5036 – Instrumentation & Electrical: Troubleshooting Motors

As power systems evolve and equipment becomes more complex, the demand for skilled electricians and technicians who can troubleshoot and maintain motor circuits continues to rise.

According to the U.S. Department of Labor’s Bureau of Labor Statistics, employment for electricians saw a 20% increase from 2012 to 2022, far exceeding the average growth rate across all professions. This growth reflects the increasing complexity of electrical systems used in modern facilities, particularly in power generation, distribution, and motor-driven equipment. As experienced professionals retire, a knowledge gap is forming in the industrial workforce, underscoring the need for targeted training programs that equip new and existing personnel with advanced diagnostic and industrial maintenance training skills.

This comprehensive five-day course focuses on the operation, diagnostics, and motor troubleshooting of motors and motor circuits, blending foundational theory with applied techniques. Designed for electricians, E&I technicians, maintenance personnel, and reliability engineers, the course explores both the theoretical and practical aspects of electrical motors, transformers, motor control systems, and programmable logic controllers (PLCs). Emphasis is placed on condition monitoring, predictive maintenance strategies, and the use of modern diagnostic tools.

Foundations of Electricity and Distribution Systems

The course begins with a solid review of electrical fundamentals essential to troubleshooting. Participants revisit key principles such as Ohm’s Law, magnetism, and electromagnetic fields. The session explores the nature of three-phase alternating current (AC) supply, which is the backbone of industrial motor systems. Learners also gain insights into the structure and operation of electrical distribution networks, setting the stage for deeper understanding of circuit behavior and system interactions.

Motor Construction, Operation, and Drive Technologies

A major portion of the course is dedicated to the construction and operation of AC and DC motors. Participants examine various motor types including three-phase induction motors, wound rotor motors, synchronous motors, as well as shunt and series DC motors. This section covers how these machines convert electrical energy into mechanical energy and the failure modes commonly associated with each.

Further, the course addresses variable frequency drives (VFDs), which are widely used for controlling motor speed and torque. Students learn the fundamentals of VFD operation, best practices for installation, and how to identify and resolve common drive issues through both theoretical discussion and hands-on exercises.

Transformer Theory and Condition Assessment

Understanding transformers is vital for diagnosing issues within power distribution systems. The training provides a thorough examination of transformer types, including star, delta, and variable tap configurations. Learners explore the principles of electromagnetic induction, voltage transformation, and how improper configurations can impact motor performance.

The course introduces IEEE 1415 standards for motor testing, providing a framework for consistent and effective diagnostics. Attendees become familiar with a suite of offline and online testing techniques, using instruments such as Megger, All-Test Pro, PDMA, and Baker analyzers. These tools are essential for motor circuit analysis (MCA) and electrical signature analysis (ESA), allowing technicians to detect insulation breakdowns, winding faults, and rotor bar issues before they lead to equipment failure.

Complementary diagnostic methods are also explored, including partial discharge testing, low resistance measurements using ductor testers, infrared thermography, and ultrasound detection. The advantages and limitations of each method are discussed in detail, helping learners choose the right approach for different failure modes.

Motor Control Systems and Safety Components

Moving beyond motors and transformers, the course delves into the architecture of motor control systems. Participants review the key components of control circuits, including safety devices such as breakers and overloads, pilot devices (e.g., push buttons, selector switches), and motor starters. Attention is paid to how these elements interact to ensure safe and reliable motor operation.

By understanding the function and integration of these devices, participants will be better equipped to troubleshoot issues related to control logic and system responsiveness. Emphasis is also placed on safe work practices, proper installation techniques, and troubleshooting strategies that align with industrial safety standards.

Introduction to Programmable Logic Controllers (PLCs)

A growing number of industrial systems now rely on PLCs to manage automated processes. This course includes a comprehensive introduction to PLC systems, covering both the hardware and software components involved in industrial automation. Topics include:

• Interpretation of ladder diagrams, the most common PLC programming language
• Identification and functionality of key PLC components such as CPUs, I/O modules, EPROMs, A/D converters, and power supplies
• Overview of PLC sizes, types, and their roles within automated control systems
• Principles of PC-based control logic and human-machine interface (HMI) integration

Participants gain hands-on experience programming PLCs using simulation trainers. These exercises reinforce theoretical knowledge and provide practical skills applicable to real-world applications. Attendees return to their workplaces with the ability to assist in system diagnostics, program logic review, and troubleshooting automation faults.

Condition Monitoring and Preventive Maintenance Practices

Throughout the course, a strong focus is placed on the application of electrical condition monitoring in preventive maintenance programs. Students learn how to interpret data gathered from static and dynamic tests, correlate those findings with potential failure modes, and incorporate them into routine inspection protocols.

Case studies and instructor-led demonstrations reinforce the importance of proactive asset management. Participants will also be introduced to machinery performance audits and asset strategy development, gaining skills to support organizational reliability goals.

Learning Environment and Instructional Methods

The course is delivered through a balanced combination of theoretical instruction, instructor-led demonstrations, and hands-on practical exercises. A wide range of measurement instruments is used to support learning, including insulation testers, VFD analyzers, thermal cameras, and ultrasonic devices.

Participants are encouraged to bring real-world challenges to class for discussion and problem-solving. The interactive structure promotes critical thinking and peer learning, enhancing each learner’s ability to diagnose complex issues independently and collaboratively.

Ideal Participants and Background Knowledge

This course is designed for individuals with a background in electrical or instrumentation trades, including electricians, E&I technicians, and maintenance professionals. It is also highly relevant for engineers, first-line supervisors, and reliability managers responsible for improving equipment performance and reducing operational downtime.

While there are no strict prerequisites, participants will benefit from a basic understanding of electrical principles, familiarity with industrial tools and measurement devices, and previous experience interpreting electrical schematics. These foundational skills will help maximize the learning value of the hands-on sessions.

By the end of this course, attendees will have deepened their understanding of motor and transformer systems, refined their troubleshooting skills, and gained practical insights into condition monitoring, control systems, and automation technologies. These competencies are essential for ensuring equipment reliability in today’s demanding industrial environments.