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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。
 

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1497-L-BASX-0-N Control Circuit Transformer

1606-XLE480EPC XLE 20 Amp Power Supply

1764-24AWA MicroLogix 1500 24 Point Controller

188-K3D400 Miniature Circuit Breaker 40 A

194L-HE4E-175I 194L Control and Load Switch Actuator

2090-CPBM7DF-08AF01 1 m Length SpeedTec Flexible Cable

2090-XXNPMF-16S02 Kinetix Drives 2m Standard Cable

BC647TRT999 CIMPLICITY HMI Viewer Runtime System with Proficy GlobalCare

GC647PSF100 Global Care for Proficy Process Systems 1000 I/O with iFIX

IC200NDD010 10 point PLC, (6) 12VDC In, (4) 12VDC Out, 12VDC Power Supply

IC646PPA772 PA-70 with 772 CPU - AC

IC647NCA000 CIMPLICITY Change Approval for Unlimited Point Server

IC690ACC901 Mini-Converter Kit with cable (RS-485/RS-232)

IC697VDQ120 Discontinued. Replacement is Embedded VMIVME-2131-110 Not UL Approved. Contact GE Embedded for more details.

IC800SSI420RP2RR 20A, 480V, Profibus S2K Servo Controller for MTR Series Motors

SLC/1746 System 1747-SN REMOTE I/O SCANNER MODULE