AUT 101

Basic Allen-Bradley Programmable Logic Controller (PLC); Programming, Troubleshooting & Maintenance using RSLogix 500

This hands-on course introduces participants to the fundamentals of Allen-Bradley PLCs using the RSLogix 500 platform. Participants will learn PLC hardware architecture, programming concepts, ladder logic development, troubleshooting techniques, and maintenance best practices. Through practical exercises and simulations, learners will gain the confidence to interpret, modify, and maintain PLC-controlled industrial systems safely and effectively.

Duration: 5 days

Prerequisites: Basic Knowledge in electrical/electronics

Course objectives

Understand PLC concepts, structure, and operating principles
Identify Allen-Bradley SLC & MicroLogix hardware components and wiring
Create, edit, download, and monitor PLC programs in RSLogix 500
Develop and interpret ladder logic programs
Apply basic instructions such as contacts, coils, timers, and counters
Diagnose and troubleshoot PLC faults and process issues
Perform routine PLC maintenance and documentation
Work safely with industrial automation systems

Course content

Day 1 Introduction to PLCs & Allen-Bradley Systems Topics

Role of PLCs in industrial automation
PLC vs relay logic
Overview of Allen-Bradley PLC families (SLC-500, MicroLogix)
PLC architecture & components
Power supply
CPU
Input/Output modules
Memory organization
Scan cycle explanation
Number systems (Binary, Decimal, Hex)
Safety practices in PLC environments

Practical Session:

Familiarization with hardware, Power-up procedures and Connecting PC to PLC

Day 2 Introduction to RSLogix 500 Programming Environment

Installing & navigating RSLogix 500
Understanding project files & setup
Processor configuration
Communication setup using RSLinx
Uploading & downloading PLC programs
Online vs offline editing
Tags & addressing structure
Inputs (I)
Outputs (O)
Internal bits (B3)
Data files

Practical Session:

Create a new project, configure communications, write a simple ladder logic program and download & test

Day 3 Ladder Logic & Basic Instructions

Ladder logic structure & rules
Normally Open & Normally Closed instructions
Output energize & latch/unlatch
Internal relays
Program scan effect on logic
Timer instructions: TON, TOF and RTO
Counter instructions: CTU and CTD

Practical Session:

Implement timer logic and Create counting system

Day 4 Intermediate Programming & Troubleshooting

Comparison instructions
Math instructions
Forcing Inputs/Outputs
PLC status & processor modes
Monitoring & testing programs
Troubleshooting common PLC faults
I/O failure
Communication loss
Program logic errors
Documentation & commenting standards

Practical Session:

Debugging live programs, correcting logic errors and using online monitoring tools

Day 5 Maintenance, Best Practices & Assessment

Preventive maintenance for PLC systems
Backup & restore procedures
Passwords & program security
Electrical & grounding considerations
Change management & version control
Real-world industrial case studies
Final review & knowledge consolidation

Practical Session:

Complete project assignment and Hands-on troubleshooting assessment