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A06B-1002-B100

　PLC控制系統(tǒng)的設備與調(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)，稍有不小心都將導致調(diào)試失利，不但延誤工期，甚至會損壞設備。本文介紹了在現(xiàn)場實踐中總結(jié)出的PLC控制系統(tǒng)的設備與調(diào)試技能經(jīng)驗，并對現(xiàn)場經(jīng)常出現(xiàn)的設備、調(diào)試相關問題，提出評論定見和解決計劃。

　　一、體系的設備與調(diào)試

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

　　1、前期技能準備

　　體系設備調(diào)試前的技能準備作業(yè)越充沛，設備與調(diào)試就會越順暢。前期技能準備作業(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)設備的操控要求要有全面的了解，在此基礎上，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，是前期技能準備的重要環(huán)節(jié)。

　　(3)熟悉各工藝設備的功用、規(guī)劃與設備狀況，特別是各設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，對應設備及各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上綜合成為全體系調(diào)試計劃。

　　2、PLC商檢

　　商檢應有甲乙兩頭共同進行，應承認設備及備品、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，兩頭應簽署交換清單。

　　3、實驗室調(diào)試

　　(1)PLC的實驗室設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：

　?、倌７罗k法：按規(guī)劃做一塊調(diào)試板，以鈕子開關模仿輸入節(jié)點，以小型繼電器模仿生產(chǎn)工藝設備的繼電器與接觸器，其輔佐接點模仿設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。

　?、趶娭棉k法：使用PLC強置功用，對程序中觸及現(xiàn)場的機械觸點(開關)，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)責任制，留下調(diào)試的第一手材料。關于規(guī)劃程序的修正部分，應在規(guī)劃圖上注明，及時征求規(guī)劃者的定見，力求準確表現(xiàn)規(guī)劃要求。

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Motion Control 2090-UXNBMP-18S03 CABLE,ULTRA,NON-FLEX,MOTOR BRAKE,MP 3 MTR.

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IC600PB553RR PDT Processor Board

IC800SKCEV050 Encoder Cable, S2K to 1 - 5 kW S-Series Servo Motors, 5 Meters

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2711-CBL-HM05 PanelView 300 5 m Operating Cable

280-PWRM22E-M3 ArmorConnect 3-PH Power Media drop cable

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1585D-M4UBDE-3 Ethernet Media M12, Patchord

1756-IB16K ControlLogix 16 Pt 12/24V DC D/I Module

1794-TB3TK Flex Terminal Base

194E-E16-1753-4A 16 A 194E Load switch

2090-CFBM4DF-CDAF02 MP-Series 2m Feedback Cable

2090-KFBE7-CAAA MP-Series Feedback Connector Kit

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GC646TDV915 Proficy GlobalCare Complete for 1500 Point I/O Development / Runtime System.

HMI-AGO-203 ANTI-GLARE OVERLAY 5 inch/ 5 per pack

IC640WMI310RR Series 90 XT/AT Serial Interface Card

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IC660BSM120RR Bus Switching Module, 24/48 Vdc

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IC756WRE024E-275 "Runtime License for Windows 1-24 Users, Per User, English v2.7.5"

FlexLogix System 1794-L34 FLEX LOGIX PROCESSOR, 512KBYTES USER MEMORY

PLC-5/1771 System D1771-6.5.7 ANALOG INPUT MODULE(8-BIT)(1771-IE)USER'S MANUAL

Process Control 1757-PLXNU OPEN DATA ACCESS - 1 USER

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Support 6626-NMU2R 6626-NMU2 SOFTWARE SUPPORT REINSTATEMENT

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Support F1785-L20C15SERC FIRMWARE UPGRADE FOR 1785-L20C15 PLC5 PROCESSOR MO

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156-B32CA3 32 A Contactor

1746-IV32 SLC 32 Point Digital Input Module

1786-TPST2T ControlNet Coaxial IP67 TNC T-Tap

193-T1DC47 35-47 A IEC Bibllic Overload Relay

20-HIM-H10 PowerFlex 20 HIM Remote Cable Kit

2090-CSBM1DF-14AF05 Kinetix Cable Single DSL 2090-Series

20AC022A3AYNAEC0 PowerFlex 70 AC Drive 22 A at 11 kW 20A

GA647TRT300 Proficy GlobalCare Assist for CIMPLICITY HMI Server 300 I/O Runtime System

GP647IFUBSTS GCP iFIX iClientTS User Base Support

IC600CM542RR 2K CMOS Logic Memory Module

IC647HSTCSEO100KM eSignature Option for Historian - Enterprise Corporate Server 100000 Points (M4 Key)

IC647WDEM WDE:Woodword Modbus Ethernet

IC693UEX011RR 14pt DC In/Relay Out, AC Pwr. Sup.

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5602 Greyline Micro MC. 4 Lines, (20) 5MM Chars. LCD. ASCII/Serial Interface. NEMA 4

IC200KIT001 The kit includes VersaPro (IC640VPS002), CAD files, programming cable, manuals and other tools to aid in the conversion process from Series 90 Micro to VersaMax Micro.

IC695PBM300 RX3i PROFIBUS Master Module (must be installed on RX3i PCI bus). The module supports PROFIBUS V1 Master functionality. The PROFIBUS Master module requires an RX3i CPU with firmware version 2.9 or later

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VSPCSE-SF10 VisualSPC SE ShopFloor includes Attribute Data Collection, Measurement Systems Analysis and A-681 interface cable. 10 license pack.

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