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TRM-21006670,

TRM-21006670

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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。
 

20F11ND2P1AA0NNNNN PowerFlex 753 AC Packaged Drive

20G11RC5P0AA0NNNNN PowerFlex 755 AC Packaged Drive

22B-E012F104 PowerFlex 40 7.5 kW (10 Hp) AC Drive

2711-NV5 PV600 Key Key Touch Antiglare Overlay

280-T35 M35 To M22 Power Tee

H3Y-2 AC220V 1S 10S 30S 60S 二開/二閉

1492-MS6X12H31-40 Connection Products

人機界面 6AV6542-0CA10-0AX0 OP270-6，覆膜按鍵，256 色，5.7 英寸，320? 240

軟啟動器 3RW44342BC36

電源 6EP1 332-4BA00 PM1507：額定輸入電壓 120 V / 230 V AC 自適應，輸出 24 V / 3 A

1585D-D4AC9-0M5 Ethernet Media

1747-L553 SLC 5/05 64K Controller

1794-ACNR15XT Flex XT Controlnet Adapter

194E-AA16 194E Load switch

2071-CONN1 Spare Connector Terminals Kinetix 3

2090-CSWM1DF-14AA06 Kinetix Cable Single DSL 2090-Series

20AC2P1A0AYNNNC0 PowerFlex 70 AC Drive 20A

GC646MNT300 Proficy GlobalCare Complete for Logicmaster 90-30

HE693IBM235 Terminal emulation SW/ 3.5 inch disk

IC600YR561RR Substitute IC600YR560

IC647HSTPIM Historian OSI PI Connector (M4 Key)

IC660BBA021RR RTD Input Block, 24/48Vdc Power, 6 Channels, Ph B

IC694MDL658 INPUT 48 VDC POS/NEG 32PT FAST. Wiring termination is two Fujitsu connectors.

IC756WDC009J-99 DV Development Sys VB, Java, C++, Japanese, Version 9.9

MicroLogix 1500/1769 System 1769-CRL1 1 FT (305 MM) RIGHT-TO-LEFT BUS EXPANSION CABLE

PLC-5/1771 System 1785-KA DATA HWY/DATA HWY PLUS INTERFACE MODULE

Distributed I/O 1797-XT CONTROLNET EX TRUNK TERMINATOR

Communications DAG-6.5.8 SCADA SYSTEM APPLICATION GUIDE

Support 9321-PI160S SUPT RENEWAL CONTRACT FOR 9321PI160

Support 9358-HSTS2100R SUPT REINSTATEMENT CONTRACT FOR 9358HSTS2100

Support F1772-LVSERA FIRMWARE UPGRADE FOR 1772-LV PLC2 PROCESSOR MODULE

RSI Software Products 9324-RLD300ITE RSLOGIX 5000 STANDARD, ITA

RSI Software Products 9304-WVPR300DU1R UPGRADE: OUT-SUPT: WINVW TO WINVW PRO RUNTIME 3000

RSI Software Products 9358-PLTM2600U2R UPGRADE: OUT-SUPT: PLANTMETRICS 10 TO 200 WORKCELL

Motion Control 8720SM-093-S6TAS1 93 KW/176 AMP, 750 VDC, AC MOTOR WITH SRS60 ENC.

A06B-0113-B175#7008 B0.5/3000 Servo Motor, Holding Brake, 32K Serial Encoder

IC200UAA007-24 Qty of 24, 28 point PLC, (16) 120VAC In, (12) 120VAC Out, 120V/240AC Power Supply. Battery (IC200ACC403) is required for data retention

IC752BCL101 Datapanel 150/160/240E to SNP (25 pin to 15 pin)

MTR-1350-N-A-E-S MTR series NEMA 34 splashproof stepping motor with parallel winding connection

ZA06B-0085-B203 B22/2000is servo motor with 128k serial encoder

20BD2P1A0AYNANC0 PowerFlex 700 AC Drive 2.1 A at 1 Hp 20B

20G11TC540AN0NNNNN PowerFlex 755 AC Packaged Drive

25-JBAD PowerFlex 520 Frame D NEMA/UL Type 1 Kit

140XCP90000C Quantum RAM電池備用模塊, 用于ESI061和EHC105, CC

FRN30F1S-4C 44 KVA 59 A 30KW 3相AC380V/50Hz/60Hz

Z-15GQ2-B 觸點:1開/1閉,15A 250VAC機械壽命:1000萬次 按鈕型

1492-SPM3C160 Mcb Supplementary Protector 16 A

軟啟動器 3RW40471TB05

熱電阻模擬量輸入模塊 6ES7 231-5PF32-0XB0 SM 1231 AI 8 x 16 位熱電阻

150-SB4NBD SMC-50 SOLID STATE MOTOR CONTROLLER 180A

1734-RTBS POINT I/O Accessory

1783-MX04T04E Stratix 8000 4+4 Port PoE Exp. Module

193-ESM-IG-60A-E3T E300/E200 60 Amp Sensing Module

20-750-I1B-C770D740 PowerFlex 750 Replacement Inverter

2090-CPWM7DF-14AF75 MP-Series 75 m Length Power Cable

2098-DSD-HV220-SE Ultra 3000 22kW with SERCOS Servo Drive

GA647IFCLNTS010 GCA iFIX iClientTS 10 Additional Users

GP-0602NT-H1SB GagePort LVDT NT (Half Bridge H1 Blocks) - Sales BOM.

IC5005TAX0110 PanelPC 15 inch Standard Unit with Windows XP and Stainless Steel Bezel

IC647HSTAE3KM Alarm and Events Option for Historian - Standard Server 2500 Points (M4 Key)

IC647SRVPPCREW PA Solutions Pack Crew Scheduler

IC693MDL740 12/24 Vdc Output, 0.5 Amp, Positive Logic (16 Points)

IC756HDV010E-99 DV Draw Development on HP/UX Op Sys, English, Version 9.9

Pico Controllers 1760-L12DWD 12 I/O PICO CONTROLLER W/RTC, 12V DC

PLC-5/1771 System 1771-IQ16K CONFORMALLY COATED,ISOLATED INPUT MODULE,24V DC

Distributed I/O 1791D-0V16PX 24 VDC COMPACTBLOCK I/O EXPANSION, 16 OUT SINK

Communications 1784-PCMS 1784PCMK/B OR 1784PCMKS/A RIO CBL (3 PIN PHOENIX)

Operator Interface 2706-P92C INVIEW MESSAGE DISPLAYS

Support 9701-VWMR015AR SUPT REINSTATEMENT CONTRACT FOR 9701VWMR015AENE

Support 9515-RSNHS005S SUPT RENEWAL CONTRACT FOR 9515RSNHS005ENE

EtherNet/IP Products 2711-T10G20L1 PV1000 GRAYSCALE TOUCH, ENET & RS232 PRINT

RSI Software Products 9301-2SE340ESU2R RSVIEW32 RUNTIME 300-32K UPGRADE OUT-SUPT (ES)

RSI Software Products 9356-PRO2300U1R UPGRADE: OUT-SUPT: RSSQL STD.150 TO PROF.1500 TAG

Motion Control 1326AB-B720F-S2L MOTOR,SERVO,460V,31.8NM,5000RPM,SINGL,IP67

4161-902-N12 4161 NEMA 12 LENS KIT

HMI-COV-202 FRONT SHEET COVER FOR 10.5"

IC693CPU350 CPU 350 Module (32K Bytes user memory, 4K I/O, 8 Racks), no built-in Serial Ports .22msec/K

SM1000SMC Obsolete - QUICKMARQUEE CONTROLLER

TRM-21006683 Connector for Target series axis module I/O connector J1 or analog I/O module connector J1 or digital I/O module connector J1

20BD011A3AYNACC0 PowerFlex 700 AC Drive 20B

20G11BC1K1JN0NNNNN PowerFlex 755 AC Packaged Drive

22B-V2P3F104 PowerFlex 40 0.4 kW (0.5 Hp) AC Drive

416NHM30030A Quantum Modbus Plus PCIadapter for PCs,with Plug

284G-FVD6P0S-25-RRG-CBG-DB1-EMI ArmorStart 284 Controller

H3CA-8 220VAC,0.1s-9990h, 二常開/閉?觸點:5A

1492-SPM1C630-N MCB Supplementary Protector 63 A

通用型變頻器 6SE6 440-2UC22-2BA1 "2.2 KW,149 x 202 x 172"

電機啟動器 3VU13402NH00

150-C25NBR SMC-3 25A Smart Motor Controller

1609-D1000E Uniterruptible Power Supply

1770-XG Dropline Connector Kit

193-EC1DE E3 9-45 A Overload Relay

195-GA02 Auxiliary Contact

2090-CPBM7E7-10AF25 MP-Series 25 m Length Cable

2093-AMP5 Kinetix 2000 Axis Module

CP8B-1WEB-0140-AZ Shielded motor power cable for B0.4is/B0.5is/B1is motors (elbow connector). 14 meters

GF-AU5V/AMS Connecting FlashCable to

IC200UEX164 VersaMax Micro 64 point expansion (40) 24VDC inputs, relay outputs, AC power supply. Compatible with Micro 20/40/64 revision -Bx hardware only version 4.0 firmware and above.

IC647AEC050 PA Efficiency Client 50 Pak

IC647PCMS03 Proficy Change Management Electronic Signature Option - 3 Concurrent Users

IC693CBL334 Cable, Right Side, Two - 24 Pin 90 Degree Connectors, .5 Meter

IC754CBL06MTD Ctrl Loaded 6 In Mono Touch DC Blank

IMC-78005773 Custom modified IMC enhanced stepping motor controller

SLC/1746 System D1746-6.16DE SLC500 THERMOC'PL/MV ISOL.INPUT MOD. USR MNL(GERMA

Distributed I/O 1732D-OB8EM8 DEVICENET 24VDC 8 0.5A OUTPUT W/M8

Application-specific products 1404-M805B-CNT-02 1404-M8 CONTROLNET PM3000 CLASS 0.2 24V P.S.

Operator Interface 2711-T10C12 PV1000 COLOR TOUCH, PBUS & RS232 PRINT

Support 9301-2SE3400FRS SUPT RENEWAL CONTRACT FOR 93012SE3400FR

Support 9381-PA10KENR SUPT REINSTATEMENT CONTRACT FOR 9381PA10KEN

DeviceNet Products 1790-T0W8X LDX I/O, 24VDC, 8 RELAY OUT EXPANSION, TERM BLK

RSI Software Products 9301-2SE3300U2R RSVIEW RUNTIME 150 TO 1500 UPGRADE: OUT-OF-SUPPORT

RSI Software Products 9358-PB10ENE RSBIZWARE BATCH FOR PROCESSLOGIX 10 UNITS

Motion Control MPL-B520K-SJ24AA MOTOR,SERVO,10.7 NM,4000RPM,SINGL,460V,BRK,13.9KG

Motion Control 9101-1478 MATING CONNECTOR KIT/J3 26 PIN MINI D(SOLDER CUP)

GQPK2D100S2P QUICKPANEL COLOR 6" STN GE LABEL

IC646MRD300 Logic PC (HRT) 300 Tag Runtime System

MTR-3T24-H-R-0-M-S MTR-Series Servo Motor, Resolver, Metric, Seal

SNAP 5C5 PC Port is 9-pin male and port on CNC is 25-pin male. This is for Xon/ Xoff communications.

20BC072A0AYNACC0 PowerFlex 700 AC Drive 72 A 37 kW 20B

20F11NE2P7AA0NNNNN PowerFlex 753 AC Packaged Drive

22148-222-01-R SOCKET CONNECTOR

140CPU53414BC Quantum Quantum 534 PLC CONTROLLER CC

281D-F23Z-25D-CR ArmorStart Direct Online RVSG Starter

C200H-OD501 多點I/O單元, TTL輸出 5VDC 35mA 32點

1492-RAIFM4-3 Connection Products

存儲卡 6ES7952-1AH00-0AA0 RAM/256K

變送器 3RS11011CK30

1497-E-M4-3-N Control Circuit Transformer

1606-XL480F-3H Power Supply XL 480 W Power Supply

1762-L40AWAR MicroLogix 1200 40 Point Controller

188-K3C630-N Miniature Circuit Breaker 63 A

194L-HC4A-175I Type A Size 4 Switch Actuator

2090-CPBM7DF-06AA03 MP-Series 3m Power and Brake Cable

2090-XXNPMF-10S05 Kinetix Drives 5m Standard Cable

BC647SPX365 "Solution Provider 1st Year Subscription includes 2 physcial M4 keys, Gl obal Care Complete (iGC SP1)

GC647PRTEE010 GlobalCare Complete - Proficy Portal Enterprise Edition Client Pack 10 Users Ver 3.0

IC200MDL650 Input 24VDC POS/NEG logic (4 groups of 8) 32 points

IC646PCMS1C Proficy Change Management Electronic Signature Module 100 Pack

IC647MPS050 Logic Developer PLC Standard 50 Pack with USB Hardware key

IC676PBM442 IP67 Mixed Block - 24 VDC Positive Logic - 4 In/4 Out 2A - Profibus

IC697PWR720RR Replacement Power Supply Adaptor

IC800SSI107S1 7.2 amp 115/230 VAC S2K servo controller for S-series motors

SLC/1746 System 1747-L30C 30 I/O FIXED HARDWARE STYLE

Industrial Computers 6189-RU310 VERSAVIEW CE FIRMWARE UPGRADE MEDIA KIT

Process Control D6190-5.3 BATCHWARE DEMOSTRATION SOFTWARE USER MANUAL

Operator Interface 2711-B5A3L3 PV550 MONO KEY&TOUCH, DH485 & RS232 PRINT

Support 9303-3CS0E31R SUPP REINSTATEMENT CNTRCT FOR 9303-3CS0E31

Support 9371-RSWDI2R SUPT REINSTATEMENT CONTRACT FOR 9371RSWDI2

ControlNet Products 2706-P94C INVIEW MESSAGE DISPLAY

RSI Software Products 9301-2SE2500JPE RSVIEW32 WORKS 100K (JAPANESE)

RSI Software Products 9358-BBKEY30U1R UPGRADE: OUT-SUPT: RSBW BACK-UP KEY 03 TO 30

Motion Control MPL-A4530K-MJ24AA MOTOR,SERVO,8.36 NM,4000RPM,MULTI,230V,BRK,11KG

Motion Control 2090-UXPC-D0930 CABLE,9/9 POS,45 DEG D/STRAIGHT D,30M

CBL-6114 Cable. IBM COMP. To Model 9650, 9 Pin PC COMM. Port

IC641LCN054 HP-UX Host Comm Runtime License

IC800SLMCONKITVL Connector Kit, 3.5 kW to 5 kW S-Series Servo Motors without Brake

OC647WFLSWF Proficy Workflow - System WF Capable

20AE9P0A0AYYNNC0 PowerFlex 70 AC Drive 9 A at 7.5 Hp 20A

20DD300A0ENNNNANE PowerFlex 700S AC Drive 20D

20S-RFC PowerFlex SCR Bus Supply Hf Filter

2711P-B6C20D9 PanelView Plus 6 Graphic Terminal

280-PWRM35A-M6 ArmorConnect 6 Meter M35 Patchcord

CPM1A-20EDR1 20點擴展 12點入, 8 點繼電器輸出

1492-MN81 IEC 6 x 10 mm Marker Card

1494V-M72 Variable Depth Circuit Breaker Operator

軟啟動器 3RW44662BC45

運行版軟件 6AV2104-3HH04-0AE0 SIMATIC WinCC Runtime Advanced 4096 PowerTags V14 Upgrade ： V11..V13 -> V14

1585J-M4TBJM-1 RJ45 Ethernet Media

1756-OB16IEF ControlLogix 16 Point Digital Output

188-K1B500 Miniature Circuit Breaker 50 A

194E-FA80E-P11-PE 194E Load switch

2090-CFBM7DF-CDAF12 MP-Series 12m Feedback Cable

2090-U5PV-D0901 Ultra 5000 1 m Length Interface Cable

BC646OEM0100 OEM Edge - iFIX Kit (Approval Required)

GC647AUR050 GC Universal Reporting Client 50 pak

IC200ACC415 VersaMax Micro and Nano RS-232 to RS-485 Converter requires IC200CBL500 or equivalent.

IC646CSPR025 Proficy Cause+ for Intelligent HMI/SCADA Runtime Server - 25X monitored KPIs

IC647IFPLSR00150C iFIX Plus SCADA 150 I/O Server (M1Component Part)

IC660MLA106 Label for IC660BBA106 (Qty 100)

IC697ALG445 Analog Input Expander, Voltage, 16 Channels gold plated terminal. WARNING: The IC697ALG445 module must be matched with IC697ACC775 terminal block ONLY. IC697ACC775 is included with the module.

IC8000DEM001 PAC8000 HYBRID CTRL AND SAFETYNET DEMO

FlexLogix System 1794-STRT1ES FLEXLOGIX STARTER KIT SPANISH

GuardPLC Systems 1754-PCS RSLOGIX GUARD SOFTWARE FOR GUARDPLC 1200

Process Control 1757-UPGSIFZB UPGRADE FSC SER MODBUS QUICKBUILDER I/F

Operator Interface 2711P-B15C15B1 PV PLUS 1500, KEY/TOUCH, CNET, AC PS, STD MEM

Support 9220-WINTAS SUPT RENEWAL CONTRACT FOR 9220WINTA

Support 2760-SFTKR 2760-SFTK SOFTWARE SUPPORT REINSTATEMENT

Support F1785-V40BSERE FIRMWARE UPGRADE FOR 1785-V40B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2350KOU3 RSVIEW32 WORKS 1500-5K UPGRADE IN-SUPT (KO)

RSI Software Products 9701-VWSTMFRE RSVIEW STUDIO FOR MACHINE EDITION (FRENCH)

RSI Software Products 9399-WABOUGES RSLINX OEM USERS GUIDE (SPANISH)

Motion Control 8720MC-AQBX5 STEGMANN TIMES 5 ENCODER BOX

BC646MRC075 Logic PC & View Runtime 75 I/O

IC300RCS061 8 DC Inputs (12/24vdc), 8 Positive Logic DC Outputs (5/12/24vdc, 0.5A with ESCP). Built-in network interface for CsCAN or DeviceNet slave.

IC754CSL06CTD 6" TFT QuickPanel Control, Loaded, 24Vdc

MTR-3T54-H-R-0-M-0 MTR series metric servo motor with resolver

20AC8P7A3AYNNDC0 PowerFlex 70 AC Drive 8.7 A at 4 kW 20A

20DC022A0NYNACANE PowerFlex 700S AC Drive 20D

20G1ANC140AN0NNNNN PowerFlex 755 AC Packaged Drive

25B-E012N104 PowerFlex 525 7.5kW (10Hp) AC Drive

2715-T19CA PanelView 5500 19 in. Graphic Terminal

FR-A740-22K 32.8KVA 43A 22KW

1492-LDAG3 IEC Term Blck 5.1x95x41mm Spr Clp

1494F-M1 Disconnect Switch Handle

軟啟動器 3RW44356BC34

ET 200SP 6ES7193-6AP20-0AA0 BA 1×SCRJ光纖/1×RJ 45

1585D-E4TBDE-0M6 Micro D-Code, QD Style Ethernet Media

1752-L24BBB SmartGuard 600 Safety Controller

1794-IB10XOB6XT Flex XT 10 Input 6 Output Digital Module

194E-AA20E-PE-TN 194E Load switch

2080-LC20-20AWBR Micro820 20 I/O ENet/IP Controller (RTB)

2090-CSWM1DF-14AA20 Kinetix Cable Single DSL 2090-Series

20AC3P5A0AYNADC0 PowerFlex 70 AC Drive 20A

GC646MPP050 Proficy GlobalCare Complete for Logic Developer - PLC Professional - 50 Pack

HE693OIU327 Full-sized VF OIU w/o LEDs powered by 80-240VAC

IC610CCM110RR I/O Link Local Module

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