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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。
CSMT-01BB1ABT3
EM-565
1492-N42 TERM BLCK 2 Pole Side Jumper
1492-SPM3D020-N MCB Supplementary Protector 2 A
软启动器 3RW40556BB45
性能信号模块 6ES7 531-7NF10-0AB0 AI 8：模拟量输入模块，高速，AI 8x U/I HS, 35mm 模块，不含前连接器
1585D-M4HBDM-40 Micro D-Code, QD Style Ethernet Media
1760-CBL-PM02 Pico Programmer Cable
1783-MCF Stratix 8000 CompactFlash Spare Card
193-ESM-IG-30A-C55 E300/E200 30 Amp Sensing Module
20-750-I1B-C460D430 PowerFlex 750 Replacement Inverter
2090-CPWM7DF-14AF25 MP-Series 25m Length Power Cable
2098-DSD-HV150-DN Ultra 3000 Servo Drive
GA647IFCLNTCDV GCA iFIX iClient Dev
GP-0602NT-F8 GagePort LVDT NT (Full Bridge for Sangamo A6G1, Standard E4-8030)
IC5005CAC0001 PanelClient 15 inch with iFIX Terminal Service License
IC647HSTAE2000KM Alarm and Events Option for Historian - Standard Server 2,000,000 Points (M4 Key)
IC647SPT001 Scheduler Proficy Plant Apps Adapter
IC693MDL733RR 12/24 Vdc Output, 05 Amp, Negative Logic (8 Points)
IC756HDV001K-99 DV Development - HP/UX Op Sys Addt'l User, Korean, Version 9.9
Pico Controllers 1760-L12AWA-NC 12 I/O PICO CONTROLLER, AC
PLC-5/1771 System 1771-IN bbbbb MODULE, 24V AC, 8 bbbbb
Distributed I/O 1791D-4B0 DNET 24VDC CBLOCK I/O, 4 IN SINK (NOT EXPANDABLE)
Communications 1784-PCM6 1784-PCMK DH+COMMUNICATION CABLE(8 PIN DIN)
Operator Interface 2706-P44R INVIEW MESSAGE DISPLAY. 1 OR 2 LINE
Support 9305-RSVADSJPS SUPT RENEWAL CONTRACT FOR 9305RSVADSJP
Support 9515-RSMCLT010S SUPT RENEWAL CONTRACT FOR 9515RSMCLT010EN
EtherNet/IP Products 2711-K10C20L1 PV1000 COLOR KEY, ENET & RS232 PRINT
RSI Software Products 9301-2SE3403ZHE RSVIEW32 RUNTIME 32K WITH RSLINX (CHINESE)
RSI Software Products 9356-PRO2200U2 UPGRADE: IN-SUPT: RSSQL STD.300 TO PROF.300 TAG
Motion Control 1326AB-B720E-M2L MOTOR,SERVO,460V,30.9NM,3500RPM,MULTI,IP67
4161-6-24-N4 BCD To 7 SEG Display . 6 Digit, 24VDC. NEMA 4
HMI-CCT-302 BACKLIGHT TUBE 10.5" COLOR TFT QPI3 Series (QPI-3xxxx-Cxx)
IC693CPU313LT 5-Slot Base With Turbo CPU in base (.6 msec), 1K Registers, (12K Bytes User Program) (LT)
SFW-CCSP-6-0.2 CCS for bbbbbbs Software Package with Comm Cable & Manual
PCI-6870
PCM-9689
TRANS B/D 1995.11.14
X9SCL LGA1155
研祥 AT 电源 PS-270A
HPU3200ADV C-9317-1201-02
30AKNSD-KS5
1492-SPM1C400 MCB Supplementary Protector 40 A
通用型变频器 6SE6 440-2UC13-7AA1 0.37 KW,73 x 173 x 149
电机启动器 3VU13402MK00
150-C251NBR SMC-3 251A Smart Motor Controller
1609-B1000E 1609-B 1000E
1770-CD9 Data Highway 900-900 ft Length Cable
193-EC1BB E3 3-15 A Overload Relay
194R-TL2 Terminal Lugs, 300Mcm, Kit
2090-CPBM7E7-10AF05 MP-Series 5 m Length Pwr and Brake Cable
2093-AC05-MP5 Kinetix 2000 Integrated Axis Module
CP6B-0WEB-0140-AZ Shielded motor power cable for B22is motor (straight connector). 14 meters
GF-AB5V Connecting FlashCable to Analog Bipolar +/-5 V (No connector).
IC200UEX013 14 point Exp.(8) 12VDC In, (6) Relay Out, 12VDC Power Supply (includes IC200CBL501)
IC647AEC001 PA Efficiency Client
IC647PCM025 Proficy Change Management Server - 25 Concurrent Users
IC693CBL329 Cable, Left Side, Two - 24 Pin 90 Degree Connectors, 1 Meter
IC754BEZ12GAS Replacement Gasket for 12In SSteel Bezel
IMC-31CP-2-DRR IMC-D Series Servo Motor Controller, Enhanced, DeviceNet, 12 Amp
SLC/1746 System 9399-RSRGR RSRULES GETTING STARTED GUIDE
Distributed I/O 1732D-8CFGM12 DEVICENET 24VDC 8 SELECTABLE POINTS W/M12
Application-specific products 1404-M805B-000 MASTER MODULE-PQ-24V P/S
Operator Interface 2711-K10G9 PV1000 GRAYSCALE KEY, RS232 (DH485) & RS232 PRINT
Support 9301-2SE3400DER SUPT REINSTATEMENT CONTRACT FOR 93012SE3400DE
Support 9381-P500ENS SUPT RENEWAL CONTRACT FOR 9381P500EN
DeviceNet Products 1790-8BV8BX LDX I/O, 24VDC, 8 UNIV IN/8 SRCE OUT EXPAN D-SHELL
RSI Software Products 9301-2SE3300PTU1 RSVIEW32 RUNTIME 300-1500 UPGRADE IN-SUPT (PT)
RSI Software Products 9358-EPBKY03ENE RSBIZWARE EPROCEDURE BACKUP KEY 3 UNITS
Motion Control MPL-B520K-MJ22AA MOTOR,SERVO,10.7 NM,4000RPM,MULTI,460V,11.3KG
Motion Control 9101-0403 CONNECTOR KIT, MOTOR BRAKE, F/H, 90 DEG
GQPJ2D100S2P QUICKPANEL JR. COLOR 5" STN GE LABEL
IC646MRC700 Logic PC & View 700 Tag Runtime System
MTR-3T21-G-R-B-M-S MTR-Series Servo Motor, Resolver, Metric, 24 Brake, Seal
SNAP 10C5 PC Port is 9-pin male and port on CNC is 9-pin female. This is for Xo n/Xoff communications.
PXIe-8430/16
813-049-01
PMPC-2
IMB-9454G-R2
02-15787-02
XMC-PO04A-PCI
1492-PRINTINK-K bbbbb Mark Printer Black Ink Cartridge
连接电缆 6ES7468-1AH50-0AA0 IM 电缆，0.75m
变送器 3RS11002CD20
1497-E-BASX-0-N Control Circuit Transbbbber
1606-XL480E-3 Power Supply XL 480 W Power Supply
1762-L24BWA MicroLogix 1200 24 Point Controller
188-K3C400 Miniature Circuit Breaker 40 A
194L-G3572 194L IP66 ABS Thermoplastic Enclosure
2090-CPBM7DF-04AA40 MP-Series 40 m Length Cable
2090-XXNFY-S15 Y-Series 15 m Length Feedback Cable
BC647SPPMK01 Solution Provider Plant Apps M4 Key includes 1 physcial M4 key that authorizes Plant Apps as well as all core products
GC647PPSOPC bbbbbb Care for Proficy Process Systems EGD OPC Server
IC200MDL640LT bbbbb 24VDC POS/NEG LOGIC (2 GROUP OF 8) 16PT (LT)
IC646PCM100 Proficy Change Management 100 user pack
IC647MPP050 Logic Developer PLC Professional 50 pack with USB Hardware key
IC676CBLPWM020 IP67 Power Cordset - 2 Meters - Male Connector w/Leads
IC697PWR710RR Power Supply, 120/240 Vac, 55 Watts
IC800SSI107RD2RR 7.2A, 115/230V, DeviceNet S2K Servo Controller for MTR Series Motors
SLC/1746 System 1747-L20B 20 I/O FIXED HARDWARE STYLE
Industrial Computers 6189-RDT12C VVCE 1250 TOUCH SCREEN DISPLAY MODULE
Process Control 9399-RSBSAPRG RSBATCH SERVER API REFERENCE GUIDE
Operator Interface 2711-B5A2L2 PV550 MONO KEY&TOUCH, DH485
Support 9303-3CS0E10S SUPP RENEWAL CNTRCT FOR 9303-3CS0E10
Support 9371-RSWD1S SUPT RENEWAL CONTRACT FOR 9371RSWD1
ControlNet Products 2706-P72CN1 INVIEW MESSAGE DISPLAY. 1 TO 4 LINE
RSI Software Products 9301-2SE2500ITU1 RSVIEW32 WORKS 32K-100K UPGRADE IN-SUPT (IT)
RSI Software Products 9358-BBBKY60ENE RSBIZWARE BATCH, EPRO BUNDLE BACKUP KEY 60 UNITS
Motion Control MPL-A4530K-HJ22AA MOTOR,SERVO,8.36NM,4000RPM,ENCDR,230V,8.2KG
Motion Control 2090-UXNPBMP-8S30 CABLE,460V,NON-FLEX,MOTOR POWER,MP,8 GAUGE,30M
CBL-3T-MP-30 Power Cable, MTR-3T4x, MTR-3T5x & MTR-3T6x Series Servo Motors, 30 Ft.
IC641CTL995 Media Kit
IC800SLM350M2KE25 3500W, 230 VAC SL Servo Motor, 2.5K Quad Encoder
OC647TSSNET000 Proficy Troubleshooter Connector: .NET Wrapper Read & Write
PXI-5124
PX-8S-RS-R30
ICE-GM45A-R10-BULK-GR
CONTEC PO-32L(PCI)
MIC-3390E
MATROX 迈创 752-0202
1492-MCGAT225 Ground Fault Circuit Breaker
1494V-L1 Door Hardware Kit
软启动器 3RW44656BC45
运行版软件 6AV2104-2FH04-0BD0 SIMATIC WinCC Runtime Advanced Powerpack 2048 PowerTags -> 4096 PowerTags V14
1585J-M4TB-2 RJ45 Ethernet Media
1756-OA8E ControlLogix 8 Point D/O Module
188-K1B250 Miniature Circuit Breaker 25 A
194E-FA63EX-P22-PE 194E Load switch
2090-CFBM7DF-CDAF03 MP-Series 3m Feedback Cable
2090-U3CK-D44 Ultra 300 Connector Kit
BC646MSS101 Logic Developer State Standard with Programming Cable with Proficy bbbbbbCare Complete
GC647AUR001 GC PA Universal Reporting Client
IC200ACC402 VersaMax Micro 14, 20, 23 and 28 spare Removable Terminal Strips, 10 per pack
IC646CSPC050 Proficy Cause+ for Inbbbligent HMI/SCADA Client Enabler - 50X CALs
IC647IFPLRNUNLMTK iFIX Plus SCADA Unlimited Runtime (M1 Kit Part)
IC660MLA100 Label for IC660BBA100 (Qty 100)
IC697ALG440 Analog bbbbb Expander, Current, 16 Channels
IC758WMM005 ibbbbbbCare Complete 1-5 Users (same site): DataViews for bbbbbbs
FlexLogix System 1794-PS3 120/230VAC TO 24VDC @3A
GuardPLC Systems 1755-IF8 GUARDPLC 2000 - ANALOG bbbbb MODULE
Process Control 1757-UPGSIFV UPGRADE ASEA CONTROLLER QUICKBUILDER INTERFACE
Operator Interface 2711P-T12C4D2 PV PLUS 1250, TOUCH, RIO/DH, DC PS, EXT MEM
Support 9220-TAR SUPT REINSTATEMENT CONTRACT FOR 9220TA
Support 2755-ASNFRS SUPT RENEWAL CONTRACT FOR 2755ASNF
Support F1785-LTSERB FIRMWARE UPGRADE FOR 1785-LT PLC5 PROCESSOR MODULE
RSI Software Products 9301-2SE2350JPU2 RSVIEW32 WORKS 300-5K UPGRADE IN-SUPT (JP)
RSI Software Products 9701-VWSTFRU1 RSVIEW STUDIO FOR ME - ENT SERIES UPGRADE (FRENCH)
RSI Software Products 9399-WAB32UGPT RSLINX USERS GUIDE (PORTUGUESE)
Motion Control 8720MC -D180-AA- 180 AMP D CHASSIS DRIVE, ENCLOSURE, LESS OPTIONS
BC646MRB150 Logic PC Runtime 150 I/O
IC300OSW001 Cscape PDA Software with Handspring Visor/Visor Deluxe/Prism Cable
IC754ACC12GAS Gasket for 12 QuickPanel View & Control"
MTR-3T45-H-R-B-M-0 MTR series metric servo motor with resolver and brake
PCI-6624
HE-842
ATX6022/6
Unisys CP I 414843345
AP-540TX
SOL2MEVCLB
1492-LD4DF IEC Term Blck 6.1x76x52.2mm Spr Clp
1494F-L1 Door Hardware Kit
软启动器 3RW44352BC44
ET 200SP 6ES7193-6AG00-0AA0 BA 2× LC 玻璃光纤，光纤最远距离 2 KM
1585D-D4UBJM-2 Micro D-Code, QD Style Ethernet Media
1747-SDN SLC DeviceNet Scanner Module
1794-CJC2 Flex I/O Accessories
194E-AA20-P11 194E Load switch
2080-LC10-12AWA Micro810 12 I/O Smart Relay Controller
2090-CSWM1DF-14AA15 Kinetix 15m Smartbbbb Single Cable
20AC2P1C0AYNANC0 PowerFlex 70 AC Drive 20A
GC646MPM001 Proficy bbbbbbCare Complete for Logic Developer - PLC Nano/Micro
HE693OIU177 Compact VF OIU powered by 24VDC with Numeric Keypad
IC609SJR121RR Series One Junior 24Vdc Src In/Rly Out, 115Vac Power
IC647HSTSC15KM Server to Server Collector for Historian - Standard Server 15000 Points (M4 Key)
IC660BBA026RR Curr Src Analog bbbbb Block, 24/48Vdc Power, 6 bbbbbs, Ph B
IC694MDL741CA Conbbbbal Coated Output module 12/24 VDC 0.5 amp 16 points NEG logic.
IC756WDJ009E-23 DV Development Sys VB and Java, English, Version 2.3
MicroLogix 1500/1769 System 1769-ECR RIGHT END CAP/TERMINATOR
PLC-5/1771 System 1771-CE 1771 I/O CHASSIS CABLE FOR 1771-P2 POWER SUPPLY
Distributed I/O 1797-IJ2 2-CHANNEL EX HIGH RESOLUTION FREQUENCY MODULE
Operator Interface 2711P-B6C1D PV PLUS 600 COLOR, KEY/TOUCH, SRIO, DC PS
Support 9323-PA1GR SUPT REINSTATEMENT CONTRACT FOR 9323PA1G
Support 9358-HSTS2400S SUPT RENEWAL CONTRACT FOR 9358HSTS2400
Support F1772-LWSERD FIRMWARE UPGRADE FOR 1772-LW PLC2 PROCESSOR MODULE
RSI Software Products 9324-RLD3U7ENE RSLOGIX 5000, STANDARD TO PRO UPGRADE, ENGLISH
RSI Software Products 9305-RSVADDCDEE RSVIEW32 ACTIVE DISPLAY DEDICATED CLIENT (GERMAN)
RSI Software Products 9358-PMSEE NET PROCESS MONITOR
Motion Control 2092-DA2 DRIVE, 2.4A/7.2A, ULTRA1500 DIGITAL SERVO DRIVE
A06B-0141-B075#7008 AC12/2000 Servo Motor, 32K Serial Encoder
IC200UAR028-24 Qty of 24, 28 point PLC< (16) 120VAC In, (12) Relay Out (2 at 10 amp & 10 at 2 amp), 120V/240AC Power Supply. Battery (IC200ACC403) is required for data retention. Battery not included.
IC752BTS450RR Display Station 1085 - 10.4" active matrix VGA (640x480) resistive touch screen with integrated keypad, Pentium 133, 32MB, 1.2 Gig hard drive, expansion slots, Ethernet, with CIMPLICITY HMI and Win NT
MTR-1362-N-A-E-0RR Stepping Motor Nema34
NI 9218
ROCKY-3702V-R4
CBP-6405R
WAFER-6612-R10-BULK
PBP-10P7 NORCO-840AE
MATROX 906-01
FB2501
1492-SPM3C320 MCB Supplementary Protector 32 A
软启动器 3RW40462BB04
数字量输入 / 输出信号板 6ES7 223-3AD30-0XB0 SB 1223 DI 2 x 5 V DC/DQ 2 x 5 V DC，200 kHz
150-SC2NBD SMC-50 SOLID STATE MOTOR CONTROLLER 260A
1734-TOP3 POINT I/O Terminal Base
1783-SFP100FX 100FX SFP Fiber Transceiver
193-ESM-VIG-30A-C55 E300/E200 30 Amp Sensing Module
20-750-I2B-C750D710 PowerFlex 750 Inverter Assembly
2090-CPWM7DF-16AA09 MP-Series 9m Servo Power Cable
2099-BM10-S Kinetix 7000 Servo Drive
GA647IFESGCLNTCRN GCA iFIX Optn: ESig & ERec iClient Run
GP-2102NT/FOWSB GagePort Digital NT 2-port bbbbb (Fowler OEM) - Sales BOM.
IC5007TAX0030 PanelPC 17 inch Standard Unit Deluxe with bbbbbbs XP
IC647HSTAE75KM Alarm and Events Option for Historian - Standard Server 75000 Points (M4 Key)
IC647SSM005 Scheduler Shop Floor Server 5 users
IC693MDL742 12/24 Vdc Output, 1 Amp, Positive Logic (16 Points), Fused
IC756LDV000E-925 "DataViews Development on Inbbb Linux/Red Hat Op Sys, English v9.25"
Pico Controllers 1760-IA12XOW6I 18 I/O EXPANSION MODULE, AC
PLC-5/1771 System 1771-OAN OUTPUT MODULE, 120V AC, 32 OUTPUTS
Distributed I/O 1791P-16B0 PROFIBUS 24VDC CBLOCK I/O, 16 IN SINKING, BASE
Communications 2760-RB FLEXIBLE INTERFACE MODULE, 2-SLOT, 1771 I/O RACK
Operator Interface 2706-PDH485P DH-485 COMMUNICATION MODULE FOR 2706-P22R
Support 9701-VWSB000AR SUPT REINSTATEMENT CONTRACT FOR 9701VWSB000AENE
Support 9515-RSNHS250S SUPT RENEWAL CONTRACT FOR 9515RSNHS250ENE
EtherNet/IP Products 2711P-K7C4B2 PV PLUS 700, KEYPAD, ENET, AC PS, EXT MEM
RSI Software Products 9301-2SE340ITU2R RSVIEW32 RUNTIME 300-32K UPGRADE OUT-SUPT (IT)
RSI Software Products 9356-PRO2300U6R UPGRADE: OUT-SUPT: RSSQL PROF.300 TO 1500 TAG
Motion Control 1326AB-B740C-S2L MOTOR,SERVO,460V,53.0NM,2200RPM,SINGL,IP67
4162-L-6 4162 CONTINUOUS LENS KIT. FOR (6) 4162s
HMI-KPN-302 QUICKPANEL KEYPAD FOR 10.5"
IC693CPU360RR CPU 360 Module (240K Bytes configurable user memory, 4K I/O, 8 racks), no built-in Serial Ports
SPS-24W-2 24 VDC PS, 1.0A, 85-265 VAC bbbbb
