaning is controlled by the start signal. The reamer turns and the lifting cylinder
pushes the reamer upwards as long as the “Start cleaning” signal is applied. The signal must be applied
for approx. 2-5 seconds.
7. Signal “reamer in upper position” should become active (+24 V on signal pin 2, X2) approx. 2 seconds
after the start of the cleaning cycle. The robot controller may monitor this signal to confirm correct
function of the reamer mechanism.
8. Reset the “Start cleaning” signal from the robot control (to 0V)
9. The reamer stops and automatically moves down out of the gas nozzle.
10.Activate the spraying process electronically by issuing the “spraying” command from the robot control.
(X1, Pin 2: +24 V, signal should be applied)
The spraying process is carried out as long as this signal is applied. We recommend a spraying duration
of approx. 0.5 seconds.
11.The clamping cylinder for the gas nozzle opens automatically
12.Query whether the output signal “Clamping cylinder open” is active (X2 Pin 4: +24 V must be applied),
Signal “Clamping cylinder open” will only become active if also the reamer is in downward position and
the Clamping cylinder is open.
13.Move the torch out of the cleaning position. Cleaning cycle is complete.
3.7.1 Flowchart
Cleaning cycle
„Clamping cylinder open”
„Start cleaning”
„reamer in upper position”
„spraying“

3.8 Setting up the station
Danger!
For the following activities it must be ensured that the station cannot be unintentionally
activated. The compressed air supply to the station (7) and the connection to the robot
control (X1, X2) must be interrupted and the compressed air line must be vented.
(See section 2.4)
The safety instructions at the start of these operating instructions must be followed.
3.8.1 Preparing the station for further setup steps

The wire cutter and guard plate must be removed to ensure optimal accessibility when first setting up the
station.
1. Disassemble the cover (11h) by unscrewing the 4

hexagonal bolts (11n)

3.8.2 Replacing the reamer

Check whether the installed reamer is appropriate for the torch prior to setting up the station. Please pay
attention to the notes and information in section 6.1. Install the appropriate reamer prior to first using the
station if this is required. Please proceed as follows:
1. Place the Allen key (approx. 4 mm) into the drill hole (4a) on the motor head to fasten the head.
2. Hold the motor head in place with the Allen key and simultaneously unscrew the reamer (5) with a
wrench (SW 17) counter clockwise. Position the integrated spanner flat on the reamer.
3. Place a new reamer (5) on the threaded mandrel of the motor head and screw in firmly using the
wrench and the Allen key.
Spanner flat

3.8.3 Determining the correct torch position for cleaning
1. Position the torch over the cleaning station so that

the gas nozzle lies centrally over the reamer and
precisely parallel to it.
Adjust the height of the torch so that the cylindrical
part of the gas nozzle is grasped by the clamping
cylinder.
2. Control the correct alignment of the torch as follows:
a. Manually push the cleaning motor upwards until
the reamer enters the gas nozzle. The annular
gap between the reamer and the gas nozzle
should be the same on all sides. Correct the
torch position if required.
b. Remove the gas nozzle from the torch and
check whether the reamer evenly covers the
contact tip.
3. Slowly move the torch vertically upwards and reassemble the gas nozzle.
4. Adjusting the gas nozzle locking rail:
c. Release the two external hexagonal bolts (2a) using an Allen key (5 mm).
d. Adjust the adjusting bolt (2b) using an Allen key (6 mm) so that the gas nozzle locking rail (2)
is positioned against the gas nozzle. Ensure that the torch neck is not pushed to one side.
Attention: This position is the subsequent fixing position. Check once again that the gas
nozzle is parallel to the reamer and the gas nozzle locking rail (2) and that it is locked in the
cylindrical area by the clamping cylinder. Adjust as necessary!
e. Now evenly retighten the two external hexagonal bolts (2a).
5. Store this torch position as the cleaning position in your robot program! (see section 3.7)

3.8.4 Setting the cleaning position of the reamer

1. Remove the gas nozzle from the torch.
2. Move the torch to the cleaning position. (see section 3.8.3)
3. Release the bolted connection (6a) of the pneumatic motor bracket with an Allen key
(5 mm). Shift the motor upwards and retighten the bolted connection.
4. Manually shift the entire cleaning unit upwards, i.e. motor (4) and bracket (6), to the stop (6c). In this
position, check how much further the reamer still has to enter the torch.
5. If the reamer has not entered the torch to a sufficient depth then release the bolted connection (6a) of
the pneumatic motor bracket (6) and shift the motor and bracket upwards by the relevant amount.
Retighten the bolted connection.
6. Once again manually shift the entire cleaning unit upwards, i.e. motor (4) and bracket (6), to the stop.
If the rotation reamer’s insertion depth into the torch is still not correct then correct the motor position
once again.
7. Repeat steps 6 and 7 until the rotation reamer’s insertion depth is correct; when the cleaning unit is
pushed against the upper stop. Ensure that the reamer is not positioned on parts of the torch head.
This may damage the part, the torch or the rotation reamer.
8. Firmly tighten the retaining screws for the motor in the final position.
Adjust the gap between the

reamer and the torch parts by
shifting the motor in the
bracket.
Important notice!
The cleaning unit (pneumatic motor /
bracket) must always be shifted to the top
end stop for inspection.
Pay attention to the transition from the
reamer to the contact tip, nozzle assembly,
gas diffusor and spatter protection.
The reamer may not come into contact with
the nozzle assembly, gas diffusor or spatter
protection!

3.8.5 Aligning the spray nozzles and setting the anti-spatter fluid dosage
The torch head is sprayed by two nozzles, whose spray position must be aligned to the torch.
Proceed as follows when setting up:
1. Fill the storage container (11e) with anti-spatter fluid.
Remove the container sideways from the housing (11k),
unscrew the lid and remove the suction hose from the
container without kinking it. Then fill the container with the
anti-spatter fluid.
2. When sealing and repositioning the container ensure that
the suction hose is inserted into the container without
kinking. It is important that the suction hose is positioned
just above the bottom of the container.
3. Move the torch to the cleaning position.

4. Align both spray nozzles (11g) to the torch’s internal gas nozzle (contact tip, nozzle assembly, spatter
protection or gas diffusor). Move the bracket, incl. the spray nozzles (11g) to the desired position using
a wrench (SW 14).
5. The anti-spatter fluid dosage depends on the air pressure and valve setting. For a given air pressure,
5 bar is recommended, the spray quantity can be adjusted using the adjustment valve (11j).
The recommended start setting for the valve is one full turn open from the completely closed position.
6. The spray quantity is increased by turning the metering screw in the direction of the arrow (+), while it
can be reduced by turning it in the opposite direction. The spray time cannot be changed.
 The spray quantity should be increased if the anti-spatter fluid does not reach the deeper areas of
the torch head. Check the spray result on the gas nozzle!
 The spray quantity should be reduced if the anti-spatter fluid drips off the gas nozzle. Check the
spray result on the gas nozzle!
3.8.6 Concluding the setup activities

1. Reassemble the cover (11h) with 3 hexagonal bolts (11n).
(see figures under section 3.8.1)
2. Only for version DAE:
Re-attach the wire cutter (12) with 2 bolts (12b)

3.8.7 Readying the station for operation
Warning!
A short spray is automatically triggered when the station is repressurised. Ensure that
no one is in the effective range of the spray nozzles. This station behaviour can be
used to vent and control the spray unit.
The station may be activated unintentionally after connecting the compressed air
supply. Ensure that no persons are in the vicinity and that access to the station has
been securely prevented! There is a risk of serious cutting or crushing injuries or the
catching of clothes or hair on rotating parts!
1. Re-connect the control line and the compressed air supply to the station
2. Vent the spray unit, if required, by repeatedly depressurising the supply line or activating the
cleaning cycle until oil is evenly sprayed.
4 Operation
Prior to operating the unit, all instructions of section 3 must be followed (Prepare product for use).
4.1 Normal operation: Switching on the device
Danger!
Follow the safety instructions at the beginning of these operating instructions.
The following points must be checked in order to ensure that the automatic torch
cleaning station is completely equipped and assembled:
1. Is the station in a permanently stable position in the robot cell?

2. Is the device installed in a shielded area so that individuals are not able to approach the station’s
immediate vicinity during operation?
3. Is the station complete and correctly equipped (reamer, wire cutter blades, anti-spatter fluid, protective
cover)?
4. Have all installation activities been performed? (see section 3)
5. Have all the necessary processes for the cleaning cycle been stored in the robot program?
6. Are all lines and tubes positioned so that they are protected against damage and breaking?
7. Has all the technical data been complied with? (see section 2)
8. The station is now ready for operation.

4.2 What to do in case of faults or maintenance
Danger!
For safety reasons the following sequence is to be strictly followed:
1. Disconnect electrical power and air from the unit, relieve air pressure from connected hose.
2. Eliminate fault (see section 7) or perform maintenance (see section 5).
3. Connect the compressed air and electrical power.
4. The device is now ready.
4.3 TCP reference point

Unscrew the reference point cover (3) in order to use the TCP (Tool Center Point) reference point installed on
the station.
Caution!
The cover must be reattached prior to working on the station or in the robot cell in order to
prevent injuries caused by the edges.

5 Service and maintenance
Danger!
Before commencing the service and maintenance activities in the robot’s operating range,
make sure that all the necessary protective measures have been taken to ensure your
personal safety and that they remain in place for the duration of the activities.
The regulations in the “Safety instructions” chapter must be followed!
The following maintenance intervals apply for the TBi BRG-2 cleaning systems:
Daily:
 Check the fill level in the spray device’s releasing agent container
 Visual inspection of all exposed lines for damage such as breaks and tears
 Visual inspection of the reamer for damage such as breaks and tears
 Clean the reamer with compressed air
 Inspect the cleaning result
Monthly:
 Clean the station with compressed air
 Remove remnants of releasing agent from the station
 Check all screws and bolts for tightness
If damage is detected on the station, this must be repaired by an expert prior to further use. The entire station
must be replaced and sent in for repair if necessary.
Danger!
The following instructions must be followed in order to prevent damage to the system or
injuries to individuals.
1. Station repairs may only be performed by qualified individuals!

2. Improper repairs or manipulations on the station may lead to injuries!
5.1 Recommended accessories
TipClean (anti-spatter liquid, 5L canister) Part no. 392P000007

Stand for TBi BRG (pivot foot) Part no. 531P101045
Elbow connector 4-pol. (Suitable for X1, X2) Part no. 375P002323
Control cable with elbow connector (Suitable for X1, X2, cable 5m) Part no. 301P400100

6 Spare and wear parts
Item Part no. Description
3 531P102073 Reference point for TCP (Tool Center Point)
4 531P102035 Pneumatic motor for TBi BRG-2
5 see section 6.1 reamer
6.1 Reamers
Please select the appropriate reamer based on the following information.
Our reamers are made of hardened steel and have a 3/8”-24 UNF connection thread. They are suitable for
TBi BRG-2 and many other cleaning devices.
Additional reamers optimized for use with the TBi RoboMIG RM2 torches are listed in our TBi RM2 catalog.
Important notice!
Reamer size must be chosen according to contact tip and nozzle used. The inner diameter
of the reamer should be 1mm larger than the outer diameter of the tip. The outer
diameter of the reamer should be 1mm smaller than the inner diameter of the nozzle.

7 Information regarding the decommissioning of the unit
Danger!
For safety reasons the following sequence is to be strictly followed:
7.1.1 Uninstalling the product

1. Disconnect electrical power and air from the unit, relieve air pressure from connected hose.
2. Disconnect all electrical connections to the TBi BRG-2.
3. Unscrew the unit from the mounting surface, put down the unit on its side to avoid any dangers of
toppling over of the unit.
4. Pack up all components of the product, including the operation manual. The original packaging
material is most suitable for transport and storage.
7.1.2 Transport and Storage

Transport and store the product according to section 1.3.1
7.1.3 Disposal and Recycling
Follow the instructions of section1.3.3
8 Troubleshooting
Fault Possible cause Corrective measure
Cleaning cycle not No compressed air supply for the Check the connection and supply pressure
starting station
No signal from the robot control Check the connection and programming, measure the
signals. Inspect the control line for the station
Signal Fault in the program sequence Check the compressed air supply (7) and establish if
“Clamping cylinder necessary
open” is not
Faulty electrical connection Check the connector assignment in line with the
indicated
connection diagram (see section 3.6), check the control
line
No or negligible Incorrect reamer Check the reamer type (see section 6.1), replace if
cleaning required
performance
Reamer damaged or extremely worn Replace the reamer
Reamer not optimally aligned to the Check the position of the reamer, adjust if necessary
torch (see section 3.8.3, 3.8.4)
Extremely difficult to remove soiling on  Ensure correct wetting by the anti-spatter fluid,
the torch adjust the spray nozzles if required. (see section
3.8.5)
 Refill the anti-spatter fluid in the spray unit if
necessary. Only use the recommended anti-spatter
liquid TipClean (Art. number 392P000007).

Fault Possible cause Corrective measure
Cleaning start Control line connected incorrectly Check in line with the connection diagram (see section
without the robot 3.6)
issuing a signal
Short-circuit / loose contact in plug or Check, remove
control line cable
Spraying unit No compressed air supply Check the compressed air supply.
Not functioning
Faulty electrical connection, fault in the Check the connector assignment in line with the
program sequence connection diagram and inspect the “Cut wire” activation
from the robot control, measure the signal if necessary
(see section 3.6)
No anti-spatter liquid  Ensure correct wetting by the anti-spatter fluid,

adjust the spray nozzles if required. (see section
3.8.5)
 Refill the anti-spatter fluid in the spray unit if
necessary
Spraying unit Faulty electrical connection, fault in the Check the connector assignment in line with the
continuously active program sequence connection diagram and inspect the “Cut wire” activation
from the robot control, measure the signal if necessary
(see section 3.6)
If the fault cannot be removed with the above table, the station may have a defect. Consult a qualified service
technician.

9 Appendix

Operation Instructions TBi BRG-2-VD - Rev 1.01 - e

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Operation Instructions TBi BRG-2-VD - Rev 1.01 - e

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Installation and Original operating instructions

Automatic torch cleaning station

TBi Industries GmbH

 2017 TBi Industries GmbH Rev. 1.01 / 01.2017 NR. DOKP44507A

page 28 / 51 Subject to change without notice.  2017 TBi Industries GmbH

1 Important basic information

Subject to change without notice.  2017 TBi Industries GmbH page 29 / 51

1.2 Symbols and Signal words

Symbol Signal word Distinction

Warning! Indicates a possible hazardous situation that could cause serious or

Caution! Indicates a possible dangerous situation that could cause light or

Notice:, Indicates a potentially dangerous situation that could cause

1.3 Conditions of intended use

1.3.2 Scope of delivery

1.3.3 Disposal and Recycling

page 30 / 51 Subject to change without notice.  2017 TBi Industries GmbH

1.4 Incorporation into a machine

The risk analysis showed the following requirements:

When the barrier is opened, automatically Required Performance level

 overloading, abusing or non-intended use of the product

Subject to change without notice.  2017 TBi Industries GmbH page 31 / 51

2 Product description, Technical data

2.2 Functional description

page 32 / 51 Subject to change without notice.  2017 TBi Industries GmbH

2.3.2 Technical specifications

Ambient temperature Storage: -10° to +50° C (14° to 122° F)

Operation: +5° to +50° C (41° to 122° F)

Program sequence Pneumatic

Subject to change without notice.  2017 TBi Industries GmbH page 33 / 51

2.4 Setup BRG-2-VD

Item Description Function / Options

page 34 / 51 Subject to change without notice.  2017 TBi Industries GmbH

3 Prepare product for use

3.1 Transport and Storage

3.3 Installing the station

Subject to change without notice.  2017 TBi Industries GmbH page 35 / 51

3.4 Installation of the waste bowl

3.5 Connection to the compressed air supply

page 36 / 51 Subject to change without notice.  2017 TBi Industries GmbH

3.6 Electrical connection to the robot control

Subject to change without notice.  2017 TBi Industries GmbH page 37 / 51

3.6.1 Configuration of the connector (X1, X2)

See section 5.1 Recommended accessories

page 38 / 51 Subject to change without notice.  2017 TBi Industries GmbH

3.7 Programming the robot control

„Clamping cylinder open”

„reamer in upper position”

Subject to change without notice.  2017 TBi Industries GmbH page 39 / 51

3.8 Setting up the station

3.8.1 Preparing the station for further setup steps

1. Disassemble the cover (11h) by unscrewing the 4

page 40 / 51 Subject to change without notice.  2017 TBi Industries GmbH

3.8.2 Replacing the reamer

Subject to change without notice.  2017 TBi Industries GmbH page 41 / 51

3.8.3 Determining the correct torch position for cleaning

1. Position the torch over the cleaning station so that

page 42 / 51 Subject to change without notice.  2017 TBi Industries GmbH

3.8.4 Setting the cleaning position of the reamer

Adjust the gap between the

Subject to change without notice.  2017 TBi Industries GmbH page 43 / 51

3. Move the torch to the cleaning position.

3.8.6 Concluding the setup activities