Hands-on Allen Bradley PLC Training using RSLogix 500 or RSLogix/Studio 5000.
Our Allen Bradley PLC Industrial Maintenance & Fault Finding Professional courses are training courses with a difference. Recognised by EAL, we aim to help you become more proactive and confident in working with PLCs safely and efficiently in day-to-day operations and fault finding situations to reduce downtime and increase profitability.
We have been working closely with EAL who is the specialist awarding organisation for the engineering, manufacturing and professional trades sectors, to help develop the first EAL recognised Industrial Maintenance & Fault Finding Professional courses that are essential for anyone who intends to be working at an industrial level with machines and processes controlled by PLCs (Programmable Logic Controllers).
No previous experience or knowledge is required before attending this course however, an understanding of electrical principles is useful.
Duration and Times
This course has currently been reduced from 5 days to 4 days in duration with the 5th day being spread across the 4 days of training, this is to help reduce the number of days you are required onsite in today’s climate.
09.00 – 17.00 (Monday - Thursday)
Recognised Training Supported by Blue-chips Companies including :
Jaguar Land Rover | Toyota | UK Royal Mail | Wellstream International | British Engines
What You'll Learn
This training course is for anyone who is interested in working with PLCs on the shop-floor while being able to fault find, make modifications and maintain the machinery/production line.
Upon completing this course, you will able to work with live PLC's in industrial environments while not compromising safety or increasing production downtime when working on the shop-floor. Based around RSLogix 500 or RSLogix/Studio 5000, we will walk through the software and the majority of its available programming instructions that are most used throughout programs on the shop-floor. You will learn how to read industrial programs and incorporate instructions into Programming Blocks, Sub-Routines, and Add-on Instructions. We will explain the Standard Operating Procedures for working on the shop-floor with PLC’s, ensuring you are working safely and efficiently. Fault Finding methods and techniques are then demonstrated and practiced, making you more pro-active when working on processes/machinery, increasing production efficiency and reducing downtime.
At the end of the course, you are expected to have a detailed understanding of the most used instructions and routines in programming, as well as being confident in approaching, maintaining and fault finding with the PLC in all situations.
Day 1 Topics
- Background to the PLC
- PLCs in Industry and where they are used
- Understanding PLC Numbering Systems and converting between them (Binary, Decimal, Hexadecimal, Octal)
- Understanding the Allen Bradley PLC Range
- Understanding the differences between Modular, Compact and Rack-based PLCs
- How to select a model of PLC for a control system
- How to use the Rockwell/Allen Bradley website and locate important areas
- Understanding what an Allen Bradley PSU is
- Understanding the Allen Bradley CPU and its features
- Understanding the Allen Bradley CPU LED indication and error displays
- Understanding how to use the CPU Mode Selector
- What is a PLC Battery and why is it important
- Understanding the Allen Bradley Digital Input and Output Cards
- The importance of the Allen Bradley Catalog Numbers and F/W Revisions
- How to wire the Allen Bradley PSU, CPU and Input/Output Cards
- Understanding the differences between NPN and PNP wiring
- Understanding how Modular PLCs are constructed and expanded
- Increasing process control via Networking
- Understanding basic PLC components
- Understanding the differences between Steps, Rungs and Networks
- Understanding Logic terminology (AND, OR, ANDN, ORN, EOR)
- Understanding the Allen Bradley PLC hardware and internal addressing
- The importance of the PLC Scan and how it can be increased
- Understanding what PC/Laptop Operating System you should use for RSLogix 500/RSLogix 5000
- Understanding the RSLogix 500/RSLogix 5000 environment
- Creating your first project
- Setting up communications between your Laptop and PC (Serial or USB)
- Setting up Hardware Configuration and why its important
- CPU Properties
- How to download safely to the PLC without accidentally shutting down production
- Using RSLogix 500/RSLogix 5000 to create your first programming routines
- Labelling your project with Tags and Aliases and the benefits of doing so
- Understanding Online Editing and the dangers
- Understanding the differences between Control Latches and Alarm Latches and their important signals
- Understanding the dangers of duplication
- Using RSLogix 500/RSLogix 5000 to create Timer delay routines using the variations of Allen Bradley Timers available
Day 2 Topics
- Understanding the differences between PLC programming languages and the positives and negatives of each
- Understanding the IEC 61131-3 Programming Standards and why we adhere to these standards
- Understanding Allen Bradley Counters and what we can use them for
- How to use programming instructions to monitor system equipment for maintenance
- Understanding what downtime is and how to prevent downtime on the shop-floor
- Undertaking an Upload and how to do so correctly
- Understanding the dangers of the PLC scan and how it can affect your programs
- Understanding the dangers of when working with PLCs and how to work with them safely to prevent accidents in industry
- Understanding data handling with the Move instruction
- How the PLC works with negative values and 2's complement
- Understanding Analogue values and how they are inputted to the PLC
- How to convert Analogue signalling from Raw to Engineering and Engineering to Raw
- Understanding the common Bit Logic instructions in the Allen Bradley catalog
- How to use the One Shot Pulse (Rising and Falling) instructions correctly inside of the Allen Bradley PLC
- Using Set and Reset inside of the PLC and why it can be dangerous when used incorrectly
Day 3 Topics
- How to undertake a PLC IO Test at the start of commissioning and installing a program
- Understanding the use of clock memory of the Allen Bradley PLC
- Adopting practices to help reducing downtime when fault finding on a PLC
- Using Allen Bradley Cross-References to navigate through your program when fault finding
- How to locate free addressing inside of the Allen Bradley PLC
- Understanding the Allen Bradley Call Structure
- Using verification to ensure accurate backups are available
- Understanding the affects that Modifying and Forcing I/O has on the PLC
- Understanding the dangers of Forcing Inputs and Outputs in your program
- Adopting advanced backup procedures
- Understanding how to monitor your programs more effectively
- How to locate intermittent faults in a program
- Using the Always On and Always Off flags effectively
- Using Allen Bradley PLC diagnostics to locate problems in the PLC
- Using Safety Interlocking to help increase the integrity of your programs
- Understanding interrupts and background routines
- How to create Add-on Instructions to further increase your program control
- How to create Alarms inside of the PLC and how to manage these within your program
Day 4 Topics
- Understanding the different types of CPU Faults
- Understanding how to replace a PLC battery on the shop-floor correctly
- Understanding how to replace faulty Input/Output cards
- Understanding how to replace a PLC memory card on the shop-floor correctly
- Understanding how to work with E-Stops and Safety Circuits and implement these inside of your program
- Understanding the differences between standard PLCs and safety PLCs
- Using Maths instructions inside of the PLC
- Using Functions for calculations and data handling giving you further control of your program
- Understanding the PLC electrical schematics and IO schedules and why we use these when commissioning and installing programs
- Practice fault finding techniques by working with a real industrial program which is currently being used on the shop-floor with the help of your tutor
- Understanding the use of sequencers inside of programs and how they can reduce downtime
- Understanding the use of a cycle stop routine inside of a program
- Using Comparators to monitor process safety limits
- Creating a DDE/OPC Connection
- Using the Tag Upload Tool to save current values to your workstation
- Using the Tag Monitor Tool to monitor and edit live values within the PLC
Day 5 Topics
- Understanding the further differences between PACs and PLCs
- Understanding preventative maintenance techniques to be used with the PLC
- Learn how to replace an Input/Output Card on a Live PLC System
- How to protect your career when working with PLCs
- Understanding SIL levels when working with a control system
- Understanding IEC Safety Standards when working with a control system
- Understanding the dangers of erratic signalling
- Identifying faults inside of real industrial programs and how they can be prevented
- Understanding best practice programming
- Learn how to replace a CPU on a Live PLC System
- Make changes to a real industrial program safely without affecting the control system
This training course includes examination periods throughout each day of training. We will also be including additional training time should anyone request further explanation of any topics covered.
Upon completion of this course you will receive an Official EAL Training Certificate, this is proof that the learner has successfully completed a recognised training course at a Recognised EAL Training Centre and has passed all of the assessments for the training course.
Training at Scantime has been changed to protect our Staff and Learners due to the COVID-19 pandemic.
Our staff have been trained in new procedures when delivering Training at our Centre and when delivering Training Onsite.
To view what changes have been made, click here.
Location & Hotels
Training Centre Information
When arriving at our Training Centre, please sign in at the reception desk and then proceed to the onsite restaurant where you can order food and drink, please mention Scantime Training at the till for the order to be added to our account.
A member of staff will then be along shortly after to collect you for your induction.
There are several hotels near to Scantime, all are within 15 minutes walking distance from our training centre. We highly recommend staying at the Holiday Inn Express which is located 0.9 miles from our training centre and is also situated opposite restaurants and within walking distance to the Metro Centre shopping and entertainment complex, alternatively, we also recommend the Premier Inn which is located 1.3 miles from our training centre.
Holiday Inn Express
Newcastle Upon Tyne,
Newcastle Upon Tyne,