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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、前期技能準備

　　體系設(shè)備調(diào)試前的技能準備作業(yè)越充沛，設(shè)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(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。

　?、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(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，力求準確表現(xiàn)規(guī)劃要求。
 

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ET-GT-5ES-5ST 3 RJ45 Ports, 2 Singlemode Fiber Port Ethernet Switch

GFK-0263 Logicmaster 90-70 Programming Software User's Manual

IC200MDL240LT INPUT 120VAC (2 GROUPS OF 8) 16PT (LT)

IC600CB537RR Communications Control Module Type 3

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IC697MDL653 24 Vdc Input, Positive/Negative Logic (32 Points)

IC756LDV010E-98 DV Draw Development on Inb/Linux RedHat Op Sys, English, Version 9.8

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PLC-5/1771 System 1771-OWN SELECTABLE CONTACT OUTPUT MODULE 32 POINT

Distributed I/O 1791-N4C2 BLOCK I/O, 120V AC, 6 POINT ANALOG MODULE

Communications 1786-FSB500 200 MICRON BULK CABLE 500 METERS (1640 FT)

Operator Interface 9399-RSVADSGR RSVIEW32 ACTIVE DISPLAY SYS GETTING RESULTS GUIDE

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Silver Series 9323-PI300D A.I SERIES PLC-5/250 OFFLINE/ONLINE PROGRAMMING

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變頻器選件 6SE6 400-1PB00-0AA0 Profibus 通訊模塊

電機啟動器 3VU16400MM00

150-CC25 SMC-3 Accessory

1715-IB16D 1715 16 Point Digital Input Module

1771-IXHR 1771 8 Point Input Module

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198-WT2 ModCenter IEC Wiring Kit

2090-CPWM4DF-16AF09 MP-Series 9m Power Cable

2094-BL75S Kinetix Line Interface Module

DEMOCD00014 Proficy Shop Floor SPC - DEMO CD

GFK-0777 Analog-100 Brushless Servo Amplifier Instruction Manual

IC210DAR010 AC (85 to 264VAC) Power Source, 6 AC in/4out (Relay 8 Amp), Expandable, with LCD/Keypad

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IC647PPSOF3 Proficy Process Systems Operator Console with iFIX - 3 Pak

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1606-XLP15B Power Supply XLP 15 W Power Supply

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2090-XXNPMF-16S90 Kinetix Drives 90m Standard Cable

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Industrial Computers 6181P-2P2KH VERSAVIEW 1200P NON DISPLAY COMPUTER 2 SLOT

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IC800SSI407RD2 7.2A, 480V, DeviceNet S2K Servo Controller for MTR Series Motors

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PXI-6528

FSP300-60ATV

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194E-Y16-1753-4G 16 A 194E Load switch

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2090-UXNFBMP-S20 MP-Series 20 m Length Feedback Cable

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GC647IFESGSR00150 GCC iFIX Optn: ESig & ERec 150 I/O Srv

IC200BEM103 PLC network communications DeviceNet master

IC646MODEV Motion Developer for S2K Series Amplifiers/Controllers

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IC660TBD024 Terminal Assembly for IC660BBD024

IC697CMM712RR Serial Communications Module for State Logic

IC800MCUB12160XNRR Stepping MotorCube 50 oz-in, Pulse/Direction

ControlLogix/1756 System 1756-IC16 30-60 VDC INPUT 16 PTS (20 PIN)

Industrial Computers 6182H-7TRH6B VVCE 700, TOUCH, STD MEM, RIO/DH, AC

Process Control 9358-PBNT60ENE RSBATCH NT FOR PROCESSLOGIX 60 UNITS

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ControlNet Products 1786-TPS CONTROLNET T-TAP/STRAIGHT

RSI Software Products 9301-2SE235KOU2R RSVIEW32 WORKS 300-5K UPGRADE OUT-SUPT (KO)

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BC647MOP001 Logic Developer PC with View - Development ONLY Supports up to 8000 I/O tags and with Proficy GlobalCare Complete and a hardware key

IC5002TAW2000 Discontinued - Order a BC5002TAW0000 & Appropriate CIM PE Software

IC800CBL066 Use IC800CBL069 for New Applications: AC12/2000 Motor Power Cable, 14 Meters

OC647HSTSCADA2500 Proficy Historian for SCADA 2500 pts

PCIe-6509

MSC-242

PS-7270F

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IPC-622

AC6111

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1756-CPR2 ControlLogix Redundant Supply Cable

1794-OA8I Flex 8 Point Digital Output Module

194E-CA32E-TN-PE 194E Load switch

2085-IA8 Micro800 8 Point 120 VAC Input Module

2090-DANBT-18S04 TL-Series 4 m Length Brake Cable

20AC5P0C0NYNANC0 PowerFlex 70 AC Drive 5 A at 2.2 kW 20A

GC646MVD000 Global Care for View OPC Driver License and Software Key

HE693THM449 4 ch. J, K, N, T, E, R, S, 0.5 deg C resolution, deg C/deg F units, open circuit alarms

IC630MDL304RR 24Vdc Sink Input/Output Module (16 In/16 Out)

IC647HSTSS3KM Historian Standard Server 2500 Points (M4 Key)

IC660BLA023 Cover w/Label for IC660BBA023

IC695ALG616CA Conbal Coated Analog Input Module,16 channel voltage/current.

IC756WDV009E-25 DV Dev Sys VB, English v2.5

CompactLogix System 1769-IT6 6 CHANNEL THERMOCOUPLE/MILLIVOLT INPUT MODULE

PLC-5/1771 System 9399-FW5FBGRDE RSLGX FRAMWKS FUNCTION BLDR GET'G RESULT GUID(GERM

Distributed I/O 1799-MP32 PLASTIC MOUNTING PLATE/4 SCREWS-32 PT BOARD

Operator Interface 2711P-T6C5A PV PLUS 600 COLOR, TOUCH, RS232, AC PS

Support 9342-L2200S SUPT RENEWAL CONTRACT FOR 9342L2200

Support 9358-PBPC10R SUPT REINSTATEMENT CONTRACT FOR 9358PBPC10ENE

Support F1779-KFMSERB FIRMWARE UPGRADE FOR 1779-KFM COMMUNICATION MODULE

RSI Software Products 9301-2SE2103ESE RSVIEW32 WORKS 150 WITH RSLINX (SPANISH)

RSI Software Products 9701-VWMR075DEU2 RSVIEW ME STATION RT 30 TO 75 DISP UPGRADE(GERMAN)

RSI Software Products 9399-2SE32GRDE RSVIEW32 GETTING RESULTS GUIDE (GERMAN)

Motion Control 2098-DSD-150 DRIVE, 65A/150A, ULTRA3000

ABI31200C2P/ABR QUICKPANEL 10.5" TFT W/AB RIO

IC200USB001 VersaMax Micro 64, RS-232 communications option board with (2) 0 - 10VDCanalog b channels built-in. The option board also supports program storage memory module. Compatible with VersaMax Micro 64 only.

IC752DNMU11 DeviceNet Master/Scanner for ControlStation CE Iix

MTR-3S32-G-R-0-E-ERR Servo Motor Nema34 Flg Explosion-Proof

NI 9501

JUKI-3711P

ADAM-4572

NCCH-DL 875P 604

FSC-1612V2N

Equinox SST-16P 910277-001/F

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152H-C201XBD-52 SMC-3 Enclosed Motor Starter

1738-OB8EM23 ArmorPoint 8 Point Output Module

1785-ACC5LB PLC-5 Accessory Kit

193-NREEHZ E1 Plus Replacement Overload Relay

20-COMM-B PF ARCH. CLASS BACNET/MSTP ADAPTER

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20AB9P6C3AYNANC0 PowerFlex 70 AC Drive 9.6 A at 3 Hp 20A

GA647IFPRSRUNLMT GCA iFIX Profsnl SCADA Unlmt Srv

GP647IFPLDV00150 GCP iFIX Plus SCADA 150 I/O Dev

IC600BF914RR Reed Relay Output Module (6 points)

IC647HSTCR2000KM Collector Redundancy Option for Historian - Standard Server 2,000,000 Points (M4 Key)

IC647TPD915 CIMPLICITY HMI ProServer 1500 I/O Development & Runtime System

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