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工作环境
温度 PLC要求环境温度在0~55℃,安装时不能放在发热量大的元件下面,四周通风散热的空间应足够大,基本单元和扩展单元之间要有30mm以上间隔;开关柜上、下部应有通风的百叶窗,防止太阳光直接照射;如果周围环境超过55℃,要安装电风扇强迫通风。
湿度 为了保证PLC的绝缘性能,空气的相对湿度应小于85%(无凝露)。
震动 应使PLC远离强烈的震动源,防止振动频率为10~55Hz的频繁或连续振动。当使用环境不可避免震动时,必须采取减震措施,如采用减震胶等。
空气 避免有腐蚀和易燃的气体,例如氯化氢、硫化氢等。对于空气中有较多粉尘或腐蚀性气体的环境,可将PLC安装在封闭性较好的控制室或控制柜中,并安装空气净化装置。
电源 PLC供电电源为50Hz、220(1±10%)V的交流电,对于电源线来的干扰,PLC本身具有足够的抵制能力。对于可靠性要求很高的场合或电源干扰特别严重的环境,可以安装一台带屏蔽层的变比为1:1的隔离变压器 b="http://byq.gkzhan.com/" target=b>变压器,以减少设备与地之间的干扰。还可以在电源输入端串接LC滤波电路。FX系列PLC有直流24V输出接线端,该接线端可为输入传感器(如光电开关或接近开关)提供直流24V电源。当输入端使用外接直流电源时,应选用直流电源 target=b>稳压电源。因为普通的整流滤波电源,由于纹波的影响,容易使PLC接收到错误信息。
安装与布线
动力线、控制线以及PLC的电源线和I/O线应分别配线,隔离变压器 b="http://byq.gkzhan.com/" target=b>变压器与PLC和I/O之间应采用双胶线连接。
PLC应远离强干扰源如电焊机、大功率硅整流装置和大型动力设备,不能与高压电器安装在同一个开关柜内。
PLC的输入与输出最好分开走线,开关量与模拟量也要分开敷设。模拟量信号的传送应采用屏蔽线,屏蔽层应一端或两端接地,接地电阻应小于屏蔽层电阻的1/10。
PLC基本单元与扩展单元以及功能模块的连接线缆应单独敷设,以防止外界信号的干扰。
交流输出线和直流输出线不要用同一根电缆,输出线应尽量远离高压线和动力线,避免并行。
I/O端的接线
输入接线
输入接线一般不要超过30米。但如果环境干扰较小,电压降不大时,输入接线可适当长些。输入/输出线不能用同一根电缆,输入/输出线要分开。尽可能采用常开触点形式连接到输入端,使编制的梯形图与继电器原理图一致,便于阅读。
输出连接
输出端接线分为独立输出和公共输出。在不同组中,可采用不同类型和电压等级的输出电压。但在同一组中的输出只能用同一类型、同一电压等级的电源。
由于PLC的输出元件被封装在印制电路板上,并且连接至端子板,若将连接输出元件的负载短路,将烧毁印制电路板,因此,应用熔丝保护输出元件。
采用继电器输出时,所承受的电感性负载的大小,会影响到继电器的使用寿命,因此,使用电感性负载时选择继电器工作寿命要长。
PLC的输出负载可能产生干扰,因此要采取措施加以控制,如直流输出的续流管保护,交流输出的阻容吸收电路,晶体管及双向晶闸管输出的旁路电阻保护。
外部安全电路
急停电路。对于能使用户造成伤害的危险负载,除了在控制程序中加以考虑之外,还应设计外部紧急停车电路,使得PLC发生故障时,能将引起伤害的负载电源可靠切断。
保护电路。正反向运转等可逆操作的控制系统,要设置外部电器互锁保护;往复运行及升降移动的控制系统,要设置外部限位保护电路。
可编程控制器有监视定时器等自检功能,检查出异常时,输出全部关闭。但当可编程控制器CPU故障时就不能控制输出,因此,对于能使用户造成伤害的危险负载,为确保设备在安全状态下运行,需设计外电路加以防护。
电源过负荷的防护。如果PLC电源发生故障,中断时间少于10秒,PLC工作不受影响,若电源中断超过10秒或电源下降超过允许值,则PLC停止工作,所有的输出点均同时断开;当电源恢复时,若RUN输入接通,则操作自动进行。因此,对一些易过负载的输入设备应设置必要的限流保护电路。
重大故障的报警及防护。对于易发生重大事故的场所,为了确保控制系统在重大事故发生时仍可靠的报警及防护,应将与重大故障有联系的信号通过外电路输出,以使控制系统在安全状况下运行。
PLC的接地
良好的接地是保证PLC可靠工作的重要条件,可以避免偶然发生的电压冲击危害。PLC的接地线与机器的接地端相接,接地线的截面积应不小于2mm2 ,接地电阻小于100Ω;如果要用扩展单元,其接地点应与基本单元的接地点接在一起。为了抑制加在电源及输入端、输出端的干扰,应给PLC接上专用地线,接地点应与动力设备(如电机)的接地点分开;若达不到这种要求,也必须做到与其它设备公共接地,禁止与其它设备串连接地。接地点应尽可能靠近PLC。
冗余系统与热备用系统
在石油、化工、冶金等行业的某些系统中,要求控制装置有极高的可靠性。如果控制系统发生故障,将会造成停产、原料大量浪费或设备损坏,给企业造成极大的经济损失。但是仅靠提高控制系统硬件的可靠性来满足上述要求是远远不够的,因为PLC本身可靠性的提高是有一定的限度。使用冗余系统或热备用系统就能够比较有效地解决上述问题。
在冗余控制系统中,整个PLC控制系统(或系统中最重要的部分,如CPU模块)由两套完全相同的系统组成如图2所示。两块CPU模块使用相同的用户程序并行工作,其中一块是主CPU,另一块是备用CPU;主CPU工作,而备用CPU的输出是被禁止的,当主CPU发生故障时,备用CPU自动投入运行。这一切换过程是由冗余处理单元RPU控制的,切换时间在1~3个扫描周期,I/O系统的切换也是由RPU完成的。
在热备用系统中,两台CPU用通讯接口连接在一起,均处于通电状态如图3所示。当系统出现故障时,由主CPU通知备用CPU,使备用CPU投入运行。这一切换过程一般不太快,但它的结构有比冗余系统简单。
本公司主营产品:
DCS集散式控制系统、PLC可编程控制器、数控系统、
(CPU处理器、模块、卡件、控制器、伺服驱动、工作站、驱动器、
马达、 内存卡、 电源,机器人备件等)各类工控产品
主要业务:
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A-B 1756,1747,1785系列 PLC CPU,
Siemens 6DD,6FX,6SC,6FC,6S5系列,
Foxboro 系统卡件,
Triconex 系统模块,
Rexroth 力士乐全系列产品,
Modicon 停产模块 等各类工控产品
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