Input and output loop debugging
1. Analog input (AI) loop debugging. Carefully check the address assignment of the I0 module; Check whether the loop power supply mode (internal power supply or external power supply) is consistent with the field instrument; A signal generator is used to add a signal to each channel at the field end, and three points are generally taken to view 0, 50% or 100%. For AI loops with alarms and interlocking values, it is also necessary to check the alarm interlocking values (such as overreporting, underreporting, interlocking points and accuracy) to recognize the correctness of the relevant alarms and interlocking conditions.
2. Analog output (AO) loop debugging. According to the requirements of circuit control, the actuator (such as valve opening, etc.) can be viewed by the method of manual output (i.e., directly set in the control system), and generally take 0, 50% or 100% three points to view; Together, they are controlled in a closed-loop to see if the output meets the relevant requirements. For AO loops with alarm and interlock values, it is also necessary to check the alarm interlock values (such as overreporting, underreporting, interlocking points and accuracy) to recognize the correctness of the relevant alarms and interlocking conditions.
3. Debugging of switching input (DI) circuit. Short or disconnect at the corresponding field terminal, check the change of the LED corresponding to the channel address of the switching input module, and check the on/off change of the channel together.
4. Debugging of switching output (DO) circuit. The output point can be viewed through the forced function provided by the PLC system. After compulsion, check the change of the LED of the corresponding channel address of the switching output module, and check the on-off change of the channel together.
Loop debugging precautions
1. For the switching input and output circuits, pay attention to the consistency criterion of adhering to the situation; Generally, the positive logic criterion is used, that is, when the input and output are live, it is the "ON" state, and the data value is "1"; On the other hand, when the input and output are powered off, it is in the "OFF" state and the data value is "0". In this way, it is easy to understand and protect.
2. The switching input and output modules with large loads should be isolated from the site by relays; That is, the field contact should not be directly connected with the input and output module as much as possible.
3. When using the mandatory function provided by PLC, it should be noted that the situation should be restored after the test; At the same time, you should not force too many points to avoid damaging the module.
Manipulation logic function debugging
The debugging of the control logic function needs to be completed together with the planning, process representatives and project management personnel. The input conditions should be set using the test function of the processor, and the change in the output status should be checked according to the processor logic to see if the change in the output status is correct, so as to recognize the function of the control logic of the system. For all interlocking circuits, the process conditions of interlocking should be imitated, the correctness of interlocking actions should be carefully checked, and debugging records and countersigning should be acknowledged.
Viewing work is the process of testing the planning and control program software, which is the most messy, the most skill-demanding and the most difficult work in the debugging process. Especially in the case of the use of patented skills and special software, it is more and more necessary to carefully check the correctness of its control, and a certain operating margin should be left to ensure the normal operation of the process operation and the safety, reliability and flexibility of the system.
Processor performance test
The processor performance test should be carried out in accordance with the requirements of the system specification to ensure that the system has the functions described in the manual and is stable and reliable, including the system communication, backup battery and other special modules. Redundancy testing is necessary for systems with redundant configurations. That is, a comprehensive view of the redundancy planning part, including power supply redundancy, processor redundancy, I 0 redundancy, and communication redundancy.
(1) Power redundancy. Intercept a power supply in the meantime, the system should continue to operate normally, and the system should be free of disturbance; The power supply that has been de-energized can recover normally after being powered on.
(2) Processor redundancy. Intercept the power supply of the main processor or switch the operation switch of the main processor, and the hot standby processor should be able to actively become the main processor, the system should operate normally, and the output should be undisturbed; The de-energized processor recovers and is in standby condition after powering up.
(3) I0 redundancy. Select the input and output points that are redundant and corresponding to each other, the input module applies the same input signal, and the output module is connected to the status indicator instrument. Switch on and off (or hot-swappable, if allowed) redundant input and output modules to see if they are in the same condition.
(4) Communication redundancy. Can pass through the power supply of a communication module in the meantime or disconnect a network, check whether the system can communicate and operate normally; After resetting, the corresponding module condition should be actively restored to normal.
For the redundancy test, all modules with redundancy planning should be viewed redundantly according to the planning requirements. In addition, the view of system functions includes system self-check, file search, file compilation and downloading, information protection, backup and other functions. For the more chaotic PLC system, the system function view also includes logic diagram configuration, loop configuration and special I0 function.
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