Course Overview
Almost all industrial equipment used in manufacturing facilities rely on a controller computer in today’s modern world. The commonly used controller is the Programmable Logic Controller (PLC). The Allen-Bradley ControlLogix, which includes the processors and I/O modules, is designed and programmed with Rockwell’s proprietary RSLogix 5000.
The overview of this course is to provide you with a thorough grasp of the fundamental values required to program, troubleshoot, and have the most comprehensive knowledge of Rockwell Automation PLC controls using RSlogix 5000 or Studio 5000. This course begins at the beginning and builds up element by element to provide the most comprehensive coverage of PLC controls. This Zoe training course will allow participants to run effective programming and maintenance services on any manufacturing computer with the RSLogix 5000. The course exposes participants to the nitty-gritty of the operation of the Allen-Bradley ControlLogix.
Why This Course Is Required?
Allen-Bradley ControlLogix PLCs programmed with RSLogix 5000/Studio 5000 are recognized worldwide for enabling robust, scalable, and high-performance industrial automation where modern manufacturing, water treatment, and process industries rely on this platform to achieve greater reliability, reduced downtime, and advanced control. The complexity of modern industrial automation requires specialized knowledge in ControlLogix programming and system integration where research, field conversions, and real-world deployments show that migrating to ControlLogix from legacy systems increases operational efficiency, supports modern communication protocols, and enhances diagnostics while systematic training and expertise development ensures organizations can leverage advanced troubleshooting capabilities and flexibility for upgrades and expansions.
The essential need for comprehensive training in Allen Bradley ControlLogix and RSLogix 5000 is underscored by its critical role in seamless modernization and uptime where proper understanding of tag-based programming, system diagnostics, and integration capabilities is crucial for achieving significant reductions in downtime and cost savings on hardware and support. ControlLogix professionals must master the principles of ladder logic programming and motion control, understand modern communication protocols and I/O configuration, and apply proper troubleshooting and maintenance techniques to ensure organizations achieve enhanced debugging capabilities, future-proof engineering solutions, and competitive advantage through reliable industrial automation and predictive maintenance integration.
Research demonstrates that Allen-Bradley ControlLogix PLCs programmed with RSLogix 5000/Studio 5000 are recognized worldwide for enabling robust, scalable, and high-performance industrial automation, with field conversions and real-world deployments showing that migrating to ControlLogix from legacy systems increases operational efficiency, supports modern communication protocols like EtherNet/IP and ControlNet, and enhances diagnostics, troubleshooting, and flexibility for upgrades and expansions.
Course Objectives
The objectives of this training course are to ensure users of the Allen-Bradley ControlLogix have:
- A complete understanding of the RSLogix modules’ design and understanding the functionality of a PLC
- Advanced knowledge of basic programming skills
- An extension of programming into the design of controller computers used in most manufacturing facilities
- Understanding of the Ladder Logic as a programming language on the PLC
- The skills to carry out a diagnostics service on a system
- Knowledge on configuring and making changes on the software to suit the needs of the organisation or manufacturing facilities
- The ability to analyse the RSNetworks and also run troubleshooting on FlexLogix, CompactLogix/ControlLogix PLC systems
- The needed skills to restore and backup developed PLC program whenever required
- Knowledge about recent development and designs for PLC operation
- Advanced competency in tag-based programming and motion control integration
- Expertise in EtherNet/IP and ControlNet communication protocols
- Enhanced understanding of digital twin integration and predictive maintenance capabilities
- Skills in advanced diagnostics and system optimization techniques
- Proficiency in Studio 5000 Logix Designer and modern automation tools
Master ControlLogix PLC excellence and drive industrial automation success. Enroll today to become an expert in Allen Bradley ControlLogix PLC Training – RSLogix 5000 Series!
Training Methodology
Zoe Talent Solutions uses a unique training methodology in delivering course content to ensure the active learning of all course participants. Experts and professionals deliver the training from the relevant domain. The course content is tailored to reflect and achieve the learning outcomes and is suitable for learners.
The training framework includes:
- Expert-led instruction by professionals with extensive Allen Bradley ControlLogix experience
- Hands-on participation that moves beyond theoretical learning approach with practical programming exercises
- Interactive case studies and scenarios that reinforce learning outcomes and achieve necessary engagement
- Practical experience with RSLogix 5000/Studio 5000 software and ControlLogix hardware
- Real-world troubleshooting scenarios and maintenance procedures
Zoe Talent Solutions makes use of the unique learning approach of the ‘Do-Review-Learn-Apply Model’ that converts learning to practical knowledge and skills. This immersive approach fosters practical skill development and real-world application of ControlLogix principles through comprehensive coverage of programming, troubleshooting, and system integration techniques.
Who Should Attend?
This Allen Bradley ControlLogix PLC Training – RSLogix 5000 Series Course is designed for:
- Beginners at programming looking to advance their skills on the job
- Advanced programmers who need to understand and use the modern RSLogix 5000 in their organisation
- Facility managers responsible for seeing the operational process in the facilities
- Project design, commission and programming engineers who work in the manufacturing facilities where the RSLogix 5000 program will be deployed
- Other professionals within or outside the industry willing to learn and acquire knowledge
- Maintenance technicians responsible for troubleshooting ControlLogix systems
- Automation engineers and control system specialists
- Instrumentation and process control professionals
- System integrators and contractors working with Allen Bradley equipment
Organisational Benefits
These are some of the ways your organisation will benefit from having their personnel enrol for the course:
- Employee well equipped with current and modern knowledge about PLC processes
- Effectively using Ladder Logic as the primary form of programming language on PLC
- Well-trained personnel to handle your organisational PLC using the modern RSLogix 5000 Series
- Improvement in the organisation’s operational process, including the design and automation of processes
- Modification of programming design to suit the operational demand of the organisational facilities
- Total support for systems diagnosis and troubleshooting of the organisational network
- Ability to restore the PLC program and routinely back up the automated PLC programs
- Significant seamless modernization and uptime through organizations converting from legacy PLCs that report substantial reductions in downtime
- Enhanced debugging and maintenance through RSLogix 5000’s tag-based programming and system diagnostics that simplify troubleshooting
- Future-proof engineering capabilities through ControlLogix and Studio 5000 adoption that supports industrial digitalization
- Strengthened competitive positioning through enhanced reliability, reduced maintenance intervals, and integration with advanced automation technologies
Studies show that organizations implementing comprehensive ControlLogix training achieve significant seamless modernization and uptime as organizations converting from legacy PLCs to ControlLogix report significant reductions in downtime, streamlined code migration, and cost savings on hardware and support, enhanced debugging and maintenance through RSLogix 5000’s tag-based programming, system diagnostics, and high integration with motion and safety modules that simplify troubleshooting enabling faster issue resolution, and future-proof engineering as adopting ControlLogix and Studio 5000 supports industrial digitalization and predictive maintenance offering agile base for automation, data analytics, and IoT initiatives.
Empower your organization with ControlLogix expertise. Enroll your team today and see the transformation in industrial automation and operational efficiency!
Personal Benefits
In addition to the benefit obtained by the organisation, the professionals who attend this training course will also benefit from the following:
- Advance your knowledge of basic programming skills
- Sufficient knowledge and understanding about how to use the RSLogix 5000 on a PLC system
- Familiar with setting up and using the Allen-Bradley ControlLogix or CompactLogix
- Well equipped to operate the system using the Ladder Logic programming language
- Understanding the project scope or functional specification and turning it into a working PLC program
- Ability to select the appropriate program or process suitable for each operational function
- Create and edit existing programs and also be able to create a blueprint to track changes made to the system
- Be able to provide technical support when trouble arises with using the PLC system
- Be able to back up and restore PLC programs quickly
- Skilled enough to take on challenging tasks when designing programs using the RSLogix model
- Advanced expertise in industrial automation and PLC programming
- Enhanced career prospects and marketability in manufacturing and automation sectors
- Improved ability to lead automation projects and manage complex control systems
- Greater competency in troubleshooting and system optimization techniques
- Increased capability to mentor and develop other automation professionals
- Enhanced understanding of emerging automation technologies and industry standards
Course Outline
The course outlines the following topics that will be taught during the training course:
Module 1: Overview of PLC and Control System
- Introduction to PLC
- Different types of PLC
- How PLC works
- Introduction to Softwares and automation processes
- Using Ladder Logic programming
- Using PLC hardware
- Consideration for Design and Maintenance
- Programmable Automation Controller (PAC) fundamentals and system architecture
- Understanding the differences between PLCs and modern PAC systems
- Industrial automation system integration and communication protocols
- Control system design principles for manufacturing environments
Module 2: Allen Bradley
- Introduction to Allen Bradley
- Allen Bradley software list and packages
- Installation of the software
- The RSLogix 5000 software
- Allen Bradley PLC Programming Basics
- Allen Bradley Function Block Programming
- Function Block Timer
- One-shot rising and falling
- Function Block Count Up and Down
- Allen Bradley Structured Text Programming
- CASE Construct
- IF…THEN…ELSE Construct
- WHILE DO Construct
- FOR DO Construct
- Studio 5000 Logix Designer interface and user environment
- Tag-based programming concepts replacing traditional memory allocation
- IEC 61131-3 programming language support including Ladder Logic, Function Block, and Structured Text
- Add-On Instructions for modular programming and code reusability
Module 3: ControlNet
- Introduction to ControlNet
- Common Industrial Protocol (CIP)
- Open Systems Interconnection model
- ControlNet Physical Layer
- Connectors
- Cables
- Topology
- Data Link Layer
- ControlLogix Processor
- I/O Modules
- ControlNet deterministic scheduling and real-time communication capabilities
- DeviceNet integration and network topology considerations
- Network configuration and diagnostics for industrial communication
- Multi-drop and point-to-point network architectures
Module 4: ETHERNET
- Concept of Ethernet
- Use of ping functions, Subnet Mask, EtherNet and IP addresses
- Appreciation for EtherNet cabling options and routers
- Configuration of I/O modules
- Troubleshooting
- EtherNet/IP protocol implementation and Producer/Consumer model
- TCP/IP fundamentals for industrial automation networks
- Network switching and VLAN configuration for industrial applications
- Remote I/O communication over Ethernet infrastructure
Module 5: Ladder Logic Programming
- Basic Ladder programs
- Ladder view
- Setting up overall control rung
- Creating batch cycles and steps
- Using expressions and procedure programming
- Ladder Logic instruction set including XIC, XIO, OTE, and timer instructions
- Boolean logic implementation in ladder programming
- Program flow control using JSR, SBR, and RET instructions
- Arithmetic and comparison instructions for data manipulation
Module 6: Organizing data and Ladder Logic Design
- Using Ladder logic for RSLogix5000 routine
- Entering instructions for the RSLogix5000 routine
- Organization and design of data
- Tasks, Programs and routines
- Controller Organizer structure and project organization
- Task types including continuous, periodic, and event-triggered tasks
- Program scheduling and multitasking concepts
- User-defined data types and structured data organization
Module 7: Project Scope
- Searching for project components
- Documenting the project scope
- Configuration of the RSLogix 5000 controllers and sharing over EtherNet network
- Communicating with I/O module over EtherNet network
- Project documentation and version control best practices
- Controller configuration and I/O module setup procedures
- Cross-reference tools for tracking tag and instruction usage
- Import/Export functionality for tag databases and project components
Module 8: Motion Application Program
- Motion State Instructions
- Motion Axis Fault Reset (MAFR)
- Motion Axis Shutdown (MASD)
- Motion Axis Shutdown Reset (MASR)
- Motion Direct Drive Off (MDF)
- Motion Direct Drive On (MDO)
- Motion Move Instructions
- Motion Axis Stop (MAS)
- Motion Axis Home (MAH)
- Motion Axis Jog (MAJ)
- Motion Axis Move (MAM)
- Motion Group Instructions
- Motion Group Stop (MGS)
- Motion Group Shutdown (MGSD)
- Motion Group Shutdown Reset (MGSR)
- Motion Group Strobe Position (MGSP)
- Motion Event Instructions
- Motion Arm Watch (MAW)
- Motion Disarm Watch (MDW)
- Motion Arm Registration (MAR)
- Motion Disarm Registration (MDR)
- Motion Configuration Instructions
- Motion Apply Axis Tuning (MAAT)
- Motion Run Axis Tuning (MRAT)
- Motion Apply Hookup Diagnostics (MAHD)
- Multi-Axis Coordinated Motion Instructions
- Master Driven Coordinated Control (MDCC)
- Motion Calculate Transform Position (MCTP)
- Motion Coordinated Transform with Orientation (MCTO)
- Motion Coordinated Circular Move (MCCM)
- Master Driven Axis Control
- Servo motor control and positioning systems integration
- Motion profile generation and velocity/acceleration control
- Electronic gearing and camming applications
- Integrated motion and logic control for manufacturing automation
Module 9: Troubleshooting and Maintenance
- Toggling bits and I/O tags
- Using a trend chart to troubleshoot a system
- Analyzing and correcting faults
- Controller’s fault
- Chassis and power supply faults
- Online diagnostics and system monitoring capabilities
- Fault diagnostic procedures and error code interpretation
- Trend and data logging for performance analysis
- Predictive maintenance integration and system optimization
- Remote monitoring and diagnostic capabilities through Ethernet connectivity
- Backup and restore procedures for program and configuration data
Real World Examples
- Hallam-ICS (Large Industrial Facility, USA)
Implementation: Over a multi-year phased project, Hallam-ICS replaced an aging Allen-Bradley PLC5 backbone with ControlLogix processors, ControlNet/Ethernet communications, and updated SCADA. This conversion included automatic code migration, custom cable design, and multi-phase RIO rack swapping.
Results: Hardware costs cut by 25%, downtime during conversion limited to days, and long-term reliability/security improved for over a decade of continued operation. - Novaspect (Global Water Treatment Product Manufacturer, USA)
Implementation: Novaspect successfully configured and deployed the Allen-Bradley ControlLogix system at the manufacturer’s pilot processing facility under a tight, one-week shutdown window. Their Engineering Services team integrated 17 instruments for PLC automation, replacing error-prone manual control.
Results: Met the organization’s strict upgrade deadline, enabled safe and efficient automatic process control, and aligned new infrastructure with the company’s sustainability and productivity goals.
Be inspired by industry-leading ControlLogix achievements. Register now to build the skills your organization needs for industrial automation excellence!
