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　PLC控制系統的設備與調試，觸及到各項作業，而且只能按序進行，一環緊扣一環，稍有不小心都將導致調試失利，不但延誤工期，甚至會損壞設備。本文介紹了在現場實踐中總結出的PLC控制系統的設備與調試技能經驗，并對現場經常出現的設備、調試相關問題，提出評論定見和解決計劃。

　　一、體系的設備與調試

　　合理安排體系設備與調試程序，是確保高效優質地完成設備與調試任務的要害。

　　1、前期技能準備

　　體系設備調試前的技能準備作業越充沛，設備與調試就會越順暢。前期技能準備作業包含下列內容：

　　(1)熟悉PC隨機技能材料、原文材料，深化了解其功用、功用及各種操作要求，制定操作規程。

　　(2)深化了解規劃材料、對體系工藝流程，特別是工藝對各生產設備的操控要求要有全面的了解，在此基礎上，按子體系制造工藝流。程聯鎖圖、體系功用圖、體系工作邏輯框圖、這將有助于對體系工作邏輯的深刻了解，是前期技能準備的重要環節。

　　(3)熟悉各工藝設備的功用、規劃與設備狀況，特別是各設備的操控與動力接線圖，并與什物相對照，以及時發現過錯并糾正。

　　(4)在全面了解規劃計劃與PC技能材料的基礎上，列出PC輸入輸出點號表(包含內部線圈一覽表，I/O所在位置，對應設備及各I/O點功用)。

　　(5)研讀規劃提供的程序，對邏輯雜亂的部分輸入、輸出點制造時序圖，一些規劃中的邏輯過錯，在制造時序圖時即可發現。

　　(6)分子體系編制調試計劃，然后在團體評論的基礎上綜合成為全體系調試計劃。

　　2、PLC商檢

　　商檢應有甲乙兩頭共同進行，應承認設備及備品、備件、技能材料、附件等的類型、數量、規范，其功用是否無缺待實驗室及現場調試時驗證。商檢成果，兩頭應簽署交換清單。

　　3、實驗室調試

　　(1)PLC的實驗室設備與注冊制造金屬支架，將各作業站的輸入、輸出模塊固定其上，按設備提要以同軸電纜將各站與主機、編程器、打印機等相銜接，查看接線正確，供電電源等級與PLC電壓選擇相契合后，按開機程序送電，裝入體系配置帶，承認體系配置，裝入編程器裝載帶、編程帶等，按操作規程將體系注冊，此刻即可進行各項操作實驗。

　　(2)鍵入作業程序

　　(3)模仿I/O輸入、輸出，查看修正程序本進程的意圖在于驗證輸入的作業程序的正確性，該程序的邏輯所表達的工藝設備的聯鎖聯系是否與規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程，闡明程序有誤，應進行修正。在這一進程中，對程序的了解將逐漸加深，為現場調試作好了準備，同時也可以發現程序不合理和不完善的部分，以便進一步優化。

　　調試辦法有兩種：

　　①模仿辦法：按規劃做一塊調試板，以鈕子開關模仿輸入節點，以小型繼電器模仿生產工藝設備的繼電器與接觸器，其輔佐接點模仿設備工作時的回來信號節點。其長處是具有模仿的真實性，可以反映出開關速度差異很大的現場機械觸點和PLC內的電子觸點相互銜接時，是否會發作邏輯誤動作。其缺陷是需求添加調試費用和部分調試作業量。

　　②強置辦法：使用PLC強置功用，對程序中觸及現場的機械觸點(開關)，以強置的辦法使其“通”、“斷”，迫使程序工作。其長處是調試作業量小，簡便，不需另外添加費用。缺陷是邏輯驗證不全面，人工強置模仿現場節點“通”、“斷”，會構成程序工作不能連續，只能分段進行。

　　依據我們現場調試的經驗，對部分重要的現場節點采納模仿辦法，其他的選用強置辦法，取二者之長互補。邏輯驗證階段要著重逐日填寫調試作業日志，內容包含調試人員、時刻、調試內容、修正記載、毛病及處理、交代驗收簽字，以樹立調試作業責任制，留下調試的第一手材料。關于規劃程序的修正部分，應在規劃圖上注明，及時征求規劃者的定見，力求準確表現規劃要求。
 

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1497B-A10-M15-0-N Control Power Transformer

1585D-E4TBDE-10 Micro D-Code, QD Style Ethernet Media

1756-EN3TR ControlLogix Ethernet Motion Module

188-K1B200 Miniature Circuit Breaker 20 A

194L-HE6E-175 194L Control and Load Switch Actuator

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IC647HSTES40KM Historian Enterprise Server 40000 Points (M4 Key)

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IC694BEM321 RX3I Communication Module, I/O Link Interface Module (Master). Module is on the high speed serial bus.

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PLC-5/1771 System 1771-WHFB FUSED WIRING ARM (1.5A FUSE)

Distributed I/O 1794-OF4I ISOLATED ANALOG OUTPUT MODULE, 16 BIT, 4 POINT

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IC200MDL644 INPUT 5/12VDC POS/NEG LOGIC (4 GROUPS OF 8) 32PT

IC697PWR711*FM Power Supply, 120/240 Vac, 100 Watts, FM Approved ( *Rev. letter)

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ZA06B-0033-B075#7008 B3/3000 servo motor with 32k serial encoder

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20G11ND034AA0NNNNN PowerFlex 755 AC Packaged Drive

22F-RF026-CS PowerFlex 4M EMC Filter Kit

110XCA28202 Momentum RS232 COMM CABLE 2M (OEM)

294E-FD1P5Z-G1-3 Variable Frequency Drive

WLCA2 觸點:1開/1閉,10A 250VAC機械壽命:1500萬次?撞壓式?滾珠擺桿型

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TS 模塊 6ES7 972-0MM00-0XA0 TS Module Modem

150-F780NBA SMC Flex Smart Motor Controller

1734-IE2V POINT I/O 2 Point Analog Input Module

1783-BMS20CGPK Stratix 5700 20 Port Managed Switch

193-EMRZ24 E1 Plus 24V DC Remote Reset Solenoid

20-750-EMC1-F2 PowerFlex 750 Frame 2 EMC Kit

2090-CPWM7DF-12AA09 MP-Series 9m Power Cable

2098-DSD-020-SE Ultra 3000 2kW with SERCOS Servo Drive

G-C441 PC to GagePort Cable and Power Supply (9 Pin)

GFK-2190 QuickPanel Nema 4X Bezels Installation Guide

IC220STR002 MOTOR STARTER DIRECT, 3.7KW/400VAC

IC647EIMM EIM:Honeywell EIM 620

IC647SBM001 Scheduler Batch Module

IC693MDL634RR 24 Vdc Input, Negative/Positive Logic (8 Points)

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IC693ACC336 Auxiliary Terminal Block for the Motion Mate DSM302

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TGT-AI0V-8-0 Target series analog module with 4 inputs and 4 outputs

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20F1ANE144AA0NNNNN PowerFlex 753 AC Packaged Drive

22B-D1P4N104 PowerFlex 40- 0.4 kW (0.5 HP) AC Drive

140DDM69000 Quantum 開關量DC混合模塊,4點輸入,125VDC;4點輸出

284E-FVD4P0Z-10-DRN-DB1-SB-EMI EtherNet Variable Frequency Drive

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194R-NE160-1753 Disconnect Non-Fused IEC 3 Poles 160A

2090-CPBM7DF-16AA60 MP-Series 60m Standard Cable

2090-XXTFMP-S30 MP-Series 30 m Length Feedback Cable

CFDA-0WPB-0070-AZ "AHVi, AHVis, Bis and BHVis Series Motor Encoder Feedback Cable, Straight Connector, 7 M"

GF-3650R Connecting FlashCable to VWR Temperature Transducer.

IC200UDR005-24 Qty of 24, 28 point PLC, (16) 24VDC In, (11) Relay Out, (1) 24VDC Out, 120V/240AC Power Supply

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GFZ-65195EN Alpha SVU Series Amplifier Maintenance Manual

IC646MPMU01 Logic Developer - PLC Nano/Micro - Upgrade

MTR-1331-J-N-D-E-0 Stepping Motor Nema34, Series Wdg

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20F11NC060JA0NNNNN PowerFlex 753 AC Packaged Drive

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280S-M35F-M1 ArmorStart Three-Phase Power Media

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1492-PDE1C142 200 A Enclosed Power Distribution Block

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變送器 3RS10001CK00

1495-N86 Variable Depth Circuit Breaker Accessory

1585J-M8TBJM-8 RJ45 Ethernet Media

1761-HHM-K64 MicroLogix 1000 Handheld Memory Module

188-K3B320-N Miniature Circuit Breaker 32 A

194L-E20-1753 20A 194L Load Switch

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2090-XXNFMF-S90 Kinetix Drives 90m Standard Cable

BC647OEM0510B OEM Edge Program Add't Key - Complete

GC647PATH105 Proficy PAT - Historian. The capability is to store spectra data from the driver into the Proficy Historian. This for a single dri

IC200MDD847 Mixed 240VAC input group 8 point / isolated 2 amp relay output 8 point.

IC646NSG000 Siemens AS511 OPC Server. Supports S5 controllers through front port

IC647MBT001 Machine Edition Traditional Development Suite with USB Hardware key

IC675PDI161 Profibus Station IP67 24VDC Positive Logic 16 Inputs

IC697MDL752CA 12 Vdc Output, 0.5 Amp, Positive Logic (32 Points) Conformal Coated

IC800SSD104S1 4.3 amp 115/230 VAC S2K servo drive for S-series motors

ControlLogix/1756 System 9399-RLD300GR RSLOGIX 5000 GETTING RESULTS GUIDE

Industrial Computers 6182H-15KEH15B VVCE 1500, KEYPAD, EXT MEM, CNET, AC

Process Control 1757-DNBEXP80 DEVICENET MODULE EXPANSION, 65-80 MAX

Operator Interface 2711P-ST7K PANELVIEW PLUS 700 KEYPAD STARTER KIT

Support 9326-AD1USS SUPT RENEWAL CONTRACT FOR 9326AD1USENE

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ControlNet Products 1794-ACN15K CONFORMAL COATED, SINGLE MEDIA ADAPTER, CONTROLNET

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CBL-204 Mitsubishi FX Cable

IC640HWC306 LM 90-30/20/Micro Serial Software w/Converter & Cables, CD-ROM docs.

IC800SLCIV030 Interface Cable, 1000W SL Amplifier to Terminal Block, 3 Meters

OC647IFWOPCM iFIX Optn: WorkSpace OPC Client (M4 Part)

20AD5P0A3AYNNNG0 PowerFlex 70 AC Drive 5 A at 3 Hp 20A

20DD022A3NYNANANK PowerFlex 700S AC Drive 20D

20P41AB7P0RA0NNN PowerFlex DC Drive 230V AC 1.5 HP

2711C-K3M PanelView Comp C300 Graphic Terminal

280-PWRM24E-M1 ArmorConnect 3-PH Power Media drop cable

SRT2-OD04 遠程I/O端子（晶體管輸出）4點

1492-MCBA290 Cb, 1 In, 10 Ka Aic, 2 Pole, 90 Amp

1494V-DJ622-A-F NEMA Flange Mtd Rod Switch Disconnect Sw

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1585D-M4UBJM-80 Micro D-Code, QD Style Ethernet Media

1756-L72SK Logix 5573S Automation Controller 4M/2M

1799-D10U10BZC 20 Point Embedded I/P/Output Comb Module

194E-FA16E-PE-TN 194E Load switch

2090-CFBM7DD-CEAA02 MP-Series 2m Servo Feedback Cable

2090-SCVG50-0 Kinetix 50-50m Fiber Optic Cable

BC646MPP010 Logic Developer PLC Professional 10 pack with Proficy GlobalCare Complete

GC647APC025 GC Production Client 25 Pak

HMI-CCT-301 BACKLIGHT TUBE 10.5 inch Color STN (QPI3xxxxS2P)

IC641VPP710 VersaPro Professional Edition 10 Pack - Windows Programming Software f or Series 90-70, Series 90-30, and VersaMax PLCs

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IC660EBR101RR Electronic Assembly Normally Open

IC697ACC715 Kit, VME Integrator, J2 Backplane Mounting

IC756WRE499J-23 DataViews Runtime for Windows 100+, Per User, Japanese, Version 2.3

FlexLogix System 1794-IR8 RTD INPUT MODULE, 8 POINT

PLC-5/1771 System D6200-6.4.18DE PLC-5 STRUCTURED TEXT REL 1.0 USER MANUAL (GERMAN)

Process Control 1757-SRM SYSTEM REDUNDANCY MODULE

Operator Interface 2711P-T10C6D1 PV PLUS 1000, TOUCH, ENET, DC PS, STD MEM

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1746-RT33 SLC Terminal Block

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GC646MBT001 Proficy GlobalCare Complete for CIMPLICITY Machine Edition Traditional Development Suite

HE693ADC405 Discontinued Part. Check with GE IP on migration path.

IC600PM503RR High Capacity I/O Rack Power Supply, 115-230Vac

IC647HSTESEO1500KM eSignature Option for Historian - Enterprise Server 1,500,000 Points (M4 Key)

IC655CPU500RR Series Five CPU (with 4K Reg and I/O Rack Terminator)

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