Afag IRG 1-S User manual

Operating instructions EN ◼IRG1-S ◼17.02.2024 ◼Version 3.0 1-28
Operating Instructions
Controller
IRG1-S
Translation of the Original Operating Instructions EN
◼Controller IRG1-S (230 V/50 Hz) Order no: 50360105
◼Controller IRG1-S (115 V/60 Hz) Order no: 50360106

2 - 28 Operating instructions EN ◼IRG1-S ◼17.02.2024 ◼Version 3.0
Dear Customer
Thank you for choosing our products and placing your trust and confidence in
our company!
This software manual contains all essential information you need about your
product. Our aim is to provide the required information as concisely and clearly
as possible. If, however, you still have any questions on the contents or
suggestions, please do not hesitate to contact us. We are always grateful for
any feedback.
Our team will also be glad to answer any further question you may have
regarding the controller or other options.
We wish you every success with our products!
With kind regards
Your Afag team
© Subject to modifications
The controllers have been designed by Afag GmbH according to the state of the
art. Due to the constant technical development and improvement of our
products, we reserve the right to make technical changes at any time.
Updates of our documentations
Unlike the printed documents, our digital instructions manuals, product data
sheets and catalogues are being continuously updated on our website.
Please keep in mind that the digital documents on our website are always the
latest versions.
© Copyright 2024 Afag GmbH
All contents of the present operating and installation instructions, in particular
the texts, photographs, and graphics, are protected by copyright. All rights
reserved. No part of these assembly and operating instructions may be
reproduced, distributed (made available to third parties), or transmitted in any
form or by any means, including photocopying, recording, or other electronic or
mechanical methods, without the prior written permission of Afag GmbH.
Afag GmbH
Wernher-von-Braun Street 1
D-92224 Amberg (Germany)
Tel.: [phone]
e-mail: [email protected]
Internet: www.afag.com
Afag Automation AG
Luzernstrasse 32
CH-6144 Zell (Switzerland)
Tel.: [phone]
e-mail: [email protected]
Internet: www.afag.com

Table of contents
Operating instructions EN ◼IRG1-S ◼17.02.2024 ◼Version 3.0 3-28
Table of contents
1General....................................................................................................................5
1.1 Contents and purpose of this manual...........................................................5
1.2 Explanation of symbols.................................................................................5
1.3 Additional symbols........................................................................................6
1.4 Warranty.......................................................................................................7
1.5 Liability..........................................................................................................7
2Safety instructions.................................................................................................8
2.1 General.........................................................................................................8
2.2 Intended use.................................................................................................8
2.3 Foreseeable misuse.....................................................................................8
2.4 Obligations of the operator and the personnel.............................................9
2.4.1 Follow these instructions........................................................................9
2.4.2 Obligations of the operating company....................................................9
2.4.3 Obligations of the personnel ..................................................................9
2.5 Personnel requirements .............................................................................10
2.5.1 Personnel qualification.........................................................................10
2.6 Personal protective equipment (PPE)........................................................10
2.7 Changes and modifications........................................................................11
2.8 General hazards / residual risks.................................................................11
2.8.1 General hazards at the workplace .......................................................11
2.8.2 Danger due to electricity ......................................................................11
3Technical data ......................................................................................................12
3.1 Dimensional drawing controller IRG1-S.....................................................12
3.2 Technical data controller IRG1-S ...............................................................13
3.3 Accessories ................................................................................................13
3.3.1 Support.................................................................................................13
4Transport and storage.........................................................................................14
4.1 Scope of supply..........................................................................................14
4.2 Transport ....................................................................................................15
4.3 Storage.......................................................................................................15
5Design and function.............................................................................................16
5.1 Design of the controller...............................................................................16
5.2 Functional description.................................................................................16
6Mounting and installation ...................................................................................17
6.1 Safety instructions......................................................................................17
6.2 Mounting the controller...............................................................................18
6.3 Installation ..................................................................................................20
7Operation and settings........................................................................................21

Table of contents
4 - 28 Operating instructions EN ◼IRG1-S ◼17.02.2024 ◼Version 3.0
7.1 Safety instructions......................................................................................21
7.2 Settings.......................................................................................................21
7.2.1 Setting of control characteristic (internal potentiometer)......................22
7.2.2 Setting the setpoint ..............................................................................23
7.2.3 Set vibration frequency (full and half wave).........................................23
7.2.4 Adjusting soft-start................................................................................24
7.2.5 Carry out release inversion ..................................................................24
8Maintenance .........................................................................................................25
8.1 Safety instructions......................................................................................25
8.2 Maintenance activities and maintenance intervals.....................................26
8.2.1 Maintenance point................................................................................26
8.2.2 Replacing the fuse................................................................................26
8.3 Spare and wear parts, repairs....................................................................26
9Decommissioning and disposal.........................................................................27
9.1 Safety instructions......................................................................................27
9.2 Disposal......................................................................................................27

General
Operating instructions EN ◼IRG1-S ◼17.02.2024 ◼Version 3.0 5-28
1 General
1.1 Contents and purpose of this manual
These assembly instructions contain important information on assembly,
commissioning, functioning and maintenance of the controller IRG1-S to ensure
safe and efficient handling and operation.
Consistent compliance with these operating instructions will ensure:
▪permanent operational reliability of the controllers,
▪optimal functioning of the controllers,
▪timely detection and elimination of defects (thereby reducing maintenance
and repair costs),
▪prolongation of the controller’s service life.
The illustrations in this manual shall provide you with a basic understanding of
the module and may vary from the actual design of your module.
1.2 Explanation of symbols
The safety notes are marked by a pictogram and a signal word. The safety notes
describe the extent of the hazard.
DANGER
Danger!
This safety note indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING
Warning!
This safety note points out a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION
Caution!
This safety note points out a potentially dangerous situation which, if not
avoided, can result in minor or slight injuries.
NOTICE
This safety note points out a potentially dangerous situation which, if not
avoided, can cause substantial damage to property and the environment.

General
6 - 28 Operating instructions EN ◼IRG1-S ◼17.02.2024 ◼Version 3.0
This note contains important additional information as well as useful tips for
safe, efficient, and trouble-free operation of the controllers.
Further warning signs:
Where applicable, the following standardised symbols are used in this manual
to point out the various potential health risks.
Warning - Dangerous electrical voltage.
Warning - Risk of hand and finger injury due to uncontrolled
movements of components.
Warning - Magnetic field
1.3 Additional symbols
In these assembly instructions the following symbols are used to highlight
instructions, results, references, etc.
Symbol
Description
1.
Instructions (steps ...)

Results of actions

References to sections
◼
Enumerations not ordered

General
Operating instructions EN ◼IRG1-S ◼17.02.2024 ◼Version 3.0 7-28
1.4 Warranty
The warranty terms for Afag feeding components and handling systems are the
following:
▪24 months from initial operation and up to a maximum of 27 months from
delivery.
▪Wear parts are excluded from the warranty (The customer is entitled to a
product free of defects. This does also apply to defective accessories and
wear parts. Normal wear and tear are excluded from the warranty.
The warranty covers the replacement or repair of defective Afag parts. Further
claims are excluded.
The warranty shall expire in the following cases:
▪Improper use of the handling system.
▪Non-observance of the instructions regarding installation, commissioning,
operation, and maintenance.
▪Improper assembly, commissioning, operation, and maintenance.
▪Repairs design changes carried out without prior technical instructions of
Afag.
▪Removing the serial number from the product.
▪Non-observance of the EC Machinery Directive, the Accident Prevention
Regulations, the Standards of the German Electrotechnology Association
(VDE) and these safety and assembly instructions.
1.5 Liability
No changes shall be made to the controllers unless described in this manual or
approved in writing by Afag.
Afag accepts no liability for unauthorized changes or improper assembly,
installation, commissioning, operation, maintenance, or repair work.

Safety instructions
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2 Safety instructions
2.1 General
This chapter provides an overview of all important safety aspects to ensure safe
and proper use of the controllers and optimal protection of personnel.
Safe handling and trouble-free operation of the controller requires knowledge of
the basic safety regulations.
Every person carrying out installation, commissioning, maintenance work or
operating the controllers must have read and understood the complete user
manual, especially the chapter on safety instructions.
Beyond this, there are rules and regulations regarding accident prevention that
are applicable to the place of installation which must be observed.
Failure to follow the directions and safety instructions given in this instructions
manual may result in serious hazards.
2.2 Intended use
The electronic controllers are designed for use in industrial systems. The IRG1-
S controller is intended for use in electromagnetic vibratory conveyors and is
used for the continuous control of inductive loads such as bowl feeders, linear
feeders, and hoppers.
The intended use of the module also includes:
▪observance of all instructions given in this manual.
▪compliance with the inspection and maintenance work and the
specifications in the data sheets,
▪using only original spare parts.
Improper use of the controller will invalidate the warranty.
2.3 Foreseeable misuse
Any use other than or beyond the intended use described is considered a
misuse of the controller.
WARNING
Risk of injury if the controller is not used for its intended use or if it is
foreseeable used incorrectly!
The improper use of the controller poses a potential hazard to the personnel.
▪The controllers may only be used in a technically perfect condition in
accordance with its intended use and the instructions in this manual as well
as in compliance with the safety requirements!

Safety instructions
Operating instructions EN ◼IRG1-S ◼17.02.2024 ◼Version 3.0 9-28
2.4 Obligations of the operator and the personnel
2.4.1 Follow these instructions
A basic prerequisite for safe and proper handling of the controllers is a good
knowledge of the basic safety instructions.
This manual, particularly the safety instructions contained therein, must be
observed by all persons working with the controllers.
2.4.2 Obligations of the operating company
In addition to the safety instructions given in this manual, the operating company
must comply with the safety, accident prevention and environmental protection
regulations valid for the field of application of the controller.
The operating company is required to use only personnel who:
▪have the necessary professional qualifications and experience,
▪are familiar with the basic rules regarding occupational safety and accident
prevention,
▪have been instructed in the correct handling of the controllers,
▪have read and understood these operating instructions.
The operating company is also required to:
▪monitor on an ongoing basis that the personnel work safely considering any
potential hazard involved and the operating instructions are observed,
▪ensure that the operating instructions are always kept at hand at the
installation in which the controllers are mounted,
▪observe and communicate universally applicable laws and regulations
regarding accident prevention and environmental protection,
▪provide the necessary personal protective equipment (e.g. protective gloves)
and instruct the personnel to wear it.
2.4.3 Obligations of the personnel
All personnel working with the modules are required to:
▪read and observe these operating instructions, especially the chapter on
safety,
▪observe the occupational safety and accident prevention regulations,
▪observe all safety and warning signs on the modules,
▪refrain from any activity that might compromise safety and health.
In addition, the personnel must wear the personal protective equipment
required for carrying out their work. (chap. 2.6).
c

Safety instructions
10 - 28 Operating instructions EN ◼IRG1-S ◼17.02.2024 ◼Version 3.0
2.5 Personnel requirements
2.5.1 Personnel qualification
The activities described in the operating instructions require specific requisites
at the level of professional qualifications of the personnel.
Personnel not having the required qualification will not be able to assess the
risks that may arise from the use of the controllers thus exposing himself and
others to the risk of serious injury. Therefore, only qualified personnel may be
permitted to carry out the described activities on the controllers.
These operating instructions are intended for skilled personnel (installers,
system integrators, maintenance personnel, technicians), electricians and
operating personnel.
The following is a description of the professional skills (qualifications) required
for carrying out the different activities:
Qualified personnel:
Qualified personnel with appropriate training who are qualified due to their
special know-how and fully familiar with the machine and who have been given
instructions on how to carry out the task entrusted to them safely.
Qualified electrician:
Persons who have obtained their electrical qualifications through appropriate
professional training and complementary courses that enables them to identify
risks and prevent possible hazards resulting from electricity.
Operator (trained personnel):
Authorized persons who due to their specialized professional training,
expertise and experience can identify risks and preventing possible hazards
arising from the use of the machine.
2.6 Personal protective equipment (PPE)
The personal protective equipment serves to protect the personnel from hazards
affecting their safety and health at work.
When working on/with the controller, the personnel must use the protective
equipment assigned by the safety officer of the operating company or as
required by safety regulations. In addition, the personnel are required to:
▪wear the personal protective equipment provided by the operating company
(employer),
▪check the personal protective equipment for proper condition, and
▪immediately notify the person responsible on site of any defects found on the
personal protective equipment.

Safety instructions
Operating instructions EN ◼IRG1-S ◼17.02.2024 ◼Version 3.0 11-28
2.7 Changes and modifications
No changes may be made to the controller which have not been described in
these operating instructions or approved in writing by Afag GmbH.
Afag accepts no liability for unauthorised changes or improper assembly,
installation, commissioning, maintenance, or repair work.
2.8 General hazards / residual risks
Observe the safety instructions in this chapter and in the other sections of this
manual to avoid damage to property and dangerous situations for the personnel.
2.8.1 General hazards at the workplace
The controller has been built according to the state-of-the-art and the applicable
health and safety requirements. However, improper use of the controller may
cause the following hazards to the personnel:
▪danger to life and limb of the operator or third parties,
▪on the controller units themselves,
▪property damage.
2.8.2 Danger due to electricity
DANGER
Risk of injury due to electric shock!
Work on the electrical system carried out unprofessionally can cause serious
or fatal injuries.
▪Work on the machine's electrical equipment may only be performed by
skilled electrician or trained personnel under the supervision of a skilled
electrician in accordance with all relevant electrical regulations.

Technical data
12 - 28 Operating instructions EN ◼IRG1-S ◼17.02.2024 ◼Version 3.0
3 Technical data
3.1 Dimensional drawing controller IRG1-S
Fig. 1 Dimensional drawing of IRG1-S controller

Technical data
Operating instructions EN ◼IRG1-S ◼17.02.2024 ◼Version 3.0 13-28
3.2 Technical data controller IRG1-S
3.3 Accessories
3.3.1 Support
Type
Designation
Order Number
Support
for 1 IRG
50450178
for 2 IRG
50450179
for 1 IRG extended
50450145
for 2 IRG extended
50450147

Transport and storage
14 - 28 Operating instructions EN ◼IRG1-S ◼17.02.2024 ◼Version 3.0
4 Transport and storage
4.1 Scope of supply
The corresponding documentation is supplied with each controller.
Fig. 2 Scope of delivery IRG1-S
[Unt]
Designation
1 x
Controller
1 x
Operating Instructions

Transport and storage
Operating instructions EN ◼IRG1-S ◼17.02.2024 ◼Version 3.0 15-28
4.2 Transport
No liability can be assumed for damages caused by improper installation on
the part of the operating company.
The following conditions must be complied with for transport and storage:
▪Storage temperature: 0-+45 °C
▪Relative air humidity: < 90%, non condensing
4.3 Storage
If the controller is stored for an extended period, observe the following:
▪Store the controller in the transport packaging in a place.
▪Do not store the telescope spindle axes outdoors or expose them to weather
conditions.
▪The storage space must be dry and dust free.
▪Room temperature of the storage space: 0-50 °C.
▪Relative air humidity: < 90% non-condensing.
▪Protect the controller from dirt and dust.

Design and function
16 - 28 Operating instructions EN ◼IRG1-S ◼17.02.2024 ◼Version 3.0
5 Design and function
5.1 Design of the controller
Fig. 3 Design of the IRG1-S controller
5.2 Functional description
The electronic controller IRG1-S is used for the control of inductive loads such
as bowl feeders and linear feeders.
The controller operates according to phase-angle control and thus generate a
variable output voltage for the drive solenoid.
The performance is adjusted using the potentiometer integrated in the front
panel. The control curve of the potentiometer can be adapted to the conveyor
device via internal trimming potentiometers Umin/Umax, so that the full control
range of 0...100 % can always be utilised.
The IRG1-S controller can be used to operate vibratory conveyors with a
vibration frequency of 6000 S/min (100Hz) or 7200 S/min (120Hz) or 3000 S/min
(50Hz) or 3600 S/min (60Hz) (full-wave or half-wave operation). The operating
mode can be set via an internal switch.
An adjustable smooth start ensures that when the unit is switched on via the
mains switch or the control input, the feeder starts up without jerks.
The controller can be switched on or off by a higher-level system, e.g. PLC,
using a 24 V, DC signal voltage via an enable input. With the factory setting, the
control unit switches "Off" when a control voltage is applied.
Mains voltage fluctuations are eliminated via an internal compensation circuit,
so that a constant performance is guaranteed.
Connection
On-/Off switch
Potentiometer

Mounting and installation
Operating instructions EN ◼IRG1-S ◼17.02.2024 ◼Version 3.0 17-28
6 Mounting and installation
For safe operation, the module must be integrated into the safety concept of the
system in which it is installed.
During normal operation, it must be ensured that the user cannot interfere with
the working area of the controller. This can be achieved through suitable
protective measures (e.g. enclosure, light grid).
When the system is running in special operating modes, it must be ensured that
there is no danger to the operator.
The system operator is responsible for the installation of the controller in a
system!
6.1 Safety instructions
No liability for damages can be assumed for damages caused by improper
installation on the part of the operator.
Observe the safety instructions in chap. 2 "Safety instructions" of this
manual as well as the instructions in chap. 6.3.
WARNING
Danger! Risk of electric shock!
If work on electrical components is required, ensure that the work is carried
out properly, failure to do so will cause serious or fatal injuries.
▪Work on the machine's electrical equipment may only be performed by
skilled electrician or trained personnel under the supervision of a skilled
electrician in accordance with all relevant electrical regulations.
▪Disconnect the power supply before assembly and disassembly work and
when making changes to the installation!

Mounting and installation
18 - 28 Operating instructions EN ◼IRG1-S ◼17.02.2024 ◼Version 3.0
6.2 Mounting the controller
Two fastening options are available for mounting the controller. The associated
mounting holes are located on the lower part of the housing and are separate
from the inside of the housing.
Connection option type 230V/50Hz
Fig. 4 Fastening of controller type 230V/50Hz
NOTICE
Damage to the circuit board!
Incorrect adjustment of the slide switches can cause a malfunction or damage
the circuit board!
▪Set the slide switch only for the respective application!
Output coupling
STAK 20
Sensor plug
M8 - 4 pol.

Mounting and installation
Operating instructions EN ◼IRG1-S ◼17.02.2024 ◼Version 3.0 19-28
Connection option type 115V/60Hz
Fig. 5 Fastening of controller type 115V/60Hz
Output coupling
STAK 20
Sensor plug
M8 - 4 pol.

Mounting and installation
20 - 28 Operating instructions EN ◼IRG1-S ◼17.02.2024 ◼Version 3.0
6.3 Installation
Important notes on the electrical connection
▪Disconnect the supply voltage before assembly or disassembly work, as well
as when changing fuses or modifying the structure.
▪Before commissioning, check whether the rated voltage of the device
matches the local mains voltage.
▪Emergency-STOP devices must remain effective in all operating modes.
Unlocking the Emergency-STOP devices must not cause an uncontrolled
restart!
▪The electrical connections must be covered!
▪Protective conductor connections must be checked for proper function after
installation!
WARNING
Danger! Risk of electric shock!
Unprofessional work can lead to serious or fatal injuries and damage to
property.
▪Work on the machine's electrical equipment may only be performed by
skilled electrician or trained personnel under the supervision of a skilled
electrician in accordance with all relevant electrical regulations.
NOTICE
Damage to the controller due to incorrect control input!
If the load circuit is interrupted via a switch or relay, the controller may be
damaged in certain applications if the wrong control input is used!
▪For applications that require constant ON and OFF switching of the
vibratory drive (e.g. accumulation shutdown, hopper control, etc.), the
control input provided for this purpose must be used!