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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：

　�、倌７罗k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。

　�、趶娭棉k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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1760-SIM Pico Training Simulator Module

188-K1C020-N Miniature Circuit Breaker 2 A

194E-A32-PE 194E Earthing-Grounding Terminal

194R-30-NN 194R30A UL 40A IEC 4th Power Pole Module

2090-CPBM7DF-10AA60 MP-Series 60m Standard Cable

2090-XXNPMP-10S90 MP-Series 90 m Length Power Cable

CBL-13-ED-20 Encoder cable for MTR-1235 or MTR-1300 or MTR-1400 or MTR-1N series stepping motors connected to IMC or S2K. 20 feet

GC647SVW001 Scheduler Desktop View Client

IC200PWR102 POWER SUPPLY WITH EXPANDED 3.3VDC 120/240VAC INPUT

IC646TBLSS150K Proficy Troubleshooter for Intelligent Historian for Hist 150000 Points

IC647NGS000 CIMPLICITY HMI SHARP TCP/IP Communications Driver

IC693ACC300 Input Simulator Module

IC698CRE040 1.8GHz CPU, Ethernet, Redundancy

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Motion Control 2090-XXNPMP-16S90 CABLE,NON-FLEX,MOTOR POWER,MP/1326AB,16 GAUGE,90M

GC646TDV915 Proficy GlobalCare Complete for Server 1500 I/O Develop/Runtime System

IC641SWP308 LM 90-30/20 ver. 4.02 for NEC 9800 Computer

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2198-H040-AP-T K5500 FR1,2 AC control conn

2711P-RAAK7 PanelView Plus 7 Series Accessory

280-PWRM35F-M30 ArmorConnect 3-PH Power Media trnk cable

CP1W-CN811 CPM1A擴展單元用IO連接電纜，80CM

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1585J-M8CBJM-60 RJ45 Ethernet Media

1756-RM2 ControlLogix Redundancy Enhanced Module

188-K1D130-N Miniature Circuit Breaker 13 A

194E-Y25M-1756-6G 25 A 194E Load switch

2090-CFBM7E7-CEAF01 1 m Length SpeedTec Extension Cable

2090-UXNFBY-S15 Y-Series 15 m Length Feedback Cable

BC646TRT000 Server Unlimited Runtime System with Proficy GlobalCare

GC647IFPLDVUNLMT GCC iFIX Plus SCADA Unlmt Dev

IC200CBL525 Series 90 SPN port, RS485 Cable to DataPanel 45/65/85

IC646MPP010 Logic Developer PLC Professional 10 pack

IC647IFPRSRUNLMTC iFIX Profsnl SCADA Unlimited Server (M1Component Part)

IC660TSD021 Terminal Assembly for IC660BBD021

IC697CPM924RR CPU, 64MHz, 12K Discrete I/O, 512K RAM (Expandable), 80486DX2

IC800PCUB00300 Powercube stepping motor power amplifier rated 12-48 VDC and 4 amp

ControlLogix/1756 System 1756-OB16D 19-30 VDC DIAGNOSTIC OUTPUT 16 PTS (36 PIN)

Industrial Computers 6182H-10BRH6D VVCE 1000, KEY/TOUCH, STD MEM, RIO/DH, DC

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Operator Interface 2711P-RBK12 PV PLUS 1250 KEYPAD REPLACEMENT BEZEL

Support 9355-WAB1CENR SUPT REINSTATEMENT CONTRACT FOR 9355WAB1CEN

Support 9351-OSFS SUPT RENEWAL CONTRACT FOR 9351OSF

ControlNet Products 1786-RPFRL CONTROLNET FIBER RING REPEATER - LONG

RSI Software Products 9301-2SE2400ESE RSVIEW32 WORKS 32K (SPANISH)

RSI Software Products 9355-WABGWEU4 UPGRADE: IN-SUPT RSLINX OEM TO RSLINX GATEWAY

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Motion Control 2090-DANPT-16S09 CABLE, NON-FLEX, MTR PWR, CABLE-MTD CONN, 16AWG, 0

BC647MQP010 View Development for QuickPanels - 10 user with Proficy GlobalCare Complete and 10 hardware keys

IC5008TAN0000 18" Intelligence Industrial PC, Standard Series WinNT

IC800MCUB12210XN Stepping Motor Cube, 100 oz-in with Pulse/Direction, NEMA 23

OC647IFESGCLNTCDVC iFIX Optn: ESig & ERec iClient Development (M1Component Part)

20AD022A3AYYAEG0 PowerFlex 70 AC Drive 22 A at 15 Hp 20A

20DC260A0EYNANCNK PowerFlex 700S AC Drive 20D

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25C-E019N104 PowerFlex 527 11kW (15Hp) AC Drive

280-PWRM22B-M1 ArmorConnect 3-PH Power Media drop cable

FX1N-485-BD RS485C 通信用適配器

1492-M5X5H11-20 Connection Products

1494H-DN3N Heavy Duty Non-Fusible Safety Switch

軟啟動器 3RW44462BC34

ET 200SP 6ES7193-6BP20-0BA0 基座單元 BU15-P16+A10+2B，類型A0，直插式端子，帶有10個AUX端子，15mm寬

1585D-M4TBDM-9 Micro D-Code, QD Style Ethernet Media

1756-ENBT ControlLogix Enet/IP Comms Module

1794-OF4IXT Flex XT 4 Point Analog Output Module

194E-CA80 194E Load switch

2090-CCMCNDS-48AA01 Comms Cable Kinetix 3 MLX to Drive 1m

2090-DANPT-16S02 TL-Series 2 m Length Power Cable

ABICTDE0000/SER 10.5 inch Color TFT/ TCP Label/ 24VDC/ with HMI-CAB-C52 & HMI-CAB-C83/ UL/ cUL/ CE/ UL1604

GC646PCMS1C GlobalCare Complete for Change Management Electronic Signature Module 100 Pack

HE697THM260 8 channel thermocouple input module for Series 90-70 with 0.1degC resol ution and resistance measurement.

IC630MDL376RR 115/230Vac Isolated Output Module (8 points)

IC647HSTSS75KM-35 Historian v3.5 Standard Server 75000 Points (M4 Key)

IC660BLD022 Cover w/Label for IC660BBD022

IC695CDEM002 RX3i type 2 demo case for Chinese market. Demo includes CPU, power supply, Ethernet, input simulator, output with ESCP, high speed counter, Universal analog and analog output modules. Demo also includes QuickPanel control/view includes thermocouple

IC756WET100E-26 Custom Editor Toolkit, English, v2.6

CompactLogix System 1769-CRR1 1FT (305 MM) RIGHT-TO-RIGHT BUS EXPANSION CABLE

PLC-5/1771 System 9399-RL53GRPT RSLOGIX 5 GETTING RESULTS GUIDE (PORTUGUESE)

Distributed I/O D1794-6.5.8 FLEX I/O ISOLATED ANALOG MOD.USER MANUAL

Operator Interface 2711P-B7C15B1 PV PLUS 700, KEY/TOUCH, CNET, AC PS, STD MEM

Support 6411-SDSCS 6411-SDSC SOFTWARE SUPPORT RENEWAL

Support 9358-PLTM2300R SUPT REINSTATEMENT CONTRACT FOR 9358PLTM2300ENE

Support F1784-KTCX15SERB FIRMWARE UPGRADE FOR 1784-KTCX15 COMMUNICATION MOD

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ABKSTDN0000/DVN 6" Color STN, TCP Label, 24Vdc, with DeviceNet, No Agency Approvals

IC300ADC010 2 channel Analog Inputs, Voltage (0-5vdc, +/-5vdc, 0-10vdc, +/-10vdc), 12 bit

IC752DPJ003RR Datapanel J+ with Advanced software, 256x64 LCD with EL backlight. Various sizes of text, bitmaps, bar graphs, real time clock. With Real Time Trends & Host Communications. Includes integrated keypad for data entry. No touch capability.

MTR-3S34-G-R-0-E-SRR Servo Motor Nema34 with Seal

ZA06B-6073-K250 Alpha i-series servo SVM amplifier spare control power fuse

20BE062A0AYNAND0 PowerFlex 700 AC Drive 62 A 60 Hp 20B

20G14NF119JA0NNNNN PowerFlex 755 AC Packaged Drive

25-RF018-CL PowerFlex 520 18.3A 480V EMC Filter Kit

2711P-RTFC PanelView Plus 400 600 Mounting Lever

FRN160G11S-4CX 232KVA 304A 160KW 3相AC380V/50Hz/60Hz

1492-JD3-B 2.5 mm Double Level Terminal Block

1492-W10-G IEC Term Blck 8x47.6x41mm Screw

軟啟動器 3RW40746BB34

CPU 模塊 6ES7 672-7AC01-0YA0 CPU 1507S，VERSION 2.0(1 個浮點授權 )，僅能在 SIMATIC IPC 上使用

153H-C85XBD-46 SMC-3 ENCLOSED COMBINATION 85A

1746-C16 SLC 50 inch Interconnect Cable

1786-CTK ControlNet Media Toolkit

193-T1AB10 0.75-1.0 A IEC Bimetallic Overload Relay

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2090-CSBM1DF-10AF15 Kinetix Cable Single DSL 2090-Series

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IC647TRT050 CIMPLICITY HMI Server 50 I/O Runtime System

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IC756MDV001K-97 DV Development - Alpha OpenVMS Addt'l User, Korean, Version 9.7

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44B295864-001 Grounding Bar, 11 Slot

IC200CHS011 I/O INTERPOSING BARRIER STYLE

IC694MDL645 INPUT MODULE 24 VDC 16 POINT POS/NEG LOGIC

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140NOM21100 Quantum MB+ 網絡適配器, 1MB, 1MB+, 單電纜

290E-FAP-G2-3 Direct Online Starter

MY3 24VDC，110VAC，220VAC，3開3閉，觸點 5A

1492-SPM2C070 MCB Supplementary Protector 7 A

軟啟動器 3RW30262BB14

電機啟動器 3VU16402LS00

150-F201NBDB SMC Flex Smart Motor Controller

1732D-IB8M8 ArmorBlock 8 Point Input Block

1771-OQ16 1771 16 Point Digital Output Module

193-ED1ED E1 Plus 5.4-27.0 A Overload Relay

199-FSMA11 Industrial Relay MOV Surge Suppressor

2090-CPWM7DF-08AA04 MP-Series 4m Standard Power Cable

2094-XL75S-C1 Kinetix 6000 Line Interface Module

DT1014 External Floppy Drive

GFK-1086 Series 90-70 Third Party VME I/O Integration Manual

IC220ACC001 MODULE LABELS NARROW, QTY 10

IC647BSP255 Batch Large Server Pak (255 Units)

IC647PRTHE025M Proficy Portal Historian Edition Client Pack 25 Users (M4 Key)

IC693CPU363RR CPU363 Module (240K Bytes configurable user memory)

IC756ADV000J-98 DV Development - AIX Op Sys, Japanese, Version 9.8

MSI-EFF-5 Efficiency Management Clients 5 Pack

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2090-CPBM7DF-10AF90 MP-Series 90 m Length Cable

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IC200TBX023 Tool box, 23 point, (IC200UAL006) DC In/Relay Out, 2 analog In, 1 anal og out, AC powered (requires AC power) provided with software, manuals and cables (IC640VPS002 and IC646MPM001)

IC646TBPAS050 Production Accounting Server 50 mass balance streams

IC647NMR000 CIMPLICITY HMI MODBUS RTU Communications Driver

IC693ACC312 Extended battery (1.45 Amp-hours) for Series 90-30 CPU memory backup. The Battery Module replaces the standard CPU RAM backup battery in your control system. Approximately 20% more capacity than the IC693ACC301. Qty of 2 batteries.

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