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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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20G11JF1K4AN0NNNNN PowerFlex 755 AC Packaged Drive

22D-D017H204 PowerFlex 40P 7.5 kW (10 Hp) AC Drive

140NOM21100 Quantum MB+ 網(wǎng)絡(luò)適配器, 1MB, 1MB+, 單電纜

290E-FAP-G2-3 Direct Online Starter

MY3 24VDC，110VAC，220VAC，3開3閉，觸點(diǎn) 5A

1492-SPM2C070 MCB Supplementary Protector 7 A

軟啟動(dòng)器 3RW30262BB14

電機(jī)啟動(dòng)器 3VU16402LS00

150-F201NBDB SMC Flex Smart Motor Controller

1732D-IB8M8 ArmorBlock 8 Point Input Block

1771-OQ16 1771 16 Point Digital Output Module

193-ED1ED E1 Plus 5.4-27.0 A Overload Relay

199-FSMA11 Industrial Relay MOV Surge Suppressor

2090-CPWM7DF-08AA04 MP-Series 4m Standard Power Cable

2094-XL75S-C1 Kinetix 6000 Line Interface Module

DT1014 External Floppy Drive

GFK-1086 Series 90-70 Third Party VME I/O Integration Manual

IC220ACC001 MODULE LABELS NARROW, QTY 10

IC647BSP255 Batch Large Server Pak (255 Units)

IC647PRTHE025M Proficy Portal Historian Edition Client Pack 25 Users (M4 Key)

IC693CPU363RR CPU363 Module (240K Bytes configurable user memory)

IC756ADV000J-98 DV Development - AIX Op Sys, Japanese, Version 9.8

MSI-EFF-5 Efficiency Management Clients 5 Pack

SLC/1746 System 1746-RT25C REPLACEMENT TERMINAL BLOCK (ORANGE)

Distributed I/O 1738-IB2M12 24VDC 2 SINKING INPUTS WITH M12 CONNECTORS

Application-specific products 9307-RSPRTD RSPOWER RT FOR AB PM1 PM2 POWER MONITORING DEVICES

Operator Interface 2711-NF7 FUNCTION KEY STRIP PV300 KEY

Support 9302-PCOS SUPT RENEWAL CONTRACT FOR 9302PCO

Support 9510-PPKENS SUPT RENEWAL CONTRACT FOR 9510PPKEN

DeviceNet Products 1787-TCABL T-STYLE CABLE FOR 1770-KFD 6 FT (1.82 METERS)

RSI Software Products 9301-2SE3350ZHU3 RSVIEW32 RUNTIME 1500-5K UPGRADE IN-SUPT (ZH)

RSI Software Products 9326-AD10WDENE WIRING DIAGRAM GENERATOR ADD-ON 10 USER

Motion Control MPG-A004-091M24 MOTOR,SERVO,GEAR RATIO 91,15NM,66RPM,MULTI,BRK

Silver Series 1756-M2 LOGIX5550 1MBYTE EXPANSION MEMORY

HE693IBS313 Interbus-S slave module for Series 90-30 autoconfiguring CPU313 rack.

IC655MDL524RR Input Simulator Module, 16 or 32 Points Switch Selectable

QPI31200S2P QUICKPANEL COLOR 10.5" STN

ST-4622 STXi analog output module 2 Channels, 0~5Vdc, 12-bit

20BC170A3ANNACC0 PowerFlex 700 AC Drive 20B

20F1AGC367JN0NNNNN PowerFlex 753 AC Packaged Drive

22A-V6P0N104 PowerFlex 4- 1.1 kW (1.5 HP) AC Drive

140DAI74000 Quantum 開關(guān)量 AC 輸入, 16點(diǎn), 48 VAC, 隔離

284D-FVD2P3D-10-CR-EMI DeviceNet Variable Frequency Drive

E3JK-T11 5m,分離式,明通，NPN晶體管輸出100mA，電源:10-30VDC

1492-SJ5-10 IEC Side Jumper, 10 PL 5mm

人機(jī)界面 6ES7810-5CC08-0YA5 "STEP7 V5.3 專業(yè)版 2004?SP1"

6ES78220AA030YE5

1497B-A11-M14-3-N Control Power Transber

1606-XLS240-UPSE Power Supplies

1769-CJC CompactLogix CJC Temperature Sensor

188-K4D130 Miniature Circuit Breaker 13 A

194R-CN60-1753-PB Non-Fused 194R Disconnect Switch

2090-CPBM7DF-10AF90 MP-Series 90 m Length Cable

2090-XXNPMP-14S60 MP-Series 60 m Length Power Cable

CBL-14-MP-10 Power cable for MTR-1235 or MTR-1300 or MTR-1400 series splashproof stepping motors. 10 feet

GF-0190 Connecting FlashCable to Federal Maxum Plus.

IC200TBX023 Tool box, 23 point, (IC200UAL006) DC In/Relay Out, 2 analog In, 1 anal og out, AC powered (requires AC power) provided with software, manuals and cables (IC640VPS002 and IC646MPM001)

IC646TBPAS050 Production Accounting Server 50 mass balance streams

IC647NMR000 CIMPLICITY HMI MODBUS RTU Communications Driver

IC693ACC312 Extended battery (1.45 Amp-hours) for Series 90-30 CPU memory backup. The Battery Module replaces the standard CPU RAM backup battery in your control system. Approximaby 20% more capacity than the IC693ACC301. Qty of 2 batteries.

IC750LCD440RR PANELWARE 4-Line x 40-Character LCD Dislplay

IC800VMCE030 Encoder cable for 100 W to 750 W VersaMotion servo motors- 3 meter

SLC/1746 System 1746-OB32E ELECTRONICALLY PROTECTED DC OUTPUT MODULE

Industrial Computers 6155R-NPXPH VERSAVIEW NON-DISPLAY COMPUTER

Application-specific products 6556-SCBM44 SLC 5/04, 5/04 PROGRAMMABLE PRESS CONTROL KIT

Operator Interface 2711-B6C12 PV600 COLOR KEY&TOUCH, PBUS & RS232 PRINT

Support 9301-2SE2300JPR SUPT REINSTATEMENT CONTRACT FOR 93012SE2300JP

Support 9307-8MGDBPS SUPT RENEWAL CONTRACT FOR 93078MGDBPENE

DeviceNet Products 1734D-IA16S 120 VAC 16 IN, DNET COMMS, SPRING

RSI Software Products 9301-2SE250JPU5R RSVIEW32 WORKS 5K-100K UPGRADE OUT-SUPT (JP)

RSI Software Products 9358-BNT30ENE RSBATCH 30 UNITS

Motion Control MPL-B320P-RJ22AA MOTOR,SERVO,2.94 NM,5000RPM,RSLVR,460V,4.6KG

Motion Control 2090-K6CK-D15F CONNECTOR, AUX FDBK, D-SHELL/TERM BLOCK, 15 PIN F

GFK-0483 Series 90 Universal Simulator User's Manual

IC641VPS002 VersaPro programming software and documentation for VersaMax Micro and Nano Only. Programming cable not included. CD bat

MSC-FRQ-V Obsolete - 1KHz in / 0-10 V out

PSPC-DC25L Prof Shop Floor SPC DC 25 User

20BC011A3AYNAND0 PowerFlex 700 AC Drive 20B