Top 20 Interview Questions & Answers for Controls Technician Roles – 2025

Preparing for a controls technician job interview? As a controls technician, you will be responsible for installing, maintaining, and troubleshooting control systems for machinery and equipment. This guide provides a list of essential questions and answers that will help you showcase your technical expertise, problem-solving skills, and experience working with automated systems and processes.

General Questions

• 1. Tell us about your experience working as a controls technician.
  I have been working as a controls technician for 8 years now. In this role, I have installed and maintained control systems for a variety of machinery and equipment, including industrial robots, PLCs, and HMI devices. I have also been involved in troubleshooting, diagnosing and repairing control system malfunctions.
• 2. What interests you in this role?
  I am interested in the technology involved in control systems and how they can improve efficiency in manufacturing processes. I am also drawn to the problem-solving aspect of the job, as I enjoy finding solutions to technical issues.
• 3. How do you stay updated on the latest advancements in control systems technology?
  I regularly attend industry conferences and seminars, and I make it a point to read technical publications and online forums related to control systems. I also stay updated on new equipment and software releases from manufacturers.
• 4. How do you ensure the safety of yourself and others while working with control systems?
  I always follow all safety protocols and guidelines set by the company and make sure to use appropriate personal protective equipment. I also conduct regular risk assessments and communicate any potential hazards to my team members.
• 5. Can you give an example of a successful troubleshooting experience?
  In a previous role, we had a production line that kept shutting down due to a faulty control system. After thorough troubleshooting, I discovered that the issue was with a faulty sensor that was sending incorrect readings to the PLC. I replaced the sensor, and the production line was up and running again.

Technical Skills & Experience

• 6. What programming languages are you proficient in?
  I am proficient in ladder logic and structured text programming for PLCs. I am also familiar with C++ and Python for HMI and SCADA systems.
• 7. Have you worked with different communication protocols before?
  Yes, I have experience working with various communication protocols, including Ethernet/IP, Modbus, and Profinet. I am also familiar with their troubleshooting processes.
• 8. How do you approach troubleshooting a control system issue?
  First, I gather all relevant data and information about the issue, such as error codes, system logs, and past troubleshooting attempts. Then, I use a systematic approach, starting with the most obvious causes and ruling them out one by one until I find the root cause of the problem.
• 9. Can you explain your experience with troubleshooting VFDs?
  I have extensive experience troubleshooting VFDs (Variable Frequency Drives). I am familiar with their components, functions, and common issues, such as overloading, overvoltage, and communication problems. I am also experienced in using diagnostic tools and software to troubleshoot VFDs.
• 10. What experience do you have with industrial robots?
  In my previous role, I worked with various types of industrial robots, such as SCARA and Cartesian robots. I have experience programming, configuring, and troubleshooting these robots for different applications, such as pick and place, welding, and assembly.

Behavioral Questions

• 11. Can you tell us about a time when you had to work under pressure to meet a tight deadline?
  In my previous role, we had a sudden breakdown of a critical control system right before a big production deadline. I stayed calm and focused, prioritizing tasks and communicating with my team effectively to get the system up and running within the time frame.
• 12. Have you ever encountered a difficult co-worker? How did you handle the situation?
  Yes, I encountered a co-worker who was resistant to change and would often disregard safety protocols while working with control systems. I addressed the issue by speaking to them privately, explaining how their actions could compromise their safety and that of others.
• 13. Can you give an example of a mistake you made and how you handled it?
  In a previous role, I accidentally deleted a crucial program from a PLC while trying to fix an issue. I immediately reported the incident and took responsibility for my mistake. I worked together with my team and used our documentation to recreate the program and ensure it was functioning correctly.
• 14. How do you prioritize tasks and manage your time effectively?
  I start each day by creating a to-do list and prioritizing tasks based on urgency and importance. I also make sure to schedule breaks and allocate enough time for each task. If I encounter any unforeseen issues, I reassess my priorities and adjust my schedule accordingly.
• 15. How do you handle conflicting priorities or deadlines?
  I make sure to communicate with all parties involved and understand the urgency and importance of each task. I then prioritize the tasks and allocate my time accordingly. If needed, I seek assistance or delegate tasks to ensure all deadlines are met.

Situational Questions

• 16. Imagine you are working on a project, and the control system goes down unexpectedly. What steps would you take to troubleshoot the issue?
  I would first check for any obvious causes, such as loose connections or power outages, and address them if necessary. Then, I would gather system logs and error codes to narrow down the issue and use diagnostic tools to identify the root cause. If needed, I would reach out to my colleagues or the manufacturer for assistance.
• 17. How would you handle a situation where a sensor is giving inaccurate readings?
  First, I would calibrate the sensor and check if that resolves the issue. If not, I would check for any physical damages or external factors that could be causing the inaccurate readings. If the issue persists, I would replace the sensor and conduct further tests to ensure accuracy.
• 18. If a production line is constantly breaking down due to control system issues, how would you address the situation?
  I would first analyze the root cause of the issues, either through system logs or by conducting a thorough inspection. Then, I would work on finding a permanent solution, such as reprogramming the control system or replacing faulty components. I would also document the issue and its resolution to prevent similar incidents in the future.
• 19. How would you handle a situation where communication between a PLC and an HMI is not established?
  I would first check the communication settings for both the PLC and HMI and ensure they are correctly configured. If needed, I would troubleshoot for any physical issues, such as damaged cables. If the issue persists, I would use diagnostic software to identify the root cause and resolve it.
• 20. What would you do if a safety feature in a control system is not functioning correctly?
  I would first stop the equipment and verify the safety issue. Then, I would thoroughly inspect the safety feature for any faults or damages and repair or replace it if necessary. Before restarting the equipment, I would conduct tests to ensure the safety feature is functioning correctly. I would also report the issue and document the resolution for future reference.