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Basic PLC: Programming, Troubleshooting & Maintenance – Allen Bradley(RS Logix 5 & 500)

Course Overview

The Basic PLC Programming, Troubleshooting, & Maintenance course focuses on Allen-Bradley PLCs, with an emphasis on RSLogix 5 and RSLogix 500 software. This training introduces participants to the fundamentals of PLC operation, ladder logic programming, and system troubleshooting. The course combines theoretical knowledge with hands-on practice to build essential skills for maintaining and programming Allen-Bradley PLC systems in industrial environments.

Course Objectives

By the end of this course, participants will:

  1. Understand the architecture and components of Allen-Bradley PLC systems.
  2. Navigate and use RSLogix 5 and RSLogix 500 software for programming and diagnostics.
  3. Develop and test ladder logic programs for basic automation tasks.
  4. Configure hardware and assign I/O addresses for Allen-Bradley PLCs.
  5. Troubleshoot and resolve common hardware and software faults.
  6. Utilize timers, counters, and program control instructions effectively.
  7. Perform basic maintenance, including backup and restoration of PLC programs.

Target group: Operation, Installation and Maintenance of PLC control systems technician/Engineers.

Prerequisites: Basic Knowledge in electrical/electronics

Duration: Five (5) days

Methodology: Lectures complemented by hands-on exercises using Siemens S7 PLC Hardware & Simulators/Software.

Contents

Module 1: Introduction to PLCs and Allen-Bradley Systems

  • Introduction to PLCs and What is a PLC?
  • Key components of a PLC system.
  • Applications and advantages of PLCs in automation.
  • Overview of Allen-Bradley PLCs
  • Key hardware families: PLC-5 and SLC 500.
  • Differences between PLC-5 and SLC 500 systems.
  • Hardware components: CPU, power supply, input/output modules, and communication ports.
  • Getting Started with RSLogix 5 and RSLogix 500
  • Overview of RSLogix software environment.
  • Navigating the interface and creating a new project.
  • Understanding project files: .RSS (RSLogix 500) and .RSP (RSLogix 5).
  • Practical Session: Setting up and wiring a basic PLC system (PLC-5 or SLC 500).
  • Practical Session: Creating a new project in RSLogix 5/500.

Module 2: Basic Programming Concepts

  • Introduction to Ladder Logic Programming
  • Ladder logic structure and elements.
  • Basic instructions: XIC (Examine If Closed), XIO (Examine If Open), and OTE (Output Energize).
  • Understanding scan cycles and program execution.
  • Timers and Counters
  • Timer instructions: TON (On-Delay Timer), TOF (Off-Delay Timer), and RTO (Retentive Timer On).
  • Counter instructions: CTU (Count Up), CTD (Count Down).
  • Applications of timers and counters in industrial automation.
  • Memory and Data Files
  • Input/Output addressing in RSLogix.
  • Data files: Binary (B3), Timer (T4), Counter (C5), and Integer (N7).
  • Basics of bit-level operations.
  • Practical Session: Writing and testing ladder logic programs with timers and counters.
  • Practical Session:  Understanding and using data files in RSLogix.

Module 3: Troubleshooting and Diagnostics

  • Troubleshooting Basics
  • Common PLC issues: hardware, wiring, and programming errors.
  • Strategies for diagnosing problems in Allen-Bradley systems.
  • RSLogix Diagnostic Tools
  • Using online editing to monitor and modify programs.
  • Forcing inputs and outputs for testing purposes.
  • Interpreting error messages and status indicators.
  • Basic Fault Handling
  • Detecting and responding to hardware faults.
  • Understanding and implementing fault routines.
  • Practical Session: Simulating and diagnosing errors in RSLogix.
  • Practical Session: Forcing and testing inputs/outputs in a controlled environment.

Module 4: Intermediate Programming and Real-World Applications

  • Intermediate Programming Concepts
  • Logical operations: AND, OR, NOT, XOR.
  • Use of latches and unlatches (OTL, OTU).
  • Sequencer instructions: SQO (Sequencer Output) and SQC (Sequencer Compare).
  • Developing Modular Programs
  • Breaking down complex problems into simpler modules.
  • Using subroutines for structured programming.
  • Practical Session: Writing and testing modular programs with subroutines.
  • Practical Session: Implementing and testing sequencer instructions in a real-world scenario.

Module 5: Maintenance, Optimization, and Final Project

  • PLC Maintenance Basics
  • Routine maintenance practices for Allen-Bradley PLCs.
  • Importance of backups: Uploading and downloading programs.
  • Updating firmware and managing version compatibility.
  • System Optimization
  • Analyzing system performance and making improvements.
  • Reducing scan times and improving program efficiency.
  • Final Project:
  • Design, program, and troubleshoot a basic automated system (e.g., traffic light control, conveyor system).
  • Testing the system in real-time conditions.