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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。
 

ET 200SP 6ES7138-6AA00-0BA0 TM Count 1x24V，高速计数模块，基座单元类型A0

150-F480NBD SMC Flex Smart Motor Controller

1756-CPR2D ControlLogix Redundant Supply Cable Down

1771-WD FIELD WIRING ARM, 12 TRMLS, TIN PLATED

194E-AA63E-PE-P11 194E Load switch

198E-AYTG2 Plastic IP65 Enclosure

2090-CSBM1DF-14AA25 Kinetix Cable Single DSL 2090-Series

2090-XXNPMF-10S04 MP-Series 4 m Length Pwr and Brake Cable

BC647SPR0X0 "Solution Provider Renewal > 30 keys includes key flashes which could be M4 or M1, Global Care Complete (iGC SP1)

GC647PRTEE005 GlobalCare Complete - Proficy Portal Enterprise Edition Client Pack 5 Users Ver 3.0

IC200MDL644LT INPUT 5/12VDC POS/NEG LOGIC (4 GROUPS OF 8) 32PT (LT)

IC646PCMS10 Proficy Change Management Electronic Signature Module 10 Pack

IC647MPS010 Logic Developer PLC Standard 10 Pack with USB Hardware key

IC676PBI016 IP67 Input Block - 24 VDC Positive Logic - 16 Pt - Profibus

IC697PWR720 Replacement Power Supply Adaptor

IC800SSI107RS1RR 7.2A, 115/230V, S2K Servo Controller for MTR Series Motors

SLC/1746 System 1747-L30B 30 I/O FIXED HARDWARE STYLE

Industrial Computers 6189-RPRH VVCE LOGIC MODULE, 128MB FLASH, 128MB RAM

Process Control D1770-6.5.21 SMART TRANSMITTER TOOLKIT USER MANUAL

Operator Interface 2711-B5A3L2 PV550 MONO KEY&TOUCH, DH485 & RS232 PRINT

Support 9303-3CS0E20UR UPGRADE: OUT-SUPT: DRIVEMONITOR TO DRIVEMONITOR32

Support 9371-RSWDI1S SUPT RENEWAL CONTRACT FOR 9371RSWDI1

ControlNet Products 2706-P92C INVIEW MESSAGE DISPLAYS

RSI Software Products 9301-2SE2500ITU5 RSVIEW32 WORKS 5K-100K UPGRADE IN-SUPT (IT)

RSI Software Products 9358-BBKEY30ENE RSBIZWARE BATCH BACK-UP KEY 30 UNITS

Motion Control MPL-A4530K-MJ22AA MOTOR,SERVO,8.36 NM,4000RPM,MULTI,230V,8.2KG

Motion Control 2090-UXPC-D0915 CABLE,9/9 POS,45 DEG D/STRAIGHT D,15M

CBL-6113 Cable. IBM COMP. To Model 9650, 25 Pin PC COMM. Port

IC641LCN053 Runtime license for DEC VAX/VMS

IC800SLMCONKITVB Connector Kit, 1 kW to 2.5 kW S-Series Servo Motors with Brake

OC647WFLRDB Proficy Workflow - Relational DB SP

PXI-5404

BP07I

W26361-W83-X-02 D1826-G31

ADT-925C

kJ060000 500XD

IAC-H671

1492-MD6X9 IEC 6 x 9 mm Marker Card

1494V-M70 Variable Depth Circuit Breaker Operator

软启动器 3RW44662BC35

运行版软件 6AV2104-3FF04-0AE0 SIMATIC WinCC Runtime Advanced 2048 PowerTags V14 Upgrade ： V11..V13 -> V14

1585J-M4TBJM-0M8 RJ45 Ethernet Media

1756-OB16I ControlLogix 16 Point D/O Module

188-K1B400-N Miniature Circuit Breaker 40 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

IC647IFPLSR00075M iFIX Plus SCADA 75 I/O Server (M4 Part)

IC660MLA105 Label for IC660BBA105 (Qty 100)

IC697ALG444 Analog Input Expander, Current, 16 Channels gold plated terminal. WARNING: The IC697ALG444 module must be matched with IC697ACC775 terminal block ONLY. IC697ACC775 is included with the module.

IC760STA100 StationPortal. Stand-alone I/O device supporting Ethernet. Includes universal power supply.

FlexLogix System 1794-STRT1DE FLEXLOGIX STARTER KIT GERMAN

GuardPLC Systems 1753-PCSUSB RSLOGIX GUARD PLUS FOR GUARDPLC - USB HARDLOCK

Process Control 1757-UPGSIFZA UPGRADE APPLICON QUICKBUILDER I/F

Operator Interface 2711P-T12C6D2 PV PLUS 1250, TOUCH, RIO/DH, DC PS, EXT MEM

Support 9220-WINTAR SUPT REINSTATEMENT CONTRACT FOR 9220WINTA

Support 2755-LHS1S SUPT RENEWAL CONTRACT FOR 2755LHS1

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RSI Software Products 9301-2SE2350KOU2 RSVIEW32 WORKS 300-5K UPGRADE IN-SUPT (KO)

RSI Software Products 9701-VWSTMENE RSVIEW STUDIO FOR MACHINE EDITION

RSI Software Products 9399-WABOUGDE RSLINX OEM USERS GUIDE (GERMAN)

Motion Control 8720MC -D180-AN- 180 AMP D CHASSIS DRIVE, OPEN ENCL., LESS OPTIONS

BC646MRC000 Logic PC & View Runtime 8,000 I/O

IC300PDA001 OCS Handheld Programmer

IC754CKL12CTD Starter Kit, 12 TFT Ctrl Loaded, 24VDC"

MTR-3T45-I-R-B-M-0RR Servo Motor Metric 24V Brake

PCI-6713

STM-5 R1.5

PCA-6186E2

Allied Telesyn安奈特 AT-2711FX/LC

ARBOR EmCORE-i6419

PIO-16/16B(PCI)

1492-LD4RB822 Terminal Block, Resistor, 8.25K Ohms

1494F-LL4 Door Hardware Kit

软启动器 3RW44352BC46

ET 200SP 6ES7193-6AP40-0AA0 BA 1×SCRJ光纤/1×FC 快连式

1585D-E4TBDE-0M3 Micro D-Code, QD Style Ethernet Media

1751-SLBA SynchLink Fiber Base Block

1794-IB10XOB6 Flex 10 Input 6 Output Digital Module

194E-AA20E-P11-TN 194E Load switch

2080-LC20-20AWB Micro820 20 I/O ENet/IP Controller

2090-CSWM1DF-14AA19 Kinetix Cable Single DSL 2090-Series

20AC2P1F0AYNANC0 PowerFlex 70 AC Drive 20A

GC646MPP010 Proficy GlobalCare Complete for Logic Developer - PLC Professional - 10 Pack

HE693OIU297 Compact VF Genius w/4-line display, powered by 24VDC

IC610CCM105RR Series One Plus Data Communications Unit (DCU)

IC647HSTSC2000KM Server to Server Collector for Historian - Standard Server 2,000,000 Points (M4 Key)

IC660BBA101RR RTD Input Block, 115Vac/125Vdc Power, 6 Chans, Ph B

IC694MDL753 Output module, 12/24VDC POS logic, 32 points. Interface uses Fujitsu connector.

IC756WDJ009J-22 DV Development Sys VB and Java, Japanese, Version 2.2

MicroLogix 1500/1769 System 9399-RL50GRFR RSLOGIX 500 GETTING RESULTS GUIDE (FRENCH)

PLC-5/1771 System 1771-CP3 1771 I/O CHASSIS CABLE FOR 1771-P7 POWER SUPPLY

Distributed I/O 1797-PS1N AC IN QUAD-EX DC OUT POWER SUPPLY- NPT CONDUIT

Operator Interface 2711P-B6C3D PV PLUS 600 COLOR, KEY/TOUCH, DH485, DC PS

Support 9323-PA1SR SUPT REINSTATEMENT CONTRACT FOR 9323PA1S

Support 9358-HSTSSROLS SUPT RENEWAL CONTRACT FOR 9358HSTSSROL

Support F1772-LXPSERD FIRMWARE UPGRADE FOR 1772-LXP PLC2 PROCESSOR MODUL

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RSI Software Products 9358-RTI20E RTI DATA COLLECTOR (20 CONFIGURATION)

Motion Control 2094-AC05-M01 MODULE, INTEGRATED, 200/230V, 3KW CONV. 9A INV.

A06B-0143-B175#7008 A12/3000 Servo Motor, Holding Brake, 64K Serial Encoder

IC200UDD112 14 point PLC,(8) 12VDC In, (6) 12VDC Out at 0.70 A, 12VDC Power Supply

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MTR-1480-E-A-E-SRR Stepping Motor Nema42 Encoder Splashproof

NI 9222

ROCKY-3702EV-R4V8

MOTOROLA HA MCP 750

OMRON 3G8F7-CLK21-V1

SP2-4300F

P51-15-K

1492-SPM3C500-N MCB Supplementary Protector 50 A

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模拟量输出信号板 6ES7 241-1CH30-1XB0 CB 1241 RS485

150-SC3NBR SMC-50 SOLID STATE MOTOR CONTROLLER 320A

1734-VTM POINT I/O Voltage Terminal Module

1783-US14T2S Stratix 2000 14+2 port unmanaged switch

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

20-750-MNT2-F10 PF755 FR10,IP00,PANEL MOUNTING KIT

2090-CPWM7DF-16AA30 MP-Series 30m Servo Power Cable

20A-EMC01 PowerFlex 70 Ferrite Core Kit

GA647IFESGDV00900 GCA iFIX Optn: ESig & ERec 900 I/O Dev

GP-2104NT/OBG GagePort Digital NT 4-port input (Owens Brockway OEM)

IC5007TBX0110 PanelPC 17 inch Performance Unit with Windows XP and Stainless Steel Bezel

IC647HSTCC10KM Calculation Collector for Historian - Standard Server 10000 Points (M4 Key)

IC647SVW001 Scheduler Desktop View Client

IC693MDL751RR 12/24 Vdc Output, Positive Logic (32 Points)

IC756LDV000J-912 DataViews Development on Intel Linux/Red Hat 32 bit Op Sys, Japanese v9.12

Pico Controllers 1760-IB12XOW4IOF 12 DC IN 4 RELAY OUT AIAO

PLC-5/1771 System 1771-OBDSK CONFORMALLY COATED, CURRENT LIMITING OUTPUT MODULE

Distributed I/O 1791R-16B0 RIO 24VDC COMPACTBLOCK, 16 IN SINKING, BASE

Communications 1786-BNCJ CONTROLNET BNC COAXIAL CONNECTOR

Operator Interface 2706-PDNETK DEVICENET COMMUNICATION MODULE FOR 2706-P7X & P9X

Support 9701-VWSB100AR SUPT REINSTATEMENT CONTRACT FOR 9701VWSB100AENE

Support 1747-PBASES BASIC DEVELOPMENT SOFTWARE SLC500 FAMILY RENEWAL

EtherNet/IP Products 2711P-K10C4B2 PV PLUS 1000, KEYPAD, ENET, AC PS, EXT MEM

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HMI-KPN-403 QuickPanel Keypad for 12.1" QPLCxxx0000

IC693CPU374CA Series 90-30 CPU374 Conformal Coated.

TGT-000A-2-0 Target 2-Axis Motion Control Module

AKD-P02406-NBEC-0000

FSC-1815

OSCILLOQUARTZ 956.300.469-9

超微P3TDE6

TVGA8900D-R

KJ020800

ATIO-032575B

1492-SPM1D060 MCB Supplementary Protector 6 A

通用型变频器 6SE6 440-2UD15-5AA1 0.55KW,73 x 173 x 149

电机启动器 3VU13403ML00

150-C3FBD-8L Encl. SMC-3 0.125 Smart Motor Controller

1609-P5000E Uninterruptible Power Supply P UPS Acces

1771-CP2 1771-P7 Power Supply Cable

193-EC2BB E3 Plus 3-15 A Overload Relay

198-H4 MECHANISM CIRCUIT BREAKERFOR STARTER

2090-CPBM7E7-16AF02 MP-Series 2m Length Pwr and Brake Cable

2094-AC16-M03-S Kinetix 6000 Integrated Axis Module

CP9I-0MPB-0140-AZ Alpha 50HVis motor power cable (14 meter)

GFK-0398 Series 90-70 PLC Genius Bus Controller User's Manual

IC200UEX264 VersaMax Micro 64 point expansion (40) 24VDC inputs, 24VDC source outputs with ESCP, 24VDC power supply. Compatible with Micro 20/40/64 revision -Bx hardware only version 4.0 firmware and above.

IC647APC010 PA ProductionClient 10 Pak

IC647PDNC PDN:Koyo PLC Direct DL405

IC693CHS397 Base, CPU, 5 Slots, Use With CPU331/CSE331 and above

IC754DVNS01 DeviceNet Slave for QP View

KIT-GFS-357-CN Proficy HMI/SCADA CIMPLICTY WKSHP KIT

SLC/1746 System D1747-6.13 REMOTE I/O ADAPTER MODULE USER MANUAL

Distributed I/O 1734D-IA8XOA8S 120 VAC 8 IN 8 OUT, DNET COMMS, SPRING

Application-specific products 1803-CT1000M PORTABLE POWERMONITOR2 CURRENT XFMR 1K/500/250

Operator Interface 2711-T10C8 PV1000 COLOR TOUCH, DH+ & RS232 PRINT

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Support 9381-PA250KENS SUPPORT RENEWAL CONTRACT FOR 9381PA250KEN

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GQPM-DEM-L02 QUICKPANEL MINI DEMO GE LABEL

IC646MSS101 Logic Developer - State Standard w/Programming Cable

MTR-3T45-I-R-B-M-0 MTR-Series Servo Motor, Resolver, Metric, 24V Brake

ST-122F STXi input module 16 points, Negative Logic, 12V/ 24VDC (connector type)

SCXI-1128

PCL-724

特伦顿 92-005927-603

MS-S0651

FHP24SX-U

PCM-4896

1492-RCDA4A63 Residual Current Device 63 A

存储卡 6ES7952-1KT00-0AA0 FEPROM 存储卡， 32M

变送器 3RS10 40-2GW50

1497-G-CXSX-0-N Control Circuit Transformer

1606-XLDNET8 1606 Power Supply

1762-OW16 MicroLogix 16 Point Relay Output Module

188-K3D080 Miniature Circuit Breaker 8 A

194L-HCDC-001 IEC Control And Load Sw Actuator

2090-CPBM7DF-08AA02 MP-Series 2m Power and Brake Cable

2090-XXNPMF-14S03 Kinetix Drives 3m Standard Cable

BC647TPR075 CIMPLICITY HMI ProServer 75 I/O Runtime System with Proficy GlobalCare

GC647PRTOSI GlobalCare Complete - Proficy Portal OSI PI Connector Ver 3.0

IC200MDL743LT OUTPUT 5/12/24VDC NEG LOGIC 0.5A PER PT (1 GROUP OF 16) 16PT (LT)

IC646PHA935 PA-70H with 935 CPU - AC

IC647MSAM MSA:Mine Safety DAN

IC684TR000321 CIMPLICITY PMCS (Level 1) (4 Days)

IC697VAL216 Remplacement is Embedded VME-3122A-420000.Contact GE IP Embedded for details.

IC800SSI228P2RR 28A, 230V, Profibus S2K Servo Controller for S-Series Motors

SLC/1746 System 1747-L542P PRO-SET 200 - 5/04 - 32K

Industrial Computers 6181P-12NPXPHDC VERSAVIEW INTEGRATED DISPLAY COMPUTER 12-INCH TFT

Application-specific products 9358-PBANT10ENE RSBATCH NT FOR PROCESSLOGIX ARCHIVER 10 UNITS

Operator Interface 2711-K5A1 PV550 MONOCHROME KEY, RIO & RS232 PRINT

Support 9303-4DTS01ENS SUPT RENEWAL CONTRACT FOR 93034DTS01ENE

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CBL-T7-MB-20 Power/Brake Cable, MTR-3T1x & MTR-3T2x Series Servo Motors, 20 Ft.

IC641PCC016 Toolkit, Function Block, C

IC800SSD107RS1 7.2A, 115/230V, S2K Servo Drive for MTR Series Motors

PR-PAT-BRK01 Proficy PAT - Driver For Bruker Ftir Spectrometers

PXI-6120

ATX6022-14G

MIC-3390

AX98690