PPA Triflex Connect Dupla - Control Board Manual

INTRODUCTION: TECHNICAL FEATURES OF THE ELECTRONIC SYSTEM

All the parameters of the Triflex Connect Dupla control unit can be set through the PROG programmer (programming tool) in three languages (Portuguese, English or Spanish) or PPA's BLUE. It can be used on all models of PPA operators with induction motors.

It is endowed with an EEProm¹ memory that stores all codes of the remote controls in an encrypted form, as well as the control unit operation parameters, such as the deceleration zone, pause time etc. The unit control is also compatible to Rolling Code Remote Controls with PPA's own protocol.

The system can be activated by remote control through a bult-in radiofrequence receiver, a loose receiver or any other device with a NO (Normally Open) contact as, for example, a pushbutton.

Triflex Connect Dupla is the ideal unit control to be used with a PPA UPS. It has some features that can reduce the energy consumption when it is operating off a battery.

The gate position control is achieved through an encoder system patented by PPA called "Reed Digital".

CONTROL UNIT

ELECTRICAL CONNECTIONS

The General Wiring Diagram can be seen below.

SYSTEM POWER SUPPLY

The operator must be connected to the power grid through the L and N inputs on the power terminal block, 110 - 220VAC connector, according to picture 1.

The operator is dual voltage (auto range); one has only to plug it into a 110 / 220V power supply; the utility frequency can be either 60Hz or 50Hz.

INDUCTION MOTOR CONNECTION

The three cables on the induction motor must be connected to the "MOTOR1" and "MOTOR2" terminal blocks. THERE IS NO CORRECT COLOR SEQUENCE². Motor 2 is factory set as the 'delay' motor.

CONNECTING THE "ENC1" AND "ENC2" ENCODERS

It is used to connect the encoder, by using a proper cable, between the motor and the control unit. Inside the operator gearbox there are sensors that provide the unit control with information about the movement direction and the position of the gate during the operation. Such information is essential for the automator's proper operation.

There are two sensors inside the encoder and each one is represented by the LEDs ECA1, ECB1, ECA1 and ECB2. Each one flashes according to the corresponding position of the disc.

CONNECTING THE "TRV" ELECTROMAGNETIC LOCK

If one decides to use an (optional) electromagnetic lock, one must connect the "Optional Relay Module" to this connector. The control unit will also recognize the module automatically and a time interval (used to start the opening movement of the operator after activating the electromagnetic lock) will be added.

CONNECTING THE "LUZ" COURTESY LIGHT

If one decides to use courtesy light, one must connect the "Optional Relay Module" to this connector. By doing so, the operation of the courtesy light is always enabled.

One must set the desired time through the DIP switch.

CONNECTING THE "RX" LOOSE RECEIVER

A loose receiver can be added to the control unit through the "RX" connector.

Before connecting the optional accessories (Electromagnetic lock and/or Courtesy Light / Traffic Light (Visual Exit Annunciator), pushbuttons etc), we strongly recommend testing the general operation of the product. To do so, send a command to the operator to start the self-learning cycle.

"FOT" CLOSING PHOTOCELL CONNECTION

This is a dedicated input port for the 'closing photocell', which is a sensor that detects an obstacle during the gate's closing cycle, preventing the gate to move if there is an obstacle along its course. If there is a blockage during the closing cycle, the operator reverses its movement to the opposite direction.

The photocells should be installed about 50 cm (1.65 ft) above the ground (in accordance with the manufacturer's recommendation), in such a way that the both the transmitter and the receiver are aligned between each other. The electrical connections must be as follows:
Terminal block 2: 15V (positive "+");
Terminal block 1: GND (negative "-");
Terminal block 3: FOT (Contact of the Photocell).

"FAB" OPENING PHOTOCELL CONNECTION

This is a dedicated input port for the 'opening photocell', which is a sensor that detects an obstacle during the gate's opening cycle, preventing the gate to move if there is an obstacle along its course. If there is a blockage during the opening cycle, the operator stops moving.

The photocells should be installed about 50 cm (1.65 ft) above the ground (in accordance with the manufacturer's recommendation), in such a way that the both the transmitter and the receiver are aligned between each other. The electrical connections must be as follows:
Terminal block 2: 15V (positive "+");
Terminal block 1: GND (negative "-");
Terminal block 4: FAB (Contact of the Photocell).

This control unit is compatible with any kind of photocell (Normally Open, Normally Closed or Resistive). In order to set the photocell intended to be used, one must connect all photocells and press the "RAMPA" (Deceleration zone) button, with all photocell aligned, i.e., with no obstacle between them. One can also calibrate the photocells by using the PROG programmer (programming tool). To do so, one must enter the "Calibration" function and press the "+" button on the device's keypad. There are LEDs used for checking the commands by the opening ("FA") and closing ("FF") photocells.

CONNECTING THE "BOT" PUSHBUTTON

The control unit acknowledges (recognizes) a pushbutton command when the BOT Terminal block is connected to the GND, i.e., a pulse to the GND.

Terminal block 1: GND (Negative "-"); Terminal block 4: BOT (NO Contact).

There is a LED used for checking the pushbutton commands ("BOT").

CONNECTING THE "ABR" OPENING-ONLY PUSHBUTTON

The control unit acknowledges an opening command when the "ABR" Terminal block is connected to the GND, i.e., a pulse to the GND. Terminal block 1: GND (Negative "-"); Terminal block 5: ABR (NO Contact).

There is a LED used for checking the pushbutton commands ("ABR").

CONNECTING THE "FEC" CLOSING-ONLY PUSHBUTTON

The control unit acknowledges a closing command when the "FEC" Terminal block is connected to the "GND" and then released, i.e., a pulse to the GND and the the button must be released.

It makes it easier using the control unit in access control systems that use photocells or inductive loops to automatically close the gate or automatic barrier.

Terminal block 1: GND (Negative "-");
Terminal block 6: FEC (NO Contact).

There is a LED used for checking the "FEC" terminal block commands.

The logic controller provides 15V (400 mA maximum DC Current) to power the photocells and receivers. If the devices need increased voltage or current, using an auxiliary power supply will be necessary.

CONNECTING THE "HIB1" AND "HIB2" LIMIT SWITCH SENSOR REEDS

The control unit acknowledges a "reed" activated when the pin corresponding to it on the HIB male pin header is connected to the GND, i.e., a pulse to the GND.

The only condition to be observed is that the reed corresponding to the gate open must be connected in such a way that the "RDA1" LED lights to the motor connector to the "MOTOR1" terminal block, pin of the connector "HIB" marked with the letter "A". And the "RDF1" LED to the motor connected to the "MOTOR1" must light when the gate is closed, pin of the connector "HIB" marked with the letter "F". The same procedure must be carried out to the second motor, connected to the "MOTOR2" terminal block.

"PROG" CONNECTOR

Connector used for communication between the control unit, and the PROG or BLUE programmers (programming tools).

"INFO_UPS" CONNECTOR

This connector is used as the communication between the control unit and the PPA UPS. With this connection installed, the control unit improves the operation when it is working without power grid supply, i.e., off the batteries.

Their improvements are:

1. The control unit reduces the energy consumption when the motor is switched on; this is accomplished by decreasing the working speed, reaching up to a 50% decrease;
2. When the control unit is in Stand-By mode, the gate is either open or closed, and the motor is switched off, it sends a command to the UPS to turn the power amplifier off and to reduce the battery consumption, increasing the autonomy in such situations. With this feature, it is possible to run out of electric energy for several hours without draining the battery. Only the RF receiver and the activation commands are powered directly off the battery, what allows the control unit to receive a command and afterwards the PPA UPS turns the voltage elevator on and the operator starts operating. This system is patented by PPA.

GATE SYSTEMS' LOGIC FUNCTION

FIRST ACTIVATION AFTER INSTALLATION (ACQUIRING / SELFLEARNING)

When the inverter is powered for the first time, after being installed to the operator, the gate must be on the middle of its travel, and must start an opening movement after an external command or if the button "CMD" has been pressed.

If it is a closing movement, open the F/R jumper to change the direction of operation of the motor. If the F/R jumper is closed again, the direction of operation returns to the previous one.

That done, press the "CMD" button or send an external command to the control unit.

Afterwards, let the gate open until it leans on the opening stopper or until it activates the 'REEDA'. Then, it will reverse the direction to close; let it lean on the closing stopper or activate the 'REEDF'.

The gate operator can operate only with ENCODER or ENCODER plus REED, but cannot operate with REED only. When the gate is closing during the self-learning, only a photocell command can reverse the gate movement.

The automatic gate is now ready to operate.

Note: If the swing gate is endowed with a rabbet (metal strip to hold one of the leaves), one must enable a motor delay through PROG. The delay will be enabled on Motor 2.

FROM THE SECOND ACTIVATION ON, WHEN THE CONTROL UNIT IS DISCONNECTED FROM THE POWER SUPPLY

After the previous operation, the gate will not need to acquire (memorize) the travel again. It will simply and slowly close after a command, until it leans on the closing stopper; the motor will turn itself off after a couple seconds. The automatic gate is now ready to operate. In case the photocell beam is obstructed or the control unit receives a command during this first closing movement, the reference point to be sought will be the opening one, in order to accelerate the acquiring of a known point of the gate's travel.

In Hybrid mode, i.e., REED plus ENCODER, if the gate is located in one of the REEDs, the gate will start with full speed, without needing to acquire the gate's travel (path). It is important to install fixed opening and closing stoppers on the gate that will be automated.

PROGRAMMING THE INVERTER PARAMETERS

'TST' FUNCTION

When the 'TST' DIP switch is turned on, the control unit enters in an operation mode which allows one to place the operator in a specific point of its travel (path) in order to set the limit switch limits or even to check the mechanical part.

In this operation mode, whenever one presses the 'VFC' button, the motor 1 is activated clockwise while the button is being pressed; once it is released, the motor turns itself off, and when the 'TX' button is pressed, the motor operates counteclockwise. The 'VEL' and 'PAUSA' buttons have the same functions, respectively, to the motor 2.

ADJUSTING PARAMETERS THROUGH THE 'TACTLED SYSTEM'

The control unit is also endowed with quick access functions through its buttons. When the 'PROG' jumper is closed, one can press the button corresponding to the desired function in order to set it. In order to increase the values, one can press the button again until one reaches the desired level. There are eight levels; the LEDs from N1 up to N8 indicate the respective level. If one wants to decrease the value, one can press the same button until the LEDs go off and start from the first again. In order to change another parameter, press the desired button and repeat the procedure.

In order to save the changes, one can open the 'PROG' jumper. The gate can now operate normally.

Programming Functions Table:

Button	Function Description
"VFC"	Limit switch travel speed Speed near the stoppers. It has an interval of 5 Hz, from 10Hz up to 50Hz. Note: The acquiring (memorization, self-learning) speed is the same as the limit switch, since it is larger than 20 Hz; in case it is smaller, the control board automatically uses 20 Hz during the acquiring procedure.
"TX"	Function for adding and erasing remote controls (TX) Adding: In order to add a remote control, press a button of the desired remote control; then, observe that the 'SN' LED quickly flashes if it is receiving the signal. Press the 'TX' button again to add the control. Observe that the 'SN' LED remains lit when it receives a signal already added to the control unit. Erasing: In order to erase the remote controls added to the memory, press the 'TX' button for 10 seconds; observe that the 'SN' LED flashes every one second. After the 10-second interval has elapsed, the 'SN' LED stops timing; at this moment, all added remote controls have been erased.
"VEL"	Speed Adjusts the opening / closing speed of the gate. Note: It has an interval of 10Hz, from 60Hz up to 140Hz.
"PAUSA"	Semi-automatic function/Pause time on automatic mode. It has an interval of 30 seconds, from 0 second up to 180 seconds. When '0' is chosen, the operator becomes semi-automatic.
"LG"	Courtesy Light time. Selects the time the 'LG' output remains active after the gate has closed. It has an interval of 30 seconds, from 0 second up to 240 seconds.
"RAMPA"	Close Limit Switch. Increases or decreases the speed the operator starts decelerating on closing and opening. It has an 8-level adjustment.

Additional functions can be programmed through the PROG programmer (Programming tool).

CLEAR (ERASE) THE MEMORIZED TRAVEL (PATH)

To clear the memorized travel of the gate, press the 'CMD' button and hold it pressed until the 'SN' LED gets lit. When the button is released, the memorized travel is cleared. Note: The 'PROG' jumper must be open.

RESTORING THE FACTORY SET DEFAULTS

To restore the factory settings, press the 'CMD' button until the 'SN' LED gets lit; do not release it; hold it pressed until the 'SN' LEd starts flashing.

When the button is released, the memorized travel is cleared, and the factory settings are restored.

Note: The 'PROG' jumper must be open.

ADDING AN RF TRANSMITTER

In order to add an RF transmitter, press the button on the transmitter and hold it pressed for at least 2 seconds. After the two seconds have elapsed, press the 'CMD' button on the control board. Observe that before the transmitter has been added, the 'SN' LED was quickly flashing; afterwards, it remains lit (on) during the transmission. A maximum 256 Fixed Code (FC) or Rolling Code (RC) can be added.

ERASING ALL ADDED RF TRANSMITTERS

In order to erase all added RF transmitters, close the 'PROG' jumper, press and release the 'TX' button once and then press it again and hold it pressed for 10 seconds; observe that the 'SN' LED flashes every one second. After the ten seconds have elapsed, the 'SN' LED stops timing; at this moment all added transmitters will have been erased.

SELECTING THE RF RECEPTION PROTOCOL (FC/RC)

The control board is factory set to receive a Fixed Code from the remote controls; in order to select the reception protocol in Rolling Code mode (RC), just activate the 'CR/CF' DIP Switch.

Caution: Whenever the state of this DIP Switch is changed, from FC to RC or vice versa, the previous described procedure, 'ERASING ALL ADDED RF TRANSMITTERS' must be repeated.

ANTI-CRUSH SYSTEM

The anti-crush feature detects the presence of obstacles on the gate travel (path). During a normal operation cycle, if an obstacle is detected, the system will do as follows:

1. When closing: the gate is activated on the opening direction.
2. When opening: The motor is turned off and it waits to receive a command to start closing.

On the acquiring (self-learning) cycle, the anti-crush feature only has the function of recognizing the opening and closing limit switches, i.e., the point in the travel where an obstacle has been detected will be considered a limit switch.

This anti-crush system is not enough to avoid accidents with people and pets; therefore, using photocells on the operators is mandatory.

ENCODER OPERATION TEST

It is possible to test the automators' encoders. In order to do so, just connect them to the control unit and check if the 'ECA1' and 'ECB1' or the 'ECA2' and 'ECB2' LEDs flash whenever the automator is operating. Each LED corresponds to a sensor; for example, the 'ECA1' LED corresponds to the sensor 'A' inside the gearmotor 1.

NOTE: For the product to function properly, if it is necessary to splice the encoder cable, we strongly recommend using a four-wire cable, each wire being at least 1 mm. The passage of the encoder cable in the conduit must be separate from the motor cable, to avoid interference.

EVENT / FAULT INDICATORS

MICROCONTROLLER OPERATION INDICATION

The main function of the 'SN' LED is to indicate that the board microcontroller is properly working; it flashes with a fixed frequency (~1Hz), since it is connected to a power supply.

MOTOR OVERCURRENT OR SHORT-CIRCUIT INDICATION

The 'SN' LED rapidly flashes in order to warn that the power amplifier has disarmed due to overcurrent or short-circuit on the motor. The control unit can operate normally 10 seconds after the Overcurrent.

OVERHEATING INDICATION

The 'FC' LED rapidly flashes to warn that the power amplifier has disarmed due to overheating of the heat sink or environment. The operator will only be able to operate again if the temperature decreases to less than 100ºC (212°F).

LACK OF EEPROM INDICATION

The 'SN' LED flashes twice whenever the memory is absent.

EEPROM WITH INVALID DATA INDICATION

The 'SN' LED flashes three times whenever the memory is present but has a content which the microcontroller does not identify as a Valid Transmitter Code.

OPEN LIMIT SWITCH INDICATION

The 'FC' LED flashes whenever the gate is in an open limit switch area.

1CLOSED LIMIT SWITCH INDICATION

The 'FC' LED remains lit whenever the gate is in a closed limit switch area.

LOAD ON THE CAPACITORS INDICATION

The 'BUS' LED indicates there is a load on the capacitors of the power amplifier.

One must not touch the power area (capacitors area) of the board whenever this LED is lit, even after the inverter has been disconnected from the power supply!

COMMANDS INDICATION

The 'FA', 'BOT', 'FF', 'ABR' and 'FEC' LEDs indicate that the control unit is receiving a command from any of the digital inputs, such as 'ABR', 'FEC', 'BOT' or 'FOT'.

FUNCTIONS ACCESSIBLE THROUGH PROG

Add a remote control	This function is used for both adding remote control and removing (erasing, deleting) them. In order to add one, one has to press a button on the remote control for 2 seconds and them press the '+' button to add it. Repeat the procedure for the other buttons to add them to the control unit memory (optional). In order to remove all remote controls, press both '-' and '+' buttons simultaneously and keep them pressed until the message "Memória Vazia!" (Empty Memory) appears on the display.
Pause time	Pause time in automatic mode; when a 0-second time is selected, it enters semiautomatic mode.
Closing ramp (deceleration zone)	Area in which the gate starts decelerating prior to the closing.
Opening ramp (deceleration zone)	Area in which the gate starts decelerating prior to the opening.
Opening speed	Frequency applied to the motor in order to open the gate.
Closing speed	Frequency applied to the motor in order to close the gate.
Opening ramp speed	Speed applied to the motor on the area near the open gate.
Closing ramp speed	Speed applied to the motor on the area near the closed gate.
Strength (Force) applied to the motor	With this function, it is possible to apply a lower strength to the operator to meet anticrush systems' requirements.
Strength (Force) in low speed	Strength applied to the motor when in low rotation, deceleration area.
Operator model	Function which applies initial values to the parameters closer to the operator being used.
Photocell Input ports calibration	This function calibrates the input ports of the photocells. To do so, one must connect all protection devices to the 'FA' and 'FF' input ports, keep all devices level (aligned / without obstruction) and press the button '+'.
Language	PROG's Language selection, available in Portuguese, English and Spanish.
Slave delay	Slave gearmotor delay (Motor 2). The time set here is used to wait to move the motor 2. During closing it is inverted, i.e., motor 2 closes first and then it waits to start closing motor 1.
Courtesy Light time	Countdown (Timer) which automatically turns the courtesy light off after the gate has closed.
Follow Photocell Mode	Function used to automatically close the gate after a vehicle passes through the photocell beam. When 0 second is selected, the function is deactivated. With a time different from 0, the gate starts closing after all sensors are clear and all preset times had been elapsed. In case any sensor is obstructed, the timing is reset.
Stop on opening	This function is usually enabled in gated communities, in order to avoid that the gate stops during the opening maneuver, due to commands from remote controls from several residents at the same time.
Lock pulse on closing	This function enables the lock during a closing maneuver in order to retract its pin (for gates which do not have the mechanical device that pushes the pin of the electromagnetic lock at the moment).
Motor starting speed	This function adjusts the first speed applied to the motor during any beginning of movement; it usually is lower in order to avoid a peak of energy consumption on starting and provides it with increased security in case the encoder is desconnected or damaged.
Stoppers' gap	Function for systems using 'ReedDigital' only, in order to avoid that the operator switches itself off with the gearmotor too pressed against the (opening and closing) stoppers. It reduces wear and tear of the pinion and other mechanical components. When the system is hybrid (Encoder plus magnetic reed), this function is automatically set to zero, since the magnetic reed determines where the gate stops.

TROUBLESHOOTING

Symptoms	Probable Cause(s)	Action(s)
The gate does not correspond to the travel where it has been installed (It brakes before the closing stopper or slams when closing).	There is a memorized travel different from the travel of the place where it has been installed.	Press both 'CMD' buttons at the same time and hold them pressed until the 'SN' LED lights.
Gate remains open and when it receives a command for opening, it closes.	Acquiring (Memorization) hasn't been performed properly.	Refer to item 3.1 First activation after installation (Acquiring / Selflearning).
'SN' LED quickly flashing and the motor shuts off.	Current sensor activated. This might happen when there is a problem with the motor.	Check the resistor of the stator. Check the motor current (it must be less than 3A RMS (Average) and 5A RMS (peak) (Maximum 2 seconds)).
To install digital systems such as encoders, photocells, among others, it is recommended that the network piping electrical or connecting cables be separated from the engine to avoid possible eletronic noise.