Allen-Bradley PLC Programming Training in Kuala Lumpur, Malaysia

This training program introduces participants to Allen-Bradley PLC programming concepts using open-source PLC simulation environments, eliminating the need for physical hardware or licensed Rockwell software. The course focuses on the fundamentals of ladder logic, tag-based programming, sequencing, timers, counters, and troubleshooting—all taught through realistic, hands-on exercises.

Participants gain practical experience by developing and testing programs using tools such as OpenPLC, Ladder Logic Simulators, and basic open-source HMI tools. Although actual Allen-Bradley hardware is not used, the training follows the workflow, logic structures, and programming style required in real Rockwell-based automation environments.

By the end of the program, attendees will be able to design, build, and troubleshoot PLC logic for common industrial automation scenarios.

PLC Basics + Allen-Bradley Ecosystem Overview + Ladder Logic Foundations

Module 1: Introduction to PLCs & Allen-Bradley Architecture

• Role of PLCs in industrial automation
• Rockwell Automation product families:
• MicroLogix
• CompactLogix
• ControlLogix
• RSLogix 500 vs Studio 5000
• Allen-Bradley tag-based programming concept
• I/O modules (DI, DO, AI, AO) – conceptual only
• Scan cycle understanding (read–execute–write)

Hands-on Exercises

Module 2: Ladder Logic Fundamentals

• Logic continuity
• Contacts and coils
• Normally Open vs Normally Closed
• Basic instructions:
• XIC
• XIO
• OTE

Hands-on Exercises

Module 3: Basic PLC Operations

• Latching & unlatching
• Interlocks
• Seal-in circuits
• Start/Stop logic

Hands-on Exercises

Module 4: Introduction to Timers & Counters

• TON (On-Delay Timer)
• TOF (Off-Delay Timer)
• RTO (Retentive Timer)
• CTU / CTD counters

Hands-on Exercises

Intermediate PLC Programming + Tag Structures + Sequencing

Module 5: Understanding Tags (Allen-Bradley Style) –

• Base tags
• Alias tags
• Atomic data types (BOOL, INT, DINT, REAL)
• Arrays & UDT (User Defined Data Types) – conceptual
• How tags map to I/O

Hands-on Exercises

Module 6: Math & Compare Instructions

• ADD, SUB, MUL, DIV
• EQU, NEQ, LES, GRT
• File operations (conceptual only)

Hands-on Exercises

Module 7: Sequencers & State Machine Logic

• Step-by-step sequences
• Using bits for step tracking
• Using integer values for states
• Simple sequencer examples

Hands-on Exercises

Module 8: Introduction to Structured Text

• Basic syntax
• IF/ELSE
• FOR loops
• Variable declarations

Hands-on Exercises

Module 9: Simulation & Testing

• Simulated I/O testing
• Forcing bits
• Debugging logic
• Troubleshooting loops, timers, counters

Hands-on Exercises

Advanced Logic, HMI Basics, Fault Handling & Final Evaluation

Module 10: Advanced PLC Functions

• Data handling
• Move instructions (MOV, COP)
• Masking (conceptual)
• Shift Registers (conceptual + simulation)

Hands-on Exercises

Module 11: PID Control – Simplified

• PID overview (conceptual only)
• How AB PLCs handle PID blocks
• Using simulated analog values

Hands-on Exercises

Module 12: Fault Handling & Troubleshooting

• PLC scan issues
• Timer & counter pitfalls
• Intermittent logic problems
• Latching problems
• Common mistakes in ladder logic

Hands-on Exercises

Module 13: Introduction to HMI Concepts

• What is an HMI
• Allen-Bradley FactoryTalk View overview (conceptual)
• Using open-source HMI simulators:
• ScadaBR
• OpenHMI

Hands-on Exercises

Final Assessment

Query Discussion

ProgNXT Certification

Allen-Bradley®, MicroLogix®, CompactLogix®, ControlLogix®, RSLogix®, Studio 5000®, and FactoryTalk® are trademarks of Rockwell Automation, Inc. This training program is independently developed and delivered by ProgNXT and is not affiliated with, endorsed by, sponsored by, or authorized by Rockwell Automation.

Hands-on exercises are conducted using simulation environments and open-source tools where applicable. FactoryTalk View concepts are covered from an architectural and design perspective.