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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。

　?、趶?qiáng)置辦法：使用PLC強(qiáng)置功用，對(duì)程序中觸及現(xiàn)場的機(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。其長處是調(diào)試作業(yè)量小，簡便，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)場調(diào)試的經(jīng)驗(yàn)，對(duì)部分重要的現(xiàn)場節(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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20-750-S PowerFlex 750 SAFE Torque-Off Opt module

2090-CSBM1DE-14AF15 Kinetix Cable Single DSL 2090-Series

20AB9P6A0AYNANC0 PowerFlex 70 AC Drive 9.6 A at 3 Hp 20A

GA647IFPRSR00075 GCA iFIX Profsnl SCADA 75 I/O Srv

GP647IFESGSR00300 GCP iFIX Optn: ESig & ERec 300 I/O Srv

IC600BF910RR 115Vac Isolated Output Module (6 points)

IC647HSTCR15KM Collector Redundancy Option for Historian - Standard Server 15000 Points (M4 Key)

IC647TPD150 CIMPLICITY HMI ProServer 150 I/O Development & Runtime System

IC693PCM300RR Programmable Coprocessor Module w/Port Expansion Cable

IC756LDV010K-98 DV Draw Development on Inb/Linux RedHat Op Sys, Korean, Version 9.8

MicroLogix 1000/1761 System 1761-L20BWA-5A 25 I/O MICROLOGIX 1000 WITH ANALOG

PLC-5/1771 System 1771-IFF FAST ANALOG INPUT MODULE

Distributed I/O 1792D-2BV0D 2 SINK/SOURCE INPUTS, 2 CONNECTORS

Communications 9300-RADES REMOTE ACCESS ETHERNET SWITCH

Operator Interface D6190-6.5.10RU CONTROLVIEW EVENT DETECTOR USER MNL (RUSSIAN)

Support 9356-SQLSAP225R SUPT REINSTATEMENT CONTRACT FOR 9356SQLSAP225

Support 1789-SLXS SUPT RENEWAL CONTRACT FOR 1789SLX

EtherNet/IP Products 9351-VSRT INTERCHANGE FOR OPEN VMS RUNTIME

RSI Software Products 9301-2SE3500ITU4 RSVIEW32 RUNTIME 150-100K UPGRADE IN-SUPT (IT)

RSI Software Products 9356-PRO2500U7 UPGRADE: IN-SUPT: RSSQL PROF.1500 TO 70000 TAG

Motion Control N-5647-2-H04AA SERV MTR,6.0NM,5000RPM,2000 LN ENCDR,BRK

44A731249 CPU313 Upgrade Kit latest revision

IC200CBL001 CABLE CPU PROGRAMMING RS232

IC694ALG222 INPUT MODULE ANALOG 16 SINGLE ENDED 8 DIFFERENTIAL VOLTAGE

MSI-SDK-UNL Unlimited SDK Connections (per site)

cFP-AIO-610

LY20C390

PS-7270B/ATX

AIMB-742 AIMB-742G2

X9SAE-V

TI XIO2200A FG-E2200-2E1I-B1-01-BC01

LC3-M40HJ-001

1492-SPM2B130 MCB Supplementary Protector 13 A

軟啟動(dòng)器 3RW30142BB04

電機(jī)啟動(dòng)器 3VU16401MK00

150-CS1FX SMC-3 Repair Part

1715-TADOF8 1715 8 Pt Duplex A/O Termination Assy

1771-NIVR 1771 Analog Module

193-EC5EE E3 Plus 18-90 A Overload Relay

198E-C0S4R Plastic IP66 and NEMA 4/4X/12K Enclosure

2090-CPWM4E2-08TR MP-Series 0.5m Length Transition Cable

2094-BMP5-S Kinetix 6000 Axis Module

DEMOCD00023 1012010

GFK-0840 Power Mate APM for Series 90-30 PLC Standard Mode User's Manual

IC210EAO002 2 channel analog out expansion (0 – 10VDC or 0 – 20mA). Requires Durus Plus controller with 3.0 version firmware.

IC647ATS001 PA Test Bed Key

IC647PRTEE002M Proficy Portal Enterprise Edition Client Pack 2 Users (M4 Key)

IC693CPU331 CPU 331 Module (16K Bytes), The battery for the CPU is now included in the CPU backplane box.

IC754VKI12CTD Starter Kit/ 12 inch View TFT Interm/ 24VDC

MSI-DASHBOARD-5 Dashboard Client 5 Pack

SLC/1746 System 1746-RL45 REPLACEMENT OCTAL LABEL KIT FOR CTLG # 1746-IV16

Distributed I/O 1734-IJ 5 VDC INCREMENTAL ENCODER MODULE