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　PLC控制系统的设备与调试，触及到各项作业，而且只能按序进行，一环紧扣一环，稍有不小心都将导致调试失利，不但延误工期，甚至会损坏设备。本文介绍了在现场实践中总结出的PLC控制系统的设备与调试技能经验，并对现场经常出现的设备、调试相关问题，提出评论定见和解决计划。

　　一、体系的设备与调试

　　合理安排体系设备与调试程序，是确保高效优质地完成设备与调试任务的要害。

　　1、前期技能准备

　　体系设备调试前的技能准备作业越充沛，设备与调试就会越顺畅。前期技能准备作业包含下列内容：

　　(1)熟悉PC随机技能材料、原文材料，深化了解其功用、功用及各种操作要求，制定操作规程。

　　(2)深化了解规划材料、对体系工艺流程，特别是工艺对各生产设备的操控要求要有全面的了解，在此基础上，按子体系制造工艺流。程联锁图、体系功用图、体系工作逻辑框图、这将有助于对体系工作逻辑的深刻了解，是前期技能准备的重要环节。

　　(3)熟悉各工艺设备的功用、规划与设备状况，特别是各设备的操控与动力接线图，并与什物相对照，以及时发现过错并纠正。

　　(4)在全面了解规划计划与PC技能材料的基础上，列出PC输入输出点号表(包含内部线圈一览表，I/O所在位置，对应设备及各I/O点功用)。

　　(5)研读规划提供的程序，对逻辑杂乱的部分输入、输出点制造时序图，一些规划中的逻辑过错，在制造时序图时即可发现。

　　(6)分子体系编制调试计划，然后在团体评论的基础上综合成为全体系调试计划。

　　2、PLC商检

　　商检应有甲乙两头共同进行，应承认设备及备品、备件、技能材料、附件等的类型、数量、规范，其功用是否无缺待实验室及现场调试时验证。商检成果，两头应签署交换清单。

　　3、实验室调试

　　(1)PLC的实验室设备与注册制造金属支架，将各作业站的输入、输出模块固定其上，按设备提要以同轴电缆将各站与主机、编程器、打印机等相衔接，查看接线正确，供电电源等级与PLC电压选择相契合后，按开机程序送电，装入体系配置带，承认体系配置，装入编程器装载带、编程带等，按操作规程将体系注册，此刻即可进行各项操作实验。

　　(2)键入作业程序

　　(3)模仿I/O输入、输出，查看修正程序本进程的意图在于验证输入的作业程序的正确性，该程序的逻辑所表达的工艺设备的联锁联系是否与规划的工艺操控要求相符，程序是否疏通。若不相符或不能工作完成全进程，阐明程序有误，应进行修正。在这一进程中，对程序的了解将逐渐加深，为现场调试作好了准备，同时也可以发现程序不合理和不完善的部分，以便进一步优化。

　　调试办法有两种：

　　①模仿办法：按规划做一块调试板，以钮子开关模仿输入节点，以小型继电器模仿生产工艺设备的继电器与接触器，其辅佐接点模仿设备工作时的回来信号节点。其长处是具有模仿的真实性，可以反映出开关速度差异很大的现场机械触点和PLC内的电子触点相互衔接时，是否会发作逻辑误动作。其缺陷是需求添加调试费用和部分调试作业量。

　　②强置办法：使用PLC强置功用，对程序中触及现场的机械触点(开关)，以强置的办法使其“通”、“断”，迫使程序工作。其长处是调试作业量小，简便，不需另外添加费用。缺陷是逻辑验证不全面，人工强置模仿现场节点“通”、“断”，会构成程序工作不能连续，只能分段进行。

　　依据我们现场调试的经验，对部分重要的现场节点采纳模仿办法，其他的选用强置办法，取二者之长互补。逻辑验证阶段要着重逐日填写调试作业日志，内容包含调试人员、时刻、调试内容、修正记载、毛病及处理、交代验收签字，以树立调试作业责任制，留下调试的第一手材料。关于规划程序的修正部分，应在规划图上注明，及时征求规划者的定见，力求准确表现规划要求。
 

2198-KITCON-CAPMOD2240 Kinetix 5700 Connector Kit Cap Module

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294D-FD4P2Z-G2 Variable Frequency Drive

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RSI Software Products 9301-2SE340FRU3R RSVIEW32 RUNTIME 150-32K UPGRADE OUT-SUPT (FR)

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Motion Control 1326AB-B740C-M2K7L MOTOR,SERVO,460V,53.0NM,2200RPM,MULTI,BRK,IP67

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281E-F23Z-25D-CR-3FR ArmorStart Direct Online RVSG Starter

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1492-RCDA2A40 Residual Current Device 40 A

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

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1762-MM1RTC MicroLogix 1200 with RTC Memory Module

188-K3D020-N Miniature Circuit Breaker 2 A

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BC647TPD075 CIMPLICITY HMI ProServer 75 I/O Development and Runtime System with Proficy GlobalCare

GC647PRTHE010 GlobalCare Complete - Proficy Portal Historian Edition Client Pack 10 Users Ver 3.0

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IC646PCN110 OpenProcess Operator Console (700 I/O)

IC647MRA150 View Runtime 150 I/O with USB Hardware key

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IC697PWR732RR Replacement Power Supply, 125 Vdc, 60 Watts

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Industrial Computers 6189-RW2 VVCE COMPACT FLASH 128MB W/ME

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Operator Interface 2711-B5A8 PV550 MONO KEY&TOUCH, DH+ & RS232 PRINT

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Support 9391-RSSS 9391-RSS SOFTWARE SUPPORT CONTRACT RENEWAL

ControlNet Products 2711-B5A15L1 PV550 MONO KEY&TOUCH, CNET & RS232 PRINT

RSI Software Products 9301-2SE2500JPU5 RSVIEW32 WORKS 5K-100K UPGRADE IN-SUPT (JP)

RSI Software Products 9358-BBKEY60U3R UPGRADE: OUT-SUPT: RSBW BACK-UP KEY 30 TO 60

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Motion Control 2090-XXNFMP-S05 CABLE,NON-FLEX,MOTOR FEEDBACK,MP/1326AB,5M

CBL-H1IC-15 Serial Cable, S2K, IMC & Target ARS RS-232 Communication, 15 Ft.

IC641PBE643 Alarm Master, 3.5" & 5.25" Format

IC800SLR002 Ext. Regen Resistor, 100 Ohm 225 W for 30-750W 230VAC SL Amplifiers

OIP-DSP1-C Operator Interface Panel

20B-PUB-IN1-EN PF700,F0-6 INSTALLATION PUB KIT,ENGLISH

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1492-MR5X8H1-20 Connection Products

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1585J-M4TBJM-20 RJ45 Ethernet Media

1756-OB32K ControlLogix 32 Point Digital Output

188-K1C005-N Miniature Circuit Breaker 0.5 A

194E-G3665 Abs Thermoplstc Encl 175 X 230 X 120 mm

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2090-UXBB-DM15 Ultra Series Breakout Board Kit

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IC200ALG240LT ANALOG INPUT 16 BIT VOLTAGE/CURRENT ISOLATED 8 CH (LT)

IC646IFCLNTCRO005C iFIX iClient Read Only 5 PK Keyless (M1Component Part)

IC647IFPLSR00900C iFIX Plus SCADA 900 I/O Server (M1Component Part)

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Industrial Computers

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Motion Control 8720MC-LR10-062B 10%,62AMP,460VAC LINE REACTOR

BC646MRD075 Logic PC Runtime (HRT) 75 I/O

IC300RCS082 8 DC Inputs (12/24vdc), 8 Positive Logic DC Outputs (5/12/24vdc, 0.5A with ESCP), 4 Analog Inputs (0-5vdc, +/-5vdc, 0-10vdc, +/-10vdc, 12 bit). 2 Analog Outputs (+/-10vdc). Built-in network interface ofr CsCAN or DeviceNet salve

IC754VBI12CTD 12" Color-TFT QuickPanel View Intermediate, Touch, 24VDC, Blank Label

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25B-E1P7N104 PowerFlex 525 0.75kW (1Hp) AC Drive

280-BRCAP-M25 Cap, Sealing for M25 Source Brake

FR-F740-1.5K 2.7KVA 3.5A 1.5KW 3相AC380V/50Hz/60Hz

1492-LG2Q IEC Term Blck 3.5x75x29.5mm Spr Clp

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1585D-E4UBDE-0M3 1585D Ethernet Media Patchcord

1753-IB8XOB8 GuardPLC Digital Combo Module

1794-IB8 Flex 8 Point Digital Input Module

194E-AA32E-PE-TN 194E Load switch

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2090-CSWM1DF-14AA50 Kinetix Cable Single DSL 2090-Series

20AC3P5A3AYNACC0 PowerFlex 70 AC Drive 20A

GC646MPS010 Proficy GlobalCare Complete for Logic Developer - PLC Standard - 10 Pack

HE693PIF104 PC Interface to Series 90-30 I/O in PC104 form factor.

IC610CHS130RR Rack, 115/230Vac Power Supply (10 Slots)

IC647HSTSC5000KM Server to Server Collector for Historian - Standard Server 5,000,000 Points (M4 Key)

IC660BBA106 Block 115Vac/125Vdc Analog Current Source 6 Inputs

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IC756WDN009E-22 DV Development Sys VB, Java, C++, C, English, Version 2.2

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Support 9323-PA2GS SUPT RENEWAL CONTRACT FOR 9323PA2G

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FRN 2.2E1S-7C 4.1 KVA 11 A 2.2KW 单相AC220V/50Hz/60Hz

A20B-2902-0070 A20B-2902-0070/02B

1492-SPM3D010-N MCB Supplementary Protector 1 A

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1783-US6T2F Stratix 2000 6+2 port unmanaged switch

193-EXP-DIO-42-120 E300 120V AC Digital Expansion Module

20-750-NEMA1-F1 PF753 & PF755 FR 1 EMC CORES W PLATE

2090-CPWM7DF-16AF03 MP-Series 3m Length Power Cable

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GP646IFCLNTCRO010 GCP iFIX iClient Read Only 25 PK Keyless Runtime Version

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IC647HSTCC1KM Calculation Collector for Historian - Standard Server 1000 Points (M4 Key)

IC647TBLCPVC001 Virtual Campus for Proficy Troubleshooter and Cause+ - 1 User

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IC756LDV000K-912 DV Development - Intel/Linux RedHat Op Sys, Korean, Version 9.12

Pico Controllers 1760-SIM INPUT SIMULATOR FOR 12 I/O DC PICO CONTROLLER

PLC-5/1771 System 1771-OD16K CONFORMALLY COATED, 120V AC ISOLATED OUTPUT MODULE

Distributed I/O 1791-0A32 BLOCK I/O, 120V AC, 32 POINT MODULE (32 OUTPUT)

Communications 1786-RPA CONTROLNET MODULAR REPEATER ADAPTER

Operator Interface 2706-PRIOK REMOTE I/O COMMUNICATION MODULE FOR 2706-P7X & P9X

Support 9701-VWSCWAS SUPT RENEWAL CONTRACT FOR 9701VWSCWAENE

Support 9324-RL0100ESR SUPT REINSTATEMENT CONTRACT FOR 9324RL0100ES

EtherNet/IP Products 2711P-K15C4B1 PV PLUS 1500, KEYPAD, ENET, AC PS, STD MEM

RSI Software Products 9301-2SE340PTU1R RSVIEW32 RUNTIME 1500-32K UPGRADE OUT-SUPT (PT)

RSI Software Products 9356-PRO2350U6R UPGRADE: OUT-SUPT: RSSQL PROF.300 TO PROF.5000 TAG

Motion Control F-4050-Q-H04AA MOTOR/ENCODER/BRAKE

4360-N 4360 WITH NEMA 4