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(dòng)化控制的系統(tǒng)是要求長(zhǎng)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(duì)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(mén)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(duì)PLC各種模塊的說(shuō)明資料的熟悉，再次現(xiàn)場(chǎng)布局的了解，最后確保自已的各種檢測(cè)工具要完好無(wú)誤。
2、日常點(diǎn)檢工作：定期進(jìn)行CPU的電池的電壓檢測(cè)，正常常情況下為3V，定期對(duì)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(duì)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(duì)于PLC系統(tǒng)的故障檢測(cè)法：一摸、二看、三聞、四聽(tīng)、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(guò)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?dòng)袥](méi)有異味，電子元件或線纜有無(wú)燒毀;四聽(tīng)，聽(tīng)有無(wú)異動(dòng)，鏍絲釘松動(dòng)、繼電器正常工作與否，聽(tīng)現(xiàn)場(chǎng)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(lái)尋找故障所在地;六對(duì)不確定的部位進(jìn)行部件替換法來(lái)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(cè)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(cè)，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(wú)電則按跡尋蹤，借助原理圖+現(xiàn)場(chǎng)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(wàn)用表則檢查空氣開(kāi)關(guān)的進(jìn)線端與出線端有無(wú)正常供電，無(wú)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(wú)電壓，或負(fù)載過(guò)重，又或嚴(yán)重過(guò)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(guò)CPU工作模式及優(yōu)先級(jí)：高優(yōu)先級(jí)有STOP、HOLDUP、STARTUP（WARMRESTART、COLDRESTART）;低優(yōu)先級(jí)有：RUN、RUN-P（PG/PC的在線讀寫(xiě)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(guò)程中用戶(hù)程序出現(xiàn)斷點(diǎn)而處于調(diào)試程序狀態(tài)，或在啟動(dòng)模式下斷點(diǎn)出現(xiàn)，對(duì)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(cè)引起STOP的原因分析：A、無(wú)電，分析無(wú)電原因，是因?yàn)楣╇姴块T(mén)出問(wèn)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(lèi)型同版本的CPU;C、有板子壞了，有序進(jìn)行板子的更換。對(duì)于硬件更換時(shí)要注意使用與原來(lái)的器件相同的產(chǎn)品同型號(hào)、同版本來(lái)進(jìn)行，否則會(huì)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(kù)中硬件配置不同而無(wú)法進(jìn)行用戶(hù)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(duì)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(kāi)關(guān)是一樣的功能且為常開(kāi)點(diǎn)，所以在線檢修該模塊的任一點(diǎn)時(shí)，只要在無(wú)接線時(shí)且該地址在控制程序不給輸出信號(hào)時(shí)來(lái)檢測(cè)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(duì)替換下來(lái)的模塊的點(diǎn)進(jìn)行測(cè)量通斷狀態(tài)，通，則該點(diǎn)壞，不通該點(diǎn)為好。對(duì)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(cè)，用表檢測(cè)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(duì)硬件接線重新?lián)Q點(diǎn)重接后均要用相應(yīng)編程軟件對(duì)控制軟件進(jìn)行0X或1X地址替換工作。對(duì)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(shuō)相當(dāng)于常閉點(diǎn)，所以檢測(cè)通道好壞的方法為用表的測(cè)通斷功能來(lái)檢測(cè)，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(cè)方法與數(shù)字量輸出模塊相同。若壞通道則對(duì)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(duì)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(kāi)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(lèi)型來(lái)選擇。進(jìn)行過(guò)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(lái)下載變化的程序而不停CPU。對(duì)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(duì)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(kāi)繼電器變?yōu)槌ｉ_(kāi)狀態(tài)，容易發(fā)生錯(cuò)誤，因此要對(duì)此類(lèi)的輸出模塊進(jìn)行檢測(cè)時(shí)，要與現(xiàn)場(chǎng)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(dòng)操作后，再撤去數(shù)字量輸出模塊的供電線后對(duì)模塊測(cè)點(diǎn)工作。
5、各類(lèi)開(kāi)關(guān)類(lèi)的檢測(cè)工作：如繼電器、接近開(kāi)關(guān)、空氣開(kāi)關(guān)等器件的檢測(cè)工作，是根據(jù)開(kāi)關(guān)的類(lèi)型是常閉型還是常開(kāi)型來(lái)區(qū)分，用表來(lái)檢測(cè)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(duì)于電路大部情況利用常開(kāi)型，它們是用來(lái)人工控制或自動(dòng)控制電流的接通與斷開(kāi)的;對(duì)于常閉型主要用在保護(hù)電路中。借此可以知道開(kāi)關(guān)類(lèi)和保護(hù)類(lèi)器件的正常狀態(tài)為如何而正常識(shí)別器件的好壞。
6、1C31132G01通迅模塊的檢測(cè)則是利用簡(jiǎn)單的用好的新的通迅模塊進(jìn)替換來(lái)識(shí)別板上的正在使用的模塊是否正常。
7、導(dǎo)線的測(cè)量方法：導(dǎo)線也是通過(guò)檢測(cè)通斷方法進(jìn)行的?？梢岳靡阎ǖ膶?dǎo)線來(lái)檢測(cè)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(lái)后測(cè)通斷狀態(tài)。
8、電阻檢測(cè)：帶電狀態(tài)時(shí)檢測(cè)電壓，不帶電時(shí)檢測(cè)相應(yīng)的電阻。
四、總結(jié)
1C31132G01通過(guò)以檢測(cè)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(shí)與常識(shí)，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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Details about NEW ROSEMOUNT 3051CG2A02A1AB1K7H2 Pressure Transmitter 0-62.2 kPa
Details about ITE SIEMENS SMFH04 NSFP SMFH04
Details about ALLEN BRADLEY 2711P-RBB10 FNFP 2711PRBB10
SICK OPTIC ELECTRONIC SRM50-HFA0-K21 FNFP SRM50HFA0K21
WESTINGHOUSE FAN-361 USPP FAN361
Details about RELIANCE ELECTRIC 419904-52AJ NSPP 41990452AJ
WESTINGHOUSE 505A684G01 NSFP 505A684G01
Details about NUMATICS SH6-021 NSFP SH6021
Details about Hitachi LWI 000 110-120VAC b module
Details about MARCON CB-7060 USPP CB7060
Details about SCHOTT 67671-35 USPP 6767135
SICK OPTIC ELECTRONIC WS/WE160-P142 NSFP WSWE160P142
SMC MXS6-50 AIr Slide Table, Dual Rod
Omron DRT1-MD16 REMOTE I/O UNIT
Details about TELEMECANIQUE XS1-M12MA250 NSPP XS1M12MA250
Details about GENERIC CR4700U50 FNFP CR4700U50
Details about DANTONA CR14250SET-P1 FNFP CR14250SETP1
Details about FURNAS ELECTRIC CO 3TX7-466-1A FNFP 3TX74661A
Details about ASCO 8320-A019-024 USPP 8320A019024
Details about HYDAC 0240D005BN4HC NSFP 0240D005BN4HC
Details about HASTINGS FILTERS FF863 FNFP FF863
Details about DODGE 2517X2-3/16 USPP 2517X2316
Details about BRONKHORST F-202AC-FDC-44V NSPP F202ACFDC44V
MICOS VT-80 & VEXTA D4CL-5.0 QR8 CLEAN DAMPER
Details about POWER ONE HDCC-150W-A NSFP HDCC150WA
Details about KB ELECTRONICS KBWC-15K FNFP KBWC15K
Details about ITE SIEMENS XEH3100 NSPP XEH3100
WESTINGHOUSE 7381A83G0 USPP 7381A83G0
Aero-Motive 6W201 Balancer 4-6 Lbs Tool Cap
RELIANCE ELECTRIC 45C-272 USPP 45C272
Details about Steam Turbine Pair Bearing Liners 3in shaft Part R24369201 8DRF99 424-369-002
WESTINGHOUSE 1F0906 NSFP 1F0906
Details about FURNAS ELECTRIC CO 3LC5167-1TB13 USPP 3LC51671TB13
Details about WIX FILTERS 51768 NSPP 51768
WESTINGHOUSE SN74LS641N NSPP SN74LS641N
RELIANCE ELECTRIC 86474-1S USPP 864741S
CMPR-FD20B1B23 Yaskawa Yasnac MOTIONPACK FD W/ PLC Fully Tested
Details about SQUARE D 2936-S1-C29B NSPP 2936S1C29B
RELIANCE ELECTRIC 0-52828-1 NSFP 0528281
Details about MALLORY CGS143U025V2C NSPP CGS143U025V2C
WESTINGHOUSE NL-752 USPP NL752
MITSUBISHI FREQROL-E500 FR-E520-2.2K INVERTER
ICOS MC4690 Lighting Controller
RELIANCE ELECTRIC 45C-92 USPP 45C92
WESTINGHOUSE NL-708 NSFP NL708
SICK OPTIC ELECTRONIC FGSS-450-25 USPP FGSS45025
Details about 5 x Allen Bradley 140M C2E Motor protection M05-10E contactor combo busbar
Details about RELIANCE ELECTRIC 404844-EL NSFP 404844EL
SICK OPTIC ELECTRONIC WEU-26-722 NSFP WEU26722
Details about GATES 23828 NSFP 23828
Details about FURNAS ELECTRIC CO 7KM2-112-0BA00-3AA0 NSFP 7KM21120BA003AA0
RELIANCE ELECTRIC 705025-1R NSPP 7050251R
SICK OPTIC ELECTRONIC LVU-706-2221 USPP LVU7062221
WESTINGHOUSE 1956071A USPP 1956071A
Details about SMC CKP1A50-150Y-P74-376-X738 USPP CKP1A50150YP7437
Details about HASTINGS FILTERS AF417 NSFP AF417
Details about REXROTH R432016663 USPP R432016663
Details about NEW BENTLY NEVADA 330850-90-05 3300 XL 22mm PROXIMITOR SENSOR works w/ all 25mm
Details about HASTINGS FILTERS LF340 NSFP LF340
Details about SMC Rodless cylinder demonstration teaching board MYC25G-300L - E73AL Ex Tafe
Details about FURNAS ELECTRIC CO 75AF42 NSFP 75AF42
Details about WIX FILTERS 557085 NSFP 557085
Details about Pro-Face Proface Digital GP377-LG41-24V 2880011-02 Touch Screen HMI
Details about KSB Laufring Impeller Wear Ring Part No 001170677 503.02 Set of 3
Omron C200H-MD501 Input / Output Unit C200HMD501
Details about GTT ELECTRONICS 21-895-025 NSFP 21895025
Details about WEATHERHEAD 68X4X4 NSPP 68X4X4
WESTINGHOUSE MST01SL USPP MST01SL
Details about FURNAS ELECTRIC CO 3RU1916-3AA01 NSFP 3RU19163AA01
Details about ITE SIEMENS CK3B200 USPP CK3B200
Details about SQUARE D 9001-K96 USPP 9001K96
WESTINGHOUSE 315C293G01 NSFP 315C293G01
Details about RELIANCE ELECTRIC 922.67.05 NSFP 9226705
RELIANCE ELECTRIC 86466-91SC USPP 8646691SC
Details about PHOENIX CONTACT VAL-MS-500-ST NSFP VALMS500ST
Details about Tieman Hydraulic Scissor Lift Platb & Power Pack. Weg Motor Type 112M1181.
Details about PYROTRONICS S-HP NSPP SHP
WESTINGHOUSE A201K3CA-Z1 USPP A201K3CAZ1
Details about SIEMENS 6SL30000BE236DA1 NSFP 6SL30000BE236DA1
Details about RELIANCE ELECTRIC RFA-70 NSPP RFA70
Details about P&H MINING EQUIPMENT 79UI6DI USPP 79UI6DI
Mitsubishi Melsec Fw-0 MT PLC Base Controller NIB
SICK OPTIC ELECTRONIC PS95W-24V-ENC NSFP PS95W24VENC
SICK OPTIC ELECTRONIC 2006578 FNFP 2006578
Details about DODGE 119184 NSFP 119184
WESTINGHOUSE 7883C40G01 USPP 7883C40G01
WESTINGHOUSE 227P452H01 USPP 227P452H01
Details about MICRO MOTION RFT97123PNS Mass Flow transmitter &. Sensor DS025S114P Pair 1/2"
WESTINGHOUSE 4D14803H01 USPP 4D14803H01
RELIANCE ELECTRIC 0-57408-D USPP 057408D
Details about FURNAS ELECTRIC CO 3RX8000-0BH3-21AF0 NSFP 3RX80000BH321AF0
Details about SIEMENS 6SL3201-0BE12-0AA0 NSFP 6SL32010BE120AA0
LEDEX 810-640-332 USPP 810640332
Details about SMC air valve manifold 8 x VQ4200-5W valves and EX124U-SMJ1 CC-Link interface
John Brooks / Warren Rupp 286009604 ST1-A PTFE Diaphragm ! NEW !
Alum-A-Lift, AMAT, Varian, Applied Materials Parts Cart and Parts for Lifts
Details about FURNAS ELECTRIC CO 52PA8A2K NSPP 52PA8A2K
Details about Hardness Tester Vickers Brinell WPM Leipzig 250kg set up Brinell
WESTINGHOUSE GB2020 USPP GB2020
Details about CROUSE HINDS DSA 12 ISTD Start Stop switch NIB flame proof Exe
Details about FESTO ELECTRIC DSM-25-270-P-CC USPP DSM25270PCC
Details about DODGE 2517X2-1/8KW NSFP 2517X218KW
Details about DODGE 1610X1-7/16KW USPP 1610X1716KW
