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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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1585D-M8UGJM-40 Gigabit Ethernet Media

1609-RSC 1609 Remote Start Cable UPS Accessory

1769-IA16 CompactLogix 16 Pt 120VAC D/I Module

188-K1C500-N Miniature Circuit Breaker 50 A

193-EMRA E1 Plus 240V AC Remote Reset Solenoid

20-750-DNET PowerFlex 750 DeviceNet Adapter

2090-CPWM7DF-12AA03 MP-Series 3m Power Cable

2098-DSD-010X Ultra 3000 1kW Servo Drive

G-0602 Connecting cable between GP-0602NT and GPA-602.

GFK-2100 IC697VHD001 VME Hard Drive

IC220PWR014 SEGMENT TERMINAL, ELEC FUSED 24VDC (REQUIRES 1 IC220TBK087)

IC647DNP050 "DNP3 Master Protocol for 50,000 points"

IC647S2GM S2G:SECS-II

IC693MDL632RR 125 Vdc Input (8 Points)

IC756DVE000J-97 EO GECK (Graphical Editor Construction Kit) - Unix, Japanese, Version 9.7

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PLC-5/1771 System 1771-ASBK CONFORMALLY COATED, PLC2, 3, 5 REMOTE I/O ADAPTER

Distributed I/O 1790D-0V16 DNET LDX I/O, 24VDC, 16 SINK OUT BASE, D-SHELL

Communications 1770-CD1 DATA HWY TWINAXIAL CABLE, 100 FT/30 M

Operator Interface 2711E-UK12EK14 PANELVIEW 1200E KEYPAD TO 1400E KEY MIGRATION KIT

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HE800ACC519 DIN-rail mount Terminal Block, 19-pin. Compatible with most SmartStack Digital I/O. Allows SmartStack I/O to be terminated on panel backplate as an alternative to direct SmartStack termination on panel door.

IC693ACC330 TBQC Base for IC693MDL740, IC693MDL742

QPK3D200L2P/B 6" Monochrome, Blank Label, 24Vdc, UL,cUL,CE,UL1604

TGT-3X6L-1-0 Target series 6 amp servo power module

20BC481A0ANNNNC0 PowerFlex 700 AC Drive 20B

20F1ANE077AA0NNNNN PowerFlex 753 AC Packaged Drive

22B-D024N104 PowerFlex 40- 11 kW (15 HP) AC Drive

140DAM59000 Quantum 开关量AC混合模块,16点输入,115VAC;8点输出

284E-FVD4P0Z-10-CR-EMI EtherNet Variable Frequency Drive

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194R-N60-1753-PYS1 Non-Fused 194R Disconnect Switch

2090-CPBM7DF-16AA25 MP-Series 25m Standard Cable

2090-XXTFMP-S15 MP-Series 15 m Length Feedback Cable

CBL-T7-MP-30 Power cable for MTR-3T10 or MTR-3T20 or MTR-3T40 series servo motors. 30 feet

GF-3215R Connecting FlashCable to Mettler PM/ SM, Toledo.

IC200UDR002-24 Qty of 24, 14 point PLC, (8) 24VDC In, (6) Relay Out, 24 VDC Power Sup ply

IC646TRT000 Unlimited I/O Point Runtime System

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SLC/1746 System 1761-CBL-AS03 CABLE: SLC FIXED, 5/01, 5/02 & 5/03 RJ45 TO PORT 3

Industrial Computers 6186-M20RK VERSAVIEW 20 INCH MONITOR, TEMPERED GLASS

Application-specific products 1404-M505A-DNT MASTER MODULE - PQ DNET COM

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RSI Software Products 9301-2SE3203ESE RSVIEW32 RUNTIME 300 WITH RSLINX (SPANISH)

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Motion Control 2090-SCVG25-0 SERCOS FBR CABL,CONN,STNDRD PVC JKT,GLASS,25.0M

GFZ-65142E Alpha Series AC Servo Motor Debions Manual

IC646MPC101 Logic Developer - PLC Configuration Tools w/Programming Cable

MTR-1324-N-D-E-S Stepping Motor Nema34, Series Wdg, Splashproof

QPJ-ABR-201 Communication Module for 5 inch & 6 inch: AB Remote I/O/ UL/ cUL/ CE/ UL1604

20BC037A0AYNANA0 PowerFlex 700 AC Drive 20B

20F11NC043AA0NNNNN PowerFlex 753 AC Packaged Drive

22-COMM-D PowerFlex DeviceNet Adapter

2711P-RGK10 PV Plus 1000 Keypad Antiglare Overlay

280G-FS-10-RG ArmorStart Spare Parts

C200HW-ME16K EEPROM存储单元 16K

1492-PDE1142 200 A Enclosed Power Distribution Block

中央处理单元 6ES7417-4XL04-0AB0 CPU417-4，20MB，30ns，电源 24VDC，MPI/PROFIBUS-DP 主站接口，PROFIBUS-DP 主站接口

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1495-N80 Line Side Cover

1585J-M8TBJM-4 RJ45 Ethernet Media

1761-CBL-AS09 MicroLogix Cable

188-K3B200-N Miniature Circuit Breaker 20 A

194L-E16-3254 16 A 194L Load Switch

2090-CPBM4DF-16AF25 MP-Series 25 m Length Cable

2090-XXNFMF-S25 Kinetix Drives 25m Standard Cable

BC647OEM0500B OEM Edge Program - Complete

GC647PATCDI0 Proficy PAT - Driver For CDI - Assist Support

IC200MDD845 Mixed 24VDC POS LOG b group 16 point / isolated 2 amp relay output 8 point.

IC646NRX005 System Sentry - 5 Node

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IC675PCB002 Profibus Cordset 2.0 Meters

IC697MDL740RR 24/48 Vdc Output, 2 Amp, Positive Logic (16 Points)

IC800SLT001 SL series amplifier terminal block for APM and DSM motion controller interface

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CBL-1C-ET-30 Encoder Cable, MTR-1216, 1221 & 1231 Stepping Motors, 30 Ft.

IC630MDL310RR High Speed Counter Module

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OC647IFSETKTM iFIX Optn: System Extension Toolkit (M4 Part)

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20P41AB360RA0NNN PowerFlex DC Drive 230V AC 100 HP

2711C-CBL-AB03 PanelView Component Accessory

280-PWRM24B-M2 ArmorConnect 3-PH Power Media drop cable

SRT2-ID08 远程I/O端子（晶体管输入）8点

1492-MCBA190 Miniature Circuit Breaker

1494V-DJ622-A-B-D-E NEMA Flange Mtd Rod Switch Disconnect Sw

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1585D-M4UBJM-5 1585D Ethernet Media Patchcord

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194E-FA16E-P11-PE 194E Load switch

2090-CFBM6DF-CBAA20 TL-Series 20m Feedback Cable

2090-SCNP5-0 Kinetix 5-5m Fiber Optic Cable

BC646MPM101 Logic Developer PLC Nano/Micro with Programming Cable with Proficy GlobalCare Complete

GC647APC001 GC PA Production Client

HMI-CCT-201 BACKLIGHT TUBE 10.5 inch Color STN (QPI2xxxxS2P) or TFT (QPI2xxxxC2P)

IC641VPD050 VersaPro Distributor Demo 50 Pack

IC647IFGLBLRLYSRVRM iFIX WebSpace Relay Server includes 25 Users

IC660EBR100 Electronic Assembly for IC660BBR100

IC697ACC700 Terminal Block, 40 Contacts (qty 6)

IC756WRE499E-28 Runtime License for Windows 100+ Users, Per User, English v2.8

FlexLogix System 1794-IE8K CONFORMAL COATED, ANALOG INPUT MODULE, 8 POINT

PLC-5/1771 System D6200-6.4.12JP PLC5 PROGRAMMING SW I/O CONFIG. MNL (JAPANESE)

Process Control 1757-SRC1 1757 REDUNDANCY MODULE CABLE - 1 METER, 3.28FT

Operator Interface 2711P-T10C4D2 PV PLUS 1000, TOUCH, ENET, DC PS, EXT MEM

Support 6001-A1DBR SUPT REINSTATEMENT CONTRACT FOR 6001A1DB

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Support F1785-L46BSERE FIRMWARE UPGRADE FOR 1785-L46B PLC5 PROCESSOR MODU

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BC646MODEV10PK Motion Developer 10-pack Proficy Global Care Complete for the S2K Series Amplifiers/Controllers

IC300OCS057 MiniOCS with 2x20 LCD & 16 keypad & onboard IO (no expansion) 8 DC bs (pos/neg)without CsCAN, 8 DC Outputs (pos), 4 ISOLATED analog in (20mA), 2 ISOLATED analog out (20mA)

IC752WFB204 Display Station 2020 Series - w/ touch - 12.1" SVGA (800x600), Pentium 233 MHz, 64 MB RAM, 6.4 GB HD, expansion slots, Ethernet, floppy drive, CD ROM front access, built-in keypad, HMI for CNC, HSSB card, Win NT

MTR-3T21-G-R-B-M-S MTR series metric servo motor with resolver and brake and shaft seal

ZA06B-6136-H201 Beta Dual SVM1-20i FSSB Servo Amp,20/20A

20D-HEID-D0 PowerFlex 700S Heidenhain Encoder Board

20G1AGD361AA0NNNNN PowerFlex 755 AC Packaged Drive

25A-V4P8N104 PowerFlex 523 0.75kW (1Hp) AC Drive

2711P-T7C4D8 PanelView Plus Terminal

6SE6430-2UD31-8DB0 18.5KW

1492-L35 IEC Term Blck 16.1x100.5x51.8mm SPr Clp

1494C-CM13 Cable Mechanism

软启动器 3RW44261BC44

附件 6ES7 954-8LL02-0AA0 存储卡：256 MB

1585A-DD4JD Accessories Ethernet Media

1746-RT28 SLC Replacement Terminal Block

1790D-T0A6 CompactBlock LDX 6 Point O/P Base Block

194E-A32-1753 32 A 194E Load switch

20-PP12001 OPTICAL FIBER SET

2090-CSBM1DF-18AF11 Kinetix Cable Single DSL 2090-Series

20AC043C3AYNANC0 PowerFlex 70 AC Drive 43 A at 22 kW 20A

GC646MBP001 Proficy GlobalCare Complete for ME Professional Development Suite

HE670IBU100 Discontinued Part. Check with GE IP on migration path.

IC600LX680RR 64K Logic/16K Register Memory Module

IC647HSTESEO100KM eSignature Option for Historian - Enterprise Server 100000 Points (M4 Key)

IC655CCM500RR Communications Control Module (CCM)

IC694MDL230 Input module, 120 VAC 8 point, isolated per point.

IC756SDV001K-99 DV Development - Solaris Op Sys Addt'l User, Korean, Version 9.9

MicroLogix 1500/1769 System 1769-IQ16 16 POINT 24 VDC SINKING/SOURCING INPUT MODULE

PLC-5/1771 System 1785-KA5 COMMUNICATION MODULE DATA HWY PLUS TO DATA HWY 485

Distributed I/O 1794-TB3G 3-WIRE GROUNDED TERMINAL BASE - SCREW CLAMP

Communications 9399-WABUG WINTELLIGENT LINX FOR A-B PROG. CONTROL USER GUIDE

Support 9311-PASJR 9311PASJ SOFTWARE SUPPORT CONTRACT REINSTATEMENT

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Support F1771-NXXSERA FIRMWARE UPGRADE FOR 1771-N SERIES I/O MODULE

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Motion Control 8720SM-022S2GAS2 22 KW/48 AMP, 750VDC, AC MOTOR WITH SRM60 ENC.

840-RC-15 15" Ribbon Cable. Term Both Ends W/16 Pin DIP Plugs

IC200MDL940 OUTPUT RELAY 2.0A PER PT ISOLATED FORM A 16PT

IC697VAL314 Analog Output, Isolated, 4 channel, 12 bit, Current - 4 to 20mA. Removable temrinal block, no cable required

MTR-1331-J-N-D-E-S MTR series NEMA 34 splashproof stepping motor with series winding connection

ZA06B-0062-B503 B2/4000HVis servo motor with 24 VDC brake and 128k serial encoder

20BD156A3ANNANC0 PowerFlex 700 AC Drive 20B

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22F-V6P0N103 PowerFlex 4M-1.1 kW (1.5 HP) AC Drive

140CFI00800 Quantum CABLEFAST, 模拟量输入块, 无保险

294E-FD2P5Z-G1 Variable Frequency Drive

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1492-SPM3B500 MCB Supplementary Protector 50 A

软启动器 3RW40372BB04

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150-F85NBRB SMC Flex Smart Motor Controller

1734-IT2I POINT I/O 2 Point Thermocouple Input

1783-HMS16TG4CGN Stratix 5400 20 Port Managed Switch

193-ER1A Remote Reset Solenoid

20-750-EMCBUS1-F8 PF750,FR8,IP00,EMC BUS, TERMINATION KIT

2090-CPWM7DF-14AA03 MP-Series 3m SpeedTec Standard Cable

2098-DSD-075-SE Ultra 3000 Servo Drive

GA646IFCLNTCRO100 GCA iFIX iClientTS Read Only 1 PK Runtime Version

GFK-2222 PACSystems CPU Reference Manual

IC220TBK123 I/O TERMINAL STRIP, 12 POSITION SPRING STYLE, OUTPUT, QTY 10

IC647GE9C GE9:GE Fanuc Ethernet

IC647SGM001 Scheduler Series and Groups Module

IC693MDL646CA Conbal Coated Input module 24 VDC 16 point POS/NEG ogic. 1msec filtering.

IC756DVE010K-99 EO GECK (Graphical Editor Construction Kit) - Inb x87, Korean, Versi on 9.9

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PLC-5/1771 System 1771-DS LATCHING INPUT MODULE, 10-27V DC, 8 INPUTS

Distributed I/O 1790D-N0C2 DNET LDX, 2 OUTPUT ANALOG CURRENT BSE,D-SHELL CONN

Communications 1770-XE DATA HWY 15 PIN CONNECTOR KIT, (FEMALE)

Operator Interface 2727-M7P20D1Q3 MOBILEVIEW MACHINE TERMINAL MT750

Support 9305-RSVADFCPTR SUPT REINSTATEMENT CONTRACT FOR 9305RSVADFCPT

Support 9515-RSAAMRCTS SUPT RENEWAL CONTRACT FOR 9515RSAAMRCTENE

EtherNet/IP Products 2706-P44R INVIEW MESSAGE DISPLAY. 1 OR 2 LINE

RSI Software Products 9301-2SE3400PTU5 RSVIEW32 RUNTIME 5K-32K UPGRADE IN-SUPT (PT)

RSI Software Products 9515-RSCMP075ENE RSGUARDIAN MIGRATION PROMOTION, <=75 DEVICES

Motion Control 1326AB-B430G-S2L MOTOR,SERVO,460V,6.4NM,5000RPM,SINGL,IP67

4161-2-24-N12 BCD To 7 SEG Display . 2 Digit, 24VDC. NEMA 12

HMI-BEZ-406 BEZEL 7.5" (QPGCXXX0000) STAINLESS STEEL

IC693BEM331 Genius Bus Controller

QPLCTAE0000 12.1" Color TFT, Ethernet, CF Card, 110VAC

TGT-E00A-2-0RR Target Axis Expansion Module, 3' Rack Linker Cable