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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)，并對現(xiàn)場經(jīng)常出現(xiàn)的設(shè)備、調(diào)試相關(guān)問題，提出評論定見和解決計(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、對體系工藝流程，特別是工藝對各生產(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)號表(包含內(nèi)部線圈一覽表，I/O所在位置，對應(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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IC300TIU201 Graphical Operator Control Station Two serial ports, (1) RS-232 and (1) RS-485/RS-232 port, (1) CAN port, 3 meg of screen memory. (4) SmartStack support. No controller support.

IC754VSI10MTD 10" Monochrome Quickpanel View Intermediate, Touch, 24VDC

MTR-3T66-H-R-B-M-0RR Servo Motor Metric 24V Brake

20AD011A3AYNAEG1 PowerFlex 70 AC Drive 11 A at 7.5 Hp 20A

20DC043A0EYNANANK PowerFlex 700S AC Drive 20D

20G1ANC367AA0NNNNN PowerFlex 755 AC Packaged Drive

25C-A4P8N114 PowerFlex 527 0.75kW (1Hp) AC Drive

280-MTR22-LC ArmorStart Three-Phase Power Media

FR-F740-S75K 110 KVA 144A 75KW 3相AC380V/50Hz/60Hz

1492-LMJ3 IEC Mini Rail 5.1x35x23.7mm Spr Clp

1494G-DF3N-421 NEMA 1494G Enclosed Disconnect

軟啟動(dòng)器 3RW44432BC44

ET 200SP 6ES7132-6HD00-0BB1 RQ 4x120VDC-230VAC/5A 繼電器輸出，常開觸點(diǎn)， 標(biāo)準(zhǔn)型，基座單元類型 B0、B1

1585D-F4DC-SH Ethernet Media

1756-A13K ControlLogix 13 Slots Chassis

1794-IF4I Flex 4 Point Analog Input Module

194E-AA80E-P11 194E Load switch

2080-LC50-24QBB Micro850 24 I/O EtherNet/IP Controller

2090-CSWM1DF-18AA12 Kinetix 12m Smartlink Single Cable

20AC3P5C0AYNANC0 PowerFlex 70 AC Drive 20A

GC646MRA150 Proficy GlobalCare Complete for View Runtime 150 I/O

HE693SER300 Discontinued Part. Check with GE IP on migration path.

IC610MDL116RR Analog Input Module, 4-20mA/1-5Vdc (4 channels)

IC647HSTSS100M-35 Historian v3.5 Standard Server 100 Points (M4 Key)

IC660BBD025 Block 5/12/24Vdc Sink I/O Block 32 Circuits

IC694TBS132 Spring clamp style High Density Terminal Block with extended depth for l arge wires - 36 Connections

IC756WDN009K-99 DV Development Sys VB, Java, C++, C, Korean, Version 9.9

CompactLogix System 1769-ADN 1769 COMPACT I/O DEVICENET ADAPTER

PLC-5/1771 System 1771-PS7K CONFORMALLY COATED, MULTIVOLTAGE 1771 RACK PWR SPL

Distributed I/O 1798-BP6 FLEXARMOR 6 SLOT BASE PLATE

Operator Interface 2711P-K6C3A PV PLUS 600 COLOR, KEYPAD, DH485, AC PS

Support 9323-PLC5S SUPT RENEWAL CONTRACT FOR 9323PLC5

Support F1775-L1SERB FIRMWARE UPGRADE FOR 1775-L1 PLC3 PROCESSOR MODULE

RSI Software Products 9324-RLD700NXPTE RSLOGIX 5000 PRO EDITION, PORTUGUESE

RSI Software Products 9305-RSVADSESE RSVIEW32 ACTIVE DISPLAY SERVER (SPANISH)

RSI Software Products 9322-ECCBENE ENTERPRISE CONTROLS CONTROL BUNDLE

Motion Control 2094-PR8 POWER RAIL, 230V OR 460V, 8 AXIS

A06B-6089-H106 Alpha Series SVU1-130 Amplifier

IC200UEX012-24 Qty of 24, 14 point expansion. (8) 24VDC In, (6) Relay Out, 24VDC Power Supply (includes IC200CBL501)

IC752CBT073RR Datapanel 320T CEG w/ Advanced s/w: 320x240 1/4 VGA Passive Color with 80386SX/40 PC processor. Analog touch screen with text, bitmaps, bar graphs, real time clock. With Real Time Trends & Host Communications. With 2Meg & Genius PC/104.

MTR-35005685 Custom modified MTR series NEMA 34 stepping motor

ZA06B-0143-B175#7008 A12/3000 servo motor with brake and 64k serial encoder

20BD600N3ANNNNC0 PowerFlex 700 AC Drive 600 A 500 Hp 20B

20G14NC140JN0NNNNN PowerFlex 755 AC Packaged Drive

25-PM1-E1P7 PowerFlex 520 0.75kW (1Hp) Power Module

OFSCSPBLU Quantum OFS LARGE SUBSCRIPTION RENEWAL

FVR0.75E11S-4JE 1. 9KVA 2.5A 0.75KW 3相AC380V/50Hz/60Hz

1492-J3-W 2.5 square mm Standard Terminal Block

1492-SPM3D080 MCB Supplementary Protector 8 A

軟啟動(dòng)器 3RW40382BB04

SIMATIC HMI 系列面板 "6AV2124-0GC01-0AX0

150-SM3 SMC-50 Analog I/O Module

1738-EXT3 ArmorPoint Bus Extension

1784-CF128 ControlLogix CompactFlash Card

193-KB16 1.1-1.6 A IEC Bimetallic Overload Relay

20-750-PBAY-LBRK-4 POWERFLEX 750 KIT,L BUSBAR,CU,4 HOLE

2090-CPWM7DF-16AF75 MP-Series 75 m Length Power Cable

20AB042C0AYNANC0 PowerFlex 70 AC Drive 42 A at 15 Hp 20A

GA647IFPLRN00300 GCA iFIX Plus SCADA 300 I/O Run

GP647IFCLNTSRO025 GCP iFIX iClientTS Read Only 50 PK Runtime Version

IC600BF819RR Type R Thermocouple Input Module (8 points)

IC647HSTCC5KM Calculation Collector for Historian - Standard Server 5000 Points (M4 Key)

IC647TDV700 CIMPLICITY HMI Server 700 I/O Development & Runtime System

IC693MDL940 Relay Output, 2 Amp (16 Points)

IC756LDV001J-99 DV Development - Intel/Linux RedHat Addt'l User, Japanese, Version 9.9