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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(chǎng)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(chǎng)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(chǎng)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(chǎng)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：

　　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(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(chǎng)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(chǎng)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(chǎng)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(chǎng)調(diào)試的經(jīng)驗(yàn)，對(duì)部分重要的現(xiàn)場(chǎng)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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ET 200SP 6ES7137-6AA00-0BA0 CM PtP, Modbus、ASCII、USS串行通訊模塊，基座單元類型A0

1585D-M4TBDM-30 Micro D-Code, QD Style Ethernet Media

1756-EN2T CLX HI-CAP ENET/IP MODULE - TP

1794-OB8 Flex 8 Point Digital Output Module

194E-CA40EX-TN-PE 194E Load switch

2085-OA8 Micro800 8 Point Triac Output Module

2090-DANFCT-S03 TL-Series 3m Feedback Cable

20AC8P7A0AYNADC0 PowerFlex 70 AC Drive 8.7 A at 4 kW 20A

GC646PCM010 GlobalCare Complete for Change Management 10 user pack

HE693THM888 Same as THM884 with 60Hz filter

IC630MDL351RR 24Vdc Sink Output Module, 2 Amp (8 points)

IC647HSTSS500M Historian Standard Server 500 Points (M4 Key)

IC660BLA103 Cover w/Label for IC660BBA103

IC695ALG704 Analog Output Module, 4 channels,that is configurable for voltage and current, configured for Current: 0 to 20mA, 4 to 20mA; Voltage: +/- 10 VDC, 0 to 10VDC per channel non isolated. Up to 16 bit resolution. Requires high capacity terminal block IC

IC756WDV009J-23 DV Development Sys Visual Basic, Japanese, Version 2.3

CompactLogix System 1761-NETENIW ETHERNET INTERFACE W/WEB FOR MICROCONTROLLER

PLC-5/1771 System 9399-PLC5MAN PLC 5, 6200 SERIES MANUAL SET(FOR 5.2 REL + NEWER)

Distributed I/O D1794-6.5.11 FLEX I/O FREQUENCY INPUT MODULE USER MANUAL

Operator Interface 2711P-T6M20A PV PLUS 600 GRAYSCALE, TOUCH, ETHERNET, AC PS

Support 6401-SDSCS 6401-SDSC SOFTWARE SUPPORT RENEWAL

Support 9358-PBRE01R SUPT REINSTATEMENT CONTRACT FOR 9358PBRE01ENE

Support F1779-KP5RSERB FIRMWARE UPGRADE FOR 1779-KP5R COMMUNICATION MODUL

RSI Software Products 9301-2SE2103ZHE RSVIEW32 WORKS 150 WITH RSLINX (CHINESE)

RSI Software Products 9701-VWMR075JPU2 RSV ME STATION RT 30 TO 75 UPGRADE (JAPANESE)

RSI Software Products 9399-2SE32UG RSVIEW32 USER GUIDE

Motion Control 2098-DSD-HV100 HIGH VOLTAGE DRIVE, 23A/46A, ULTRA3000

ABI3D200C2P/SER QUICKPANEL 10.5" TFT W/SE 24VDC

IC220PWR003 POWER TERMINAL, FUSED W/DIAG 24VDC (REQIRES 1 IC220TBK087)

IC752DPA260RR Datapanel 1060IR with infrared touch. 10.4" VGA (640x480) active matrix TFT color display. No bezel - mounts from inside panel. Supports all WinCfg functionality.

MTR-3S32-H-R-0-E-SRR Servo Motor Nema34 with Seal

ZA06B-0286-B310 A100/2.5KHVis Motor w/ Fan Tp Shft & Brk

20BE032A0AYNANC0 PowerFlex 700 AC Drive 32 A at 30 Hp 20B

20G14NE289AA0NNNNN PowerFlex 755 AC Packaged Drive

25-PTG1-FB PowerFlex 520 Fr B Power Terminal Guard

2711P-RR128 PV Plus Logic Module 256 MB Ram Module

FRN30G11S-4CX 46 KVA 60 A 30KW 3相AC380V/50Hz/60Hz

1492-J6-OR 6 square mm Feed-Through Terminal Block

1492-TAIFM16-F-3 Connection Products

軟啟動(dòng)器 3RW40736BB34

CPU 模塊 6ES7 512-1DK01-0AB0 CPU 1512SP-1 PN，200KB 程序，1 MB 數(shù)據(jù)；48 ns；集成 1x PN 接口 ( 可用 ET 200SP 總線適配器再拓展 2 個(gè) PN 接口 )

153H-C135FBD-50 135 A Encl. Smart Mtr Ctrlr CB

1738-OV4EM12 ArmorPoint 4 Point Output Module

1785-L80C15 PLC-5 ControlNet 1.5 Processor

193-NREENZ E1 Plus Replacement Overload Relay

20-COMM-H PowerFlex HVAC Comm Adapter

2090-CSBM1DE-18AF09 Kinetix Cable Single DSL 2090-Series

20AC011A0AYYANC0 PowerFlex 70 AC Drive 20A

GA647IFSTDVUNLMT GCA iFIX Std HMI Unlmt Dev

GP647IFPLRN00150 GCP iFIX Plus SCADA 150 I/O Run

IC600BF924RR 120Vdc Output Module (8 points)

IC647HSTCR3KM Collector Redundancy Option for Historian - Standard Server 2500 Points (M4 Key)

IC647TPR150 CIMPLICITY HMI ProServer 150 I/O Runtime System

IC693PIF350 Series 90-30 I/O PCI Bus interface board. Enables users to connect Series 90-30 I/O to a PCI interface board.

IC756MDV000K-98 DV Development - Alpha OpenVMS Op Sys, Korean, Version 9.8

MicroLogix 1000/1761 System 1761-CBL-AC00 CABLE: 9-PIN PORT OF 1761-NET-AIC TO 9-PIN PORT

PLC-5/1771 System 1771-NB4S HIGH RESOLUTION ISOLATED ANALOG MODULE

Distributed I/O 1792D-8BVT8CD MAXUM 8IN/8OUT WITH POINT LEVEL DIAGNOSTICS

Communications 9351-AIX INTERCHANGE FOR AIX

Operator Interface D6190-6.5.20 CNTRLVW STAT. PROCESS CONTROL(SPC)(6190-SPC)MANUAL

Support 9356-STD2300S SUPT RENEWAL CONTRACT FOR 9356STD2300

Support 9392-CDRSDEU UPGRADE TO ENGLISH/GERMAN BUNDLE

EtherNet/IP Products 9355-WABOEMENE RSLINX OEM - ENGLISH

RSI Software Products 9301-2SE3500KOU1 RSVIEW32 RUNTIME 32K-100K UPGRADE IN-SUPT (KO)

RSI Software Products 9356-SQLSAP250U1 UPGRADE: IN-SUPT: RSSQL GATEWAY SAP TO SAP PREMIUM

Motion Control TL-A130P-BJ32AA MOTOR, SERVO, 0.32NM, 5000RPM, 17BIT SERIAL FEEDBA