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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。
 

194E-FA63-P11 194E Load switch

2080-IQ4OV4 Micro800 8 Point Digital Combo (Sink)

2090-CPBM7E7-16AF07 MP-Series 7m Length Pwr and Brake Cable

20AB6P8A0AYNNNC0 PowerFlex 70 AC Drive 6.8 A at 2 Hp 20A

BC647MVSU02 View Standard Edition Upgrade from View for QuickPanel View Standard Edition with Proficy GlobalCare Complete with USB Hardware key

GC647IFGLBLCLN005M iFIX WebSpace 5 Additional Clients (GC Complete)

HMI-CAB-C49 DOWNLOAD CABLE PROG TTL TO RS232

IC600CB501RR Basic Logic Control

IC646NWV005 WebView - 5 Pack License

IC647MMPC MMP:Modicon Modbus Plus

IC676CBLPBM100 IP67 Profibus Cordset - 10 Meters - Male Connector w/Leads

IC697MSC701RR Series 90-70 Demonstration Case

IC800SSI104RS1 4.3 amp 115/230 VAC S2K servo controller for MTR series motors

SoftLogix System 1789-SLOTL SOFTLOGIX STARTER KIT DOCUMENTATION SET

Industrial Computers 6182H-15TRH6D VVCE 1500, TOUCH, STD MEM, RIO/DH, DC

Process Control 9399-RSBACLRG RSBATCH ACTIVE X CONTROLS LIBRARY REF. GUIDE

Operator Interface 2711-B5A15L2 PV550 MONO KEY&TOUCH, CNET & RS232 PRINT

Support 9303-23S0E40R SUPPORT REINSTATEMENT CONTRACT FOR 9303-23S0E40

Support 9371-EPCO3S SUPT RENEWAL CONTRACT FOR 9371EPCO3

ControlNet Products 9355-WABGWENE RSLINX GATEWAY - ENGLISH

RSI Software Products 9301-2SE2500ESU3 RSVIEW32 WORKS 300-100K UPGRADE IN-SUPT (ES)

RSI Software Products 9358-BANT60ENE RSBATCH ARCHIVER 60 UNITS

Motion Control MPL-A4530F-HK22AA MOTOR,SERVO,8.36NM,2800RPM,ENCRD,8.2KG

Motion Control 2090-UXNPBMP-14S30 CABLE,460V,NON-FLEX,MOTOR POWER,MP,14 GAUGE,30M

CBL-3C-RD-20 Resolver Cable, MTR-3S & MTR-3N Series Servo Motors, 20 Ft.

IC641CTL936 CIMPLICITY Control Developer Tooolkit

IC800SLM040N1XE25 400W, 115 VAC SL Servo Motor, Holding Brake, 2.5K Quad Encoder

OC647IPWRTS1CLN iPower Option - TS per Client

PXI-4462

ROBO-505

VisiCom VigraVision 540-7100-004

PCI-6204

PIA-662PRO

IOWA-MARK-800-128MB-R11

1492-MCEA130 30 A Ul489 Miniature Circuit Breaker

1494V-FS100 Fuse Block

軟啟動器 3RW44652BC34

運行版軟件 6AV2103-0XA00-0AL0 SIMATIC WinCC 專業版 max. PowerTags

1585J-M4EBJM-0M3 RJ45 Ethernet Media

1756-M08SEG ControlLogix Generic Motion Module

188-K1B080 Miniature Circuit Breaker 8 A

194E-FA40E-PD10 194E Load switch

2090-CFBM7DD-CEAF15 Kinetix 15m Flexible Cable

2090-U3BC-D4401 Ultra 3000 Breakout Board Cable

BC646MRA159 View Runtime 1500 I/O with Proficy GlobalCare Complete

GC647ASC001 GC PA SDK

IC200ACC003 EZ program store, CPU RS485 port update device, VersaMax CPU001,002/00 5/E05 and Series 90-30 CPU374/CPU372/CPU370

IC646APS30050 CSense Predictive Soft Sensor 50 KPI's

IC647IFPLRN00150C iFIX Plus SCADA 150 I/O Runtime (M1Component Part)

IC660MBM503 Hand-Held Monitor Panel Mount Kit

IC697ACC822 DIN Rail Transition Module 96 Pin for IC697Vxxxxx modules

IC756XRT001 Intel x86 DV Tools Runtime

FlexLogix System 1794-TBN NEMA TERMINAL BASE

GuardPLC Systems 1753-L32BBBP8A GUARDPLC 1800 - SAFETY PLC W/ PROFIBUS, 32 I/O

Process Control 1757-UPGSIFJ UPGRADE HW XLNET NETWORK NODE QUICKBUILDER I/F

Operator Interface 2711P-K12C6B2 PV PLUS 1250, KEYPAD, RIO/DH, AC PS, EXT MEM

Support 6640-NAA0R 6640-NAA0 SOFTWARE SUPPORT REINSTATEMENT

Support 1771-PCBS CONTROL COPROCESSOR SOFTWARE RENEWAL

Support F1785-L80ESERC FIRMWARE UPGRADE FOR 1785-L80E PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2350FRE RSVIEW32 WORKS 5K (FRENCH)

RSI Software Products 9701-VWSS250ENU2 RSVIEW SE 100 TO 250 DISPLAY UPGRADE

RSI Software Products 9399-WAB32LUGDE RSLINX LITE USER GUIDE (GERMAN)

Motion Control 8720MC -D065-AA- 65 AMP C CHASSIS DRIVE, ENCLOSURE, LESS OPTIONS

BC646MQPS99 Machine Edition View for Quick Panel, Unlimited Site License

IC300OCS390 OCS350 DEMO KIT WITH CASE

IC752WTD853 Display Station 2000 Series - 18.1" active matrix SXGA (1280x1024) resistive touch screen, Pentium 350 MHz, 128 MB RAM, 6.4 GB HD, expansion slots, Ethernet, with unlimited point count CIMPLICITY HMI R&D and Win 95

MTR-3T44-H-R-0-M-0RR Servo Motor Metric

PCI-6527

BBWW-HSC

IPC-6108

CN-0W808F

MES-G2+/MSDP/8B

AX2-5300FB-2S

1492-L6 IEC Term Blck 8.1x65x38mm Spr Clp

1494F-D100 Disconnect Switch

軟啟動器 3RW44342BC45

電源 6ES7 507-0RA00-0AB0 PS：60 W，額定輸入電壓 AC / DC 120 / 230 V

1585BZ-MCAP Variant 1 Metal Plug Dust Cap

1747-L552 SLC 5/05 32K Controller

1794-ACNR15 Flex Controlnet Adapter

194E-AA00E-TN-PE 194E Load switch

2071-AP8 Kinetix 3 800W Component Servo Drive

2090-CSWM1DF-14AA05 Kinetix Cable Single DSL 2090-Series

20AC2P1A0AYNANC1 PowerFlex 70 AC Drive 20A

GC646MFL001 FANUC Ladder III-C with Proficy GlobalCare Complete

HE693HHP232 Hand Held Programmer Emulation Software (and hardware)

IC600YR560RR 19 inch I/O Rack with High Capacity P/S/ 115-230Vac (11 Slots)

IC647HSTMK035 Historian Media Kit v3.5

IC660BBA021 Block 24/48Vdc RTD Input 6 Channels

IC694MDL655CA Conformal Coated Input module 24 VDC POS/NEG logic 32 points. 1msec filter. Interface is a Fujitsu connector.

IC756WDC009J-23 DV Development Sys VB, Java, C++, Japanese, Version 2.3

MicroLogix 1500/1769 System 1761-NET-AIC AIC+ ADVANCED INTERFACE CONVERTER

PLC-5/1771 System 1784-PCM6 1784-PCMK DH+COMMUNICATION CABLE(8 PIN DIN)

Distributed I/O 1797-TPYS CONTROLNET EX Y-TAP STRAIGHT

Communications DACIG-UM001BENP DEVICELOGIX USER MANUAL

Support 9321-PI160R SUPT REINSTATEMENT CONTRACT FOR 9321PI160

Support 9358-HSTCLTENS SUPT RENEWAL CONTRACT FOR 9358HSTCLTEN

Support F1772-LSP FIRMWARE UPGRADE FOR 1772-LSP PLC2 PROCESSOR MODUL

RSI Software Products 9324-RLD300FRE RSLOGIX 5000 STANDARD, FRE

RSI Software Products 9304-WVPR300DU1 UPGRADE: IN-SUPT: WINVW TO WINVW PRO RUNTIME 3000

RSI Software Products 9358-PLTM2600U2 UPGRADE: IN-SUPT: PLANTMETRICS 10 TO 200 WORKCELL

Motion Control 8720SM-075S6SAS3 75 KW/137 AMP, 750 VDC, AC MOTOR WITH SNS60 ENC.

A06B-0113-B075#7008 B0.5/3000 Servo Motor, 32K Serial Encoder

IC200UAA007 28 point; (16) AC In, (12) AC Out, AC Power Supply. Battery (IC200ACC403) is required for data retention. Battery not included.

IC752BCL001 Download cable for DataPanel 30/35/50/55 Series

MTR-1350-N-A-E-0RR Stepping Motor Nema34

NI 9207

ROCKY-538TXV-R7

MIC-3368

orbotech vint-021584-rev

威達工控機底板 PCI-6S

HAL-8063

PCI-1720U

1492-SPM3C150-N MCB Supplementary Protector 15 A

軟啟動器 3RW40471BB05

熱電阻模擬量輸入模塊 6ES7 231-5PD32-0XB0 SM 1231 AI 4 x 16 位熱電阻

150-SB3NUR SMC-50 SOLID STATE MOTOR CONTROLLER 140A

1734-RTBCJC POINT I/O Accessory

1783-MX04S Stratix 8000 4 Port SFP Exp. Module

193-ESM-IG-60A-C55 E300/E200 60 Amp Sensing Module

20-750-I1B-C750D710 PowerFlex 750 Replacement Inverter

2090-CPWM7DF-14AF60 MP-Series 60 m Length Power Cable

2098-DSD-HV150X-DN Ultra 3000 Servo Drive

GA647IFCLNTS001 GCA iFIX iClientTS Each Additional User

GP-0602NT-H GagePort LVDT NT (Half Bridge)

IC5005TAX0010 PanelPC 15 inch Standard Unit with Windows XP

IC647HSTAE300M Alarm and Events Option for Historian - Standard Server 300 Points (M4 Key)

IC647SQM001 Scheduler Sequencing Module

IC693MDL734LT 125 Vdc Output, (6 Points) (LT)

IC756HDV010E-97 DV Draw Development on HP/UX Op Sys, English, Version 9.7

Pico Controllers 1760-L12BWB-NC 12 I/O PICO CONTROLLER, DC

PLC-5/1771 System 1771-IQ SELECTABLE INPUT MODULE, 5-30V DC, 8 INPUT

Distributed I/O 1791D-8V8P DNET 24VDC CBLOCK I/O, 8 IN SOURCE 8 OUT SINK,BASE

Communications 1784-PCMK PCMCIA COMMUNICATIONS CARD

Operator Interface 2706-P74CN1 INVIEW MESSAGE DISPLAY. 1 TO 4 LINE

Support 9305-RSVADSZHR SUPT REINSTATEMENT CONTRACT FOR 9305RSVADSZH

Support 9515-RSMSVRS SUPT RENEWAL CONTRACT FOR 9515RSMSVRENE

EtherNet/IP Products 2711-T10C20L1 PV1000 COLOR TOUCH, ENET & RS232 PRINT

RSI Software Products 9301-2SE340DEU5R RSVIEW32 RUNTIME 5K-32K UPGRADE OUT-SUPT (DE)

RSI Software Products 9356-PRO2300 RSSQL PROFESSIONAL VERSION WITH 1500 TAG LIMIT

Motion Control 1326AB-B720F-M2L MOTOR,SERVO,460V,31.8NM,5000RPM,MULTI,IP67

4161-6-5-N4 BCD TO 7 SEG DISPLAY. 6 DIGIT. 5 VDC. NEMA 4

HMI-CLP-200 MOUNTING CLAMP FOR QP2 & QP3 Series ONLY - 1 Set

IC693CPU340 CPU 340 Module (32K Bytes user memory), 10K Registers, .3 msec/K

SM1000HWB QUICKMARQUEE BRACKETS SINGLE WALL OR HANGING MOUNT (SET OF 2)

PCI-7030VG

PPC-177

PILA8485

艾崴-DPX2

IPC-610 L H

PIA-650DV

60-0377-02

1492-SPM1C630 MCB Supplementary Protector 63 A

通用型變頻器 6SE6 440-2UC21-5BA1 "1.5 KW,149 x 202 x 172"

電機啟動器 3VU13402MP00

150-C25NBD SMC-3 25A Smart Motor Controller

1609-BRK Bul 1609 UPS 2 Screw Mounting Bracket

1770-XF DATA HIGHWAY TERMINATOR SET

193-EC1DD E3 9-45 A Overload Relay

195-GA01 Auxiliary Contact

2090-CPBM7E7-10AF15 MP-Series 15 m Length Cable

2093-AMP2 Kinetix 2000 Axis Module

CP8B-1WEB-0070-AZ Shielded motor power cable for B0.4is/B0.5is/B1is motors (elbow connector). 7 meters

GF-AU5V Connecting FlashCable to Analog Unipolar +5 V (No connector).

IC200UEX122 14 point Exp (8) 24VDC In, (6)24V DC Out with ESCP, 24VDC Power Supply (includes IC200CBL501)

IC647AEC025 PA Efficiency Client 25 Pak

IC647PCMS01 Proficy Change Management Electronic Signature Option - 1 Concurrent User

IC693CBL333 Cable, Left Side, Two - 24 Pin 90 Degree Connectors, .5 Meter

IC754CBL06CTD 6 inch TFT QuickPanel Control/ Loaded/ Blank Label/ 24VDC

IMC-78005702RR IMC Controller, Spec Order

SLC/1746 System D1746-6.16 SLC 500 THERMOCOUPLE/MV ISOLATED INPUT MOD.USR MNL

Distributed I/O 1732D-OB8EM12 DEVICENET 24VDC 8 0.5A OUTPUT W/M12

Application-specific products 1404-M805B-CNT 1404-M8 CONTROLNET PM3000 24V P.S.

Operator Interface 2711-T10C10L1 PV1000 COLOR TOUCH, DNET & RS232 PRINT

Support 9301-2SE3400FRR SUPT REINSTATEMENT CONTRACT FOR 93012SE3400FR

Support 9381-P5KENS SUPT RENEWAL CONTRACT FOR 9381P5KEN

DeviceNet Products 1790-T0V16X LDX I/O, 24VDC, 16 SINK OUT EXPANSION, TERM BLK

RSI Software Products 9301-2SE3300U2 RSVIEW RUNTIME 150 TO 1500 UPGRADE: IN-SUPPORT

RSI Software Products 9358-GTSSEE GTS - GAGE TRACKING AND CALIBRATION SYSTEM

Motion Control MPL-B520K-SJ22AA MOTOR,SERVO,10.7 NM,4000RPM,SINGL,460V,11.3KG

Motion Control 9101-1477 MATING CONNECTOR KIT/J2 20 PIN MINI D(SOLDER CUP)

GQPK2D100L2P QUICKPANEL MONO 6" LCD GE LABEL

IC646MRD159 Logic PC (HRT) 1500 Tag Runtime System

MTR-3T23-G-R-B-M-S MTR-Series Servo Motor, Resolver, Metric, 24V Brake, Seal

SNAP 4C5 PC Port is 25-pin male and port on CNC is 25-pin female. This is for hardware handshake communications.

PXIe-8510/2

PCI-I4DA

AIMB-782

PEAK-703P(LF)

LDI200-PCI

686LCD/MG

1492-RAFB4250 IEC Term Blck 10 x 110 x 44.8mm Spr Clp

存儲卡 6ES7952-0AF00-0AA0 RAM/64K

變送器 3RS11011CK20

1497-E-M4-0-N Control Circuit Transformer

1606-XL480F Power Supply XL 480 W Power Supply

1762-L40AWA MicroLogix 1200 40 Point Controller

188-K3C630 Miniature Circuit Breaker 63 A

194L-HC4A-175 194L Control and Load Switch Actuator

2090-CPBM7DF-06AA02 MP-Series 2m Power and Brake Cable

2090-XXNPMF-10S04 MP-Series 4 m Length Pwr and Brake Cable

BC647SPR0X0 "Solution Provider Renewal > 30 keys includes key flashes which could be M4 or M1, Global Care Complete (iGC SP1)

GC647PRTEE005 GlobalCare Complete - Proficy Portal Enterprise Edition Client Pack 5 Users Ver 3.0

IC200MDL644LT INPUT 5/12VDC POS/NEG LOGIC (4 GROUPS OF 8) 32PT (LT)

IC646PCMS10 Proficy Change Management Electronic Signature Module 10 Pack

IC647MPS010 Logic Developer PLC Standard 10 Pack with USB Hardware key

IC676PBI016 IP67 Input Block - 24 VDC Positive Logic - 16 Pt - Profibus

IC697PWR720 Replacement Power Supply Adaptor

IC800SSI107RS1 7.2 amp 115/230 VAC S2K servo controller for MTR series motors

SLC/1746 System 1747-L30A 30 I/O FIXED HARDWARE STYLE

Industrial Computers 6189-RPEH VVCE LOGIC MODULE, 256MB FLASH, 256MB RAM

Process Control 9399-SAPRG RSBATCH SERVER API REFERENCE GUIDE

Operator Interface 2711-B5A3L1 PV550 MONO KEY&TOUCH, DH485 & RS232 PRINT

Support 9303-3CS0E20S SUPP RENEWAL CNTRCT FOR 9303-3CS0E20

Support 9371-RSWDI1R SUPT REINSTATEMENT CONTRACT FOR 9371RSWDI1

ControlNet Products 2706-P74CN2 INVIEW MESSAGE DISPLAY. 1 TO 4 LINE

RSI Software Products 9301-2SE2500ITU4 RSVIEW32 WORKS 150-100K UPGRADE IN-SUPT (IT)

RSI Software Products 9358-BBKEY10U1R UPGRADE: OUT-SUPT: RSBW BACK-UP KEY 03 TO 10

Motion Control MPL-A4530K-HK24AA MOTOR,SERVO,8.36NM,4000RPM,ENCDR,230V,BRK,11KG

Motion Control 2090-UXPC-D0909 CABLE,9/9 POS,45 DEG D/STRAIGHT D,9M

CBL-3T-RD-30 Resolver Cable for MTR-3T Series Servo Motors, 30 Ft.

IC641HBR302 Max-ON "Extended" Software for 90-30 Hot Stand By Redundancy

IC800SLMCONKITV Connector Kit, 1 kW to 2.5 kW S-Series Servo Motors without Brake

OC647TSSTDB000 Proficy Troubleshooter Connector: Tabular Database Read & Write

PXI-5402

PCE-5B13-08

PDSLA 945G

DSA628/328

IPC-6105P4

SYS7180CVE

1492-MCS5X10 IEC 5 x 10 mm Marker Card