IC-101: Troubleshooting Industrial Controls & Ladder Logic

Course Description

This 32-hour, 4-day training program is designed to familiarize electricians with industrial control components such as relays, timers, proximity switches, limit switches, sensors and other control devices. Participants will also work with protective devices such as fuses, circuit breakers and overloads. Participants will troubleshoot Ladder Logic circuits using a DMM (Digital Multimeter). Participants will also learn and work with Polyphase Circuits including single phase and three phase wiring of motors. Participants will then transition from troubleshooting hardwired ladder logic circuits to PLC Ladder Logic.

Topical Outline

  • Electrical Review
  • Machine Control and Control Devices
  • Documentation for Troubleshooting
  • Protective Devices
  • Polyphase Circuits
  • Three Phase Motors
  • Troubleshooting Tips and Techniques
  • PLC Concepts
  • Use the PLC to Demonstrate Basic Concepts
  • The PLC as an Advanced Troubleshooting Tool


Persons successfully completing this course will be able to:
  • Wire up and find problems in relay logic. Understand the operation of and repair/replace defective input devices such as: limit switches, proximity sensors, photo eyes & reed switches. Understand the operation of and repair/replace defective output devices such as: timers, motor starters, contactors & solenoids.
  • Find and use the correct documentation needed to troubleshoot and repair machine breakdowns.
  • Safely analyze and repair faults detected by protective devices such as: fuses, circuit breakers & GFIs.
  • Explain how 3-phase electricity is generated and distributed to a plant.
  • Troubleshoot 3-phase motors using a DMM and a megger - find shorts, opens and insulation breakdown.
  • Develop a step by step troubleshooting plan to find the root cause of a shutdown. Implement countermeasure that will prevent the reoccurrence of a problem.
  • Explain how real world (field) devices interface with a PLC.
  • Read a PLC program and explain how it relates to relay logic.
  • Use a PLC as the starting point for troubleshooting problems

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