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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，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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22A-A8P0N104 PowerFlex 4- 1.5 kW (2 HP) AC Drive

TSXMFPP001M Quantum Unity V2 PCMCIA存儲(chǔ)擴(kuò)展卡，程序存儲(chǔ)1x1024K（Flash）

284-PWRM22A-M1 ArmorConnect 3PH Pwr Media Shld Mtr Cbl

CJ1M-CPU12 CPU單元I/O點(diǎn)數(shù)320，10K程序容量，不可接擴(kuò)展機(jī)架。

1492-RCDA4C80 Residual Current Device 80 A

6ES7195-7HB00-0XA0 安裝兩個(gè) 40mm 寬的 I/O 模板，熱插拔

變送器 3RS11 42-1GW80

1497-K-HXDX-0-N Control Circuit Transber

1606-XLE480EP XLE Power Supply

1763-MM1 MicroLogix 1100 Memory Module

188-K3D320 Miniature Circuit Breaker 32 A

194L-HE4A-875 IEC Control And Load Sw Actuator Type A

2090-CPBM7DF-08AA60 MP-Series 60m Power and Brake Cable

2090-XXNPMF-14S90 Kinetix Drives 90m Standard Cable

BC647TRT915 CIMPLICITY HMI Server 1500 I/O Runtime System with Proficy GlobalCare

GC647PSF025 Global Care for Proficy Process Systems 250 I/O with iFIX

IC200NAL211 10 point PLC, (6) 24VDC In, (4) Relay Out, (1) Analog Input (0-10VDC, 8 bit), 24VDC Power Supply

IC646PPA364 PA-30 with 364 CPU - AC

IC647NAC003 CIMPLICITY Alarm Cast Enterprise Version

IC687RCM711 Half Slot Redundant Communications Module for HSB Systems

IC697VDD100 Discontinued. Replacement is Embedded VME-1182A-020000. Contact GE Embedded for more details.

IC800SSI420RD2RR 20A, 480V, DeviceNet S2K Servo Controller for MTR Series Motors

SLC/1746 System 1747-SCNR CONTROLNET SCANNER FOR SLC PLATFORM

Industrial Computers 6181P-15NSXPH VERSAVIEW INTEGRATED DISPLAY COMPUTER 15-INCH TFT

Application-specific products 9358-PBEPB30ENE RSBIZWARE BATCH & EPROCEDURE BNDLE PLX 30 UNITS

Operator Interface 2711-K5A16 PV550 MONOCHROME KEY, DF1 & RS232 PRINT

Support 6171-PCSR SUPT REINSTATEMENT CONTRACT FOR 6171PCS

Support 9393-RSTLX5KS SUPT RENEWAL CONTRACT FOR 9393RSTLX5K, PLX5K

ControlNet Products 2711P-K10C15B2 PV PLUS 1000, KEYPAD, CNET, AC PS, EXT MEM

RSI Software Products 9301-2SE2500U4R UPGRADE: OUT-SUPT: RSVIEW32 WORKS 150 TO 100K

RSI Software Products 9358-BEPB60U3 UPGRADE: IN-SUPT: RSBW BATCH & EPROCEDURE 30 TO 60

Motion Control MPL-A4540F-MK22AA MOTOR,SERVO,10.2 NM,3000RPM,MULTI,230V,9.5KG

Motion Control 2090-XXNFY-S25 CABLE,NON-FLEX,MOTOR FEEDBACK,Y,25M

GABI3D200C2P/AD QUICKPANEL 10.5" TFT W/AB DH+ 24VDC GE LABEL

IC641SWC306 LM 90-30/20/Micro Serial Software, 3.5"/5.25" disks + CD-ROM docs.

IC800SSI104S1 4.3 Amp S2K Series Servo Amplifier/Controller, 115/230 VAC

PSPC-ADMIN Prof Shop Floor SPC Admin 1 User

20BB042A0AYNBNC0 PowerFlex 700 AC Drive 42 A at 15 Hp 20B

20DE017A0EYNANASE PowerFlex 700S AC Drive 20D

2198-BARCON-100DC100 Kinetix 5700 100mm Control Bus Bar Kit

2711P-K15C4A8 PanelView Plus Terminal

280-PWRM35D-M14 ArmorStart Three-Phase Power Media

CPM2A-60CDR-A 60點(diǎn)主機(jī) AC100-220V 36點(diǎn)入24點(diǎn)繼電器輸出 自帶RS232C口

1492-MS5X9H31-40 Connection Products

1495-N73 1-1/4 in. Hub

行程開關(guān) 3SE53120SJ11

運(yùn)行版軟件 6AV2105-0TA14-0AA0 SIMATIC WinCC Runtime 專業(yè)版 262144 PowerTags ASIA V14

1585J-M4UBJM-20 RJ45 Ethernet Media

1756-OX8I ControlLogix 8 Pt Digital Relay Module

188-K1C200-N Miniature Circuit Breaker 20 A

194E-KA32E-P11 194E Load switch

2090-CFBM7DF-CEAF02 Kinetix 2m Flexible Cable

2090-UXNBMP-18S03 MP-Series 3 m Length Brake Cable

BC646SPH365 Solution Provider Annual license w/Additional HMI Suite

GC647IFCLNTSRO100 GCA iFIX iClient Read Only 1 PK Keyed Runtime Version

IC200ALG328 Analog Output, 13 Bit, Current, 12 Channel

IC646MBSS99 Machine Edition Standard Development Suite Unlimited Seat Site License

IC647IFPRDVUNLMTM iFIX Profsnl SCADA Unlimited Development (M4 Part)

IC660SLD021 Red Safety Label Kit for IC660BBD021 Genius Blocks

IC697CHS750 Rack, 5 Slots, Rear Mount

IC800CBL062 Power cable for A12/3000 or A22/2000 motor. 14 meters

ControlLogix/1756 System 1784-CF64 INDUSTRIAL COMPACTFLASH CARD 64MB

Industrial Computers 6182H-7KRH15D VVCE 700, KEYPAD, STD MEM, CNET, DC

Process Control 9358-PBANT60ENE RSBATCH NT FOR PROCESSLOGIX ARCHIVER 60 UNITS

Operator Interface 2711P-T15C15D1 PV PLUS 1500, TOUCH, CNET, DC PS, STD MEM

Support 9352-WGE200S SUPT RENEWAL CONTRACT FOR 9352WGE200

Support 9325-WL5140S SUPT RENEWAL CONTRACT FOR 9325WL5140