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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：

　?、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，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。

　　②強置辦法：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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IC756WRE499J-22 DataViews Runtime for Windows 100+, Per User, Japanese, Version 2.2

MSI-SDK SDK Connections

PLC-5/1771 System 1771-CT 1771 I/O CHASSIS CABLE FOR 1771-P4S, 6S POWER SPLY

Industrial Computers 6155R-7PXPH VERSAVIEW NON-DISPLAY COMPUTER, 7 SLOT

Application-specific products 9358-PBA60ENE RSBIZWARE BATCH FOR PROCESSLOGIX ARCHIVER 60 UNITS

Operator Interface 2711P-RGK10 PV PLUS/VVCE PROTECTIVE ANTIGLARE OVERLAYS QTY 3

Support 9325-L3140R SUPT REINSTATEMENT CONTRACT FOR 9325L3140

Support 9301-2SE3100ITS SUPT RENEWAL CONTRACT FOR 93012SE3100IT

Support 9380-RSBAR500R SUPT REINSTATEMENT CONTRACT FOR 9380RSBAR500

DeviceNet Products 1734-TBCJC SCREW TERMINAL BASE CJC SPRING TERMINAL BASE CJC

RSI Software Products 9301-2SE3200PTU1 RSVIEW32 RUNTIME 150-300 UPGRADE IN-SUPT (PT)

RSI Software Products 9358-BPCNT30U2 UPGRADE: IN-SUPT: RSBATCH PC-BASED 10 TO 30

Motion Control MPL-B4520P-RJ24AA MOTOR,SERVO,6.1 NM,5000RPM,RSLVR,460V,BRK,9.5KG

Motion Control 2090-SCNP8-0 SERCOS FBR CABL,CONN,HARSH DUTY,JKT,PLASTIC,8.0M

GFK-1885A ViewStation/ControlStation CE II (6") HW User's Guide

IC646MDE700 Logic Developer - PC & View (HRT) 700 Tag Runtime & Development System

MTR-1221-N-D-E-0 Stepping Motor Nema23, Series Wdg

QPI3D200E2P/B 9 inch Monochrome EL/ Blank Label/ 24VDC/ UL/ cUL/ CE/ UL1604

20BC030A3AYNAEC0 PowerFlex 700 AC Drive 30 A at 15 kW 20B

20F11NC015AA0NNNNN PowerFlex 753 AC Packaged Drive

21G1ALC567JN2NNNNN-ND-L1-P3-P11-P14 PowerFlex Air Cooled 755 Packaged Drive

2711P-RFK12 PanelView Plus Accessory

280G-F12D-10B-RRG-CBG ArmorStart 280/1 Starter

C200HW-BI051 擴展機板?可安裝5個I/O單元

1492-PD3C112 255 A Power Distribution Block

中央處理單元 6ES7412-1XF04-0AB0 CPU412-1，144KB，100ns，電源 24VDC， MPI/PROFIBUS-DP 主站接口

變送器 3RS17252FD00

TIA 博途數(shù)字化選件 6ES7823-1AA04-0YA5 TIA Portal Multiuser V14

1585J-M8TBJM-15 RJ45 Ethernet Media

1760-USB-GFX PicoGFX USB Programmer Cable

188-K3B100 Miniature Circuit Breaker 10 A

194L-E12-C34 Terminal Cover 3 Pole 12 - 16 A

2090-CPBM4DF-16AF04 MP-Series 4 m Length Pwr and Brake Cable

2090-XXNFMF-S04 Kinetix Drives 4m Standard Cable

BC647OEM0401 OEM Edge Program Renewal - Historian

GC647NXV001 Proficy GlobalCare Complete for Tracker Order Execution Management Web Viewer

IC200MDD842 Mixed 24VDC POS LOG b group 16 point / output 24VDC 0.5 amp with ESCPoutput 16 point.

IC646NMR000 Modbus RTU Communications

IC647M32C M32:Moore MYCRO 320 Independent Computer Interface

IC670MFP100 Micro Field Processor

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

IC800SLMCONKITVL connector kit for 3.5 kW to 5 kW S-series servo motors without brake

ControlLogix/1756 System 1751-SL4SP SYNCHLINK FIBER 4-PORT SPLITTER BLOCK

Industrial Computers 6182H-15BEH15D VVCE 1500, KEY/TOUCH, EXT MEM, CNET, DC

Process Control 1757-PFBUPG100 PROFIBUS LIC UPG 100 IOMS

Operator Interface 2711P-ST15B PANELVIEW PLUS 1500 KEY/TOUCH STARTER KIT

Support 9326-AD10APR SUPT REINSTATEMENT CONTRACT FOR 9326AD10APENE

Support 9371-EDBA3S SUPT RENEWAL CONTRACT FOR 9371EDBA3

ControlNet Products 1734-RTBS REPLACEMENT IEC SPRING TERMINAL BLOCK

RSI Software Products 9301-2SE240FRU1R RSVIEW32 WORKS 1500-32K UPGRADE OUT-SUPT (FR)

RSI Software Products 9358-B60ENE RSBIZWARE BATCH 60 UNITS

Motion Control MPL-A430P-MJ22AA MOTOR,SERVO,5.42 NM,5000RPM,MULTI,230V,6.4KG

Motion Control 2090-UXNFDN23-K01 CABLE,ULTRA,NON-FLEX, MOTOR FEEDBACK,N,SKW,1M

CBL-154 Cable. IBM COMP. To Operator Workstation, 9 Pin PC COMM. Port

IC610MDL157RR 24Vdc Sink Out, w/Removable Term. Block, w/LEDs (16 pts)

IC800SLCBZ050 Brake Cable, 30-750 W SL Servo Motor with Brake, 5 Meters

OC647IFHAVC iFIX Optn: High Availability (M1Component Part)

20AD3P4C3AYNNNC0 PowerFlex 70 AC Drive 3.4 A at 2 Hp 20A

20DD022A0EYNACGNE PowerFlex 700S AC Drive 20D

20P41AB093RA0NNN PowerFlex DC Drive 230V AC 25 HP

2711-NV4T PV550 and PV600 Touch Antiglare Overlay

280-PWRM24A-M3 ArmorStart Three-Phase Power Media

3G3RV-A4110 NEW 18KVA 24 11KW 3相AC380-460V/50HZ/60HZ

1492-MCAA2H30 Ckt Brkr, 30A 2Pole Ul489/Csa Ul489/Csa

1494U-R1 1494U Connecting Rod

軟啟動器 3RW44562BC35

工程組態(tài)編程軟件 6AV2100-0AA04-0AA7 SIMATIC WinCC 基本版 V14, 試用授權(quán)

1585D-M4UBJM-2 Micro D-Code, QD Style Ethernet Media

1756-L63XT ControlLogix XT 8 MB Memory Controller

1797-TPS FlexEx Accessories

194E-E80-1753-6N 80 A 194E Load switch

2090-CFBM6DF-CBAA03 TL-Series 3m Feedback Cable

2090-SCNP1-0 Kinetix 1-1m Fiber Optic Cable

BC646MPC101 Logic Developer PLC Configuration Tools with Proficy GlobalCare Complete with Programming Cable

GC647AEC010 GC Efficiency Client 10 Pak

HMI-CAB-C88 CABLE MITSUBISHI SERIES A1S

IC641SWP714 GMR Phase 2 System and Configuration Software

IC647IFCLNTSRO050K iFIX iClientTS Read Only 50 PK (M1 Kit Part)

IC660EBD100RR Ph B 115Vac 8 CKT Electronic Assembly

IC695STK001 RX3i Power PACkage 1 Starter Kit includes RX3i with software. (includesRX3i with software. (includes one each IC695CP305,IC695CHS012, IC695LRE001, IC695PSA040, IC695ETM001, IC694ACC300, IC694MDL940 and IC646MPP001.) Limited one RX3i starter kit per

IC756WRE099K-22 DataViews Runtime for Windows 50-99, Per User, Korean, Version 2.2

FlexLogix System 1794-OM8 220V AC OUTPUT MOD, 8 PT.

PLC-5/1771 System D1785-6.8.7 REF.GUIDE CONNEC PLC-5 PR

Process Control 1757-PLXSR100 PLX 100 POINT REDUNDANT SERVER LICENSE

Operator Interface 2711P-T10C15B1 PV PLUS 1000, TOUCH, CNET, AC PS, STD MEM

Support 9324-FWRTENS SUPT RENEWAL CONTRACT FOR 9324FWRTEN

Support 2707-NP2R SUPT REINSTATEMENT CONTRACT FOR 2707NP2

Support F1785-L40LSERB FIRMWARE UPGRADE FOR 1785-L40L PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2303ESE RSVIEW32 WORKS 1500 WITH RSLINX (SPANISH)

RSI Software Products 9701-VWSS000DEU2 RSVIEW SE 100 TO UNLTD DISP UPGRADE (GERMAN)

RSI Software Products 9399-RL53GRFR RSLOGIX 5 GETTING RESULTS GUIDE(FRENCH)

Motion Control 1394C-SJT05-C MODULE,SYSTEM,5KW,IMCS,NO RIO,NO AXIS LINK

BC646MDE075 Logic Developer - PC & View Development/Runtime (HRT) 75 I/O

IC300OCS042 OCS with 2x20 LCD Display and with 16-key keypad. Built in I/O no expansion. 16 DC Inputs (12/24vdc), 12 DC Outputs (5/12/24vdc, 0.5A neg. logic with ESCP). No network interface

IC752SKT016 DATAPANEL 240E STARTER KIT

MTR-3T13-G-R-0-M-S MTR series metric servo motor with resolver and shaft seal

ZA06B-6130-K201 CX19A or CX19B connector for BSVM1-20i or BSVM1-40i Beta i series amplifier

20CD590B0ANNBNA0 PowerFlex 700H AC Drive 590 A 500 Hp 20C

20G1AGC205JA0NNNNN PowerFlex 755 AC Packaged Drive

25A-E0P9N104 PowerFlex 523 0.4kW (0.5Hp) AC Drive

2711P-T7C21D8S PanelView Plus 7 Standard 700

6SE6440-2UD38-8FB1 90KW

1492-L2Q-RE 1-Ckt Feed-Through Blk 2 Conn Pts 1.5mm

1492-XIMF-F24-2 FUSIBLE EXPANDER MODULE, 24V DC, 8 FUSES

軟啟動器 3RW44251BC46

附件 6ES7 590-1AB60-0AA0 S7-1500 安裝導(dǎo)軌：160 mm

1585-C8TB-S300 Cable Spool Ethernet Media

1746-RL51 SLC Octal Label Kit

1790-T8BV8VX CompactBlock LDX 16 Expansion Block

194E-A25-1753 25 A 194E Load switch

20-PP11002 WIRE SET 2

2090-CSBM1DF-18AF04 Kinetix Cable Single DSL 2090-Series

20AC043A3AYNAEC0 PowerFlex 70 AC Drive 43 A at 22 kW 20A

GC646IFCLNTCRO005 GCC iFIX iClient Read Only 10 PK Keyless Runtime Version

HE660GGM100 Discontinued Part. Check with GE IP on migration path.

IC600LR632RR 16K/16K Combined Memory

IC647HSTES500M Historian Enterprise Server 500 Points (M4 Key)

IC655ALG566RR Analog Output (2 Channels)

IC694CHS392 Base Expansion 10 Slots

IC756SDV001E-98 DV Development - Solaris Op Sys Addt'l User, English, Version 9.8

MicroLogix 1500/1769 System 1764-24AWA ML 1500 BASE 120V AC IN / RELAY OUT / AC POWER

PLC-5/1771 System 1771-AF FIBER OPTIC CONVERTER MODULE

Distributed I/O 1794-IJ2K CONFORMAL COAT, 2-CHANNEL HI RES FREQUENCY MODULE

Communications 9399-WABLUG WINTELLIGENT LINX LITE USER'S GUIDE

Support 6233-5VTLS SUPT RENEWAL CONTRACT FOR 62335VTL

Support 9358-BPMG03S SUPT RENEWAL CONTRACT FOR 9358BPMGR03ENE

Support F1771-KF FIRMWARE UPGRADE FOR 1771-KF COMMUNICATION MODULE

RSI Software Products 9324-RLD0U6ITE RSLOGIX 5000 SERVICE ED TO FULL UPG, ITA

RSI Software Products 9301-2SE350PTU5R RSVIEW32 RUNTIME 5K-100K UPGRADE OUT-SUPT (PT)

RSI Software Products 9358-MTRCK03ENE RSBIZWARE MATERIALTRACK (1 - 10 BATCH SERVER)

Motion Control 8720SM-018S2FBS1 18.5 KW/47.1 AMP, 460VAC, AC MOTOR WITH SRS60 ENC.

829-8-1 Thumbwheel Assembly. 8 Digit, 1 True. Dust Seal

IC200MDL740 OUTPUT 24VDC POS LOGIC 0.5A PER PT (1 GROUP OF 16) 16PT

IC697VAL216 Analog Input, 16 channel, jumper selectable for 0 to 5VDC, 0 to 10VDC, +/-2.5VDC, +/-5VDC, +/-10VDC. 16bit Resolution

MTR-1324-N-D-E-SRR Stepping Motor Nema34 3A Splashproof

ZA06B-0034-B175#7008 B6/2000 servo motor with holding brake and 32k serial encoder

20BD125A3ANNANC0 PowerFlex 700 AC Drive 20B

20G11ND065AA0NNNNN PowerFlex 755 AC Packaged Drive

22F-RF6P0-AL PowerFlex EMC Filter Kit

140CFA04000 Quantum CABLEFAST, 通用連接塊, 直頭連接

294E-FD1P5Z-G2-3-SB Variable Frequency Drive

WLCA12-2N 觸點:1開/1閉,10A 250VAC機械壽命:1500萬次?撞壓式高度可調(diào)可單惻動作

1492-SPM3B250-N MCB Supplementary Protector 25 A

軟啟動器 3RW40261TB04

TS 模塊 6GK7 972-0MG00-0XA0 TS Module GSM

150-F84 SMC Flex Protective Module

1734-IE8C POINT I/O 8 Point Analog Input Module

1783-BMS4S2SGL Stratix 5700 6 port managed switch

193-EOS-SDS E300 Diagnostic Station

20-750-EMC1-F5 PowerFlex 750 Frame 5 EMC Kit

2090-CPWM7DF-12AA20 MP-Series 20m Power Cable

2098-DSD-030 Ultra 3000 3kW Servo Drive

G-C475 GagePort to VAX 4-Wire/Host

GFK-2199 VME3570Dual Channel Incremental Encoder Interface

IC220TBK062 I/O TERMINAL STRIP W/DUAL SHIELD, 6 POSITION SPRING STYLE-QTY 5

IC647EURM EUR:Eurotherm 800 Series

IC647SCMT001 Scheduler Macro Tool

IC693MDL643RR 24 Vdc Input, Positive Logic (16 Points)

IC756DVE010E-98 EO GECK (Graphical Editor Construction Kit) - Inb x87, English, Vers ion 9.8

MSI-QUAL-5 Quality Management Clients 5 Pack

PLC-5/1771 System 1771-A3B1K CONFORMALLY COATED, I/O CHASSIS ASSEMBLY, 12 SLOT

Distributed I/O 1790D-T0V16 DNET LDX I/O,24VDC,16 SINK OUT BASE, TERMINAL BLK

Communications 1770-CD7 DATA HWY TWINAXIAL CABLE, 700 FT/213 M

Operator Interface 2711E-UK14EK10 PANELVIEW 1400E KPD TO 1000E KPD MIGRATION KIT

Support 9305-RSVADFCESS SUPT RENEWAL CONTRACT FOR 9305RSVADFCES

Support 1754-PCSR SUPT REINSTATEMENT CONTRACT FOR 1754PCS

EtherNet/IP Products 1788-ENBT ETHERNET/IP LOGIX DAUGHTERCARD

RSI Software Products 9301-2SE3400KOU2 RSVIEW32 RUNTIME 300-32K UPGRADE IN-SUPT (KO)

RSI Software Products 9515-RSAAMPRVENE RSMACC AUTO ASSET MGMT, PREVENTIVE MAINT

Motion Control 1326AB-B430E-M2K4L MOTOR,SERVO,460V,6.6NM,3000RPM,MULTI,BRK,IP67

3414-128-C Greyline OS, 2 Line, (20) 9MM Chars, VFD, Quick Connect, 128K Memory W/Clock/Date, NEMA 4

HMI-BEZ-201 BEZEL 5" STAINLESS STEEL

IC693ACC350 Redundant Power Supply Adapter (RPSA) Module. The RPSA replaces the power supply on a CPU base or expansion base and connects to a Redundant Power Supply Base.

QPL21100C2P QUICKPANEL COLOR 12.1" TFT

TGT-DI0L-32-0RR Target Digital I/O 16 Inputs and 15 Inputs/Outputs

20BC5P0A0AYNAND0 PowerFlex 700 AC Drive 5 A at 2.2 kW 20B

20F1ANE242AN0NNNNN PowerFlex 753 AC Packaged Drive

22B-D2P3H204 PowerFlex 40- 0.75 kW (1 HP) AC Drive

140ACI03000 Quantum 模擬量輸入,單極性高速,8通道,4-20mA或1-5V

284E-FVD4P0Z-10-RR-3-DB1-EMI EtherNet Variable Frequency Drive

E2E-X1R5E1 1.5mm,電感式,三線,常開 100mA NPN電源:10-30VDC圓M8

1492-SPM1C020-N MCB Supplementary Protector 2 A

通用型變頻器 6SE6 420-2UC24-0CA1 "4.0 KW，185 x 245 x 195"

電機啟動器 3VU13400MP00

1497D-A17-M22-0-N 1En Purpose Transber

1608N-012A240V2S 12 A Mini DySC Sag Corrector

1769-OF8V CompactLogix 8 Pt A/O Voltage Module

190S-BND2-CB63C 4.0-6.3 A Compact Comb Starter W/Ckt-Bkr

194R-NE630-1753 Disconnect Non-Fused IEC 3 Poles 630A

2090-CPBM7DF-16AF02 MP-Series 2 m Length Pwr and Brake Cable

2090-XXTPMP-10S12 MP-Series 12 m Length Power Cable

CFDA-3WPB-0070-AZ This cable has been replaced by cable CFDA-7WPB-0070-AZ

GF-3910R Connecting FlashCable to Ohaus Model C/ E/ GT/ MB/ TP/ TS series.

IC200UDR010-24 Qty of 24, 28 point PLC, (16) 24VDC In, (11) Relay Out, (1) 24VDC Out, 24VDC Power Supply

IC646TRT915 1500 I/O Point Runtime System

IC647PATH105 Proficy PAT - Historian. The capability is to store spectra data from the driver into the Proficy Historian. This for a single dri

IC693APU302RR Axis Positioning Module (APM), 2 Axis, requires (1) or (2) CBL311

IC752PBI100 PC/104 Profibus Card

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