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　PLC控制系統(tǒng)的設(shè)備與調(diào)試，觸及到各項(xiàng)作業(yè)，而且只能按序進(jìn)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(chǎng)實(shí)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(yàn)，并對(duì)現(xiàn)場(chǎng)經(jīng)常出現(xiàn)的設(shè)備、調(diào)試相關(guān)問題，提出評(píng)論定見和解決計(jì)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(huì)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(jī)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(duì)體系工藝流程，特別是工藝對(duì)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(duì)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(dòng)力接線圖，并與什物相對(duì)照，以及時(shí)發(fā)現(xiàn)過錯(cuò)并糾正。

　　(4)在全面了解規(guī)劃計(jì)劃與PC技能材料的基礎(chǔ)上，列出PC輸入輸出點(diǎn)號(hào)表(包含內(nèi)部線圈一覽表，I/O所在位置，對(duì)應(yīng)設(shè)備及各I/O點(diǎn)功用)。

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

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

　　2、PLC商檢

　　商檢應(yīng)有甲乙兩頭共同進(jìn)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(wú)缺待實(shí)驗(yàn)室及現(xiàn)場(chǎng)調(diào)試時(shí)驗(yàn)證。商檢成果，兩頭應(yīng)簽署交換清單。

　　3、實(shí)驗(yàn)室調(diào)試

　　(1)PLC的實(shí)驗(yàn)室設(shè)備與注冊(cè)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(jī)、編程器、打印機(jī)等相銜接，查看接線正確，供電電源等級(jí)與PLC電壓選擇相契合后，按開機(jī)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(cè)，此刻即可進(jìn)行各項(xiàng)操作實(shí)驗(yàn)。

　　(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(jìn)程的意圖在于驗(yàn)證輸入的作業(yè)程序的正確性，該程序的邏輯所表達(dá)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(jìn)程，闡明程序有誤，應(yīng)進(jìn)行修正。在這一進(jìn)程中，對(duì)程序的了解將逐漸加深，為現(xiàn)場(chǎng)調(diào)試作好了準(zhǔn)備，同時(shí)也可以發(fā)現(xiàn)程序不合理和不完善的部分，以便進(jìn)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(guān)模仿輸入節(jié)點(diǎn)，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(diǎn)模仿設(shè)備工作時(shí)的回來信號(hào)節(jié)點(diǎn)。其長(zhǎng)處是具有模仿的真實(shí)性，可以反映出開關(guān)速度差異很大的現(xiàn)場(chǎng)機(jī)械觸點(diǎn)和PLC內(nèi)的電子觸點(diǎn)相互銜接時(shí)，是否會(huì)發(fā)作邏輯誤動(dòng)作。其缺陷是需求添加調(diào)試費(fèi)用和部分調(diào)試作業(yè)量。

　　②強(qiáng)置辦法：使用PLC強(qiáng)置功用，對(duì)程序中觸及現(xiàn)場(chǎng)的機(jī)械觸點(diǎn)(開關(guān))，以強(qiáng)置的辦法使其“通”、“斷”，迫使程序工作。其長(zhǎng)處是調(diào)試作業(yè)量小，簡(jiǎn)便，不需另外添加費(fèi)用。缺陷是邏輯驗(yàn)證不全面，人工強(qiáng)置模仿現(xiàn)場(chǎng)節(jié)點(diǎn)“通”、“斷”，會(huì)構(gòu)成程序工作不能連續(xù)，只能分段進(jìn)行。

　　依據(jù)我們現(xiàn)場(chǎng)調(diào)試的經(jīng)驗(yàn)，對(duì)部分重要的現(xiàn)場(chǎng)節(jié)點(diǎn)采納模仿辦法，其他的選用強(qiáng)置辦法，取二者之長(zhǎng)互補(bǔ)。邏輯驗(yàn)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(shí)刻、調(diào)試內(nèi)容、修正記載、毛病及處理、交代驗(yàn)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(shí)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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GC646MRA000 Proficy GlobalCare Complete for View Runtime 8,000 I/O

HE693RTU900 Single Port RTU Slave Interface Module w/RS-232 and RS-485

IC610MDL110RR High Speed Counter Module

IC647HSTSS100KM-35 Historian v3.5 Standard Server 100000 Points (M4 Key)

IC660BBD024 Block 12/24Vdc Source I/O 32 Circuits

IC694TBB132 Box Style High Density Terminal Block with extended depth for large wires - 36 Connections

IC756WDN009K-22 DV Development Sys VB, Java, C++, C, Korean, Version 2.2

CompactLogix System 1769-L35CR COMPACTLOGIX REDUNDANT CONTROLNET

PLC-5/1771 System 1771-P7K CONFORMALLY COATED, POWER SUPPLY, 16A, 120/220V AC

Distributed I/O 1798-BP2 FLEXARMOR 2 SLOT BASE PLATE

Operator Interface 2711P-K6C20A PV PLUS 600 COLOR, KEYPAD, ETHERNET, AC PS

Support 9323-PI300S SUPT RENEWAL CONTRACT FOR 9323PI300

Support 9358-PBA10R SUPT REINSTATEMENT CONTRACT FOR 9358PBA10ENE

Support F1775-KA FIRMWARE UPGRADE FOR 1775-KA PLC3 PROCESSOR MODULE

RSI Software Products 9324-RLD700NXFRE RSLOGIX 5000 PRO EDITION, FRENCH

RSI Software Products 9305-RSVADSDEE RSVIEW32 ACTIVE DISPLAY SERVER (GERMAN)

RSI Software Products 9308-RSFB256ENE RSFIELDBUS 256 FB BASE CONFIG SW

Motion Control 2094-PR4 POWER RAIL,230V OR 460V , 4 AXIS

A06B-6073-K250 Fuse, Beta & I/O Link Series Amplifier Control Power

IC200UEX011-24 Qty of 24, 14 point expansion. (8) 24VDC In, (6) Relay Out, 120V/240AC Power Supply (includes IC200CBL501)

IC752CBT070 Mature, order QuickPanel instead. DataPanel 320T CEG (Color Expansion w/ Genius): 320x240 1/4 VGA Passive Color with 80386SX/40 PC processor. Analog touch screen with text, bitmaps, bar graphs, real time clock. W/ 2Meg and Genius PC/104.

MTR-1N42-H-N-A-E-0RR Stepping Motor Nema42

ZA06B-0143-B075#7008 A12/3000 servo motor with 64k serial encoder

20BD5P0A3AYYAEC1 PowerFlex 700 AC Drive 5 A at 3 Hp 20B

20G14NC140AN0NNNNN PowerFlex 755 AC Packaged Drive

25-PM1-E032 PowerFlex 520 22kW (30Hp) Power Module

OFSCSPBLF Quantum OFS LARGE 200 LIC SUBSCR RENEWAL

FRN15E1S-2J 22KVA 60A 15KW 3相AC220V/50Hz/60Hz

1492-J3-OR 2.5 square mm Standard Terminal Block

1492-SPM3D070 MCB Supplementary Protector 7 A

軟啟動(dòng)器 3RW40382TB05

SIMATIC HMI 系列面板 6AV2124-2DC01-0AX0 KTP400 精智 4英寸，按鍵+觸摸

150-SF3R SMC-50 Frame D 24V DC Replacement Fan

1738-EP24DC ArmorPoint I/O Extension Power Module

1783-ZMS8T8E2TGP ArmorStratix 5700 18 Port managed switch

193-KB10 0.75-1.0 A IEC Bibllic Overload Relay

20-750-PBAY-INS-3 POWERFLEX 750 KIT,INSULATOR,3 BAR

2090-CPWM7DF-16AF50 MP-Series 50 m Length Power Cable

20AB042A0AYNANC0 PowerFlex 70 AC Drive 42 A at 15 Hp 20A

GA647IFPLRN00075 GCA iFIX Plus SCADA 75 I/O Run

GP647IFCLNTSRO005 GCP iFIX iClientTS Read Only 10 PK Runtime Version

IC600BF816RR Type T Thermocouple Input Module (8 points)

IC647HSTCC500KM Calculation Collector for Historian - Standard Server 500,000 Points (M4 Key)

IC647TDV075 CIMPLICITY HMI Server 75 I/O Development & Runtime System

IC693MDL931 Relay Output, 8 Amp Form B/C contacts, Isolated in groups of 4

IC756LDV001J-925 DataViews Development on Inb Linux/Red Hat 32 bit, Addt'l User, Japanese v9.25

Pico Controllers 1760-NDM MEMBRANE PROTECT DISPLAY

PLC-5/1771 System 1771-OND 24VAC OUTPUT MODULE, 16 OUTPUTS

Distributed I/O 1791-24BR BLOCK I/O, 24V DC, 32 POINT MODULE

Communications 1786-TPR CONTROLNET T-TAP/RIGHT ANGLE

Operator Interface 9701-VWSTMFRE RSVIEW STUDIO FOR MACHINE EDITION (FRENCH)

Support 9701-VWSTMS SUPT RENEWAL CONTRACT FOR 9701VWSTMENE

Support 9324-RL0300ENR SUPT REINSTATEMENT CONTRACT FOR 9324RL0300EN

EtherNet/IP Products 1747-L553 SLC 5/05 CONTROLLER

RSI Software Products 9301-2SE3500DEU1 RSVIEW32 RUNTIME 32K-100K UPGRADE IN-SUPT (DE)

RSI Software Products 9356-PRO2450U5 UPGRADE: IN-SUPT: RSSQL PROF.150 TO PROF.32000 TAG

Motion Control F-6300-R-H00AA BRUSHLESS MOTOR/ENCODER

44A728335-002 Test Only - PLC

IC200ALG260 ANALOG INPUT 12 BIT VOLTAGE/CURRENT 8CH

IC693MDL740LT 12/24 Vdc Output, 0.5 Amp, Positive Logic (16 Points) (LT)

TRM-21006670 Connector, 4.3 Amp, 115/230V S2K AC Power

VMEM-IMOD VisualMEM MEMPort Input Module. Requires (1) Gateway module per PC.

20BD022A0AYYADD1 PowerFlex 700 AC Drive 22 A at 15 Hp 20B

20G11FC060JA0NNNNN PowerFlex 755 AC Packaged Drive

22C-D022N103 PowerFlex 400- 11 kW (15 HP) AC Drive

140CRP93100C Quantum RIO 處理器接口, S908 Head, 單電纜, CC

285-BRC25-M4 Source Brake Cordset Cable

繼電器輸出:一常開/閉250VAC 5A,電壓輸入,帶鍵鎖. 面板尺寸:48*48.mm

1492-SPM1D250-N MCB Supplementary Protector 25 A

通用型變頻器 6SE6 440-2UD37-5FB1 "75 KW,350 x 850 x 320"

電機(jī)啟動(dòng)器 3VU13401TH00