Indicate interest

Advanced Logix 5000: Programming, Troubleshooting Maintenance(RSLogix 5000)

Course Overview

The Advanced Logix 5000: Programming, Troubleshooting & Maintenance course with a focus on analog programming is designed for professionals who want to deepen their expertise in handling complex automation systems using Allen-Bradley Logix 5000 PLCs. This advanced course emphasizes analog signal processing, including configuration, scaling, and control techniques such as PID loops. Participants will also learn to troubleshoot and maintain analog systems, ensuring precise and efficient control in industrial environments. Through hands-on exercises, the course prepares participants to design, implement, and optimize advanced analog control strategies using RSLogix 5000 software.

Course Objectives

By the end of this course, participants will:.

  1. Understand the advanced features of Allen-Bradley Logix 5000 PLCs and their analog I/O capabilities.
  2. Program analog I/O modules, including scaling and signal conversion techniques.
  3. Implement and optimize PID control loops for precise analog process control.
  4. Utilize advanced analog programming techniques such as filtering and compensation.
  5. Work with advanced data handling, including the use of tags, arrays, and UDTs for analog data.
  6. Troubleshoot and resolve analog system issues using RSLogix 5000 diagnostic tools.
  7. Integrate and configure analog devices with Logix 5000 PLCs for complex control applications.
  8. Perform maintenance tasks, including program optimization, system backups, and restoring analog systems.

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.

Module 1: Introduction to Logix 5000 and RSLogix 5000 (Studio 5000)

  • Overview of Logix 5000 Family
  • Introduction to Logix 5000 Controllers: CompactLogix, ControlLogix, and SoftLogix.
  • Key components: CPU, power supply, I/O modules, communication interfaces.
  • Differences between Logix 5000 and older Allen-Bradley PLCs (SLC 500, PLC-5).
  • RSLogix 5000 Environment Overview
  • Introduction to Studio 5000 (RSLogix 5000) software interface and project structure.
  • Navigating the Project Browser, Controller Organizer, and Ladder Diagram editor.
  • Creating a new project, adding controllers, and configuring hardware.
  • Basic Programming Concepts in RSLogix 5000
  • Ladder Logic programming basics: Inputs, outputs, and coils.
  • Basic instructions: XIC, XIO, OTE, TON, TOF, CTU, CTD.
  • Understanding scan cycles and program execution.
  • Practical Session: Creating and configuring a new Logix 5000 project in Studio 5000.
  • Practical Session : Programming and simulating basic ladder logic.

Module 2: Intermediate Programming Techniques

  • Data Types and File Organization
  • Understanding data types: BOOL, INT, DINT, REAL, STRING, etc.
  • Organizing and managing data in the Controller Tags, Program Tags, and Arrays.
  • Using the Controller Tags and Local Tags effectively.
  • Structured Programming and Subroutines
  • Using Programs, Routine Types (Main Program, Subroutines, etc.), and organizing code.
  • Creating reusable code with Function Blocks (FB), Functions (FC), and Add-On Instructions (AOIs).
  • Modular program design for large applications.
  • Control Structures and Logic
  • Advanced ladder logic: Bitwise instructions (AND, OR, NOT), move instructions (MOV, MVM).
  • Sequences and state machines.
  • Jump and subroutine calling: JMP, LBL, CALL, RET.
  • Practical Session: Programming intermediate ladder logic with structured programming and reusable function blocks.
  • Practical Session: Testing and simulating sequences and state machines.

Module 3: Troubleshooting Techniques and Diagnostics

  • Understanding the Troubleshooting Process
  • Common PLC faults: I/O errors, communication issues, hardware faults, logic errors.
  • Systematic troubleshooting approach: Start from the basics and move towards complex issues.
  • RSLogix 5000 Diagnostics Tools
  • Using Online Mode: Monitor, Force, and Bypass commands.
  • Using the Diagnostic and Alarm Viewer to read system errors and faults.
  • How to use the tag monitor, watch tables, and trend data for troubleshooting.
  • Using the Fault Log and Event Log for troubleshooting critical errors.
  • Common Troubleshooting Techniques
  • Diagnosing I/O issues: Checking for wiring problems, module configuration issues, and sensor faults.
  • Communication troubleshooting: Identifying network issues, device communication problems (Ethernet/IP, DeviceNet, ControlNet).
  • Diagnosing program logic faults: Step-by-step checking and simulation of program flow.
  • Practical Session: Using RSLogix 5000 diagnostics tools to simulate and troubleshoot a system.
  • Practical Session: Troubleshooting common hardware and communication faults in a PLC system.

Module 4: Advanced Programming and Control Techniques

  • PID Control Implementation
  • Introduction to PID control and its role in process control.
  • Using the PID instruction (PIDE) in RSLogix 5000.
  • Tuning PID parameters for system optimization.
  • Practical PID control applications: Temperature, level, pressure control.
  • Handling Analog Signals
  • Configuring analog input/output modules and understanding signal scaling.
  • Programming with analog values: Scaling, filtering, and converting raw data to engineering units.
  • PID control with analog signals.
  • Communication Protocols and Configuration
  • Configuring EtherNet/IP, DeviceNet, and ControlNet communications.
  • Using Logix 5000’s communication features to link multiple controllers and devices.
  • Basic network troubleshooting and diagnostics.
  • Practical Session: Implementing a PID control loop for an analog-based application.
  • Practical Session: Configuring and testing a networked system with multiple Logix 5000 controllers.

Module 5: System Maintenance, Backups, and Real-World Application Project

  • Logix 5000 Maintenance Best Practices
  • Routine maintenance: Backup and restore procedures.
  • Performing firmware updates for controllers and I/O modules.
  • Managing system resources and performance optimizations.
  • Setting up a program for automatic logging and event tracking.
  • System Backups and Recovery
  • Backing up projects, controller configurations, and network settings.
  • Restoring configurations after hardware failure.
  • Version control and software lifecycle management.
  • Final Project: Real-World Application
    • Designing and programming a complete real-world application using Logix 5000.
    • Integrating PID control, analog signals, and communication features.
    • Testing and troubleshooting the final project.