Allen Bradley PLC Learning Path

In this post, I'm going to lay out a learning path for anyone who is interested in learning how to program Allen Bradley Logix 5000 PLCs with Rockwell Automation's Studio 5000 Logix Designer software.

The idea here is to provide a structured path that will help someone with no knowledge of PLC programming understand what skills they need to prioritize in order to get their first job as a PLC programmer and to excel in their career as an automation professional.

I've decided to right this post because although there is no shortage of information on how to start PLC programming or how to do basic PLC programming, there is very little information on the skills that intermediate or advanced programmers should work on. If you read this post and think that there is something that I've missed, feel free to drop me a message at ken@kb-controls.io and I'll update the article.

So let's start by talking about the skills that beginner PLC programmers need to learn.

Fundamentals

These are the fundamental concepts that you should know before learning how to program PLCs.

PLC Concepts

Any aspiring PLC programmer should know what a PLC is, why we use PLCs in industrial automation, what components make up a PLC, and how a PLC is used to control an automated process.

You can learn these fundamentals here.

Allen Bradley PLC Product Lines

If you are planning to program Allen Bradley PLCs, then you should understand the different product lines that are available and their features and functions.

You can learn about Allen Bradley PLCs here, and dive more deeply into the CompactLogix and ControlLogix product lines here and here respectively.

Basic PLC Programming

These are the basic practical skills that you need to get your first job as a PLC programmer.

Basic PLC Programming with Studio 5000 Logix Designer

You should know how to use basic bit instructions such as Examine On, Examine Off, Output Energize, One-Shot, Output Latch and Output Unlatch instructions.

You should be able to combine instructions using program elements like rungs and branches to create Boolean logic to control a simple process.

You should also know what tags are and how to define and use tags in Studio 5000 Logix Designer.

I cover these skills in this course.

Simulation and Testing with FactoryTalk Logix Emulate

You should be able to set up a FactoryTalk Logix Emulate controller and download a project to the controller.

You should be able to go online with a controller and test your logic by monitoring application logic while it is executing in the PLC and by modifying the value of tags to simulate events occurring.

I cover these skills in this course.

Programming Timers and Counters in Studio 5000 Logix Designer

You should be able to use timers to delay signals from turning on and off and use counters to count the number of times that an event has occurred.

I cover these skills in this course.

Working with Numeric Data Types

You should know what numeric data types exist in Studio 5000 Logix Designer and understand the key differences between the DINT and the REAL data type.

You should be able to compute values using math instructions and compare values using comparison instructions.

You should be able to apply these skills to solve simple numeric applications such as scaling an analog input or converting a temperature from degrees Celsius to Fahrenheit.

I cover these skills in this course.

Applied Basic PLC Programming

After learning these basic PLC programming skills, you should be able to apply what you have learned to write the logic to control different automated processes.

This gives you a chance to use what you have learned so far and to build a small portfolio of projects that you can discuss in interviews with potential employers.

I cover these skills in this course.

Intermediate PLC Programming

These are the practical skills that you need to learn to work more efficiently with Logix 5000 PLCs to tackle larger, more advanced projects.

Structured Programming with Arrays in Studio 5000 Logix Designer

You should know what arrays are as well as how to fill arrays with data and retrieve data from arrays.

Structured Programming with UDTs in Studio 5000 Logix Designer

You should know what a User-Defined Type is.

You should also know how to create and use UDTs in Studio 5000 Logix Designer to group related data together.

Modular Programming with Subroutines in Studio 5000 Logix Designer

You should know how to use subroutines to split a large project up into multiple parts.

You should also know what instructions exist in Studio 5000 Logix Designer to pass data to and retrieve data from a subroutine.

Modular Programming with Programs in Studio 5000 Logix Designer

You should know how to use programs to split a large project up into multiple parts.

You should also know how to use program parameters to pass data from one program to another.

Modular PLC Programming with Add-On Instructions in Studio 5000 Logix Designer

You should know how to create and use Add-On Instructions in Studio 5000 Logix Designer.

You should also know the key differences, advantages, and disadvantages of using add-on instructions, programs, and subroutines to split a project up.

Programming with Function Block Diagram in Studio 5000 Logix Designer

You should know the basics of building logic using Function Block Diagram.

You should also understand what applications FBD is particularly suited for.

Programming with Structured Text in Studio 5000 Logix Designer

You should know the basics of building logic using Structured Text.

You should also understand what applications ST is particularly suited for.

Programming with Sequential Function Chart in Studio 5000 Logix Designer

You should know the basics of building logic using Sequential Function Chart.

You should also understand what applications SFC is particularly suited for.

Debugging Techniques

You should know what tools are available in Studio 5000 Logix Designer for debugging.

You should be able to use common tools like trap bits, breakpoint instructions, and traces to debug your Studio 5000 Logix Designer projects.

This course teaches you how to debug your Studio 5000 Logix Designer projects when your logic doesn’t work as expected.

By the end of the course, you will know how to use trap bits, breakpoint instructions, and traces to debug your Studio 5000 Logix Designer projects.

Applied Intermediate PLC Programming

After learning these intermediate PLC programming skills, you should be able to apply what you have learned to write the logic to control different automated processes.

This gives you a chance to use what you have learned so far and to build a small portfolio of projects that you can discuss in interviews with potential employers.

Working with Hardware

These are the practical skills that you need to learn to work with physical Logix 5000 PLCs rather than emulated controllers running on a computer.

Work with a Logix 5000 PLC

You should know how to wire a Logix 5000 PLC.

You should also know how to download a project to a PLC using an Ethernet and USB cable.

Work with a Logix 5000 Local I/O

You should know how to install a local I/O module for a Logix 5000 PLC.

You should also be able to configure the module in a Studio 5000 Logix Designer project and use the data from the module in a project.

Work with a Logix 5000 Remote I/O

You should know how to use a communication adapter to connect remote IO to a Logix 5000 PLC over an industrial network.

You should also be able to configure the communication adapter and remote I/O module in a Logix Designer project and use the data from the module in a project.

Logix 5000 PLC to PLC Communication

You should be able to send data from one Logix 5000 PLC to another using message instructions and produced and consumed tags.

This course teaches you how to configure communication between two Logix 5000 PLCs.

Logix 5000 Firmware Updates

You should know how to update the firmware of a PLC using Studio 5000 Logix Designer and ControlFLASH plus.

Integrate Third-Party Devices

You should know how to connect third party devices to a Logix 5000 controller by installing the EDS file for the device and using manufacturer provided AOIs.

Advanced Skills

These are the practical skills that you need to learn to be a true Logix 5000 specialist.

Organizing Execution with Tasks in Studio 5000 Logix Designer

You should know what types of tasks are available in Studio 5000 Logix Designer.

You should also be able to prioritise the execution of different tasks and understand how the timing of overlapping tasks work.

Get and Set System Values in Studio 5000 Logix Designer

You should be able to get system values to understand the configuration of a Logix 5000 PLC.

You should be able to set system values to programmatically update the configuration of a Logix 5000 PLC.

Alarm Instructions

You should know what instructions are available to manage alarms in Studio 5000 Logix Designer.

Updates

You should know what new features have become available in each release of Studio 5000 Logix Designer.

Other Skills

After mastering PLC programming with Studio 5000 Logix Designer, you should focus on other in demand skills for controls engineers including HMI development, SCADA development, working with Variable Frequency Drives, motion control with Servo Drives, safety engineering, and robotics.

Wrap Up

In this post, I have laid out a learning path for anyone to become a competent, confident PLC programmer specializing in programming Allen Bradley Logix 5000 PLCs. As you can see, there is a lot to cover.

At KB Controls, I'm building courses to cover all of these topics and you can get access to the complete course catalog with a membership. You can learn more about a KB Controls membership here.

If you think there is something missing from this list (or something is in the wrong place), feel free to drop me a message at ken@kb-controls.io. If I agree with your point, I'll update the post and give you credit.