Top organizations train their team with RealPars

daimler mercedes benz uses RealPars platform
Ford motors uses RealPars platform
General Electric uses RealPars platform
Pfizer uses RealPars platform
Tesla uses RealPars platform

After taking this course, you’ll be able to:

  • Identify common problems that are encountered with PLC hardware and software

  • Take a zoomed-out approach to PLC troubleshooting

  • Better understand the problem

  • Identify resources such as engineering sequence of operations, functional design specification, electrical drawings, vendor documentation, and more

  • Use common PLC programming development software tools to search and audit programs

  • Verify code from hardwired input to hardwired output and everything in between

  • Troubleshoot external instrumentation and wiring

  • Troubleshoot or “Debug” errors in PLC code using resources such as spare PLCs, simulators, error messages, etc.

  • Troubleshoot HMI problems related with PLCs

  • Troubleshoot PLC I/O modules and other PLC hardware

Course curriculum

  1. 1
    • 1. PLC Troubleshooting for Beginners - Introduction

    • 2. What Will You Learn by Completing This Course?

  2. 2
    • 3. External Instrumentation and Control Device Issues

    • 4. PLC I/O Modules, Other Hardware, and PLC Firmware Issues

    • 5. PLC Communication Issues

    • 6. PLC Software, Programming, and SCADA/HMIs Issues

    • 7. Introduction and Documentation

    • 8. Multimeter and Electrical Drawings or Schematics

    • 9. Functional Design Specification (FDS)

    • 10. I/O List, PFD, P&ID, and Loop Diagrams

    • 11. Internet and Brand Specific Support

    • 12. Understanding Standard IEC61131-3 Programming Languages

  3. 3
    • 13. Programming Environment Navigation, Search, and Debugging Tools

    • 14. 3rd Party IDEs

    • 15. Simulated Environments, Spare PLCs, Trending, and Data Analysis

    • 16. PLC Troubleshooting Approach | Part 1

    • 17. PLC Troubleshooting Approach Part 2

    • 18. Audit Concept

  4. 4
    • 19. Troubleshooting Details Introduction

    • 20. Troubleshoot Wiring | Part 1

    • 21. Troubleshoot Wiring | Part 2

    • 22. Troubleshoot Wiring | Part 3

    • 23. Troubleshoot Instrumentation | Wiring

    • 24. Troubleshoot Instrumentation | Improper Specification or Installation

    • 25. Troubleshoot Instrumentation | Environmental or Ambient Effects

    • 26. Troubleshoot Instrumentation | Improper Scaling and Parameter/PLC Programming

    • 27. Troubleshoot Instrumentation | Instrument Calibration

    • 28. Troubleshoot Control Devices | Wiring

    • 29. Troubleshoot Control Devices | Improper Specification or Installation

    • 30. Troubleshoot Control Devices | Equipment Wear

    • 31. Troubleshoot Control Devices | Lack of Direct Control (Vendor packaged or OEM Equipment)

    • 32. Troubleshoot Control Devices | Environmental or Ambient Effects

    • 33. Troubleshoot Control Devices | Digital Output Signal Considerations

    • 34. Troubleshoot Control Devices | PLC Programming

    • 35. Troubleshoot Control Devices | Importance of Analog Outputs Using Feedback Control Loop Examples

    • 36. Troubleshoot Control Devices | Improper Analog Output Signal Scaling, Output Device Parameters, and Programming

    • 37. Troubleshoot PLC I/O Modules | Wiring

    • 38. Troubleshoot PLC I/O Modules | Specification

    • 39. Troubleshoot PLC I/O Modules | Signal Congruency

    • 40. Troubleshoot PLC I/O Modules | Software and PLC Programming Errors

    • 41. Troubleshoot PLC I/O Modules | I/O Mapping

    • 42. Troubleshoot CPUs

    • 43. Memory Corruption/Data Loss/Program Loss | ROM and RAM memories

    • 44. Memory Corruption/Data Loss/Program Loss | Power Consumption Limitations

    • 45. Memory Corruption/Data Loss/Program Loss | Electromagnetic and Radio Frequency Interference

    • 46. Memory Corruption/Data Loss/Program Loss | PLC Incompatibility

    • 47. Memory Corruption/Data Loss/Program Loss | Maximum Memory Capacity

    • 48. Memory Corruption/Data Loss/Program Loss | Caution and Safety Considerations

    • 49. Power Surges

    • 50. Ambient Damages

    • 51. Modular PLCs and Compact PLCs

    • 52. PLC Communication Modules


Hey guys, welcome to our PLC Troubleshooting course here at RealPars! We’re happy to have you here.

This PLC beginners course is designed to be a beginner crash course in PLC troubleshooting. Industrial systems are most often very large and complicated. This means that the PLC hardware, software, and code that automate and control these industrial systems are also large and complicated.

As an automation professional, you may find yourself developing a brand new plant or facility, but most often you are integrating, updating, maintaining, or problem-solving at an existing plant or facility. This means you will be tasked with developing or maintaining a combination of new and existing PLC systems, both of which can present unique challenges.
Despite your best efforts, problems will present themselves that you will need to fix. The process we use to analyze, test, and fix these kinds of issues is called troubleshooting.

This PLC troubleshooting course will teach you practical methods that you can use to properly identify PLC-related problems, develop an organized troubleshooting approach, learn your resources and how to effectively use them, and break down troubleshooting details to the most common problems that you’ll face. We’ll wrap up the course with an extensive walk-through troubleshooting example.

Prepare for better pay & bigger responsibility

Jake Watkins

Since I started training a few months ago, I can see there’s been a huge difference in how much more efficiently and effectively I can handle PLC repairs in the field. Our clients are telling management how happy they are to get back online more quickly and save money because I’m turning around faster fixes. I definitely recommend it for anyone who needs PLC training at any level.

Mario Flores

I needed to get up to speed on working with Siemens PLC equipment and came across RealPars training on YouTube. I watched my first video and immediately went to the website and signed up as a student. I like the way information is explained step-by-step and that it’s broken down into small chunks…I can go back and review anytime I want. I’m already seeing that I can perform repairs faster and with more confidence. Three of my co-workers were so impressed, they signed up for RealPars, too.

Meet your instructor

Ryan Kitchen

Ryan Kitchen is an experienced process automation and control engineer. He has project and support experience with mission-critical data center facilities, industrial and municipal water/wastewater treatment and distribution, oil and gas refining, power distribution, large mining conveyor systems, and industrial and commercial HVAC. In his free time, he shares with the automation community as a RealPars instructor.

Ideal for you if…

  • Entry-level to intermediate PLC programmer

  • Engineers, electricians, technicians, or other field maintenance personnel that can benefit from PLC troubleshooting

  • PLC programmers who develop or integrate new code

  • PLC programmers who support and maintain existing code

Here’s why you’ll succeed

  • One-on-one support

    Stuck or have a question? You get unlimited support from our team of proven PLC programming experts.

  • Laser-focused lessons

    We only teach you exactly what you need to know to master a PLC course. No fluff, filler, or wasting your time.

  • Experienced instructors

    All PLC training courses include step-by-step instructions from the world’s best so you can join their ranks and gain an unfair advantage.

Start learning now

You'll get lifetime access to this course.


  • Can I get a certificate for this course?

    "PLC Troubleshooting for Beginners" is a free course. No certificate will be granted for completing a free course. However, You will receive a personalized certificate of completion once you have fully finished a course (that provides a certificate) while being a Pro member.

  • What are the requirements of the course?

    Entry-level to intermediate knowledge of PLCs, electrical fundamentals, circuits, and programming

  • What is the required software?

    No software needed to complete this course

  • Can my employer purchase a course for me?

    Yes. Most people enroll individually, and then submit their receipt to their employer for reimbursement. However, if your employer has a tuition budget and wants to train 5 people or more, you can send us an email at [email protected] and we will help you with bulk signup.

  • Can I register for a course if I am working full time?

    Of course. All of our course content is pre-recorded, so you can work and study on your own time.