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　PLC控制系統(tǒng)的設(shè)備與調(diào)試，觸及到各項作業(yè)，而且只能按序進行，一環(huán)緊扣一環(huán)，稍有不小心都將導(dǎo)致調(diào)試失利，不但延誤工期，甚至?xí)p壞設(shè)備。本文介紹了在現(xiàn)場實踐中總結(jié)出的PLC控制系統(tǒng)的設(shè)備與調(diào)試技能經(jīng)驗，并對現(xiàn)場經(jīng)常出現(xiàn)的設(shè)備、調(diào)試相關(guān)問題，提出評論定見和解決計劃。

　　一、體系的設(shè)備與調(diào)試

　　合理安排體系設(shè)備與調(diào)試程序，是確保高效優(yōu)質(zhì)地完成設(shè)備與調(diào)試任務(wù)的要害。

　　1、前期技能準(zhǔn)備

　　體系設(shè)備調(diào)試前的技能準(zhǔn)備作業(yè)越充沛，設(shè)備與調(diào)試就會越順暢。前期技能準(zhǔn)備作業(yè)包含下列內(nèi)容：

　　(1)熟悉PC隨機技能材料、原文材料，深化了解其功用、功用及各種操作要求，制定操作規(guī)程。

　　(2)深化了解規(guī)劃材料、對體系工藝流程，特別是工藝對各生產(chǎn)設(shè)備的操控要求要有全面的了解，在此基礎(chǔ)上，按子體系制造工藝流。程聯(lián)鎖圖、體系功用圖、體系工作邏輯框圖、這將有助于對體系工作邏輯的深刻了解，是前期技能準(zhǔn)備的重要環(huán)節(jié)。

　　(3)熟悉各工藝設(shè)備的功用、規(guī)劃與設(shè)備狀況，特別是各設(shè)備的操控與動力接線圖，并與什物相對照，以及時發(fā)現(xiàn)過錯并糾正。

　　(4)在全面了解規(guī)劃計劃與PC技能材料的基礎(chǔ)上，列出PC輸入輸出點號表(包含內(nèi)部線圈一覽表，I/O所在位置，對應(yīng)設(shè)備及各I/O點功用)。

　　(5)研讀規(guī)劃提供的程序，對邏輯雜亂的部分輸入、輸出點制造時序圖，一些規(guī)劃中的邏輯過錯，在制造時序圖時即可發(fā)現(xiàn)。

　　(6)分子體系編制調(diào)試計劃，然后在團體評論的基礎(chǔ)上綜合成為全體系調(diào)試計劃。

　　2、PLC商檢

　　商檢應(yīng)有甲乙兩頭共同進行，應(yīng)承認(rèn)設(shè)備及備品、備件、技能材料、附件等的類型、數(shù)量、規(guī)范，其功用是否無缺待實驗室及現(xiàn)場調(diào)試時驗證。商檢成果，兩頭應(yīng)簽署交換清單。

　　3、實驗室調(diào)試

　　(1)PLC的實驗室設(shè)備與注冊制造金屬支架，將各作業(yè)站的輸入、輸出模塊固定其上，按設(shè)備提要以同軸電纜將各站與主機、編程器、打印機等相銜接，查看接線正確，供電電源等級與PLC電壓選擇相契合后，按開機程序送電，裝入體系配置帶，承認(rèn)體系配置，裝入編程器裝載帶、編程帶等，按操作規(guī)程將體系注冊，此刻即可進行各項操作實驗。

　　(2)鍵入作業(yè)程序

　　(3)模仿I/O輸入、輸出，查看修正程序本進程的意圖在于驗證輸入的作業(yè)程序的正確性，該程序的邏輯所表達的工藝設(shè)備的聯(lián)鎖聯(lián)系是否與規(guī)劃的工藝操控要求相符，程序是否疏通。若不相符或不能工作完成全進程，闡明程序有誤，應(yīng)進行修正。在這一進程中，對程序的了解將逐漸加深，為現(xiàn)場調(diào)試作好了準(zhǔn)備，同時也可以發(fā)現(xiàn)程序不合理和不完善的部分，以便進一步優(yōu)化。

　　調(diào)試辦法有兩種：

　　①模仿辦法：按規(guī)劃做一塊調(diào)試板，以鈕子開關(guān)模仿輸入節(jié)點，以小型繼電器模仿生產(chǎn)工藝設(shè)備的繼電器與接觸器，其輔佐接點模仿設(shè)備工作時的回來信號節(jié)點。其長處是具有模仿的真實性，可以反映出開關(guān)速度差異很大的現(xiàn)場機械觸點和PLC內(nèi)的電子觸點相互銜接時，是否會發(fā)作邏輯誤動作。其缺陷是需求添加調(diào)試費用和部分調(diào)試作業(yè)量。

　　②強置辦法：使用PLC強置功用，對程序中觸及現(xiàn)場的機械觸點(開關(guān))，以強置的辦法使其“通”、“斷”，迫使程序工作。其長處是調(diào)試作業(yè)量小，簡便，不需另外添加費用。缺陷是邏輯驗證不全面，人工強置模仿現(xiàn)場節(jié)點“通”、“斷”，會構(gòu)成程序工作不能連續(xù)，只能分段進行。

　　依據(jù)我們現(xiàn)場調(diào)試的經(jīng)驗，對部分重要的現(xiàn)場節(jié)點采納模仿辦法，其他的選用強置辦法，取二者之長互補。邏輯驗證階段要著重逐日填寫調(diào)試作業(yè)日志，內(nèi)容包含調(diào)試人員、時刻、調(diào)試內(nèi)容、修正記載、毛病及處理、交代驗收簽字，以樹立調(diào)試作業(yè)責(zé)任制，留下調(diào)試的第一手材料。關(guān)于規(guī)劃程序的修正部分，應(yīng)在規(guī)劃圖上注明，及時征求規(guī)劃者的定見，力求準(zhǔn)確表現(xiàn)規(guī)劃要求。

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1783-MX08T Stratix 8000 Copper 8 Port Exp. Module

194E-CA32 194E Load switch

194R-N60-1753-PYS1 Non-Fused 194R Disconnect Switch

2090-CPBM7DF-16AA25 MP-Series 25m Standard Cable

2090-XXTFMP-S15 MP-Series 15 m Length Feedback Cable

CBL-T7-MP-30 Power cable for MTR-3T10 or MTR-3T20 or MTR-3T40 series servo motors. 30 feet

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IC647PATBRK0 Proficy PAT - Driver For Bruker Ftir Spectrometers

IC693APU300CA Conbal Coated High Speed Counter

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Motion Control 2090-SCVG25-0 SERCOS FBR CABL,CONN,STNDRD PVC JKT,GLASS,25.0M

GFZ-65142E Alpha Series AC Servo Motor Debions Manual

IC646MPC101 Logic Developer - PLC Configuration Tools w/Programming Cable

MTR-1324-N-D-E-S Stepping Motor Nema34, Series Wdg, Splashproof

QPJ-ABR-201 Communication Module for 5 inch & 6 inch: AB Remote I/O/ UL/ cUL/ CE/ UL1604

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20F11NC043AA0NNNNN PowerFlex 753 AC Packaged Drive

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GC647PATCDI0 Proficy PAT - Driver For CDI - Assist Support

IC200MDD845 Mixed 24VDC POS LOG b group 16 point / isolated 2 amp relay output 8 point.

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IC647MBP001 Machine Edition Professional Development Suite with USB Hardware key

IC675PCB002 Profibus Cordset 2.0 Meters

IC697MDL740RR 24/48 Vdc Output, 2 Amp, Positive Logic (16 Points)

IC800SLT001 SL series amplifier terminal block for APM and DSM motion controller interface

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CBL-1C-ET-30 Encoder Cable, MTR-1216, 1221 & 1231 Stepping Motors, 30 Ft.

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20DD022A3EYNACASE PowerFlex 700S AC Drive 20D

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GC647APC001 GC PA Production Client

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PLC-5/1771 System D6200-6.4.12JP PLC5 PROGRAMMING SW I/O CONFIG. MNL (JAPANESE)

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20G1AGD361AA0NNNNN PowerFlex 755 AC Packaged Drive

25A-V4P8N104 PowerFlex 523 0.75kW (1Hp) AC Drive

2711P-T7C4D8 PanelView Plus Terminal

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HE670IBU100 Discontinued Part. Check with GE IP on migration path.

IC600LX680RR 64K Logic/16K Register Memory Module

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IC655CCM500RR Communications Control Module (CCM)

IC694MDL230 Input module, 120 VAC 8 point, isolated per point.

IC756SDV001K-99 DV Development - Solaris Op Sys Addt'l User, Korean, Version 9.9

MicroLogix 1500/1769 System 1769-IQ16 16 POINT 24 VDC SINKING/SOURCING INPUT MODULE

PLC-5/1771 System 1785-KA5 COMMUNICATION MODULE DATA HWY PLUS TO DATA HWY 485

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Motion Control 8720SM-022S2GAS2 22 KW/48 AMP, 750VDC, AC MOTOR WITH SRM60 ENC.

840-RC-15 15" Ribbon Cable. Term Both Ends W/16 Pin DIP Plugs

IC200MDL940 OUTPUT RELAY 2.0A PER PT ISOLATED FORM A 16PT

IC697VAL314 Analog Output, Isolated, 4 channel, 12 bit, Current - 4 to 20mA. Removable temrinal block, no cable required

MTR-1331-J-N-D-E-S MTR series NEMA 34 splashproof stepping motor with series winding connection

ZA06B-0062-B503 B2/4000HVis servo motor with 24 VDC brake and 128k serial encoder

20BD156A3ANNANC0 PowerFlex 700 AC Drive 20B

20G11NE011AA0NNNNN PowerFlex 755 AC Packaged Drive

22F-V6P0N103 PowerFlex 4M-1.1 kW (1.5 HP) AC Drive

140CFI00800 Quantum CABLEFAST, 模擬量輸入塊, 無保險

294E-FD2P5Z-G1 Variable Frequency Drive

HL-5030 觸點:1開/1閉,5A 250VAC機械壽命:1000萬次?撞壓式 可調(diào)滾珠擺桿型

1492-SPM3B500 MCB Supplementary Protector 50 A

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中央處理單元 6ES7 212-1AE40-0XB0 CPU 1212C DC/DC/DC

150-F85NBRB SMC Flex Smart Motor Controller

1734-IT2I POINT I/O 2 Point Thermocouple Input

1783-HMS16TG4CGN Stratix 5400 20 Port Managed Switch

193-ER1A Remote Reset Solenoid

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2090-CPWM7DF-14AA03 MP-Series 3m SpeedTec Standard Cable

2098-DSD-075-SE Ultra 3000 Servo Drive

GA646IFCLNTCRO100 GCA iFIX iClientTS Read Only 1 PK Runtime Version

GFK-2222 PACSystems CPU Reference Manual

IC220TBK123 I/O TERMINAL STRIP, 12 POSITION SPRING STYLE, OUTPUT, QTY 10

IC647GE9C GE9:GE Fanuc Ethernet

IC647SGM001 Scheduler Series and Groups Module

IC693MDL646CA Conbal Coated Input module 24 VDC 16 point POS/NEG ogic. 1msec filtering.

IC756DVE010K-99 EO GECK (Graphical Editor Construction Kit) - Inb x87, Korean, Versi on 9.9

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PLC-5/1771 System 1771-DS LATCHING INPUT MODULE, 10-27V DC, 8 INPUTS

Distributed I/O 1790D-N0C2 DNET LDX, 2 OUTPUT ANALOG CURRENT BSE,D-SHELL CONN

Communications 1770-XE DATA HWY 15 PIN CONNECTOR KIT, (FEMALE)

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HMI-BEZ-406 BEZEL 7.5" (QPGCXXX0000) STAINLESS STEEL

IC693BEM331 Genius Bus Controller

QPLCTAE0000 12.1" Color TFT, Ethernet, CF Card, 110VAC

TGT-E00A-2-0RR Target Axis Expansion Module, 3' Rack Linker Cable

20BC5P0A3NYYACA0 PowerFlex 700 AC Drive 5 A at 2.2 kW 20B

20F1ANF023JA0NNNNN PowerFlex 753 AC Packaged Drive

22B-D6P0C104 PowerFlex 40- 2.2 kW (3 HP) AC Drive

140AII33010C Quantum 模擬量輸入, 8通道, 電流, 本安型,CC

284E-FVD6P0Z-25-CR-OC EtherNet Variable Frequency Drive

E2E-X2ME1 2mm,非屏蔽電感式,三線,常開200mA NPN 電源:10-30VDC圓M8

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