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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)p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：

　?、倌７罗k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。

　?、趶?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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1769-SDN CompactLogix DeviceNet Scanner Module

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194E-HE8N-175 194E Load Switch Actuator

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2090-CPWM7DF-16AF07 MP-Series 7m Length Power Cable

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GFK-1535 Manual VersaMax Genius Network Communications

IC220ALG321 ANALOG OUT, 16 BIT, VOLTAGE, 1CH (REQUIRES 1 IC220TBK061)

IC647CSAS00 SAIC CIMPLICITY Server Site License (For SAIC Only)

IC647PRTPRFYM Proficy Portal SQL Connector for use with other Proficy products (M4 Key)

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194R-HM4 194R 100-400-625 A Operating Handle

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Industrial Computers 6189V-CDRW CD DRIVE WRITEABLE

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PLC-5/1771 System D1771-6.5.77 THERMOCOUPLE/MILLIVOLT INPUT MODULE(1771-IXE/B)MNL

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IC752MNL000 Mature. Datapanel Perbance Series Operator's Manual

MTR-3S46-H-R-B-E-SRR Servo Motor 24V Brake, Seal

ZA06B-6114-K200#E Encoder connector for BM0.5 or BM1 servo motor

20BP260A0ANNANC0 PowerFlex 700 AC Drive 20B

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25A-B048N104 PowerFlex 523 11kW (15Hp) AC Drive

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156-B32CB3 32 A Contactor

1746-N3 SLC Mating Connector

1786-TPYS ControlNet Coaxial Straight Y-Tap

193-T1DC60 45-60 A IEC Bibllic Overload Relay

20-IP20DR-600 PowerFlex 700H/S Door Kit

2090-CSBM1DF-14AF07 Kinetix Cable Single DSL 2090-Series

20AC022A3AYNANC0 PowerFlex 70 AC Drive 22 A at 11 kW 20A

GA647TRT915 Proficy GlobalCare Assist for CIMPLICITY HMI Server 1500 I/O Runtime System

GPA-602-F LVDT Expansion Unit (Full Bridge), includes G-0602 connecting cable.

IC600CM548RR 8K CMOS Logic Memory Module (for use in Model 600 or 6000)

IC647HSTCSEO1500KM eSignature Option for Historian - Enterprise Corporate Server 1,500,000 Points (M4 Key)

IC647WFL001 Proficy Workflow - 1 User License

IC694ACC300 Input simulator module, 16 points.

IC756RDV001K-98 DV Development - Irix Op Sys Addt'l User, Korean, Version 9.8

MicroLogix 1200 System 1762-L40BXB MICROLOGIX 1200, 40 PT.

PLC-5/1771 System 1771-LC4B LOOP CONTROLLER W/RTD OPTION,240V AC SUPPLY

Distributed I/O 1794-IM8 220V AC INPUT MOD, 8 PT.

Communications 9355-WABOEMFRE RSLINX OEM - FRENCH

Operator Interface D6195-6.5.3DE CONTROLVIEW BUILDER SOFTWARE USER MANUAL (GERMAN)

Support 9358-BEPB60S SUPT RENEWAL CONTRACT FOR 9358BEPBNT60ENE

Support F1770-KF2SERB FIRMWARE UPGRADE FOR 1770-KF2 COMMUNICATION MODULE

RSI Software Products 9324-RL0300NXENE RSLOGIX 500 STANDARD; RSNETWORX FOR CONTROLNET

RSI Software Products 9301-2SE350DEU1R RSVIEW32 RUNTIME 32K-100K UPGRADE OUT-SUPT (DE)

RSI Software Products 9358-HSTS2300U2 UPGRADE: IN-SUPT: HISTORIAN 300 TO 1500 TAG

Motion Control W-4030-P-H00AA MOTOR,SERVO,WASHDOWN,AF,2.8 NM,3000RPM,12.0KG

601 Numeric Keypad, Flat Membrane keys. NEMA 4

IC200MDD840LT MIXED 24VDC POS LOG INPUT GRP 20PT / OUTPUT RELAY 2.0A PER PT GRP 12PT (LT)

IC695PSD040 Power supply 24VDC 40 watts occupies one slot on system base

MTR-1220-E-D-E-0 MTR series NEMA 23 stepping motor with series winding connection and encoder

VSPCSE-SF50 VisualSPC SE ShopFloor includes Attribute Data Collection, Measurement Systems Analysis and A-681 interface cable. 50 license pack.

20BD077A0ANNAND0 PowerFlex 700 AC Drive 77 A 60 Hp 20B

20G11NC011JA0NNNNN PowerFlex 755 AC Packaged Drive

22F-A8P0N113 PowerFlex 4M- 1.5 kW (2 HP) AC Drive

990NAD21110 Quantum MB+ 站電纜,2.4M

291E-FBZ-G1 Direct Online Reversing Starte

PF113A-E 導(dǎo)軌安裝型，MK3P-I

1492-SPM2D300 MCB Supplementary Protector 30 A

軟啟動(dòng)器 3RW30472BB14

電機(jī)啟動(dòng)器 3VU16401CN00

150-F361NBDB SMC Flex Smart Motor Controller

1732E-OB16M12 ArmorBlock 16 Point Output

1771-WD FIELD WIRING ARM, 12 TRMLS, TIN PLATED

193-EELZ E1 Plus 100-500 A Overload Relay

20-750-APS PowerFlex 750 Auxillary Power Supply

2090-CPWM7DF-10AA05 MP-Series 5m Servo Power Cable

2097-V32PR2 Kinetix 300 Servo Drive

ET-GT-3ES-2ST 2 RJ45 Ports, 1 Multimode Fiber Port Ethernet Switch

GFK-1911 VersaPoint Profibus NIU User's Manual

IC220MDD841 ABSOLUTE ENCODER INPUT, 4IN/4OUT 24VDC (REQUIRES 1 IC220TBK202)

IC647CSPR050 Proficy Cause+ for Inbligent HMI/SCADA Runtime Server - 50X monitored KPIs

IC647PSF050 Proficy Process Systems 500 I/O with iFIX

IC693MDL231RR 240 Vac Isolated Input (8 Points)

IC756CDV000J-98 DV Development - Compaq True64 Op Sys, Japanese, Version 9.8

MSI-MGMT-50 Production Management Clients 50 Pack

PLC-5/1771 System 1785-L40E ETHERNET/IP PLC-5/40 CONTROLLER, 48K WORD SRAM

Distributed I/O 1738-ADN18 DEVICENET ADAPTER WITH MINI CONNECTORS

Communications 1787-USADPTR U.S. P/S ADAPTER FOR 1770-KFD

Operator Interface 2711-NR5K CUTOUT ADAPTER TO MOUNT 1000/1000E/6182 12" KEYPAD

Support 9304-WVD256S SUPT RENEWAL CONTRACT FOR 9304WVD256

Support 9324-RLD25U6ESE RSLOGIX 5000 LITE SPANISH TO FULL UPGRADE

DeviceNet Products 2711-K5A10L1 PV550 MONOCHROME KEY, DNET & RS232 PRINT

RSI Software Products 9301-2SE335PTU1R RSVIEW32 RUNTIME 150-5K UPGRADE OUT-SUPT (PT)

RSI Software Products 9371-EDESI1U5R UPGRADE: OUT-SUPT: RSWIRE DET IEC/ACAD TO DES IEC

Motion Control MPG-B025-031M24 MOTOR,SERVO,GEAR RATIO 31,100NM,156RPM,MULTI,BRK

Silver Series 2711-T14C10 PV1400 COLOR TOUCH, DNET & RS232 PRINT

HE693STP104 One axis stepper bing module for Series 90-30 with Normally Closed Limit Inputs

IC670MDL240 120VAC Input 16 Pt. Grouped

QPJ2D100L2P QUICKPANEL JR. MONO 5" LCD

ST-7408 STXi Potential Distribution module for Shield module, with module ID type with LED

20BC2P1A0AYNANA0 PowerFlex 700 AC Drive 20B

20F1ANC302JA0NNNNN PowerFlex 753 AC Packaged Drive

22B-B033N104 PowerFlex 40- 7.5 kW (10 HP) AC Drive

140DAO84210C Quantum 開關(guān)量AC輸出,16點(diǎn),110-230VAC,隔離,4組

284D-FVD6P0Z-25-CR-3-DB-SB-EMI DeviceNet Variable Frequency Drive