Garage Door Opener Refurb...
So after reading this, I can almost guarantee you guys are going to consider me nuts, but here goes.
What I'm starting out with is an old Overhead Door, model R80 CZ residential garage door opener, 110VAC 1PH, with 24VAC controls. Currently, the motor is controlled by an electromagnetic relay, which seems to act like a reversing contactor, with the light controlled by a thermal light delay. Not sure if anyone else is familiar with these, but it uses 110VAC off the motor to heat up an element, which causes one leg of the delay to bend and close the circuit against the other.
The machine itself is fine. I'm just a tinkerer who collects garage door openers, and I'm trying to find a way to not only keep them running, but upfit them to current safety standards - IE: adding in non-contact safety sensors as required by UL325-2010, and updating the existing built in safety device - a basic pivot bar which detects flex between the rail and the power head, and is adjusted with a wing nut pressing a spring to control how much flex is required to activate the safety switch.
What I would like to do, is have a programmable controller, either onboard control, or PC uploadable control settings, and have the ability to use either 1 button to control the door, or a commercial Open/Close/Stop station. I'd also like to add in a safety system, either something like a 24VAC Omron beam, or a safety edge, or both. As far as programmability, I'm looking to be able to program things such as the courtesy light timer, a travel timer as a back up safety system, what actions to take if it encounters an obstruction (stop, run up 1 sec, or reverse to full open), flash lights on safety trigger, things like this.
I was looking at parts on eBay, but the more I looked, the more I realised I'm not sure what all I'd need to do this. I know I'd need the PLC itself, and some type of single phase either reversing contactors or relays, breakers or fuse blocks for overload protection, another relay or contactor for the light control, then a way to program the PLC - most likely from my Windows7 laptop. Beyond that, I'm not sure what's needed. So, here goes the questions:
When buying a PLC for something like this, is there a brand that is better for a project like this? The only two brands I've heard or seen frequently over the years are Allen Bradley and Siemens.
Is thre a specific type of PLC that I need to have to do what I'm looking for?
For the motor control, is there a specific type of contactor or relay that would be recommended for a 1/3HP motor with an external starting capacitor?
What would I need to operate the courtesy light?
What's the simplest way to program a PLC for something like this, or what application would you recommend to upload programing to the PLC?
I would prefer to have something that I could change some of the settings at the PLC, but how much complexity will that add to the programming?
I'd also like to have a N/O momentary button (I'll most likely build a wall station for this) to control the light, and another that I could push and hold for approximately 1 second to lock out radio controls. (I say this realising that I would have to have seperate input terminals for the radio controls) Could a noob like me do this?
I'm open to suggestions. If y'all have a different way that you would do it, I'm all ears. I'm looking for a project to keep myself busy with for a while, and this seemed like a good venture.
Thanks in advance.