MXPA99003638A - Controller for a pue operator - Google Patents

Abstract

A controller for controlling an engine and other functions in a door or commercial barrier operator is described. The controller includes a single motor starting circuit to start an AC motor that uses two double pole, double throw (DPDT) relays to activate the starter coil in combination with a single triac to activate the main motor coil, eliminating the dV / dt sensitivity. A motor start control for a gate or barrier operator includes a speed control integrated in the controller to detect when to stop the AC power to the starter coil in a single phase motor. The integrated speed control uses an RPM sensor to detect the speed of the operator limit arrow coupled to software executed by the processor. Switches to operate opening, closing, stopping and learning functions are located in the controller to facilitate installation, maintenance and programming by a service provider in the door operator. In addition, a cycle counter provides a warning or alternate when the number of barrier movements equal a predetermined, programmable number of movement.

Description

CONTROLLER FOR A DOOR OPERATOR BACKGROUND OF THE INVENTION This invention relates to a controller for controlling a commercial door operator or barrier operator, and more particularly, to a controller for controlling the motor, interface, safety systems, and other functions of an operator. commercial or barrier door. Commercial door operators, depending on the voltage requirements required by the size and weight of the door or barrier to be moved, use single-phase and three-phase induction motors to move the door. Some door operator applications require the use of a direct current motor, which is a bit easier to start. The creation of sufficient starting torque, and being able to select the direction of rotation of an induction motor, are an important function of a door operator. In a single-phase induction motor, the rotor is of the squirrel-cage type. The stator has a main coil that produces a field in pulses. In standby, the pulsed field can not produce rotor currents that act on the flow of the air gap to produce the rotor torque. However, once the rotor is rotating, it produces a transverse flow at right angles to the main field, and produces a rotating field comparable to that produced by the stator of a two-phase motor. To start a single-phase motor, a starter coil is used. In a capacitive motor, the start coil is connected to the supply through a capacitor. This results in the current of the starter coil driving the applied voltage. Then the motor has standby coil currents that are almost 90 ° apart in time and space, thus producing a high starting torque and a high power factor. A three-phase motor has three coils, so that the application of current to each coil always produces a current that drives the applied voltage, resulting in enough starting torque to start the motor. Traditionally, due to the high current required to operate the motor used to drive a commercial door, commercial door operators used an electromechanical control package. The electromechanical control package normally used relays for logic functions, and contacts for motor control. The contacts are essentially relays that can switch large currents. Although electromechanical control packages are considered reliable in the field and effective because of the cost, they have limited versatility. Its logic functions are wired at the factory, and can not be programmed in the field, so customers can not change the configuration of their door operators after purchasing them. Also, electromechanical control packages do not easily accommodate additional features, although additional features, such as a delay on the reel and start coil control, can be provided by expensive additional modules. Other features, such as an RS-232 interface, an RPM system, and a maximum work stopwatch, are not entirely possible. To overcome some of the limitations of electromechanical control packages, some commercial door operators employ a solid-state controller. The solid state controller includes microelectronics to control some of the logic functions, and power control electronics to control the motor. The controller, or the logic control device, is usually constructed on a printed circuit board, which is normally located inside the electronic control box at the operator's head. Specialized programmable functions, such as storage and response to transmitter codes (if the operator has a radio control feature), and the fail-safe operation characteristics (such as for the fire door), are usually handled in a separate programmable logic board, which also sits in the electronic control box. The solid state logic control device includes DIP switches to select control options, such as options B2, C2, DI, and E2 described below. Other functions can be provided by software programs in a non-volatile memory on board, and can be executed by an on-board microprocessor. A particular prior art solid state logic control device employs five triacs instead of the contacts to control the motor. Four of the triacs are used in a bridge circuit H to direct the current in order to control the direction of rotation (the motor start coil of a single phase motor), a torque for the forward direction, and the other pair for the reverse direction; The fifth triac is used to control the main coil of the motor. Since a triac is a solid-state device, and in theory, it should not have maximum useful switching cycles, a triac must be more reliable than a contact. A contact, or relay, will eventually fail due to mechanical fatigue or erosion of electrical contacts or some other mechanical part anywhere from 50,000 to 500,000 cycles. Although the five triacs solution provides cost reductions on the contacts and relays used in the electromechanical control package, the triacs have proven to be less reliable than the contacts. Triacs, although solid state, are susceptible to voltage peaks through the power line, or local tolerance of dV / dt. The control of the prior art engine, where the two pairs of triacs were joined together on either side of the engine starting coil, one triac of each pair was connected to the alternating current neutral, and the other side of the pair of triacs was connected to hot AC power. This made it possible for the triacs to invert the polarity of the motor start coil, thus reversing the direction of rotation of the motor. However, the peaks of the power line, high dV / dt, can trigger triacs, when they do not have to. Without a pair of triacs are activated simultaneously, this causes a short dead between the neutral of alternating current and the hot of alternating current through the pair of triacs, burning the triacs or the strokes of the printed circuit board. In addition to the effect of the peaks of the power line on the triacs, the motor itself can sometimes produce enough noise to activate the triacs in the bridge circuit H. Many of the traditional techniques have been tried to minimize the effect of the triacs. peaks of the power line: capacitors through the triacs, MOVs (metal oxide varistors), and buffer networks. Unfortunately, none of the traditional techniques has worked. Many commercial door operators are equipped with single-phase capacitor start motors, which include a starter coil and a main coil. The motor is activated by supplying alternating current to the starter coil and to the main coil. As described above, the starter coil is used to give the motor its initial rotation direction (forward or reverse), and characteristics of high starting torque. During operation, the motor accelerates to approximately 80 percent of its synchronous speed, at which point, a mechanical regulator opens the circuit of the starter coil, opening an in-line breaker. After the motor reaches 80 percent (or another percentage specified by the manufacturer of the maximum rated motor speed), the starter coil is no longer needed. Actually, if the start coil is left energized, the copper losses would cause the motor to overheat. The mechanical regulators used in single-phase motors generally consist of a centrifugal regulator and switch assembly. Although they are relatively inexpensive, they are not reliable. The most common malfunctions of the centrifugal regulator and switch assembly are the controller shutdown and the switch contact failure. Once the mechanical regulator fails, the start coil can no longer be activated when starting, resulting in no motor rotation. Some engine manufacturers (and third-party suppliers) offer integrated or aggregated electronic modules to deactivate the starter coil. These electronic packages are more expensive than mechanical regulators. For example, some motor controllers rely on a set time delay and have no measurement of the RPM. In these systems, the starter coil is energized for a predetermined time, say half a second, and then released. This approach works whenever the engine starts and continues to rotate in the desired direction, given the temperature variations, the load variations, the starting torque requirements for the application. Commercial door applications generally require RPM measurements to properly control the starter coil. To assist in the maintenance of a commercial door operator, many include a cycle counter. A cycle counter increases a mechanical odometer type counter each time the commercial door cycles open or close. The odometer is then read, for example, during the routine service of the operator and the door. If the odometer reading is beyond a certain cycle count, the service provider may choose to replace certain hardware, or even the entire operator. In operators that have an electromechanical control package, the cycle counter is an aggregate unit, which increases the cost of the operator. The cycle counter is also normally mounted inside the operator's head, requiring the service provider to climb a ladder to read it. Also, the cycle counter does not provide any warning when cycle threshold accounts are reached. Most commercial garage door operators include a wall-mounted switch to allow a user to order the open / close / stop functions. When the service provider installs the operator or performs maintenance, it is often inconvenient for him to leave the operator and climb the ladder to operate the open / close / stop switches on the wall. There is a need for a controller to control a commercial door or barrier operator that is not sensitive to the peaks of the power line, dV / dt, or to motor noise. There is also a need for a controller that is robust and economical. There is an additional need for a controller that includes an integrated start coil control, eliminating the requirement of a mechanical regulator. There is a need for an engine start control circuit that causes the engine to start and continue to rotate in the desired direction, given temperature variations, load variations, and starting torque requirements for the application. There is a need for a controller that can support additional functions, such as an integrated cycle counter, and open / close / stop switches for adjustments. SUMMARY OF THE INVENTION In order to achieve the above and other objects, a controller for controlling an engine and other functions in a commercial door or barrier operator according to the invention is described. The controller eliminates the sensitivity of dV / dt by eliminating the four triacs in the H-bridge circuit of current direction, to select the direction of rotation (for example, in a single-phase motor to activate the start coil ), and replacing them with two double pole and double shot relays (DPDT). The fifth triac is used to control the current to the main (or third) coil of the motor. Although the fifth triac can still be activated by the peaks of the power line and the motor noise, since it is in series with the large impedance of the motor, it is not susceptible to shorts. In this application, the use of DPDT relays is not a problem due to its apparent shorter life. In the single-phase motor, the main commutation and the containment current flows through the main coil of the motor, so that the start coil is energized only for about half a second per cycle of operation. After the engine reaches a previously determined percentage (for example, 80 percent) of the maximum synchronous speed defined by its manufacturer, the starting coil is released, and the main coil and its switching element provide the electrical work force. And, since DPDT relays are less expensive than triacs, the use of a combination of two DPDT relays to control the current of the starter coil (or to control the direction of rotation in a three-phase motor) and a triac to control The main coil of the motor (third), provides a very robust and economical system. An integrated motor start control for a barrier operator in accordance with the invention includes a speed controller integrated in the controller. The integrated speed controller has an RPM sensor to detect the speed of the operator limit arrow coupled with the software executed by the microprocessor. The engine output speed depends on the manufacturer, the manufacturer's batch, the operating temperature and environment, and the load and start requirements. The measurement of the motor output itself, as described above, can be expensive, especially if an RPM sensor is integrated into the motor. The measurement of the RPM of the operator limit arrow is an easier and more effective means of determining the output of the motor. The limit arrow is used to set the travel limits of opening and closing the door. It is coupled with the motor output shaft, but rotates at a reduced percentage of the motor output shaft, using gear reduction. When the motor is installed on the operator, the speed of the limit arrow can be measured, and the previously determined percentage can be calculated, and stored in the on-board memory. The microprocessor or other digital control device, such as an ASIC, a gate array, or a programmable logic device, is programmed to open a switch when the RPM limit arrow reaches a fixed percentage, say 80 percent of the arrow speed maximum limit measured. A simple switch coupled with the programmable feature provides greater reliability, convenience, and lower cost than a centrifugal switch. Many different types of RPM sensors can be used. A preferred RPM sensor consists of a switch cup and a switch module. An on-board cycle counter makes it possible for the installer or the service provider to program a desired cycle count in the on-board memory. When the microprocessor detects that the number of cycles (such as the number of times the microprocessor opens the starter coil switch) reaches the previously determined amount, a warning light is activated. The warning light may be a light-emitting diode (LED) mounted on the head unit and / or an LED mounted on the wall control unit. In this way, the client is alerted to the fact that the door has cycled the previously determined number of cycles, and that service must be provided. Alternatively, a visual display can be mounted on the head unit and / or on the wall unit. A visual display can show the value of the real account stored in the memory. Additionally, if the operator has an RS-232 port, the value of the cycle counter can be interrogated and inspected at any time in a remote location, and the value displayed, for example, in a visual computer display. For example, the cycle count can be verified when a part of the operator or the door is being replaced, in order to have knowledge of the field life of the item. To facilitate the installation, adjustment, and testing of the commercial door operator, open / close / stop switches on board are provided on the logic control device. This makes it possible for the service provider to open, close, or stop the operation of the door from the operator, without having to go up and down the stairs, or walk to the wall switch. Additionally, open / close / stop onboard switches can be used to program different functions for the operator. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a perspective view of a door operator mounted on a rail / chain driven door. Figures 2A and 2B are perspective views of a door operator mounted on a door driven by a transverse axis. Figures 3A, 3B, 3C, and 3D are external views of an electrical box of the door operator of Figure 1. Figure 4 is a block diagram of a door operator that includes a logic control device in accordance with the invention. Figure 5 is a schematic of a control circuit for a commercial door operator motor according to the invention. Figure 6A is a diagram showing some of the electrical connections between the elements shown in Figure 1; Figure 6B shows motor connections for a single-phase motor of 115 volts and 208/230 volts. Figure 7 is a flow chart showing the engine starting procedure. Figure 8 is a flow chart showing the programming of the cycle counter. Figure 9 is a flow chart showing the operation of the cycle counter. Figure 10 is a flow diagram showing the programming of the RPM sensor. Figure 11 is a detailed diagram showing the electrical connections between the elements of the logic control device of Figure 4. Detailed Description of the Preferred Modes Referring now to the drawings, and especially to Figure 1, an operator of door or barrier incorporating the present invention, and is generally identified by the reference numeral 100. The door operator 100 is located at one end of the rail 102 to move a door 104. They are also illustrated, although they are not essential for the invention, with the letters A to H, the support bracket A, the medium support bracket B, the upper roller C, the curved door arm D, the straight arm E, the central line of the door F, the bracket of door G and pivot pin H. Figure 2A shows a wall mounted operator 100 driving a transverse shaft type door. Figure 2B shows the operator 100 mounted in the door housing 106. Each door operator 100 includes a motor 14 and the electronic box 10, where the controller is located. Figures 3A, 3B, 3C, and 3D are side views of portions of the operator 100. The electronic box 10 houses the controller 20, the alternating current transformer 18, the overload protection 12, and the limit arrow assembly, with limit arrow switches 11. Also illustrated, without being essential, in FIG. 3A, the contact device I and in FIG. 3B a switch part J. A schematic display of the box is shown in FIG. electronic 10 of the commercial door operator 100. The terminal connections for the controller 10 are shown in Figures 6A and 6B.The electronic box 10 houses a motor 14, a solenoid brake 16, an alternating current transformer 18, the overload 12, the limit switch / arrow assembly 22, the RPM sensor assembly 24, and the controller 20. The overload protection 12 includes an in-line thermal circuit breaker.The brake / solenoid 16 is in line with the bo Main motor bina. The alternating current transformer 18 is used to provide secondary connections. Preferably, it will provide primary voltages of 120 VAC, 240 VAC, 480 VAC, or 600 VAC, with a secondary voltage range of 24 VAC RMS, a minimum of 20 volt-amperes, and a maximum of 100 volt-ampares, at a 50/60 Hz frequency. The logic control device 20 includes a processor 32 that controls the operation of all electronic functions of the control device. A Zilog microprocessor with 8K ROM on board (Z86E43), provides additional programming functionality. Although the Zilog microprocessor includes some on-board memory, preferably an additional EEPROM memory chip (not shown) is used to store different values and data of programmable functions. Two form C relays are used to select the direction of rotation for the motor (up or down, open or close). A single triac is used to operate the main motor coil. This puts the non-solid state components at the critical point of bridge H, eliminating the quality problem with the five triacs system of the prior art. The directional relays 36 and 37 activate the starter coil to set the direction of motor rotation 14 (up / down or open / close). Preferably, two C-shaped relays (DPDT) are used to switch the polarity or phase of the motor start coil 53. The preferred manufacturer is P &; B, part number T92. The triac 38 activates the main coil of the motor 14, allowing the current of the main coil to flow. Preferably, the triac 38 includes a triac coupled with an opto-isolation triac, which is used to provide a high current switching capability in line with the main motor coil. The 115-volt single-phase and 230-volt single-phase / three-phase connection is made directly to the high-voltage terminal 39. For higher-voltage or higher-horsepower motors, the secondary of the transformer 18 is It will connect to the high voltage terminal 39. The controller 20 will have the option to directly interconnect with contacts sizes 0 and 00 for operators at higher voltages. The contacts (not shown) would then be used to handle the high-voltage switching, and would be controlled by the relays 36, 37, and the triac 38. The direct-current power supply 35 includes two separate direct-current power supplies. A 5 volt supply provides a 5 volt potential to the controller 20, and a 24 volt power supply provides a 24 volt potential to service the relay coil pulse. Local switches are provided to open / close / stop, in order to make it possible for the installer or the service provider to make adjustments directly in the electrical box, and for operator programming. The switches 40 include a four-pole DIP switch used to set the modes and operator programming. Switch 40 also includes four momentary switches for radio listening, opening, closing, and stopping functions. These functions can be used by a service provider during installation, testing, and maintenance. The indicator board 33 includes light emitting diodes to indicate, for example, when the cycle counter has counted a previously determined number of cycles. The terminal strip 34 provides the connection to other boards, sensors, and power supply connections in the commercial door operator. The limit switch assembly 22 provides for the setting of the open (or up) and close (or down) limits of the door travel. The RPM 4 sensor in combination with the microprocessor 32, is used to eliminate the centrifugal switch. The RPM sensor and the microprocessor control the current to the starter coil, and allow to control in a more precise way the cutting of the starting coil. The RPM sensor 34 measures the rotation of the limit arrow. Additional connectors can be provided to interconnect with accessory boards, such as an infrared self-monitoring system, and a warning signal board (not shown). In Figure 5 there is shown a control circuit for controlling the operation of a single-phase motor 14. The triac 38 is shown in series with the main coil 51 of the motor 14, between the hot alternating current and the current neutral alternate When the triac 38 is activated, it supplies alternating current to the main coil 51 of the motor 14. When the user selects to open (up) or close (down) from a wall switch (not shown), either the directional relay is activated. 36 (above) or relay 37 (below) to supply alternating current to start coil 53. With either relay 36 or 37 in the circuit, starting coil 53 is in series with main coil 51. When the switch 54 detects that the motor 14 has reached a previously determined percentage of its maximum rotating speed, opens the starter coil 53 to remove it from the circuit, leaving only the main coil 51 to drive the motor 14. The switch assembly 54 can be a mechanical switch, such as a centrifugal switch assembly, or an RPM sensor assembly. The inserts in Figure 6A show single-phase motor connections of 115V and 208 / 230V. If the switch assembly 54 comprises the preferred RPM sensor assembly, a photo-switch measures the speed of the limit arrow (reduced value of the motor output arrow speed), and applies the value to the microprocessor 32.

The microprocessor 32 compares the detected speed of the limit arrow with a stored value, Sm, the maximum value of the arrow in the non-volatile memory. When the detected speed of the limit arrow reaches, for example, 80 percent of the Sm, the microprocessor 32 deactivates the directional relay 36 or 37, decoupling the start coil 53. The main coil 51 continues to operate the motor 14 until the microprocessor deactivates the alternating current energy to the main coil. Figure 6B shows the connections for a 230 VAC three-phase motor, where the triac 38 applies current to the coil T3 of the motor 14 at the ElO connection, and the relays 36 and 37 are connected at the E16 and E17 connections, to provide current and direction of rotation to the coils TI and T2 of the motor 14. The inserts of Figure 6B show three-phase motor connections of 208/230 VAC and 460 VAC. Referring to Figure 11, the 832 microprocessor is shown as a Zilog brand model Z86743. Additional programmable non-volatile memory is provided by the EEPROM 850. Connectors Pl and P7 provide a connection for optional contacts, in the event that a higher voltage gate operator is required. For small voltage systems that use smaller motors with 115V or 208 / 230V supplies, control is provided by the triac / DPDT relay control. In response to a user command, the microprocessor 832 sends an enabling command to the optoisolator triac 838 via the peak P01, which enables the triac 840. In response to a directional input from the user, the microprocessor 832 enables the 836 relay. 837 by means of peaks P00 and P35. The RPM input from the off-board RPM sensor is provided in terminal 803 to microprocessor 832. In a similar manner, board off limit switch information is provided to microprocessor 832 via terminal 802. On board switches S3, S4, and S2 provide the functions of open, close, and stop, with the corresponding light emitting diodes. The SI switch board contains 4 DIP switches to establish the different operating modes described herein. Figure 7 shows a flow diagram of the engine start procedure. The microprocessor 32 controls the current to the motor starting and working coils. After the motor reaches the speed, the starter coil is deactivated, and the work coil (main) is left activated. As a safety precaution, if the motor does not reach a predetermined speed after a set time, the motor is deactivated interrupting the current to the main coil and to the starter coil. Referring to Figure 7, the microprocessor responds to a command from the open or close switch, and activates the motor (or main) work coil, by activating the triac in Step 401. In Step 402, the routine determines the state of travel of the door. In Step 403, check the status of travel up. If the answer is yes, it activates the start coil of the motor, by activating the relay up in Step 405. If the answer is no, in Step 404, it verifies the state of travel down. If the answer to either is yes, it activates the engine start coil by activating the relay down in Step 406. If the answer is no, set the error indicator in Step 407, and then in Step 408, deactivates the start relay and the triac, deactivating the motor in this way, and exits. In Step 409, check the engine RPM. If the RPMs are up to speed, or the default timer has expired in Step 410, the starter relay is deactivated only, and allows the engine to continue working in Step 402, and then it goes out. If the RPM is not up to speed, or the stopwatch has not expired, check the maximum time in Step 411. If the answer is no, cycle back to Step 409. If the answer is yes, go to Step 408 A logic control device for use in a commercial door operator must be capable of operating at temperatures from -40 degrees Celsius to +65 degrees Celsius. The logic control device must operate with single-phase and three-phase gate operators (50 and 60 Hz) of 115V, 208V, 240V, 380V, 460V, and 575V. Although in general the higher voltage operators (460V and 575V) may require contacts instead of relays, due to extremely high currents. The logic control device should last 250,000 cycles without a minor failure. Integrated Motor Start Coil Control To properly control the starter coil, the motor RPM must be measured. At 80 percent (or at some previously determined percentage, depending on the particular engine selected for the operator) of the engine's nominal RPM, the starting coil is released, and the engine continues to work in the same direction, activated by the main coil. Many motor controllers measure the RPM on the main rotor shaft. This is generally problematic, and requires the invention of the engine itself. For the measurement of the RPM, the measurement of the speed of the limit arrow of the door operator provides several advantages. The limit arrow assembly is used to maintain the proper relationship between the position of the door and the control status of the operator. It is a separate arrow and is not part of the engine. The RPM of the limit arrow is directly related to the engine arrow RPM, but reduced. The amount of RPM reduction depends on the type of operator, and must be calibrated for each operator and when the engine is replaced. In order to measure the RPM of the limit arrow, a switching cup and a photo-switch module are used. Alternatively, a Hall effect sensor and a ring magnet or one of the numerous methods available to measure the revolution speed of the arrow can be used. In general there is no fixed relationship between the speed of revolution of the limit arrow and that of the motor; The ratio varies from engine to engine, even when the engines are of the same type and evaluation. Since the speed of the limit arrow is used to predict the speed of the motor shaft, it is critical to obtain the ratio for each gate operator. Given the unit differences, each unit must be calibrated when it occurs, and whenever an engine is replaced. The calibration includes the following steps. First, the door operator is placed in the factory test mode. Then the unloaded operator is operated (without gate), and the RPM of the limit arrow is measured after 2 seconds (Sm). Sm is stored in the non-volatile memory as a representation of a motor at full speed. 80 percent of Sm is calculated, and used as the cutoff value of the limit arrow speed, to release the starter coil. Figure 10 shows other details of the RPM programming process, the engine RPM learning process. When the door operator is working in a stable door opening and door closing manner, the learning button, Step 701, is pressed to put the operator in the RPM detection mode. The maximum learning time is limited to 15 seconds. In step 702, the routine checks to see if the 15 second timer is active. If the 15-second timer is not active, Step 703, the routine activates the stopwatch. Then the routine checks if the door is in the upward travel state, Step 704. If not, the routine checks if the door operator is in the downward travel state, Step 705. If it is not, the routine returns to Step 701. If the answer is yes to either of Steps 704 or 705, the routine is derived to Step 706, where it obtains the count of the number of RPM pulses within the RPM count interval. In Step 707, the routine checks if the RPM account is greater than the previous account. If yes, update the account to the new RPM account in Step 708. If it is not, check if the learning button is still pressed in Step 709. If the learning button is not pressed, the routine saves the account of RPM in memory in Step 711, and exit. If the learning button is still depressed, the routine checks the 15 second timer in Step 710. If the 15 second timer is still active, indicating that less than 15 seconds have elapsed, the routine is drifted to Step 704. If the 15-second timer is not active, indicating that it is already time out, the routine saves the RPM account in memory in Step 711. Integrated Programmable Cycle Counter The cycle count information can be recovered in many ways different The simplest method is to activate a light emitting diode or other light when the cycle counter reaches the previously established limit. Alternatively, the cycle count data can be downloaded or interrogated through an RS-232 link having an RS-232 port connected to the microprocessor 32 in the controller 20. A transmitting diode can be located diagnostic light on both the logic control device and the wall unit, followed by the three-button controls (open / close / stop). The diagnostic light emitting diodes flash both in the controller of the head unit and in the wall unit when the cycle counter reaches the previously programmed cycle count. The previously programmed cycle count can be stored in the non-volatile memory of the controller in the installation by the service provider, using DIP switches or push button inputs. Each time the door operator opens or closes the door, the microprocessor 32 increments a counter which is then compared to the previously programmed cycle count. When the microprocessor detects a match, enables the light emitting diode indicators. Prior to the indication of the light emitting diode, a service provider can download the cycle count stored from the microprocessor through the RS-232 port, to obtain information on the number of cycles the door operator has cycled. The RS-232 link can be built directly on the logic control device, or it can be implemented as an additional alternative board, which is plugged into one of the option slots available in the logic control device. With the board added, the microprocessor can be interrogated, and can produce the exact cycle count. The cycle count can be obtained through a computer connected to the RS-232 port, or an integrated monitoring module with an RS-232 interface, and a visual display to display the current account. The number of cycles previously determined for the cycle counter is learned or programmed by programming the microprocessor according to the steps described in Figure 8. Referring to Figure 8, the routine checks first to see if the processor is in any other modes in Step 501. The routine checks whether the microprocessor is in the diagnostic mode in Step 502. If the answer is no, it is derived to Step 501. The cycle count can not be stored unless the microprocessor is in diagnostic mode. If the answer is yes, check if the learning switch is pressed in Step 503. If not, it is derived to Step 501. If yes, increase the counter in Step 504. In Step 505, check the switch for DIP mode. If yes, it is derived until Step 503. If it is not, multiply the counter by 5,000 in Step 506. In Step 507 it stores the cycle count in memory, and exits. The cycle counter increments an account of the number of times the door is opened and closed. The counter is incremented when the door operator is in the upstream state, after exiting the low limit. Referring to Figure 9, the cycle count begins at Step 601, with the facilities initialized at the factory. In Step 602, the routine verifies a state change. If not, the routine checks for a mode change in Step 603. If it is not, the routine is derived back to Step 601. If yes, in Step 604, the routine checks the timer to close set earlier. If yes, the routine stores the new stopwatch value to close in Step 606. If it is not, in Step 605, the routine checks whether the previous mode was the average stop position set. If yes, it stores the new average stop position in Step 607. If it is not, the routine checks any limits up or down in Step 613. If yes, it reads the maximum work time value in Step 614, and is derived back to Step 603. If it is not, it is cycled back to Step 613. If the answer to Step 602 is yes, the routine checks a new step up state in Step 608. If it is not , the routine reads the value of the stopwatch to close in Step 609, and then verifies if the door has left the limit below, and is now on the upward run in Step 615. If the answer to Step 615 is no, it is derived to Step 610. If the answer to Step 615 is yes, it reads the value of the cycle counter in the memory in Step 616. It then increments the cycle counter by one in Step 617. In Step 618, the routine check if the value of the cycle counter is equal to a stored value. If it is not, the routine is derived to Step 602. If yes, the routine issues a cycle count alert in Step 619, and then it is derived back to Step 612. If the answer to Step 608 is yes, the routine verifies if the door is no longer in the downstream state in Step 610. If the answer is yes, the routine is derived to Step 613. If the answer is no, the routine checks whether the mode is being set now in Step 611 (changes of DIP switches). If the answer is yes, the routine is derived to Step 613. If the answer is no, the routine obtains the average stop value from the memory in Step 612. A separate routine is provided for the reset procedure of the trigger sequence of alert to the user . In Step 620, the routine checks if the operator is in diagnostic mode, and cycles until it is. When in diagnostic mode, the unit resets the cycle count, and the alert signal, storing a zero value in memory, and disabling the warning light in Step 621. Open / Close / Stop Typical controls of opening / closing / stopping for commercial door operators, are in the form of three-button wall control stations. Wall controls for electromechanical door operators switch 24 volts of alternating current to the open and close contact coils, which in turn energize the motor. These wall control switches must be large enough (in the contact design) to commute up to two amperes of alternating current through the coils. A prior art controller uses a three-button wall control station that switches the micro-electronic logic levels to 5 volts. In this controller, the microprocessor controls the triacs, which in turn control the motor. The microprocessor, which operates at 5 volts, responds to the inputs from the open / close / stop controls, and then applies the appropriate signal to the triac control circuit. Since it only takes approximately 500 microa perios to switch the open / close / stop controls, wiring advantages are obtained over the wiring required to commute 24 volts of alternating current. Due to the lower current requirements, and the relatively low impedance of the wire, when compared to the impedance of the microprocessor input port, lower-gauge wiring, or the same gauge required by electromechanical openers, can be used, and longer working distances can be achieved. As discussed above, many door operator installations are extraordinarily time consuming, due to the need for the operator to repeatedly traverse back and forth between the operator and the wall mounted controls. Operator calibration for electromechanical or logic units normally involves, at a minimum, establishing the open / close, and auxiliary limits. This calibration takes place at the operator's head, and activation of the unit takes place on the wall. To overcome this deficiency, the controller includes open, close, and stop switches mounted on the head. These switches operate in parallel with the wall-mounted switches, but provide additional convenience, and reduce the installation and testing time for the service provider. Head-mounted switches require small current levels of 500 microamps and provide only a minimal cost impact on the cost of the operator. In addition to allowing the operation of the unit from the electrical box in the head, the open / close / stop switches mounted on the head are also used to program different characteristics of the unit. The stopwatch to close, the cycle counter, and the adjustable average stop, can now easily be programmed into the head unit using these buttons as input devices, if the service provider has to go up and down the ladder to operate the open / close / stop switches mounted on the wall. Some of the features of the door operator that can be programmed are described below. Although some features, such as modes, are programmed by setting DIP switches, others are programmed by a combination of DIP switch establishments and programmable inputs from the open / close / stop switches, and an optional learning switch.

DIP switch positions Mode 1 2 3 4 (l = deactivated, 0 = activated) B2 1 1 1 1 B2 failure test 1 1 1 0 C2 0 1 1 1 C2 fail-safe 1 0 0 0 DI 1 0 1 1 fail-safe DI 1 0 1 0 E2 0 0 1 1 E2-proof failures 0 0 1 0 T 1 1 0 1 TS 0 1 0 1 Set Stop Average - 0 1 1 0 Set Stopwatch to Close 1 1 0 0 FSTS 0 1 0 0 Clear memory 0 0 0 1 Diagnostics 0 0 0 0 Set counter cycles Setting Modes You can set different modes by setting the different DIP switches and the learning mode switch. Preferably, the door operator can be operated in operating modes B2, C2, DI, E2, T, and TS. The B2 mode includes the momentary contact to open, close, and stop, plus the wiring for a detection device, for the reverse and auxiliary devices, to open and close with the opening cancellation. The C2 mode includes a momentary contact to open and stop with constant pressure to close, open override, plus wiring for the detection device for reverse. The Di mode includes a constant pressure to open and close with wiring for the detection device to stop. The E2 mode includes a momentary contact to open with null and constant pressure to close. The release of the close button will cause the door to reverse, plus the wiring for the detection device for reverse. The T mode includes a momentary contact to open, close, and stop, with opening override and stopwatch to close. The T mode includes a momentary contact to open, close, and stop, with opening override and stopwatch to close. To set the maximum work stopwatch, the door must be in the closed position, and then the positions of the DIP switches are adjusted. The open switch is pressed and the door is allowed to travel to the fully open position. The door operates in C2 mode during the maximum work stop position. The DIP switch is changed to the desired operating mode (B2, etc.). Now the maximum work stopwatch is set in the door travel time plus 10 seconds.

To set the adjustable average detection, start with the door in the closed position. The DIP switch is set at the appropriate position. The open button is pressed, and the door is allowed to open uninterruptedly to the desired average stopping position. The detection switch is depressed. The DIP switch is changed to the desired operating mode that allows medium detection. To disable the average detection, the door is run from the limit down to the limit up without stopping. The average detection will be disabled and the DIP switch can be placed in the desired operating mode. To set the timer to close, start with the door in the closed position. The DIP switch positions are set in the desired configuration. In this mode, the door will not travel. The open / close / stop control buttons are pressed while in this mode, and the stopwatch is set to close. The diagnostic light will illuminate each time the electronics receives a valid button closure. The close button will reset the time to close at its minimum factory set value of 0 seconds. The open button will increase the value of the time to close for 5 seconds each time it is pressed. Once the time is set, the DIP switch is changed to the desired operating mode. When the diagnostic mode is selected on the DIP switch, the diagnostic light will flash twice every second, and the door will not operate while in this mode. If the DIP switch is set to the memory clean mode for 30 seconds, the unit will illuminate the diagnostic light, and the unit will pre-set the memory with the default values of 90 seconds for the maximum work stopwatch, 0 seconds for the stopwatch to close, will disable the average stop, and 0 seconds for the cycle counter. When the DIP switch is in cycle timer learning mode, the cycle counter warning light will flash the number of tens of thousands of times the unit has cycled, followed by a 3 second pause. For example, if the unit has gone from 10,000 to 19,999 cycles, the light will flash once followed by a delay of 3 seconds. To program the trigger point of the cycle counter, the following commands are used. Pressing the close button will erase the timer to 0. Each time the open button is pressed, the cycle counter trigger point is increased by 10,000 cycles. Once the cycle threshold or trigger point is reached, the operator will flash the diagnostic light once every 2 seconds for 2 seconds, until the unit is serviced and the cycle counter is cleaned. Although a particular embodiment of the present invention has been illustrated and described, it will be appreciated that those skilled in the art will think of numerous changes and modifications, and it is intended in the appended claims to cover all the cabs and modifications that follow the true spirit and scope. of the present invention.

Claims (39)

1. CLAIMS 1. A barrier operator, comprising: an alternating current motor having a start coil to create a starting torque component for the motor and a main coil for driving the motor; a transmission connected to the motor to be driven by it and for connection to a barrier to be moved; and a controller for starting and stopping the motor, the controller comprising: a first relay coupled to the starter coil to supply current having a first polarity to the starting coil; a second relay coupled to the starting coil to supply current having a second polarity to the starting coil; a triac coupled to the main coil to supply current to the main coil; and a decoupler for decoupling the starter coil when an output speed of the motor reaches a predetermined percentage of a maximum rated output speed.
2. 2. The operator of claim 1, wherein the decoupler comprises a centrifugal switch.
3. 3. The operator of claim 1, wherein the decoupler comprises an RPM sensor for detecting an output speed of the motor.
4. The operator of claim 1, wherein the operator further comprises a limit arrow to establish open limit and closed limit positions of the door, where the limit arrow rotates at a predetermined percentage of an engine output speed and where the decoupler comprises an RPM sensor to detect the rotation of the limit arrow.
5. 5. The operator of claim 4, wherein the RPM sensor comprises a switch cup and a photo-switch module.
6. 6. The operator of claim 1, further comprising a cycle counter to count the number of opening and closing movements of the door.
7. The operator of claim 6, further comprising a memory for storing a predetermined number.
8. The operator of claim 7, further comprising an indicator light to indicate when the number of movements of the door counted by the cycle counter reaches the predetermined number.
9. The operator of claim 8, further comprising a learning routine for learning the predetermined number of cycles and for storing the number in the memory.
10. 10. The operator of claim 4, further comprising a learning routine to learn a rotational speed of the limit arrow to learn the maximum nominal motor output speed.
11. 11. A barrier position controller for controlling an engine and other functions in a barrier operator, the motor having a start coil for changing the polarity of the motor and a main coil for driving the motor, comprising: a first coupled relay to the starting coil to supply current having a first polarity to the starting coil; a second relay coupled to the starting coil to supply current having a second polarity to the starting coil; a triac coupled to the main coil to supply current to the main coil; and a decoupler for decoupling the starter coil when an output speed of the motor reaches a predetermined percentage of a maximum rated output speed.
12. The logic control device of claim 11, wherein the decoupler comprises a switch and a microprocessor that responds to an output of an RPM sensor that detects a rotation speed of the motor.
13. The control logic device of claim 11, wherein the operator further comprises a limit arrow to establish open limit and closed limit door positions, where the limit arrow rotates at a predetermined percentage of an exit velocity of the motor and where the decoupler comprises a switch and a microprocessor that responds to an output of an RPM sensor that detects a rotation speed of the limit arrow.
14. 14. The logic control device of claim 13, where the RPM sensor comprises a switch cup and a photo-switch module.
15. 15. The logic control device of claim 11, comprising a cycle counter for counting the number of opening and closing movements of the door.
16. 16. The control logic device of claim 15, further comprising a memory for storing a predetermined number of cycles.
17. The control logic device of claim 16, further comprising an indicator light to indicate when the number of movements of the door counted by the cycle counter reaches the predetermined number.
18. The control logic device of claim 17, further comprising a learning routine for learning the predetermined number of cycles and for storing the number in memory.
19. 19. The control logic device of claim 13, further comprising a learning routine for learning a rotation speed of the limit arrow when coupled to the motor and learning the maximum rated output speed of the motor.
20. 20. A controller for controlling an engine and other functions in a commercial door operator, the motor having a start coil for changing the polarity of the motor and a main coil for driving the motor, comprising: a processor, which responds to a output of an RPM sensor that detects a motor rotation speed; and a motor starting circuit, comprising: a first relay coupled to the starter coil to supply current having a first polarity to the starting coil; a second relay coupled to the starting coil to supply current having a second polarity to the starting coil; a triac coupled to the main coil to supply current to the main coil; and a switch, responsive to the microprocessor, for decoupling the starter coil when an output speed of the motor reaches a predetermined percentage of a maximum rated output speed.
21. The control logic device of claim 20, wherein the operator further comprises a limit arrow to establish open limit and closed limit door positions, where the limit arrow rotates at a predetermined percentage of an exit velocity of the motor and where the RPM sensor detects a rotation speed of the limit arrow.
22. 22. The control logic device of claim 20, further comprising a cycle counter for counting the number of opening and closing movements of the door.
23. 23. The control logic device of claim 22, further comprising a memory for storing a predetermined number of cycles.
24. The control logic device of claim 23, further comprising an indicator light for indexing when the number of movements of the door counted by the cycle counter reaches the predetermined number.
25. 25. The control logic device of claim 20, further comprising a plurality of switches for providing open, close and stop functions in the logic control device and for providing programming inputs to the microprocessor.
26. 26. The control logic device of claim 25, further comprising a learning routine, which responds to user inputs to the plurality of switches, to learn the predetermined number of cycles and to store the number in the memory.
27. 27. The control logic device of claim 25, further comprising a learning routine, which responds to user inputs to the plurality of switches, to learn a rotation speed of the limit arrow when coupled to the motor and to learn the maximum nominal output speed of the motor.
28. 28. A logic control device for controlling an engine and other functions in a barrier operator, the motor having first, second and third coils, comprising: a first relay coupled to the first and second coils to supply current having a first polarity; a second relay coupled to the first and second coils to supply current having a second polarity; and a triac coupled to the third coil to supply current to the third coil.
29. 29. The logic control device of claim 28, further comprising a cycle counter for counting the number of opening and closing movements of the door.
30. 30. The control logic device of claim 29, further comprising a memory for storing a predetermined number of cycles.
31. 31. The control logic device of claim 30, further comprising an indicator light to indicate when the number of movements of the door counted by the cycle counter reaches the predetermined number.
32. 32. The control logic device of claim 31, further comprising a learning routine for learning the predetermined number of cycles and for storing the number in memory.
33. 33. A controller for controlling a barrier operator, comprising: a cycle counter for counting the number of opening and closing movements of the barrier; a memory for storing a predetermined number of cycles and the number of opening and closing movements counted by the cycle counter; and an indicator to indicate when the number of movements of the door counted by the cycle counter reaches the predetermined number.
34. 34. The controller of claim 33, wherein the indicator comprises a warning light.
35. 35. The controller of claim 33, wherein the controller further comprises a screen for representing the number of cycles counted in the cycle counter and stored in memory.
36. 36. The controller of claim 33, further comprising a data link for downloading the data stored in the effective memory to remotely represent and store the number of cycles counted and the predetermined number.
37. 37. The control logic device of claim 33, further comprising a microprocessor and a plurality of switches for providing open, close and stop functions in the logic control device and for providing programming inputs to the digital circuit.
38. 38. The control logic device of claim 34, further comprising a learning routine, which responds to user inputs to the plurality of switches, to learn the predetermined number of cycles and to store the number in the memory.
39. 39. A controller for controlling a door operator, located in the door operator, comprising: a digital circuit for processing opening, closing, stopping and other functions of the door operator; a memory that stores instructions for operating the gate operator and data values relating to the operation of the gate operator; and a plurality of logic controlled switches to provide opening, closing and stopping functions in the controller and to provide programming inputs to the digital circuit effective to enable service to a user, maintain and test the door operator in the door operator.