一、1C31132G01運(yùn)行環(huán)境的保證
因?yàn)镻LC為精密電子產(chǎn)品,自動化控制的系統(tǒng)是要求長時(shí)間不間斷運(yùn)行,因此PLC的運(yùn)行環(huán)境要求極高,要防塵、防火、防水,防高溫,防雷電,因此電氣控制室一般都安排在具有雙層玻璃的、安裝有水式制冷空調(diào)的二樓,電控室的溫度一般控制在28度左右;對于防塵則是將PLC安裝在1M*2.2M*0.6M的帶鎖前面板為玻璃門的控制柜中,此柜上部安裝有防塵罩的抽風(fēng)系統(tǒng)進(jìn)行柜內(nèi)降溫。
二、做好日常工作
1、日常準(zhǔn)備工作:首要的熟悉工藝流程,其次是對PLC各種模塊的說明資料的熟悉,再次現(xiàn)場布局的了解,最后確保自已的各種檢測工具要完好無誤。
2、日常點(diǎn)檢工作:定期進(jìn)行CPU的電池的電壓檢測,正常常情況下為3V,定期對構(gòu)成PLC系統(tǒng)的相關(guān)設(shè)備的點(diǎn)檢和維護(hù),如UPS定期維護(hù),利用停機(jī)時(shí)機(jī),對PLC各控制柜進(jìn)行人工除塵、降溫,PLC程序的定期人工備份和電池備份及各相關(guān)壞器件的更換等工作。
三、PLC故障的診斷
?。ㄒ唬┛偡▌t:
對于PLC系統(tǒng)的故障檢測法:一摸、二看、三聞、四聽、五按跡尋蹤法、六替換法。
一摸,查CPU的溫度高不高,CPU正常運(yùn)行溫度不超過60℃,因手能接受的溫度為人體溫度37~38℃,手感為宜;二看,看各板上的各模塊指示燈是否正常;三聞,聞有沒有異味,電子元件或線纜有無燒毀;四聽,聽有無異動,鏍絲釘松動、繼電器正常工作與否,聽現(xiàn)場工作人員的反映情況;五出現(xiàn)故障根據(jù)圖紙和工藝流程來尋找故障所在地;六對不確定的部位進(jìn)行部件替換法來確定故障。
?。ǘ┚唧w步驟:
1C31132G01當(dāng)PLC的軟件不正常時(shí),主要看CPU的RUN狀態(tài)是否正常,不正常則進(jìn)行CPU清除后重新下載控制程序。
當(dāng)PLC硬件不正常時(shí)則要按以下順序進(jìn)行檢查工作:
1、查看PLC電源是否有電:有電則測量電壓是否在+24V的±5%范圍之內(nèi),有電且正常,則進(jìn)行下一步;有電不正常則進(jìn)行電源模塊的輸出端與輸入端進(jìn)行檢測,若輸出端不正常而輸入端正常,則更換模塊;若輸入端不正常,則進(jìn)行輸入端的逆流法則進(jìn)行相應(yīng)檢查,如進(jìn)行24V交直流變壓器的輸入電壓端的交流電壓220V的±10%檢查,正常,則更換直流24V變壓器。無電則按跡尋蹤,借助原理圖+現(xiàn)場布置總圖+接線圖紙,檢查給電源模塊供電的各種電器器件的輸出端的接線是否正確,不正確,重新接線;正確用萬用表則檢查空氣開關(guān)的進(jìn)線端與出線端有無正常供電,無正常供電,查明是外界還是自身原因,若為外界則是電壓不足還是根本無電壓,或負(fù)載過重,又或嚴(yán)重過流等等的分析,一直到將事故排除正常供電為止;若為本身器件壞則更換之。
2、了解過CPU工作模式及優(yōu)先級:高優(yōu)先級有STOP、HOLDUP、STARTUP(WARMRESTART、COLDRESTART);低優(yōu)先級有:RUN、RUN-P(PG/PC的在線讀寫程序)。查看CPU是在RUN模式,或是在STOP模式,又或是RUN模式的閃爍狀態(tài)和STOP模式兼有的保持模式或叫調(diào)試模式。如果僅是RUN模式則CPU和各板為正常進(jìn)行第3步。如果是保持模式出現(xiàn),可能是運(yùn)行過程中用戶程序出現(xiàn)斷點(diǎn)而處于調(diào)試程序狀態(tài),或在啟動模式下斷點(diǎn)出現(xiàn),對此情況重新調(diào)試好程序,再次將控制程序下載到CPU中方可。
1C31132G01如果是STOP模式,目測引起STOP的原因分析:A、無電,分析無電原因,是因?yàn)楣╇姴块T出問題,還是異常掉電(因有有1K3AH的UPS保證很少發(fā)生異常掉情況),通常情況下為檢修拉電了,待檢修結(jié)束后進(jìn)行人工送電。再利用PLC的在線功能將CPU的工作模式從STOP轉(zhuǎn)換為RUN;B、CPU壞,更換新的好的同種類型同版本的CPU;C、有板子壞了,有序進(jìn)行板子的更換。對于硬件更換時(shí)要注意使用與原來的器件相同的產(chǎn)品同型號、同版本來進(jìn)行,否則會造成實(shí)際的PLC配置與相應(yīng)編程軟件中硬件配置數(shù)據(jù)庫中硬件配置不同而無法進(jìn)行用戶控制程序的正常循環(huán)執(zhí)行。
3、1C31132G01進(jìn)行各個(gè)主板和擴(kuò)展板上的通迅電纜檢查和各模塊各LED燈的檢察,看是否有壞模塊出現(xiàn)fault燈亮,若有則該模塊不正常。對于數(shù)字量輸出模塊上各點(diǎn)其實(shí)與現(xiàn)實(shí)生活上的電燈開關(guān)是一樣的功能且為常開點(diǎn),所以在線檢修該模塊的任一點(diǎn)時(shí),只要在無接線時(shí)且該地址在控制程序不給輸出信號時(shí)來檢測其通不通就可以了,若通,則該點(diǎn)不正常,不通則正常;不正常時(shí)要進(jìn)行硬件連接線的另選點(diǎn)重接工作;另外我們也可以用新模塊進(jìn)行更換后,對替換下來的模塊的點(diǎn)進(jìn)行測量通斷狀態(tài),通,則該點(diǎn)壞,不通該點(diǎn)為好。對于數(shù)字量輸入模塊的點(diǎn)當(dāng)于導(dǎo)通的線圈,為常閉狀態(tài),它可以在線或下線檢測,用表檢測若是壞點(diǎn)的話則是不通的狀態(tài),則換點(diǎn)重接線;好點(diǎn)則為通狀態(tài)。只要對硬件接線重新?lián)Q點(diǎn)重接后均要用相應(yīng)編程軟件對控制軟件進(jìn)行0X或1X地址替換工作。對于模擬量輸入模塊是與數(shù)字量輸入模塊相同,每個(gè)通道都相當(dāng)于一根導(dǎo)線形式,也就是說相當(dāng)于常閉點(diǎn),所以檢測通道好壞的方法為用表的測通斷功能來檢測,當(dāng)通狀態(tài)時(shí)為好,斷狀態(tài)時(shí)為壞通道;模擬量輸出模塊的檢測方法與數(shù)字量輸出模塊相同。若壞通道則對硬件接線需要更換通道與并同時(shí)替換控制程序中的相應(yīng)3X或4X地址;另外對于模擬量模塊則要進(jìn)行量程塊的選擇的檢查,保險(xiǎn)絲是否斷開的檢查等工作。軟件配置是否正常,一般為電壓1~5V或電流4~20mA,這根據(jù)所用的傳感器與智能轉(zhuǎn)換器類型來選擇。進(jìn)行過硬件點(diǎn)或通道更換工作后條件允許的話均要STOP PLC的CPU,再重新下載程序,若條件不允許則直接用更新變化來下載變化的程序而不停CPU。對于不用的輸入模塊的好通道/好點(diǎn)與最后一個(gè)已用的一好通道/好點(diǎn)進(jìn)行串聯(lián)或在軟件中進(jìn)行特別設(shè)置。
4、對大量輸出模塊的板子上的電源模塊在正常生產(chǎn)狀態(tài)時(shí)是不能斷電的,因?yàn)榇藭r(shí)斷電的話,將使繼電器柜中的常開繼電器變?yōu)槌i_狀態(tài),容易發(fā)生錯(cuò)誤,因此要對此類的輸出模塊進(jìn)行檢測時(shí),要與現(xiàn)場操作人員進(jìn)行聯(lián)系,進(jìn)行該部分相關(guān)設(shè)備進(jìn)行手動操作后,再撤去數(shù)字量輸出模塊的供電線后對模塊測點(diǎn)工作。
5、各類開關(guān)類的檢測工作:如繼電器、接近開關(guān)、空氣開關(guān)等器件的檢測工作,是根據(jù)開關(guān)的類型是常閉型還是常開型來區(qū)分,用表來檢測其通與不通的狀態(tài),其狀態(tài)與好器件狀態(tài)相反,則該器件壞了,更換之。對于電路大部情況利用常開型,它們是用來人工控制或自動控制電流的接通與斷開的;對于常閉型主要用在保護(hù)電路中。借此可以知道開關(guān)類和保護(hù)類器件的正常狀態(tài)為如何而正常識別器件的好壞。
6、1C31132G01通迅模塊的檢測則是利用簡單的用好的新的通迅模塊進(jìn)替換來識別板上的正在使用的模塊是否正常。
7、導(dǎo)線的測量方法:導(dǎo)線也是通過檢測通斷方法進(jìn)行的??梢岳靡阎ǖ膶?dǎo)線來檢測不知是否好壞的導(dǎo)線,方法是將好的導(dǎo)線與未知導(dǎo)線連接起來后測通斷狀態(tài)。
8、電阻檢測:帶電狀態(tài)時(shí)檢測電壓,不帶電時(shí)檢測相應(yīng)的電阻。
四、總結(jié)
1C31132G01通過以檢測可以排除工作中的大部分故障,另外由于本工作涉及到交流單相電220V與直流電24V的交叉作業(yè),工作時(shí)要注意積累安全用電知識與常識,以及在工作時(shí)的安全防范措施和煤氣安全規(guī)程,以確保安全作業(yè)。
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