Understanding, Maintaining, and Troubleshooting ControlLogix Systems
-with Studio 5000 Designer Software-
Full Course
Purpose & Objectives
The Understanding, Maintaining, and Troubleshooting ControlLogix Systems Training Series contains 10 modules that cover the most critical and fundamental ControlLogix skills that every maintenance technician needs to know, resulting in more efficient and effective troubleshooting and increased business competitiveness.
Certificate of Achievement ControlLogix + Studio 5000
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- Develop Expert Teams. Close the skills gap.
Designed for refreshing maintenance personnel and onboarding new hires - Practical instruction and real-life assessments to develop immediate skills
- Ensure effective and efficient problem-solving in any ControlLogix environment
$4,956 Full Course
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Modules
Click + to view Module Details
Module 1: Introduction to the ControlLogix—General Structure, Number Systems, and Basics of Boolean Logic
- Point out the benefits of PLCs and ControlLogix in automation. Master the components of a ControlLogix system, Inputs and Outputs as well as the “main” controller.
- Understand the operation of standard PLCs and the operation of the ControlLogix platform—Synchronous vs Asynchronous.
- Know how the memory system of a PLC is arranged and why the memory system is “where things happen” in a system.
- Understand number systems and those used in a ControlLogix.
- Know about binary and word formats which define the ControlLogix “Data Types” used in the system.
- Use logic and binary concepts which are used as a foundation in control systems.
- Understand AND, OR and NOT Boolean logic and how these functions are used to implement from simple to complex control output decisions.
Module 2: ControlLogix Hardware Composition, I/O Structure and Architecture—Introduction to Tags
- How the chassis forms an integral part of the system and the different sizes available for the ControlLogix.
- The different types of ControlLogix controllers/processors.
- The different types of Power Supply available.
- How are the Inputs and Outputs modules inserted into slots of the chassis.
- What does the insertion of an I/O module means in terms of memory addressing of the field devices wired to I/O modules.
- How to do the system configuration, and how the input and output modules are inserted into the chassis.
- Identify modules’ components such as diagnostics, status indicator, RTB connection and others.
- How the Remote I/O Subsytems and its I/O Placement and Configuration is done.
- Know what “Rack Optimization” is and how tags are shown for this type of Remote I/O configuration.
- Know what tradeoffs we have to make when using Rack Optimization.
Module 3: Navigating the Studio 5000 Software and Creating, Opening and Understanding Projects
- How to launch a new project or an already created, and to create a New Project using the Studio 5000 software.
- Learn the differences between the Classic and Contemporary look of the Studio 500 software.
- How to open other projects from the splash screen of the Studio 5000 such as Existing Projects, Sample Project, From Upload and others.
- How to create a New Project and where to store it.
- Learn about the Screen Zones of the Studio 5000 software both in the Classic and Contemporary look.
- How to use the Controller Organizer and Logical Organizer.
- How to add/discover module by the programmer after going online and connecting to the controller.
- How to navigate into the I/O module properties, Routine coding editor and Controller Tags monitoring.
- How to use the Floating, Dock and other windows as well as the Toolbars.
- Insertion and Additions of I/O modules to a Project.
- How Tags are created when adding modules to a project.
- How the I/O Tag memory mapping works.
- How are Tags created from the Controller Tags’ window.
Module 4: Connecting to the Controller—Establishing RSLinx Connection to the Network
- Know what is required in order to establish communication between the Studio 5000 in a computer and a ControlLogix in a network.
- Set up a computer’s network configuration to be ready to create a driver.
- Understand IP addresses, network subnet masks, gateways and how these parameters are important during the setting and troubleshooting of network components.
- Device a proper way to distribute and use IP addresses in your plant to avoid problems.
- Learn about RSLinx and why we refer to it as “The Communicator”
- Know how to set up the two types of Ethernet drivers required to communicate with the network.
- Backup and Restore drivers by using the RSLinx utility.
- Know how to download a project properly using created drivers and go online.
- Know how to upload a project and some “precautions” we have to take during uploading to avoid overwriting on an existing project.
- Understand thoroughly the operating modes of the ControlLogix and what is needed to keep a Remote control of the operating modes at the Studio 5000.
- Monitor discrete and analog tags in the ladder editor as well as in the tags display monitoring.
- Understand the basics of discrete and analog I/O module configuration including scaling of analog I/O (more detail configuration information later in later modules).
Module 5: ControlLogix Project Organization and Frequently Used Tag Structures
- Thoroughly understand the hierarchical organization of the ControlLogix of Tasks-Programs-Routines and what each of these sections holds as content.
- Understand the order of execution of a project in a ControlLogix system and how to change this order if necessary and their implications.
- See what effects the “asynchronous” function of a ControlLogix has in the evaluation of code.
- How to add routines and Subroutines to a project if necessary.
- What are the different types of tasks and how to add programs and routines to these tasks.
- Understand Continuous, Periodic and Event task functions and how one task interrupts another one during the execution of code.
- Know how Periodic and Event task are triggered.
- Take into consideration certain aspects of task functionality during troubleshooting.
- Recognize Subroutine’s potential problems during execution of code instructions and how this behavior can affect the ControlLogix project.
- How “parameters” are passed and work from the main routine to a Subroutine and what to look for when troubleshooting a project that has Subroutines passing parameters.
Module 6: Troubleshooting Ladder Diagram Logic in the ControlLogix System
- Master ladder diagram code execution in a ControlLogix system.
- Understand the functionality of “Bit” instructions and know how to troubleshoot code that utilizes these instructions.
- Know the difference between Retentive and Non-Retentive outputs and what to watch for during troubleshooting.
- The use of One-Shot instructions and when and why they are used extensively in ladder diagrams.
- The use of “Gotcha” circuits to capture very fast signals—this is a great troubleshooting technique.
- How to program a normally closed input field device (like a Stop PB) and why it is programmed normally open.
- Master the different types of Timers (TON, TOF, RTO) and things to watch for during the examination of code.
- Know how to troubleshoot code that used Counters, Math, Compare instructions.
- How to use program control instructions during troubleshooting to disable sections of code in a ladder diagram.
Module 7: Creating and Editing Tags and Code—Documenting Troubleshooting Changes
- Determine by looking at a tag if it is Global or Local, and if local what is the parameter usage and if there are any connections made.
- Assign “connections” to Local tags with Input or Output parameter usage.
- See how connected Input/Output parameter Local tags are represented in the code and how to make changes to these tags.
- Edit and monitor any type of tag (Global or Local) and make changes if necessary.
- Make changes online while the controller is running and know how to use the “test” mode to check code changes.
- Use “best practices” for documenting changes made, techniques that will be very useful during collaboratory troubleshooting a ControlLogix-based system.
- Understand the functionality of Arrays which are used extensively in applications and what to look for when an Array creates a Major Recoverable Fault and shuts down the system.
- Troubleshoot a system that uses User-defined Data Types or UDTs and thoroughly understand how UDTs are created and represented in tags in the code.
Module 8: Troubleshooting Using the Studio 5000 Software—Using I/O Forcing and Toggling Functions
- Understand and apply the searching tools: Find, Find and Replace, Go To, Browse Logic and Cross Reference.
- Implement the searching and finding of tags and trace back what it takes for the rung being troubleshooted achieve continuity.
- Use and apply the Cross Reference tool to tags to find continuity problems in the code and properly apply bookmarks during the troubleshooting of several rungs.
- Know what “Destructive” is during cross referencing tags and how to use this information to find and trace back power continuity in a rung.
- Master the use of Bookmarks during the use of the Cross Reference tool so that we can easily find the rungs we are troubleshooting.
- Use Program Control instructions to facilitate troubleshooting and temporary end of code execution, and implement by-passes of code in routines.
- How to use the Forcing tool for Discrete as well as Analog I/O and things to look for during forcing.
- Understand the two phases of Forcing—Installing the force and Enabling the force.
- Understand that the “logic” follows the input devices forcing and that the “logic” does not follow the output devices forcing.
- How to apply Toggling of internal tags during troubleshooting.
Module 9: Troubleshooting ControlLogix Hardware—Discrete and Analog I/O
- Identify important safety situations in ControlLogix applications and know what to do to be safe.
- Prevent potential arcing conditions which can create critical safety situations.
- Thoroughly understand what is the Requested Packet Interval (RPI) communication.
- Know what Change of State is in the input settings and how this setting operates.
- Understand what “Ownership” of a module is and what are the implications in the module’s configuration.
- Know the difference between “Data” and “Listen Only” communication settings.
- Know “why” output modules have an “I” base tag not to be confused with the input module’s “I” base tag.
- Know exactly what to do when replacing I/O modules during troubleshooting and how to correct revision problems caused by configuration mismatches.
- Deal with ownership problems during troubleshooting of a system and how to fix it.
- How module diagnostics operate and when their functionality takes place, when the bit is ON or OFF.
- Use diagnostic I/O statuses and indicators to pinpoint problems quickly along with the Studio 5000 software.
- Properly set and configure diagnostics in discrete and analog I/O modules.
- Understand analog I/O configurations needed for troubleshooting, including scaling, alarms, dead-bands, limits and proper wiring connections necessary for proper analog I/O operations.
- Know how to detect non-linearities in analog readings due to disturbances in the system and suggest possible solutions to programming personnel.
Module 10: Troubleshooting Remote I/O, Controller and Power Supply—Using the Trend and Compare Tools to Troubleshoot
- Know how to troubleshoot a ControlLogix system which has additional chassis in a subsystem configuration using a top- down strategy.
- Know how to solve network interference in remote subsystem and minimize wiring crosstalk.
- Understand Major Recoverable and Non-Recoverable faults that can occur in a controller and how to get back into operation by clearing the faults.
- Clear a Major Recoverable fault using the controller’s front panel switch.
- Understand how the Fault Routine works so that troubleshooting can take place.
- Procedure to download to a previously faulted controller—what needs to be done.
- Know how to detect and clear Minor Faults in a system.
- Troubleshoot Power Supply problems as well as how to avoid potential problems.
- Understand how voltage sags affect controller voltages as well as I/O power.
- Deal with noise and heat problems in a control system, recognize it and how to fix the problem.
- Know how to use the Trend tool to troubleshoot a ControlLogix system.
- Use the Compare tool to find differences between two projects when troubleshooting.
💡 If you have a ControlLogix in your plant, this is essential training for the safety of your maintenance personnel and efficiency of your facility.
01
✔️ Complete, Engaging Training
- Interactive lessons with real-world, practical examples
- Simple, user-friendly interface for stress-free learning
- Includes review questions and a final exam to reinforce retention
- Earn a Certificate of Achievement upon completion
02
✔️ Real Business Impact
- Reduced downtime through faster, more confident troubleshooting
- Lower training costs – no travel, no classroom, no additional software
- Measurable results you can see on the plant floor
03
✔️ Workforce Development & Safety
- Upskill existing technicians to close the skills gap
- Boost onboarding efficiency for new hires
- Improve plant safety through a better understanding of automation systems
Training Tablet
For Companies, Individuals
Delivered on a pre-installed Windows Tablet and includes one set of physical Handbooks.
Expand your training with additional Lessons and Courses available through the tablet’s Store.
$4,956 Full Course
Course pre-installed on TPA Windows Tablet. Includes one set of physical Handbooks. Course License renews yearly at 25% off the list price.
Additional Handbook Collection (Modules 1-10) available for $486 per printed set
Want multiple Tablets for your Company’s Training Ecosystem?
Add additional TPA-compatible Tablet(s)
Enterprise Tablet Extension
$3,317.00
Add extra training tablets for your team. Train individually offline or sync progress seamlessly across devices with an internet connection. (SYNC COMING SOON)
Boost your ControlLogix maintenance and troubleshooting performance
Empower Your Maintenance Team to Master ControlLogix Troubleshooting.
- Designed specifically for maintenance personnel
- Comprehensive program delivers practical instruction and real-life assessments
- Sharpen their skills and ensure effective problem-solving in any ControlLogix environment
Leverage optimization for improved efficiency. Experience increased performance.
CLX Training Features
✓ Rich Learning: 17,000+ diagrams & interactive graphics
✓ Effective Practice: aseesments with instant feedback
✓ Learning Library: Always-available tablet & handbooks
For a detailed overview of each Module,
View the CLX Course Brochure HERE 📄
• Cost & Comparison
Elevate Your Team: The All-in-One Tablet Portal for Complete ControlLogix Learning. Compared to the traditional, outdated options of costly and forgettable off-site seminars or insufficient online video tutorials, ours is the most complete and comprehensive solution for your company. The all-in-one tablet portal makes it easy for learners to access lessons and administrators to check their status, progress, and scores.
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