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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)�損壞設(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：

　　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。

　　②強(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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IC693PWR332 Power Supply, 12 Vdc input, 30-watt output, High Capacity

Silver Series 9500-CPAKWENE CONTROLPAK DEVELOPMENT SYSTEM

VSPC32-ANLYST10 VisualSPC Analyst. 10 License Pack.

20BD027A3AYNANC0 PowerFlex 700 AC Drive 27 A at 20 Hp 20B

20G11GC022JA0NNNNN PowerFlex 755 AC Packaged Drive

22C-D6P0N103 PowerFlex 400- 2.2 kW (3 HP) AC Drive

490RIO00400 Quantum MP COAXIAL CABLE STRIPPING TOOL

286040 Kit 500 V 16 A Fuse HRC FA

E6CP-AG5C 12-24VDC,集電極開路輸出16mA,10線,8位,256P/R

1492-SPM2B060 MCB Supplementary Protector 6 A

軟啟動(dòng)器 3RW30132BB04

電機(jī)啟動(dòng)器 3VU16401MG00

150-CS1AX SMC-3 Repair Part

1715-TADIB16D 1715 16 Pt Duplex D/I Termination Assy

1771-NIS 1771 Analog Module

193-EC5CB E3 Plus 5-25 A Overload Relay

198E-C0C4R Plastic Enclosure, 250mm x 125mm x 125mm

2090-CPWM4DF-16AF50 MP-Series 50 m Length Power Cable

2094-BM03-S Kinetix 6000 Axis Module

DEMOCD00020 Proficy Maintenance Gateway - DEMOCD

GFK-0827 Series 90-70 Hot Standby CPU Redundancy User's Guide

IC210DDR024 24V DC Power Source, (12) 24VDC in/8 out (Relay, 8 Amp), (4) analog inputs, Expandable, with LCD/Keypad

IC647ASG001 PA Electronic Signature

IC647PRTDB2C Proficy Portal DB2 Connector (M1 Key)

IC693CPU323CA Conformal Coated CPU323 10 slot base. CPU built into base.

IC754VKI06MTD Starter Kit/ 6 inch View Mono Interm/ 24VDC

MSI-DASHBOARD-25 Dashboard Client 25 Pack

SLC/1746 System 1746-RL42 REPLACEMENT OCTAL LABEL KIT FOR CTLG # 1746-IG16

Distributed I/O 1734-OE2V 24V DC 2 CHANNEL ANALOG VOLTAGE OUTPUT MODULE

Application-specific products 1803-SKCT20 PEMS STARTER KIT, 2000:5 CT'S

Operator Interface 2711E-ND1ES SPANISH PANELBUILDER 1400E WINDOWS CONFIG. SOFTWAR

Support 9302-DDER SUPT REINSTATEMENT CONTRACT FOR 9302DDE

Support 9381-PP5KENS SUPT RENEWAL CONTRACT FOR 9381PP5KEN

DeviceNet Products 1794-ADNK CONFORMALLY COATED, DEVICENET ADAPTER

RSI Software Products 9301-2SE3350JPE RSVIEW32 RUNTIME 5K (JAPANESE)

RSI Software Products 9307-8MGDBPENE RSEMETRIX MGR(0-8 METERS),W/1MSSQL PROCESSOR LIC

Motion Control MPL-B960C-MJ22AA MOTOR,SERVO,102.0NM,1500RPM,MULTI,460V

Silver Series 1398-DDM-020 DRIVE,20A PEAK, ULTRA 200

HE670ADC840 Field Control Analog Input Module, 8 Ch, 4 to 20ma, 400Vdc Channel to Channel Isolation, 1000Vdc Channel to Bus Isolation, 12Bits

IC646TPR075 Pro Server 75 I/O Point Run Time System

QM1204ROA QUICKMARQUEE 1 X 20 4.8" OR 2 X 40 2.1" RED

ST-3444 STXi analog input module 4 Channels, 0~10Vdc, 14-bit

20BC125A0AYNANA0 PowerFlex 700 AC Drive 20B

20F14NC456JN0NNNNN PowerFlex 753 AC Packaged Drive

22A-D1P4F104 PowerFlex 4 0.4 kW (0.5 Hp) AC Drive

140CPS42400 Quantum 電源, 48/60 VDC, 冗余, 8A

284D-FHD6P0B-25-CR-3-SB DeviceNet Variable Frequency Drive

CJ1W-OD211 16點(diǎn)晶體管輸出單元漏型

1492-RIFM40F-F24-2 Connection Products

WinCC 上位監(jiān)控軟件 6GK1713-5FB63-3AA0 FMS-5613 驅(qū)動(dòng)

變送器 3RS17022AD00

1497A-A13-M7-0-N Control Power Transformer

1606-XLP50B Power Supply XLP 50 W Power Supply

1766-L32BXB MicroLogix 1400 32 Point Controller

188-K4C030 Miniature Circuit Breaker 3 A

194L-HE8N-175 194L Control and Load Switch Actuator

2090-CPBM7DF-10AA09 MP-Series 9m Standard Cable

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

CBL-12-MP-10 Power cable for MTR-1216 or MTR-1221 or MTR-1231 stepping motors. 10 feet

GC647SPT001 GCScheduler Proficy Plant Apps Adapter

IC200PWR002 POWER SUPPLY WITH EXPANDED 3.3VDC 24VDC INPUT

IC646TBLH005 Proficy Troubleshooter for Intelligent Historian 5 Seats

IC647NET000 CIMPLICITY HMI MMS Ethernet Communications Driver

IC690PWR124 Field Power Supply 24 VDC 10 Amps

IC698CMX016 PACSystems RX7i Control Memory Xchange 16MB Memory

IC800VMACONCN3 VersaMotion amplifier CN3 communication connector

SLC/1746 System 1746-IG16 DC INPUT MODULE FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6180W-15BPXPH VERSAVIEW 15-INCH WORKSTATION, KEYPAD & TOUCH

Application-specific products 6556-MLCBK MICRO LOGIX C/B KIT AC

Operator Interface 2711-K5A8L2 PV550 MONOCHROME KEY, DH+ & RS232 PRINT

Support 9301-2SE2200ESS SUPT RENEWAL CONTRACT FOR 93012SE2200ES

Support 9501-RL0H150ENS SUPT RENEWAL CONTRACT FOR 9501RL0H150EN

ControlNet Products 9904-XTAL CONTROLNET 60.00 MHZ CRYSTAL (500 PIECE REEL)