PAC Basics Extended

As explained in Lesson 1.01 (available as a free preview before purchasing the course), those with no prior Programmable Controller experience are encouraged to take my PLC Basics course first. It covers several beginner-level topics that are not included in this course, including:

1. What a Programmable Controller is and how it works
2. What Ladder Logic is and how it works
3. What Data Types are and how they are used

If you’re already familiar with those topics, and you know how to use a Windows PC, then you’re ready to take this course.

I specifically designed this training for industrial electricians, maintenance technicians, and controls engineers who need to learn how to set up, program, and troubleshoot ControlLogix systems.

Whether you’re an experienced controls engineer or technician who has worked with other PLC platforms and wants to learn ControlLogix, or you’re an industrial electrician or maintenance technician responsible for keeping a ControlLogix-controlled machine or system running, this course will help you develop the skills needed to confidently setup, program, and troubleshoot ControlLogix systems.

I also focus on the practical skills industrial automation professionals actually use every day. You’re not just going to learn how to write basic Ladder Logic—you’ll learn how to select, configure, program, and troubleshoot complete systems using real-world industrial applications and examples.

The required video lessons total more than nine hours of instruction. However, that does not include any additional time you choose to spend completing the optional hands-on exercises.

Most required lessons are 20 minutes or less, allowing you to complete them whenever your schedule permits without having to set aside several hours at a time.

And since all of my courses include lifetime access, you can return and review any lesson as often as you like.

No. You do not need a physical ControlLogix controller or hardware trainer to complete this course.

While owning a ControlLogix controller and trainer can certainly enhance your ability to complete the optional hands-on exercises, I recognize that many students cannot justify spending $10,000 or more on a ControlLogix controller and a Studio 5000 software license just for learning purposes.

So to make this training accessible to as many students as possible, all hands-on exercises are completely optional, and I also provide several free and low-cost alternatives that allow you to complete the labs without purchasing expensive hardware and software licenses.

One free option I provide my students is a license of my PLC Application Simulator. This lightweight Windows 10 and Windows 11 application simulates a generic PLC along with my classic “Widget Machine,” allowing you to build and test the Ladder Logic solutions covered in the optional exercises without requiring any other hardware or software. While it doesn’t exactly replicate a specific Programmable Controller, it’s very similar and a license is provided free to all my PLC/PAC students.

For students looking for a more advanced experience, I also offer Logic Design’s PLCLogix 5000 (currently $299 when bundled with my PLCLogix 5000 Applications course). This lifetime license simulates:

1. RSLogix/Studio 5000
2. A Logix controller with I/O
3. Ten different plant simulations (I/O Worlds)
4. A traditional PLC hardware trainer

And for students who own a physical ControlLogix controller (or have a license of FactoryTalk Logix Echo), I’ve partnered with MHJ Software to provide a free digital twin of the physical trainer used throughout this course, along with a complimentary 90-day license of PLC Lab 3D Studio (a $50 value!)

This allows you to complete the optional hands-on exercises using a virtual trainer inside PLC Lab 3D Studio with your own ControlLogix controller (or FactoryTalk Logix Echo), eliminating the need to purchase a physical trainer or wire dozens of buttons, switches, lights, and motors to your controller.

Finally, for those students who have a ControlLogix controller (or FactoryTalk Logix Echo) and FactoryTalk View Studio Machine Edition, I also include a complete View ME project bundled with a ControlLogix project file which contains simulation logic. This combination allows you to complete all of the optional programming exercises using View ME and your own controller.

For more detailed information about these and other available options, please watch Lesson 1.02, which is available as a free preview before purchasing the course.

I created this course knowing that not everyone who takes it will have access to a license of RSLogix 5000 or Studio 5000 Logix Designer.

While there are certainly advantages to having a Windows PC running RSLogix or Studio 5000, you do not need to purchase a license (starting around $1,720) to complete this course.

Instead, as discussed in the previous answer (and in Lesson 1.02 – available as a free preview before purchasing the course), I do cover several free and low-cost alternatives to purchasing a controller and software license.

Yes.

When you enroll in this course, you receive more than just the video lessons and downloadable materials—you also receive direct access to the instructor for lesson-related questions.

At the bottom of every lesson is a discussion area where students can post questions, and I personally answer them.

And if a written response isn’t enough to resolve your question, eligible students may also schedule a short Microsoft Teams meeting with me during office hours (see Lesson 1.11).

Note that the number of complimentary live meetings available depends on the course you’ve purchased, and these sessions are specifically intended to answer questions related to the course material, and not as a free consulting or tech support service.

For those students seeking assistance beyond the course content, paid mentoring services are also available for topics covered in my training (see Lesson 1.12).

Yes.

The course is completely self-paced, allowing you to progress through the lessons according to your own schedule and learning style.

Because all of my courses include lifetime access, you can also revisit and review any lesson as many times as necessary.

Yes.

This course includes numerous optional hands-on exercises that allow you to apply what you’ve learned throughout the video lessons and demonstrations.

For students who don’t own a ControlLogix controller or RSLogix/Studio 5000, I also discuss several free and low-cost ways to complete the optional exercises in Lesson 1.02, which is available as a free preview before purchasing the course.

Absolutely.

Completing this course is a significant achievement, and I want to make sure you have professional documentation recognizing your accomplishment.

Once you’ve passed all required quizzes and marked every lesson complete, a link will appear on the course homepage allowing you to view, print, and download your course completion certificate. You’ll also find links to leave course feedback, request a discount on your next course, and submit a course review.

Your certificate also lists the Professional Development Hours (PDHs) you’ve earned while completing the course. These hours are calculated based on the time required to complete all required lessons and successfully pass the quizzes (students may retake quizzes as needed), ensuring they represent meaningful professional development.

Please note that time spent completing the optional hands-on exercises is not included in the PDHs listed on your certificate.

However, upon request, I do offer an optional “exercise review” service for an additional fee. This allows you to earn additional PDHs by having me personally review each of the programs you created while completing the optional exercises. Interested students should reach out to me directly using the “Contact” link at the top of the site.

I’ve designed this course to cover the entire ControlLogix family, however since the 5580 and 5590 we’re not available when I originally filmed this course, I discuss them more in my new ControlLogix course which is bundled with this one at no additional charge.

As to the controller this course covers in-depth, I begin with the first-generation L1 controller, also known as the 5550. From there, I move onto the second-generation L55 family. The I cover the L6x family, both series A and B.

The course also covers the L7 (5570) series, and I finsih with a quick overview of the L8 (with more information included in the bundled updated course.)

Yes. Both RSLogix 5000 and Studio 5000 Logix Designer are covered.

I cover RSLogix 5000 because it is the required programming software for controllers running firmware version 20 or earlier. I also cover Studio 5000 Logix Designer because it is required to program Logix controllers running firmware version 21 and newer.

To ensure students are prepared to support legacy systems, I demonstrate several RSLogix 5000 versions including 13, 16, and 20.

On the Studio 5000 side, I also cover versions 21, 24, 31, and 34. And in my 2026 ControlLogix course—which is bundled with this course at no additional charge—I also cover versions 31, 36, 37, and 38.

I even show students how to request a free 30-day trial license directly from Rockwell so they can practice the hands-on exercises on their own PC.

Yes.

The course begins with the fundamentals of setting up ControlNet and EtherNet/IP communications, as well as setting device addresses.

I also include a dedicated lessons on Adding and Testing Point I/O, Flex I/O, and 1756 I/O on both ControlNet and EtherNet/IP.

The course does cover RSNetworxs for ControlNet, explaining what it is, when it is needed, and how to use it.

And on the Ethernet side, the course covers how to assign static IP addresses, and troubleshoot common I/O connection problems directly within the I/O tree.

For students designing or expanding EtherNet/IP networks, I demonstrate the EtherNet/IP Capacity Wizard. This tool calculates controller Packets-per-Second (PPS) utilization so you can determine whether adding another VFD, HMI, or other Ethernet device will exceed the controller’s communication capacity.

Absolutely.

Requested Packet Intervals (RPIs) are one of the most overlooked settings within the Logix architecture, yet they play a critical role in overall system performance.

In this course, I explain exactly how RPIs determine how the controller exchanges data with modules across both the backplane and the network.

Yes.

Since modern controllers are shipped with factory-installed firmware set to v1.x, every ControlLogix programmer should know how to safely update controller firmware to match the program version.

So in this course I made sure to demonstrate how to use ControlFlash and RSLogix / Studio 5000 to install the desired firmware revision on your controller.

Yes.

The course includes analog module configuration of the 1756 Analog Input and Output modules.

No.

As explained in free preview Lesson 1.01, this course does not cover GuardLogix controllers, safety programs, or safety I/O. I may cover it in a future course, but it is not covered in this one.

Yes. I cover integrating VFDs wired into I/O as well as on EthernetNet in this course.

I also cover how to use AOI’s and PlantPAX with VFDs as well.

No.

As explained in free preview Lesson 1.01, this course does not cover Motion Control (aka Servo) applications or instructions. I may cover it in a future course, but it is not covered in this one.

Yes.

The course covers implementing and troubleshooting distributed ControlNet and EtherNet/IP I/O using 1734 Point I/O, 1794 FLEX I/O, and 1756 I/O.

Additional Ethernet I/O platforms will be covered in the new course that is bundled with this course.

Yes.

Understanding Tasks, Programs, and Routines is essential to mastering the Logix operating system, and I cover each of them in detail so students develop a complete understanding of how they work together.

Rather than simply showing you where they are in the software, I explain why they exist, how the controller executes them, and how they should be used when designing and troubleshooting real-world applications.

Yes.

Understanding Arrays is an important part of transitioning from older file-based PLCs to the modern tag-based Logix architecture.

In this course, I explain not only how the controller manages memory, but also how to create and use both Controller Tags and Local (aka Program) Tags, including Tag Arrays, in practical applications.

Yes, but it assumes you already understand how Ladder Logic works.

Put another way, I don’t explain concepts such as power rails, rungs, read and write instructions, or logical continuity in this course as I do in my PLC Basics course.

That said, I spend a significant amount of time writing, explaining, and troubleshooting Ladder Logic programs because Ladder Logic remains the most widely used programming language for Programmable Controllers in North America.

Yes.

Making changes to a running machine is one of the most valuable skills a Logix programmer can have, but it’s also one that should only be performed with a complete understanding of the process and its potential consequences.

In this course, I explain the entire Online Editing workflow in detail, including how edits are tested and accepted, as well as situations where you should avoid using options such as Finalize All.

Absolutely.

Timers and Counters are fundamental instructions that every PLC programmer and troubleshooter should understand.

Throughout this course, you’ll use them in real-world applications, including production tracking and machine sequencing. I also demonstrate several practical techniques that can simplify your programs and eliminate unnecessary rungs of Ladder Logic.

Yes.

Function Block Diagram (FBD) programming is covered in the course, and I cover the fundamentals as well as develop an example based on real-world industrial applications.

Yes.

Structured Text (ST) programming is introduced during the Extended portion of the course, and I cover the fundamentals as well as develop an example based on real-world industrial applications.

Yes.

SFC programming is introduced during the Extended portion of the course, and I cover the fundamentals as well as develop an example based on real-world industrial applications.

Yes.

UDTs and AOIs are introduced during the Extended portion of the course, and I cover the fundamentals as well as develop an example based on real-world industrial applications.

No.

I may cover it in a future course, but it is not covered in this one.

Yes. I specifically cover Produced/Consumed Tags in this course, as well as using the MSG instruction.

Yes.

I’ve designed this course to take you from the fundamentals to more advanced real-world applications.

Early in the course, you’ll learn how to identify ControlLogix hardware, locate wiring diagrams, establish RSLinx communications, update controller firmware, and configure network settings.

From there, you’ll configure both local and distributed I/O, learn how to Force I/O safely, and build motor control, interlock, presence sensing, and production tracking applications.

You’ll also learn how to perform Online Edits, understand automated sequences, and work with more advanced programming techniques used in industrial automation.

The goal isn’t simply to teach software—it’s to teach the practical skills you’ll use to set up, program, and troubleshoot real ControlLogix systems.

Absolutely, and troubleshooting isn’t confined to a single lesson—it’s integrated throughout the entire course.

We begin with hardware diagnostics by learning how to interpret the controller’s front-panel LED indicators, including RUN, I/O, OK, FORCE, and BATT, so you can quickly determine whether you’re dealing with a major fault, a communication problem, or another issue.

Then, while configuring I/O, we take a deep dive into what causes the dreaded “Yellow Triangle.” You’ll learn how to use the Module Info and Connection tabs to diagnose Electronic Keying mismatches, communication timeouts, incorrect IP addresses, and other common configuration problems.

I also spend significant time covering Forcing I/O, including the proper procedures for safely overriding inputs and forcing outputs when troubleshooting field devices.

Yes.

I answer a similar question earlier in this FAQ (“Do I need physical PLC/PAC hardware and/or a physical PLC Trainer?”), so I’ll simply reiterate that you do not need a physical PLC or an expensive software license to successfully complete this course.

When I created this course, I knew many students wouldn’t have access to equipment and licenses to learn on, nor would they have the budget to purchase a ControlLogix controller and a Studio 5000 software license (starting at roughly $3,000).

To address that, I provide every PLC/PAC student of mine with a license for my PLC Application Simulator for Windows 10 and Windows 11, along with information about several additional free and low-cost alternatives.

For more information, please refer to Lesson 1.02 or the previous hardware question.

Yes.

As long as your version of RSLogix or Studio 5000 supports the version of Emulate or FactoryTalk Logix Echo you’re using, either can serve as your Logix controller while completing many of the course demonstrations and optional exercises.

Although I don’t cover either product in detail in this course, both work well as controller alternatives for students who don’t have physical hardware.

Absolutely.

This course was specifically designed for people who have experience with other PLC platforms and want to transition to ControlLogix.

And as I demonstrate throughout the course, the Ladder Logic editor and instruction set in RSLogix and Studio 5000 are very similar to those found in RSLogix 5, 500, and Micro, making the transition much easier than many people expect.

The course also focuses on helping experienced PLC users understand what’s new in the Logix platform while building on the knowledge they already have.

Yes.

As described in the previous answer about ControlFlash, firmware revisions are covered in detail throughout the course.

You’ll learn why firmware revisions matter, how they affect software compatibility, and how to determine which software version is required for a particular controller.

Yes.

As described in the previous answer about ControlFlash, updating controller firmware is an important skill for every Logix programmer.

In this course, I explain the firmware update process in detail so you’ll understand not only how to perform the update, but also when it should—and should not—be done.

Yes.

As described in the previous answer about troubleshooting, knowing how and when to Force I/O safely is an important skill for everyone using or maintaining programmable controllers.

Yes.

ControlLogix continues to be one of Rockwell Automation’s best-selling controller families and remains one of the most widely used PLC/PAC platforms in North America.

Rockwell also recently released the next generation of ControlLogix controllers in the fall of 2025, and I discuss this new platform in the updated course that’s included with this course at no additional charge.

Whether you’re maintaining existing equipment or designing new systems, ControlLogix remains an excellent platform to learn.

Great question.

My first recommendation is to learn whichever platform your employer currently uses—or the platform used by the company where you’d like to work.

That said, from a software perspective, CompactLogix and ControlLogix are remarkably similar. I often compare them to different vehicles from the same manufacturer: while the body styles may differ, the dashboard, controls, and visual display/media center are often nearly identical.

The biggest differences are found in the hardware, which is why I generally recommend learning on the platform you’ll actually be using.

If you’re paying for your own training, there’s another important consideration. CompactLogix hardware—and the CompactLogix-only editions of Studio 5000 (Mini and Lite, discussed in Lesson 1.02)—are significantly less expensive than their ControlLogix counterparts.

So, for students learning on a budget, I generally recommend starting with CompactLogix because it provides an affordable path to learning both the Logix platform and Studio 5000.

Absolutely.

I built this course specifically with maintenance electricians in mind.

For many maintenance professionals, the PLC isn’t just something they program—it’s one of the most valuable diagnostic tools available for determining why a machine isn’t running.

Because of that, I focus heavily on practical troubleshooting skills, including interpreting controller indicator lights, understanding software error messages, Force I/O safely, performing Online Edits, and clearing controller faults.

I also explain why the Destructive column in the Cross Reference window is one of the most valuable troubleshooting tools available, as well as how understanding how Modular Programs work can make both troubleshooting and machine maintenance much easier.

Yes.

If your goal is to work for an Original Equipment Manufacturer (OEM), this course will prepare you to set up, program, and troubleshoot ControlLogix systems.

Because OEMs build machines that need to be modular, repeatable, and easy for customers to maintain, I incorporate those concepts throughout the course.

You’ll also learn how to use Non-Volatile Memory to back up and restore controller programs, which is one way OEMs provide customers with updated “programs on a card” that often eliminates the need for an on-site service visit.