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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。
 

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VIOLA NVSAT 957593-025 150A0674-52

W26361-W64-Z2-06-36

XPC SG31G2

COGNEX VM16A 203-0075-RE

Orbot-NAIO-2-N-NAIO-REV-H

PCA-6194VG

1492-MS5X9H11-20 Connection Products

1495-N71 3/4 in. Hub

行程开关 3SE53120SG13

运行版软件 6AV2105-0PA14-0AA0 SIMATIC WinCC Runtime 专业版 102400 PowerTags ASIA V14

1585J-M4UBJM-10 RJ45 Ethernet Media

1756-OW16I ControlLogix 16 Pt Digital Relay Module

188-K1C160-N Miniature Circuit Breaker 16 A

194E-KA20 194E Load switch

2090-CFBM7DF-CEAA90 MP-Series 90m Servo Feedback Cable

2090-UXLF-HV350 Ultra Series 50A AC Line Filter

BC646SPD365 Solution Provider Batch Key

GC647IFCLNTSRO025 GCC iFIX iClientTS Read Only 50 PK Runtime Version

IC200ALG326 Analog Output, 13 Bit Current, 8 Channel

IC646MBPS99 Machine Edition Professional Development Suite with Unlimited Seat Site License

IC647IFPRDVUNLMTC iFIX Profsnl SCADA Unlimited Development (M1Component Part)

IC660SLA106 Red Safety Label Kit for IC660BBA106 Genius Blocks

IC697CGR935 Hot Standby Genius Dual Bus CPU, 486DX4, 12K Discrete I/O, 1M fixed us er memory, Floating Pt.

IC800CBL023 Encoder cable for B2/3000 or B6/2000 motor. 14 meters

ControlLogix/1756 System 1756-M23 LOGIX5555 1.5MBYTE NONVOLATILE MEMORY

Industrial Computers 6182H-7KEH6D VVCE 700, KEYPAD, EXT MEM, RIO/DH, DC

Process Control 9358-PBANT10ENE RSBATCH NT FOR PROCESSLOGIX ARCHIVER 10 UNITS

Operator Interface 2711P-T15C15B1 PV PLUS 1500, TOUCH, CNET, AC PS, STD MEM

Support 9352-WDN100S SUPT RENEWAL CONTRACT FOR 9352WDN100

Support 9324-RSECSENS SUPT RENEWAL CONTRACT FOR 9324RSECSEN

ControlNet Products 1786-BNC2TNC CONTROLNET BNC-TNC COAXIAL CONN - ISOL BULKHEAD

RSI Software Products 9301-2SE235DEU1R RSVIEW32 WORKS 150-5K UPGRADE OUT-SUPT (DE)

RSI Software Products 9352-WABGW WINTELLIGENT LINX GATEWAY

RSI Software Products 9399-WVDUG WINTELLIGENT VIEW USER GUIDE

Motion Control 2090-DANBT-18S01 CABLE, NON-FLEX, MTR BRK FOR CABLE-MTD CONNS, 01M

BC646MVSU02 View Standard Edition with SAFE - Upgrade from View for QuickPanel View Standard Edition

IC300TRM008 Spring-clamp style I/O plug, 8-terminal

IC800APK080 80 Amp Alpha Series Amplifier Package

MTR-3T69-G-R-0-M-0 MTR series metric servo motor with resolver

PCI-8513/2

SBS P37076

FSC-1612VN

ACE-A140A

FI-CBXSB-000/6

PCI-1612BU

1492-LS2-BR IEC Sensor Blck 5.1x68x38.5mm Spr Clp

1494G-EF3N-420 NEMA 1494G Enclosed Disconnect

软启动器 3RW44436BC34

ET 200SP 6ES7134-6HB00-0CA1 AI 2xU/I 2/4 线制 高性能型，基座单元类型 A0、A1

1585D-M4HBDM-10 Micro D-Code, QD Style Ethernet Media

1756-A7K ControlLogix 7 Slot Chassis

1794-IJ2 Flex 2 Point Input Frequency Module

194E-CA16-P11 194E Load switch

2080-LC50-48QWB Micro850 48 I/O EtherNet/IP Controller

2090-CSWM1DF-18AA18 Kinetix Cable Single DSL 2090-Series

20AC5P0A0AYNANC0 PowerFlex 70 AC Drive 5 A at 2.2 kW 20A

GC646MRB150 Proficy GlobalCare Complete for Logic PC Runtime 150 I/O

HE693STG883 8 channel +/-20mV, +/-25mV, +/-30mV strain gage input module for Serie s 90-30 with 16-bit resolution and weighing functions.

IC610MDL176RR 115/230Vac Isolated Output Module (4 points)

IC647HSTSS150KM-35 Historian v3.5 Standard Server 150000 Points (M4 Key)

IC660BBD110RR 115Vac Input Block, 16 Circuit, Ph B

IC695ACC600 RX3i Cold Junction Compensation Kit \ for Universal Analog Input IC695ALG600

IC756WDS000E-26 DV Development Suite, English, v2.6

CompactLogix System 1769-IQ32 1769 32 POINT 24VDC INPUT MODULE

PLC-5/1771 System 1770-XYV PLC-5 VME PROCESSOR BATTERY (1785VXXX)

Distributed I/O 1799-12SPCON 12-POSITION GOLD-PLATED I/O MATING CONNECTOR (2)

Operator Interface 2711P-K6M1A PV PLUS 600 GRAYSCALE, KEYPAD, SRIO, AC PS

Support 9323-WL5300S SUPT RENEWAL CONTRACT FOR 9323WL5300

Support 9358-PBBK10R SUPT REINSTATEMENT CONTRACT FOR 9358PBBK10ENE

Support F1775-MX FIRMWARE UPGRADE FOR 1775-MX PLC3 PROCESSOR MODULE

RSI Software Products 9324RSFBCU1 UPGRADE RSFIELDBUS CONFIG SW 64 TO 256 FB

RSI Software Products 9701-VWMR015AENE RSVIEW ME STATION RUNTIME 15 DISPLAY

RSI Software Products 9330-GC200UR UPGRADE: OUT-SUPT: RSGUARDIAN CORE 24 TO 128 NODE

Motion Control 2094-PRS5 POWER RAIL, SLIM, 230V OR 460V, 5 AXIS

A06B-6093-H101 Beta Series SVU-12 12 Amp Amplifier

IC200UEX210 28 point expansion. (16) 120VAC In, (12) 120VAC Out, 120/240VAC Power Supply. (Includes IC200CBL501)

IC752CKT014 DATAPANEL 150 STARTER KIT

MTR-3N31-H-R-0-N-SRR Servo Motor Nema34 with Seal

NI 9402

WAFER-LX-800-R12-BJWD

M-7017I

CPA200-4530G

SBC8155

PCA-6002

1492-J3P 2.5 square mm Standard Terminal Block

1492-SPM3D150 MCB Supplementary Protector 15 A

软启动器 3RW40381TB04

SIMATIC HMI 系列面板 6AV2124-0MC01-0AX0 TP1200 精智 12 英寸，触摸

150-SPPB2BR SMC-50 POWER POLE ASSEMBLY 110A

1738-IB4DM12 ArmorPoint 4 Point Input Module

1784-CP6 PLC-5 Communication Cable

193-KB48 3.5-4.8 A IEC Bimetallic Overload Relay

20-750-PBAY-RHBB-975 POWERFLEX 750 KIT,SIDE BUSBAR,975Amps

2090-CSBM1DE-10AF01 Kinetix Cable Single DSL 2090-Series

20AB2P2A0AYNANC0 PowerFlex 70 AC Drive 20A

GA647IFPLSR00300 GCA iFIX Plus SCADA 300 I/O Srv

GP647IFESGCLNTS GCP iFIX Optn: ESig & ERec iClientTS

IC600BF841RR 0-10Vdc Analog Input Module (8 channels)

IC647HSTCCP1M Historian Client Connection Pack 1 Users (M4 Key)

IC647TDV999 CIMPLICITY HMI Viewer Development & Runtime System

IC693MDR390LT Mixed I/O, 24Vdc Input (8 points), Relay Output (8 points) (LT)

IC756LDV001K-99 DV Development - Intel/Linux RedHat Addt'l User, Korean, Version 9.9

Pico Controllers D1760-UM001AENP PICO CONTROLLER USER MANUAL

PLC-5/1771 System 1771-OW16 CHANNEL-ISOLATED CONTACT OUTPUT MODULE

Distributed I/O 1791-IOBX BLOCK I/O, 24V DC, 128 PT MODULE

Communications 1786-FS200 200 MICRON CABLE ASSEMBLY 200 METERS (656.2 FT)

Operator Interface 9399-2SE32RUG RSVIEW32 RUNTIME USER GUIDE

Support 9356-PRO2200S SUPT RENEWAL CONTRACT FOR 9356PRO2200

Support 9324-RL0300PTR SUPT REINSTATEMENT CONTRACT FOR 9324RL0300PT

EtherNet/IP Products 1785-L80E ETHERNET/IP PLC-5/80 CONTROLLER, 100K WORD SRAM

RSI Software Products 9301-2SE3500ESU3 RSVIEW32 RUNTIME 300-100K UPGRADE IN-SUPT (ES)

RSI Software Products 9356-PRO2500 RSSQL PROFESSIONAL 70K

Motion Control N-3406-2-H00AA MOTOR,NEMA 34,6 LB-IN,6000 RPM

44A730464-G21 Connector Kit, A30/3000 & A40 Motor Power

IC200ALG325 ANALOG OUTPUT 13 BIT VOLTAGE 8CH

IC693PCM300-MP Prog. Coproc. Mdl., 160 KB (35 KB Basic Prgm), w/Port Exp. Cbl. Modified for use by OEMs

Silver Series 9321-L2EXD PLC-2 T3 STYLE;PLC-2/1774 PLC A.I. SER 3.5 1.44M

cDAQ-9181

PCM-9375

Opt002 PCL-718/812/002

ATX M-342

PX-14S5-RS-R41

A5E00104787

AIMB-267VG

1492-SPM1D500-N MCB Supplementary Protector 50 A

变频器选件 6SE6 400-0AP00-0AA1 AOP 高级操作面板 420/440

电机启动器 3VU16400MJ00

150-CA10 Smart Motor Controller Accessory

1715-A3IO 1715 3 Slot Input/Output Base Unit

1771-IT 1771 8 Point Digital Input Module

193-EC4BB E3 Plus 3-15 A Current Relay

198-W109 ModCenter IEC Wiring Kit

2090-CPWM4DF-16AF04 MP-Series 4 m Length Power Cable

2094-BL10S Kinetix Line Interface Module

DEMOCD00011 Proficy MMI DEMO CD

GFK-0750 OnTOP for Series 90-30 Online Troubleshooting and Operator Program User's Manual

IC210BDR024 24V DC Power Source, (12) 24VDC in/8 out (Relay, 8 Amp), (4) analog inputs, Expandable, without LCD/Keypad

IC647ASC001 PA SDK

IC647PPSOC5 Proficy Process Systems Operator Console with CIMPLICITY - 5 Pak

IC693CPU311CA Conformal Coated CPU311 5 slot base. CPU built into base.

IC754VBL06MTD View Loaded 6 In Mono Touch DC Blank

MSI-DASH-UNL Unlimited Dashboard Clients

SLC/1746 System 1746-R13 REPLACEMENT COVER & LABELS FOR SPECIALTY I/O MOD.

Distributed I/O 1734-OV4E 24V DC 4 CHANNEL SINK OUTPUT MODULE

Application-specific products 1803-EEM21 EEM,32 PULSES,24V DC, 8 ANALOG, 4 TO 20 MA

Operator Interface 2711E-K10C6 PANELVIEW 1000E KEYPAD TERMINAL, 10.4" FLAT PANEL

Support 9302-BATS SUPT RENEWAL CONTRACT FOR 9302BAT

Support 9381-PP250ENR SUPT REINSTATEMENT CONTRACT FOR 9381PP250EN

DeviceNet Products 1791D-8B8P DNET 24VDC CBLOCK I/O,8 IN SINK 8 OUT SOURCE, BASE

RSI Software Products 9301-2SE3350ESU3 RSVIEW32 RUNTIME 1500-5K UPGRADE IN-SUPT (ES)

RSI Software Products 9358-PBRENT01ENE RSBATCH NT FOR PROCESSLOGIX REPORT EDITOR

Motion Control MPL-B860D-SJ24AA MOTOR,SERVO,83.0NM,2000RPM,SINGL,460V,BRK

Silver Series 1398-DDM-009-DN DRIVE,15A PEAK, ULTRA 100 W/DNET

HE660BGM424 Genius BASIC Prog. Co-processor with RS-232 and RS-422/485 ports

IC646TJV000 CIMPLICITY?Tracker Display-Intel

QDA-EDT-001/L QuickDesigner Lite (download cable NOT included)

ST-3114 STXi analog input module 4 Channels, 0~20mA, 12-bit

USB-4431

PCI-1718U

ASTEC MP8-3L-2D-1E-05

ACS TECH80 SPiiPLUS PCI-4/8

POD-6601

AC6652

1492-RIFM20F-F120-2 Connection Products

上位网卡 6GK1561-1AA01 CP5611,PCI 卡，用于台式机

变送器 3RS17001AD00

1497A-A10-M6-0-N Control Power Transformer

1606-XLP100F Power Supply XLP 100 W Power Supply

1764-MM3 MicroLogix 1500 Memory Module

188-K4B200 Miniature Circuit Breaker 20 A

194L-HE6E-175I 194L Control and Load Switch Actuator

2090-CPBM7DF-08AF30 30 m Length SpeedTec Flexible Cable

2090-XXNPMF-16S30 Kinetix Drives 30m Standard Cable

CA-870-1 Adapter for LMI-241 to GP-3102NT GagePort.

GC647SEP001 GCScheduler ERP Project Mod.Adapter

IC200PKG102 I/O starter kit Profibus-DP NIU

IC646TBLCLT001 Proficy Troubleshooter for Intelligent Historian Standard, Enterprise and Corporate Clients Access 1 Users

IC647NCN010 CIMPLICITY HMI for CNC (1 connection)

IC690CBL711 CIMPLICITY 70 Keyboard Cable

IC698ACC701 RX7i CPU Lithium Battery and Spare Door

IC800VMA022 200 W VersaMotion servo amplifier

SLC/1746 System 1746-C7 6-INCH RACK INTERCONNECT CABLE

Industrial Computers 6181P-17TPXPHSS VERSAVIEW STAINLESS STEEL DISPLAY COMPUTER 17-INCH

Application-specific products 9358-PBPC30ENE RSBIZWARE BATCH FOR PLX PC BASED PHASE 30 UNITS

Operator Interface 2711-K5A3L1 PV550 MONOCHROME KEY, DH485 & RS232 PRINT

Support 9301-2SE2100PTR SUPT REINSTATEMENT CONTRACT FOR 93012SE2100PT

Support 9500-CPAKPMENS SUPT RENEWAL CONTRACT FOR 9500CPAKPMEN

ControlNet Products 9904-CNA10M CONTROLNET CNA10M ASIC (BOX OF 66)

RSI Software Products 9301-2SE2503FRE RSVIEW32 WORKS 100K WITH RSLINX (FRENCH)

RSI Software Products 9358-BEPNT60U1 UPGRADE: IN-SUPT: EPROCEDURE FOR NT 03 TO 60

Motion Control MPL-A520K-SK22AA MOTOR,SERVO,10.7 NM,4000RPM,SINGL,230V,11.3KG

Motion Control 2090-XXNPMP-14S25 CABLE,NON-FLEX,MOTOR POWER,MP/1326AB,14 GAUGE,25M

GC646MDA000 Proficy GlobalCare Complete for View Development/Runtime 8,000 I/O""

IC641SWM336 LM 90-30/20 ver. 4.02, multi-language, Std. Comm., disks + paper docs.

IC800SSI228P2 28 Amp S2K Series Amplifer/Controller with Profubus, 230 VAC

PSPC-DC Prof Shop Floor SPC DC 1 User

PXI-6514

IEI 威达电 BP-10S

KEBA G4E606-P-G

CISCO N2K-PAC-200W

ROBO-8710VLA

TEK-AT2 T701-5-25-DC

1492-MS6X12V11-20 Connection Products

数字量输入/输出模块SM 6ES7 321-1FH00-0AA0 DI/16 110/230VAC，光电隔离，20pin 前连接器

行程开关 3SE53122SF12

运行版软件 6AV2105-2FF04-0AC0 SIMATIC WinCC Runtime 专业版 Powerpack Runtime Advanced 2048 PowerTags -> Runtime 专业版 2048 PowerTags V14

1585J-M8CBJM-1 RJ45 Ethernet Media

1756-PB72K ControlLogix DC Power Supply

188-K1D005-N Miniature Circuit Breaker 0.5 A

194E-Y100-1753-6N 100 A 194E Load switch

2090-CFBM7DF-CEAF50 50 m Length SpeedTec Flexible Cable

2090-UXNFBMP-S09 MP-Series 9 m Length Feedback Cable

BC646TDV935 Server 35,000 I/O Develop/Runtime System with Proficy GlobalCare

GC647IFESGRN00900 GCC iFIX Optn: ESig & ERec 900 I/O Run

IC200ALG630 Analog input 16 bit Thermocouple, 7 channel

IC646MDG001 GE FANUC SRTP OPC Server

IC647IFPRRN00900M iFIX Profsnl SCADA 900 I/O Runtime (M4 Part)

IC660TBA106 Terminal Assembly for IC660BBA106

IC697CMM711 Communications Coprocessor, CCM, RTU, SNP, and SNPx Protocols

IC800MCUB12160XE 50 oz-in stepping Motorcube with pulse/direction interface and encoder feedback

ControlLogix/1756 System 1756-IB16D 10-30 VDC DIAGNOSTIC INPUT 16 PTS (36 PIN)

Industrial Computers 6182H-7TRH15D VVCE 700, TOUCH, STD MEM, CNET, DC

Process Control 9358-PBNT03ENE RSBATCH NT FOR PROCESSLOGIX 03 UNITS

Operator Interface 2711P-RAK12S PVP/VVCE1250 KEY/COMB TO PV1400 KEY ADAPTER

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ControlNet Products 1786-TNCLP4 CONTROLNET TNC COAXIAL CONN - PLUG TO PLUG

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