Installation and commissioning of the system
Reasonable arrangement of system installation and commissioning procedures is the key to ensure that the installation and commissioning mission is completed efficiently and with high quality.
1. Preliminary skill preparation
The more abundant the skills to prepare for the commissioning of the system device, the smoother the installation and commissioning will be. The Pre-Skills Preparation assignment consists of the following:
(1) Understand the PC random skill materials and original materials, deepen the understanding of its functions, functions and various operation requirements, and formulate operating procedures.
(2) Deepen the understanding of planning materials, have a comprehensive understanding of the system process flow, especially the control requirements of the process for each production equipment, and on this basis, make the process flow according to the subsystem. Cheng interlocking diagram, system function diagram, system operation logic block diagram, which will help to have a deep understanding of the system operation logic, is an important part of the early skill preparation.
(3) Understand the function, planning and device status of each process equipment, especially the control and power wiring diagram of each equipment, and compare it with the real thing, so as to find faults and correct them in time.
(4) On the basis of a comprehensive understanding of the planning plan and PC skill materials, list the PC input and output point number list (including the list of internal coils, the location of I/O, the corresponding equipment and the function of each I/O point).
(5) Study the program of planning and supply, make a sequence diagram of some input and output points with complex logic, and some logical errors in the plan can be found when making a sequence diagram.
(6) The molecular system is prepared and debugged, and then summarized into the whole system debugging plan on the basis of collective discussion.
2. PLC commodity inspection
Commodity inspection should be carried out together with both sides of A and B, and the type, quantity, and standard of equipment and spare parts, spare parts, technical materials, accessories, etc., should be recognized, and whether their functions are intact will be verified in the laboratory and on-site commissioning. As a result of the commodity inspection, both sides should sign the exchange list.
3. Laboratory debugging
(1) The laboratory device of PLC is registered to make metal brackets, the input and output modules of each operation station are fixed on it, and each station is connected with the host, programmer, printer, etc. with coaxial cable according to the device summary, check that the wiring is correct, and the power supply level is consistent with the PLC voltage selection, send power according to the start-up program, load the system configuration belt, recognize the system configuration, load the programmer loading belt, programming belt, etc., and register the system according to the operating procedures, and then carry out various operation experiments.
(2) Type in the job procedure
(3) Imitate I/O input and output, check the correction program, the intention of this process is to verify the correctness of the input operating program, whether the interlocking relationship of the process equipment expressed by the logic of the program is consistent with the planned process control requirements, and whether the program is dredged. If it does not conform or cannot be operated to complete the whole process, it means that the procedure is wrong and should be corrected. In this process, the understanding of the program will gradually be deepened, ready for on-site commissioning, and at the same time, it will be possible to identify unreasonable and imperfect parts of the program for further optimization.
There are two debugging methods: (1) imitation method: make a debugging board according to the plan, imitate the input node with the toggle switch, imitate the relay and contactor of the production process equipment with a small relay, and the auxiliary contact imitates the return signal node when the equipment is running. The advantage is that it has the authenticity of imitation, and it can reflect whether logical malfunctions can occur when the mechanical contacts in the field and the electronic contacts in the PLC are connected to each other, which have large switching speeds. The disadvantage is that you need to add debugging costs and part of the debugging workload. (2) Forced method: The PLC is used to force the mechanical contacts (switches) involved in the program to make them "on" and "off" by forcing the program to operate. Its advantages are that the amount of debugging work is small, it is simple, and there is no additional cost. The disadvantage is that the logic verification is not comprehensive, and the artificial imitation of the on-site node "on" and "off" will form the program operation can not be continuous, and can only be carried out in sections.
According to our experience of on-site commissioning, the imitation method is adopted for some important field nodes, and the forced method is used for the rest, so as to complement each other's strengths.
In the logic verification stage, it is necessary to focus on filling in the debugging operation log day by day, including debugging personnel, time, debugging content, correction records, faults and processing, handover and acceptance signatures, so as to establish a debugging operation responsibility system and leave first-hand materials for debugging. Amendments to the planning process should be noted on the planning plan, and the opinions of planners should be sought in a timely manner to accurately reflect the planning requirements.
4. On-site installation and viewing of PLC
After the laboratory commissioning is completed, the equipment will be moved to the field installation when the conditions are ripe. The device should meet the requirements, the plug-in insertion should be reliable, and fastened with bolts; Communication cables should be of the same type, can not be mixed, if necessary, use instruments to check the line signal attenuation, and its attenuation value does not exceed the indicators proposed by technical materials; Measure the insulation resistance of the host, I/O cabinet, connection cable, etc.; Grounding resistance for measuring the special grounding of the system; Check the power supply, etc., and make a record, and wait until all items are in line with the requirements before turning on the power.
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