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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。
 

20BD096A0NYNANC0 PowerFlex 700 AC Drive 96 A 75 Hp 20B

20DD077A3EYNANANE PowerFlex 700S AC Drive 77 A 60 Hp 20D

20P-S5V62 PowerFlex DC IO Expansion Board

25A-D043N114 PowerFlex 523 22kW (30Hp) AC Drive

140EHC20200 Quantum 高速計數模塊, 24 VDC, 500Hz, 2通道

OPC-G11S-SY(同步卡)

E3X-A11 光纖放大器, 晶體管輸出 NPN 80mA, 電源:12-30VDC

1492-SPM3C040 MCB Supplementary Protector 4 A

模擬量輸入/輸出模塊SM 6ES7 332-5HD01-0AB0 AO/4 通道，電壓、電流，光電隔離，20pin 前連接器

行程開關 3SE53220SG23

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1585J-M8FBJM-5 RJ45 Ethernet Media

1756-SPESMNRM L7SP Energy Storage Module-Non Remove

188-K1D250-N Miniature Circuit Breaker 25 A

194E-Y32M-1753-6G 32A 3P LOADSW. IN M/THREAD BOX

2090-CFBM7E7-CEAF09 9 m Length SpeedTec Extension Cable

2090-UXNPAMP-10S03 MP-Series 3 m Length Power Cable

BC646TRT915 Server 1500 I/O Runtime System with Proficy GlobalCare

GC647IFPLSR00075 GCC iFIX Plus SCADA 75 I/O Srv

IC200CBL602 Cable expansion shielded 2M 2 connectors

IC646MPS005 Logic Developer PLC Standard 5 Pack

IC647IFSCTSSPRT03M iFIX TS SCADA Support on SCADA -3 Clients (M4 Part)

IC670ALG230 Analog Input, Current, 8 Channel, Grouped

IC697CPU772RR CPU, 12 MHz, 2K Discrete I/O, Expandable Memory, Floating Pt

IC800PCUBC10S050 Powercube flying lead interface cable configured for 1000 steps/revolution and power save enabled. 5 meters

ControlLogix/1756 System 1756-OB8EI 10-30 VDC ISOLATED ELEC FUSED OUTPUT 8PTS (36 PIN)

Industrial Computers 6182H-10KEH6D VVCE 1000, KEYPAD, EXT MEM, RIO/DH, DC

Process Control 1757-FIMEXP035 FOUNDATION FIELDBUS FIM MODULE EXPANSION

Operator Interface 2711P-RBT7 PV PLUS 700 TOUCH REPLACEMENT BEZEL

Support 9355-WAB1OEMENR SUPT REINSTATEMENT CONTRACT FOR 9355WAB1OEMEN

Support 9351-VSRTR SUPT REINSTATEMENT CONTRACT FOR 9351VSRT

ControlNet Products 1785-L40C15 PLC-5/40C FOR CONTROLNET PHASE 1.5

RSI Software Products 9301-2SE2400FRU1 RSVIEW32 WORKS 1500-32K UPGRADE IN-SUPT (FR)

RSI Software Products 9355-WABJBENE RSLINX OEM/RSJUNCTIONBOX BUNDLE

Motion Control MPL-A320H-SJ22AA MOTOR,SERVO,2.26 NM,3500RPM,SINGL,230V,4.0KG

Motion Control 2090-DAPC-D0903 CABLE, NON-FLEX, CN3 SERIAL COMMUNICATIONS, 03M

CBL-114-1 Cable. Allen Bradley PLC5 Channel 0 (RS-232)

IC5008TBW2000 Discontinued - Order a BC5008TBW0000 & Appropriate CIM PE License

IC800PCUBC02S050 PowerCube Flying Lead Interface Cable, 200 Steps/Rev & Power Save Enabled, 5 Meters

OC647IFESGDV00075C iFIX Optn: ESig & ERec 75 I/O Development (M1Component Part)

20AD027A0AYYANC0 PowerFlex 70 AC Drive 27 A at 20 Hp 20A

20DC300A0ENNBNANE PowerFlex 700S AC Drive 20D

20G1ANF263JA0NNNNN PowerFlex 755 AC Packaged Drive

25C-E3P0N104 PowerFlex 527 1.5kW (2Hp) AC Drive

280-PWRM22B-M8 ArmorStart Three-Phase Power Media

FX2N-32MR-001 主機16入/16出?繼電器輸出

1492-M6X10 IEC 6 x 10 mm Marker Card

1494H-EF3N Heavy Duty Non-Fus Safety Discon Switch

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IC640BLD304RR Series Six Terminator Board

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IC660BLD110 Cover w/Label for IC660BBD110

IC695CMM002 RX3i serial communications module. Two isolated RS-232/485 port. Supports Serial Read/Write and Modbus Master/Slave. Requires Unversal Backplane.

IC756WET100J-99 Custom Editor Toolkit, Japanese, Version 9.9

CompactLogix System 1769-ECL LEFT END CAP/TERMINATOR

PLC-5/1771 System D1771-6.5.115 ANALOG INPUT MODULE (1771-IFE, SER C) USER MANUAL

Process Control 1757-FFLD4 4 H1 / HSE FOUNDATION FIELDBUS LINKING DEVICE

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Support 6500-PS2S SUPT RENEWAL CONTRACT FOR 6500PS2

Support 9358-PLTM2600R SUPT REINSTATEMENT CONTRACT FOR 9358PLTM2600ENE

Support F1785-BEMSERA FIRMWARE UPGRADE FOR 1785-BEM COMMUNICATION MODULE

RSI Software Products 9301-2SE2200KOU1 RSVIEW32 WORKS 150-300 UPGRADE IN-SUPT (KO)

RSI Software Products 9701-VWSB000FRU2 RSV SE STATION 100 - UNLTD DISP UPGRADE (FRENCH)

RSI Software Products 9399-COMPGR RSBIZWARE COMPLIANCE TRACK GETTING RESULTS GUIDE

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BC5002TAN0000 12 Inch Intelligence Industrial Computer - Bundled - Standard Series - w/ Windows NT

IC300ASC100 ASCII BASIC. Three ports, two active at any one time. 64K of program memory.

IC752DTX300 DataPanel 30, 2 x 20 LCD message center, used DataDesigner to program messages

MTR-3S35-G-R-B-E-SRR Servo Motor Nema34 24V Brake, Seal

ZA06B-6079-K811 Motor power straight connector for B8/3000is or B12/3000is motor

20BE144A0ANNAND0 PowerFlex 700 AC Drive 20B

20G14TC540JN0NNNNN PowerFlex 755 AC Packaged Drive

25-RF029-EL PowerFlex 520 29.2A 600V EMC Filter Kit

2711P-RW3 PanelView Plus Accessory

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1746-F3 SLC Power Supply Fuse

1786-FS60 ControlNet Fiber Optic Cable

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IC647TRT915 CIMPLICITY HMI Server 1500 I/O Runtime System

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IC756MDV010J-97 DV Draw Dvlpnt on Alpha OpenVMS, Japanese, Version 9.7

MicroLogix 1000/1761 System 9399-RL50GRIT RSLOGIX 500 GETTING RESULTS GUIDE (ITALIAN)

PLC-5/1771 System 1771-NOC HIGH RESOLUTION ISOLATED ANALOG MODULE

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5003S Obsolete - Message Center. 1 Line, 9MM, Green VFD. SLAVE Unit. NEMA 4

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MSI-WEB-10 Web or Excel Reporting Clients 10 Pack

VSPCSE-ADMIN50 VisualSPC SE Administration Bundle includes Attributes, Analyst, Desig ner, Wizard, Importer and Reports. 50 license pack.

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20G11LC1K0JN0NNNNN PowerFlex 755 AC Packaged Drive

22D-D4P0H204 PowerFlex 40P- 1.5 kW (2 HP) AC Drive

140NWM10000 Quantum TSX QUANTUM FCHMI MODULE

290E-FBP-G2 Direct Online Starter

LY4J 24VDC，110VAC，220VAC，4開4閉，觸點10A

1492-SPM2C200 MCB Supplementary Protector 20 A

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電機啟動器 3VU16403MM00

150-F201NZD SMC Flex Smart Motor Controller

1732DS-IB8 Guard I/O 8 Point Digital Comb Module

1771-P4R 1771 Power Supply

193-EECB E1 Plus 1-5 A IEC Overload Relay

199-LF1 Terminal Lugs

2090-CPWM7DF-08AA20 MP-Series 20m Standard Power Cable

2094-XNLIM-2 Kinetix 6000 Connector Set

EDS-308-M-SC-T C1 D2 7-port 10/100, 1 port multi-mode SC fiber (-40 to 75 deg C op temp)

GFK-1277 Genius Modular Redundancy User's Manual

IC220ACC101 MOTOR STARTER BRAKE MODULE AC/DC

IC647BWI005 Batch Opt: WorkInstruction Pilot Server Pak (5 Units)

IC647PRTKIT002M Proficy Portal Enterprise Edition Starter Kit 2 User (M4 Key)

IC693CPU374 CPU 374 Module (240K Bytes configurable user memory) The battery for the CPU is now included in the CPU backplane box, Embedded Ethrnet 10/ 100Mbs w/built-in switch. No serial ports. Note: The CPU37x CPUs may not work with Horner Electric modules

IC756ADV001E-98 DV Development - AIX Op Sys Addt'l User, English, Version 9.8

MSI-EFF-UNL Unltd Site Clients - Efficiency Mgmt

SLC/1746 System 1746-RT29 REPLACEMENT TERMINAL BLOCK - RIO COMMUNICATION

Distributed I/O 1738-IV4M12 24VDC 4 SOURCING INPUT WITH M12 CONNECTORS

Communications 1788-CN2FF CONTROLNET TO FIELDBUS LINKING DEVICE

Operator Interface 2711-NM232 32MB FLASH ATA MEMORY CARD

Support 9302-RT15S SUPT RENEWAL CONTRACT FOR 9302RT15

Support 9324-RL5300ENS SUPT RENEWAL CONTRACT FOR 9324RL5300EN

DeviceNet Products 2706-P22R INVIEW PANEL MOUNT DISPLAY

RSI Software Products 9301-2SE3353JPE RSVIEW32 RUNTIME 5K WITH RSLINX (JAPANESE)

RSI Software Products 9326-AD25WDENE WIRING DIAGRAM GENERATOR ADD-ON 25 USER

Motion Control MPG-A010-031S24 MOTOR,SERVO,GEAR RATIO 31,26NM,157RPM,SINGL,BRK

Silver Series 1770-HT8 HART 8 CHANNEL NON-ISOLATED TERMINAL BLOCK

HE693OIU197 Compact VF Fenius OIU w/numeric keypad, powered by 24VDC

IC660BBR101 Block Relay Output Normally Open 16 Circuits

QPI3D200S2P QUICKPANEL COLOR 10.5" STN

ST-5211 STXi Serial Interface module RS-232C, 1 Channel

20BC1P3A0AYNANA0 PowerFlex 700 AC Drive 20B

20F1AGD361AN0NNNNN PowerFlex 753 AC Packaged Drive

22B-A2P3N104 PowerFlex 40- 0.4 kW (0.5 HP) AC Drive

140DDI35300 Quantum 開關量 DC 輸入, 32點, 24 VDC, 4組隔離

284D-FVD4P0B-10-CR-DB-SB DeviceNet Variable Frequency Drive

E3JM-DS70M4 70cm,擴散反射式,觸點輸出3A 電源:24-240V AC/DC

1492-SJ8-10 IEC Term Blck 10 pole Side Jumper

人機界面 6AV6542-0BB15-2AX0 OP170B 操作員面板，5.7 英寸，藍色

6ES78331FC020YA5

1497B-A13-M11-0-N Control Power Transformer

1606-XLS240F AC or DC Input 48 to 56VDC Out 240W PS

1769-CRR1 CMPLX 0.3 m Right to Right Bus Exp Cable

188-K4D400 Miniature Circuit Breaker 40 A

194R-D630-1753 Disconnect, Fused, Din-Type, 630 A

2090-CPBM7DF-12AA07 MP-Series 7m Power and Brake Cable

2090-XXNPMP-16S04 MP-Series 4 m Length Power Cable

CBL-15-MP-30 Power cable for MTR-1N splashproof stepping motors. 30 feet

GF-0196/OBG Connecting FlashCable to Brown & Sharpe Digit Dial plus (Owens Brockwa y OEM).

IC200TBX114 Tool box, 14 point (IC200UDR001) 24VDCIn/Relay Out, AC Powered (requires AC power), V ersaMax DataPanel DP45 (requires 24VDC supply) with Programming software and cables, (IC640VPS 00, IC752DDZ000, IC200CBL555, IC646MPM001)

IC646TBSPMPS100 Smart Process Monitoring Process+ server 100 loops

IC647NRP000 CIMPLICITY HMI Recipes Option

IC693ACC319 Spare Parts Kit (I/O, CPU, PCM)

IC752BDT000RR Datapanel 240T, 240x128 LCD with CCFT backlight. 6x8 Matrix Resistive touch screen with text, bitmaps, bar graphs, real time clock.

IC800VMCE1200 Encoder cable for 1 kW to 3 kW VersaMotion servo motors- 20 meter

SLC/1746 System 1746-OV16 DC OUTPUT MODULE FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6189V-1ACPS AC POWER SUPPLY 1U STANDARD

Application-specific products 6556-SPLS PROGRAMMABLE LIMIT SWITCH SOFTWARE FOR THE SLC

Operator Interface 2711-B6C16L1 PV600 COLOR KEY&TOUCH, DF1 & RS232 PRINT

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Support 9307-EM643PXS SUPT RENEWAL CONTRACT FOR 9307EM643PXENE

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Motion Control MPL-B320P-SK22AA MOTOR,SERVO,2.94 NM,5000RPM,SINGL,460V

Motion Control 2090-MPPC-S KIT CONNECTOR,POWER STRAIGHT MF

GFK-0585 Series 90 PLC SNP Communication's Driver Reference Manual

IC641VPS950 VersaPro Standard Edition 50 Seat Site License - Windows Programming Software for Series 90-30 and VersaMax PLCs

MSCPU-21280698 Marathon Std CPU - 333 MHz AMD CPU, 128M, 6G, Win98, no expansion slots

PSPC-DC5/E-220L Prof Shop Floor SPC DC 5 User eSig 220v

20BC015A0AYNANC0 PowerFlex 700 AC Drive 20B

20F11FC015JA0NNNNN PowerFlex 753 AC Packaged Drive

2198-KITCON-CAP1300 CONKIT,K5500,CAP MODULE

2711P-RBB10 PanelView Plus Accessory

280-PWRM35H-M20 ArmorConnect 3-PH Power Media trnk cable

CQM1-PR001-E 編程器?（配1.5米連接電纜）如需連CQM1H系列CPU,需加CS1W-CN114

1492-N22 TERM BLCK Rigid MTG Rail

通訊處理器CP 6GK7 343-1EX21-0XE0 "CP343-1 工 業 以 太 網 通 訊 處 理 器10/100Mbit/s,RJ45 接口"

行程開關 3SE53222SE22

TIA 博途 WinCC 選件 6AV2107-0KP00-0BB0 SIMATIC WinCC WebNavigator for Runtime Professional 150 Clients

1585J-M8HBJM-2M5 RJ45 Ethernet Media

1760-DUB PicoGFX with Keypad Display

188-K2B200 Miniature Circuit Breaker 20 A

194E-Y80-1753-6N 80 A 194E Load switch

2090-CHBP8S8-12AA02 Kinetix 6000M IDM Hybrid Cable

2090-UXPC-D0909 Ultra Series 9m Interface Cable

BC647MODEV Motion Developer for S2K Series Amplifiers/Controllers with Proficy GlobalCare Complete with USB Hardware key

GC647IFPRRNUNLMT GCC iFIX Profsnl SCADA Unlmt Run

IC200CHS014 I/O interposing box style Thermocouple cold junction compensation

IC646MRA300 View Runtime 300 I/O

IC647IFSTDV00900M iFIX Standard HMI 900 I/O Development (M4 Part)

IC670CBL002 21 inch I/O Expansion Cable

IC697CPX935 CPU, 96 MHz, 12K Discrete I/O, 1M byte fixed user memory

IC800SKCEZ050 Encoder cable to connect an S2K to any 30 Watt to 750 Watt S-series servo motor. 5 meters

ControlLogix/1756 System 1756-IT6I2 ENHANCED ISOL THERMOCOUPLE/MV INPUT 6PTS (20 PIN)

Industrial Computers 6182H-10TRH15D VVCE 1000, TOUCH, STD MEM, CNET, DC

Process Control 1757-FIMUPG010 FIELDBUS LICENSE UPGRADE, 10 FIMS

Operator Interface 2711P-RGK15 PV PLUS/VVCE PROTECTIVE ANTIGLARE OVERLAYS QTY 3

Support 9355-WABITR SUPT REINSTATEMENT CONTRACT FOR 9355WABIT

Support 9354-LN100S 9354-LN100 SOFTWARE SUPPORT CONTRACT RENEWAL

ControlNet Products 1784-PCIC CONTROLNET PCI BUS MESSAGING CARD WITH

RSI Software Products 9301-2SE2400KOE RSVIEW32 WORKS 32K (KOREAN)

RSI Software Products 9355-WABSNEU1 UPGRADE: IN-SUPT: RSLINX SINGLE NODE TO RSLINX OEM

Motion Control MPL-A320P-SK22AA MOTOR,SERVO,2.94 NM,5000RPM,SINGL,230V,4.1KG