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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。
 

2098-DSD-HV100-SE Ultra 3000 10kW with SERCOS Servo Drive

ET-GT-5ES-5ST 3 RJ45 Ports, 2 Singlemode Fiber Port Ethernet Switch

GFK-0263 Logicmaster 90-70 Programming Software User's Manual

IC200MDL240LT INPUT 120VAC (2 GROUPS OF 8) 16PT (LT)

IC600CB537RR Communications Control Module Type 3

IC647HSTESEO20000KM eSignature Option for Historian - Enterprise Server 20,000,000 Points (M4 Key)

IC660BPM500 Hand-Held Monitor Battery Pack

IC697MDL653 24 Vdc Input, Positive/Negative Logic (32 Points)

IC756LDV010E-98 DV Draw Development on Intel/Linux RedHat Op Sys, English, Version 9.8

MicroLogix 1000/1761 System 1761-L10BWA 10 I/O MICROLOGIX 1000

PLC-5/1771 System 1771-OWN SELECTABLE CONTACT OUTPUT MODULE 32 POINT

Distributed I/O 1791-N4C2 BLOCK I/O, 120V AC, 6 POINT ANALOG MODULE

Communications 1786-FSB500 200 MICRON BULK CABLE 500 METERS (1640 FT)

Operator Interface 9399-RSVADSGR RSVIEW32 ACTIVE DISPLAY SYS GETTING RESULTS GUIDE

Support 9356-PRO2350R SUPT REINSTATEMENT CONTRACT FOR 9356PRO2350

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Motion Control N-3412-2-H04AA SERV MTR,1.6NM,6000RPM,2000 LN ENCDR,BRK

44A731202-G03 Upgrade Kit Genius IC660BBA103

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IC693PWR321 Power Supply, 120/240 Vac, 125 Vdc, Standard

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cDAQ-9188XT

MEIDEN IZ48Z

ACL-7130

AIMB-212

AIMB-767

ISO-350PP

3G8F7-DRM21-E

1492-SPM2B005 MCB Supplementary Protector 0.5 A

變頻器選件 6SE6 400-1PB00-0AA0 Profibus 通訊模塊

電機啟動器 3VU16400MM00

150-CC25 SMC-3 Accessory

1715-IB16D 1715 16 Point Digital Input Module

1771-IXHR 1771 8 Point Input Module

193-EC4EE E3 Plus 18-90 A Current Relay

198-WT2 ModCenter IEC Wiring Kit

2090-CPWM4DF-16AF09 MP-Series 9m Power Cable

2094-BL75S Kinetix Line Interface Module

DEMOCD00014 Proficy Shop Floor SPC - DEMO CD

GFK-0777 Analog-100 Brushless Servo Amplifier Instruction Manual

IC210DAR010 AC (85 to 264VAC) Power Source, 6 AC in/4out (Relay 8 Amp), Expandable, with LCD/Keypad

IC647ASC010 PA SDK 10 Pak

IC647PPSOF3 Proficy Process Systems Operator Console with iFIX - 3 Pak

IC693CPU313 5-Slot Base With Turbo CPU in base (.6 msec), 1K Registers, (12K Bytes User Program) Battery included

IC754VGI06SKD View Interm 6In STN Keypad DC GEF Ovrlay

MSI-DASHBOARD Dashboard Client

SLC/1746 System 1746-R15 REPLACEMENT RETAINER CLIP FOR MODULES

Distributed I/O 1734-OW4 24V DC COIL N.O. DPST 4 RELAY MODULE

Application-specific products 1803-EEM21E4 EEM,32 PULSES,24V DC,8 ANALOG,4 TO 20 MA, NEMA 4

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DeviceNet Products 1791D-0B16PX 24 VDC BLOCK I/O EXPANSION, 16 OUT SOURCE, RTB

RSI Software Products 9301-2SE3350FRU1 RSVIEW32 RUNTIME 150-5K UPGRADE IN-SUPT (FR)

RSI Software Products 9358-PBVNT01ENE RSBATCH NT FOR PLX BATCH VIEW ADDITIONAL CLIENTS

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HE660CGM424 Genius "C" Prog. Co-processor with RS-232 and RS-422/485 ports

IC646TPD075 Pro Server 75 I/O Point Development and Run Time System

QDA-EDT-SITE QuickDesigner Site License

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1606-XLP15B Power Supply XLP 15 W Power Supply

1764-RPLTB1 MicroLogix Replacement Part

188-K4B320 Miniature Circuit Breaker 32 A

194L-HE6G-175 194L Control and Load Switch Actuator

2090-CPBM7DF-08AF90 90 m Length SpeedTec Flexible Cable

2090-XXNPMF-16S90 Kinetix Drives 90m Standard Cable

CB4N-0WPM-0070-AZ AHVi and AHVis Motor Brake Power Cable with Straight Connector, 7 M

GC647SJM001 GCScheduler Project Module

IC200PNS001 PROFINET Scanner (PNS) module interfaces a remote node of VersaMax modules to a PROFINET IO Controller. Two 10/100 Mbps copper interfaces. Requires Proficy Machine Edition 7.0

IC646TBLCLT010 Proficy Troubleshooter for Intelligent Historian Standard, Enterprise and Corporate Clients Access 10 Users

IC647NDF000 CIMPLICITY HMI AB DF1 COMM Driver

IC690CDR002 InfoLink CD-ROM Documentation, single-user license

IC698CHS009 RX7i 9 Slot Rear Mount Rack

IC800VMA102 1 kW VersaMotion servo amplifier

SLC/1746 System 1746-IA4 AC INPUT MODULE FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6181P-2P2KH VERSAVIEW 1200P NON DISPLAY COMPUTER 2 SLOT

Application-specific products 9358-PBPCNT10ENE RSBATCH NT FOR PROCESLGIX PC BASED PHASES 10 UNITS

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Support 9500-CPAKSENR SUPT REINSTATEMENT CONTRACT FOR 9500CPAKSEN

ControlNet Products 9904-HYBS CONTROLNET SINGLE CHANNEL HYBRID (BOX OF 90)

RSI Software Products 9301-2SE2503KOE RSVIEW32 WORKS 100K WITH RSLINX (KOREAN)

RSI Software Products 9358-BEPNT60U2R UPGRADE: OUT-SUPT: EPROCEDURE FOR NT 10 TO 60

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GC646MDB159 Proficy GlobalCare Complete for Logic Developer PC w/Runtime 1,500 I/O""

IC641SWM713 LM 90-70 S/W, TCP/IP Ethernet, 3.5"/5.25" disks + paper docs.

IC800SSI407RD2 7.2A, 480V, DeviceNet S2K Servo Controller for MTR Series Motors

PSPC-DC/E Prof Shop Floor SPC DC 1 User w/ eSig

PXI-6528

FSP300-60ATV

DeKTec Digital Video B.V DTA-107

Advanet Adpci1551

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1756-PB75R ControlLogix DC Redundant Power Supply

188-K1D020 Miniature Circuit Breaker 2 A

194E-Y16-1753-4G 16 A 194E Load switch

2090-CFBM7DF-CEAF90 90 m Length SpeedTec Flexible Cable

2090-UXNFBMP-S20 MP-Series 20 m Length Feedback Cable

BC646TPD075 ProServer 75 I/O Develop/Runtime Systems with Proficy GlobalCare

GC647IFESGSR00150 GCC iFIX Optn: ESig & ERec 150 I/O Srv

IC200BEM103 PLC network communications DeviceNet master

IC646MODEV Motion Developer for S2K Series Amplifiers/Controllers

IC647IFPRRNUNLMTM iFIX Profsnl SCADA Unlimited Runtime (M4 Part)

IC660TBD024 Terminal Assembly for IC660BBD024

IC697CMM712RR Serial Communications Module for State Logic

IC800MCUB12160XNRR Stepping MotorCube 50 oz-in, Pulse/Direction

ControlLogix/1756 System 1756-IC16 30-60 VDC INPUT 16 PTS (20 PIN)

Industrial Computers 6182H-7TRH6B VVCE 700, TOUCH, STD MEM, RIO/DH, AC

Process Control 9358-PBNT60ENE RSBATCH NT FOR PROCESSLOGIX 60 UNITS

Operator Interface 2711P-RAK6 CUTOUT ADAPTER TO MOUNT PV PLUS 600 KEYPAD

Support 9352-WPM200R SUPT REINSTATEMENT CONTRACT FOR 9352WPM200

Support 9351-AIXRTS SUPT RENEWAL CONTRACT FOR 9351AIXRT

ControlNet Products 1786-TPS CONTROLNET T-TAP/STRAIGHT

RSI Software Products 9301-2SE235KOU2R RSVIEW32 WORKS 300-5K UPGRADE OUT-SUPT (KO)

RSI Software Products 9355-WABESE RSLINX PRO - SPANISH

Motion Control MPL-A310P-HJ22AA MOTOR,SERVO,1.58NM,5000RPM,ENCDR,230V,3.0KG

Motion Control 2090-DANFCT-S05 CABLE, NF, MTR FBACK FOR CABLE-MTD CONN, T, 05M

BC647MOP001 Logic Developer PC with View - Development ONLY Supports up to 8000 I/O tags and with Proficy GlobalCare Complete and a hardware key

IC5002TAW2000 Discontinued - Order a BC5002TAW0000 & Appropriate CIM PE Software

IC800CBL066 Use IC800CBL069 for New Applications: AC12/2000 Motor Power Cable, 14 Meters

OC647HSTSCADA2500 Proficy Historian for SCADA 2500 pts

PCIe-6509

MSC-242

PS-7270F

PCI-1753E-B

IPC-622

AC6111

1492-M5X12 IEC 5 x 12 mm Marker Card

1494H-BN3N Heavy Duty Non-Fus Safety Discon Switch

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ET 200SP 6ES7136-6BA00-0CA0 故障安全型模塊F-DI 8x24VDC 高性能型，基座單元類型A0

1585D-M4TBDM-15 Micro D-Code, QD Style Ethernet Media

1756-CPR2 ControlLogix Redundant Supply Cable

1794-OA8I Flex 8 Point Digital Output Module

194E-CA32E-TN-PE 194E Load switch

2085-IA8 Micro800 8 Point 120 VAC Input Module

2090-DANBT-18S04 TL-Series 4 m Length Brake Cable

20AC5P0C0NYNANC0 PowerFlex 70 AC Drive 5 A at 2.2 kW 20A

GC646MVD000 Global Care for View OPC Driver License and Software Key

HE693THM449 4 ch. J, K, N, T, E, R, S, 0.5 deg C resolution, deg C/deg F units, open circuit alarms

IC630MDL304RR 24Vdc Sink Input/Output Module (16 In/16 Out)

IC647HSTSS3KM Historian Standard Server 2500 Points (M4 Key)

IC660BLA023 Cover w/Label for IC660BBA023

IC695ALG616CA Conformal Coated Analog Input Module,16 channel voltage/current.

IC756WDV009E-25 DV Dev Sys VB, English v2.5

CompactLogix System 1769-IT6 6 CHANNEL THERMOCOUPLE/MILLIVOLT INPUT MODULE

PLC-5/1771 System 9399-FW5FBGRDE RSLGX FRAMWKS FUNCTION BLDR GET'G RESULT GUID(GERM

Distributed I/O 1799-MP32 PLASTIC MOUNTING PLATE/4 SCREWS-32 PT BOARD

Operator Interface 2711P-T6C5A PV PLUS 600 COLOR, TOUCH, RS232, AC PS

Support 9342-L2200S SUPT RENEWAL CONTRACT FOR 9342L2200

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Support F1779-KFMSERB FIRMWARE UPGRADE FOR 1779-KFM COMMUNICATION MODULE

RSI Software Products 9301-2SE2103ESE RSVIEW32 WORKS 150 WITH RSLINX (SPANISH)

RSI Software Products 9701-VWMR075DEU2 RSVIEW ME STATION RT 30 TO 75 DISP UPGRADE(GERMAN)

RSI Software Products 9399-2SE32GRDE RSVIEW32 GETTING RESULTS GUIDE (GERMAN)

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ABI31200C2P/ABR QUICKPANEL 10.5" TFT W/AB RIO

IC200USB001 VersaMax Micro 64, RS-232 communications option board with (2) 0 - 10VDCanalog input channels built-in. The option board also supports program storage memory module. Compatible with VersaMax Micro 64 only.

IC752DNMU11 DeviceNet Master/Scanner for ControlStation CE Iix

MTR-3S32-G-R-0-E-ERR Servo Motor Nema34 Flg Explosion-Proof

NI 9501

JUKI-3711P

ADAM-4572

NCCH-DL 875P 604

FSC-1612V2N

Equinox SST-16P 910277-001/F

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1492-SPM3D630 MCB Supplementary Protector 63 A

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152H-C201XBD-52 SMC-3 Enclosed Motor Starter

1738-OB8EM23 ArmorPoint 8 Point Output Module

1785-ACC5LB PLC-5 Accessory Kit

193-NREEHZ E1 Plus Replacement Overload Relay

20-COMM-B PF ARCH. CLASS BACNET/MSTP ADAPTER

2090-CSBM1DE-18AA09 Kinetix Cable Single DSL 2090-Series

20AB9P6C3AYNANC0 PowerFlex 70 AC Drive 9.6 A at 3 Hp 20A

GA647IFPRSRUNLMT GCA iFIX Profsnl SCADA Unlmt Srv

GP647IFPLDV00150 GCP iFIX Plus SCADA 150 I/O Dev

IC600BF914RR Reed Relay Output Module (6 points)

IC647HSTCR2000KM Collector Redundancy Option for Historian - Standard Server 2,000,000 Points (M4 Key)

IC647TPD915 CIMPLICITY HMI ProServer 1500 I/O Development & Runtime System

IC693PCM311 Prog. Coproc. Mdl., 640 KB (190 KB Basic Prgm), w/Port Exp. Cbl.

IC756MDV000E-99 DV Development - Alpha OpenVMS Op Sys, English, Version 9.9

MicroLogix 1000/1761 System 1761-L32BBB 32 I/O MICROLOGIX 1000

PLC-5/1771 System 1771-IR RTD INPUT MODULE, 3-WIRE RTD'S

Distributed I/O 1792D-4BVT4D 4 SINK/SOURCE INPUTS, 4 SOURCING 0.5 AMP OUTPUTS

Communications 1787-DNPS DEVICENET CLASS II 24VDC POWER SUPPLY

Operator Interface D6190-6.5.18 CONTROLVIEW BATCH MANAGEMENT SW(6190-BAT)MANUAL

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44A735709-003 Failure Analysis - PowerMotion

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IC694ALG442 ANALOG COMBINATION MODULE CURRENT VOLTAGE 4 INPUT 2 OUTPUT

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PCM-9577F

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電機啟動器 3VU16401MP00

150-F108NBR SMC Flex Smart Motor Controller