AUT 104

Advanced Allen-Bradley Programmable Logic Controller (Analog); Programming, Troubleshooting & Maintenance using RSLogix 5000

This practical training introduces participants to Allen-Bradley ControlLogix and CompactLogix PLCs using RSLogix 5000 / Studio 5000 Logix Designer, with strong emphasis on analog (4–20mA, 0–10V, RTD, thermocouples) signals used in process industries. Participants will learn how to configure, scale, program, monitor, and troubleshoot analog inputs and outputs for field instruments such as transmitters, sensors, actuators, and control valves. Target group: Technicians, Engineers, and Operators who wish to learn PLC programming, troubleshooting, and maintenance with a focus on Allen-Bradley systems.

Duration: 5 days

Prerequisites: Basic Knowledge in electrical/electronics

Course objectives

By the end of the course, participants will be able to:
Understand analog measurement principles and signal standards
Configure ControlLogix / CompactLogix analog I/O modules
Create & manage tags, tasks, and routines in RSLogix 5000
Scale raw analog data into engineering units
Program & troubleshoot analog-based process control logic
Diagnose hardware, wiring, grounding, & signal faults
Perform online edits, backup, and system maintenance
Ensure safe handling of live automation systems

Course content

DAY 1 PLC & RSLogix 5000 Fundamentals + Industrial Signals

Introduction to PLCs in industrial automation
Allen-Bradley PLC Families
CompactLogix & ControlLogix
Hardware components overview
RSLogix 5000 / Studio 5000 environment
Project structure:
Controller
Tasks
Programs
Routines
Industrial Signal Foundations
Digital vs Analog signals
Analog standards:
4–20 mA
0–10 V
Why 4–20 mA is preferred
Loop power vs self-powered devices
Signal grounding & shielding basics
Safety & lock-out / tag-out

Practical Session:

Identify PLC modules, ca new project, connect to PLC via USB/Ethernet and Identify analog I/O modules physically

DAY 2 Tags, Data Types & Analog I/O Configuration

Tags — Controller vs Program tags
Data types:
BOOL
INT
DINT
REAL
Understanding PLC Scan Cycle
Analog I/O Module Configuration
Input module setup (e.g., 1756-IF8, 1769-IF8)
Output module setup (e.g., 1756-OF8)
Channel enable/disable
Range selection
Fault handling
Wire-off detection

Practical Session:

Configure analog input channels
Wire a 4–20mA transmitter (demo/system)
Monitor raw counts in RSLogix 5000
Create tags & aliasing
Understand raw value behavior during live changes

DAY 3 Scaling & Analog Programming Techniques

Raw counts vs Engineering units
Typical ranges:
0–16383
−32768 to 32767
Scaling methods:
Linear scaling formula
SCP equivalent logic in Studio 5000
AOI / ADD-ON Instructions
Noise, drift & filtering
Troubleshooting unstable signals
Process examples:
Level measurement
Pressure
Temperature
Flow

Practical Session:

Scale 4–20mA → 0–100%
Scale 0–10V → engineering units
Create analog alarms:
High
Low
Trip
Create trending graphs
Build a tank level monitoring program

DAY 4 Advanced Analog Diagnostics & Maintenance

Diagnosing analog faults:
Loop break
Short circuit
Noise interference
Power supply issues
Ground loop
Module & CPU fault handling
Online vs offline editing
Backup & restore
Documentation & commenting best practice
Maintenance culture & records

Practical Session:

Simulate sensor failure, monitor module fault status, clear major/minor faults, replace module & recover configuration and restore archived PLC project

DAY 5 Applied Analog Control + Final Project & Assessment

Configure an analog input & output
Scale engineering values
Implement alarms
Control a simulated actuator / valve
Trend & analyze performance
Troubleshoot introduced faults
Control loop basics:
Manual control
Automatic control
Concept of PID (Intro Level)
Tuning concept (overview only)
Connecting PLC to HMI (conceptual)
Ethernet/IP communication basics
Safety in process control troubleshooting
Final Practical Project (Hands-On)
Each participant (or group) will: