Automation and Controls Fundamentals

Course Description

This combined lecture and laboratory course (ETM 1600C) introduces students to the fundamental principles of industrial and building automation and control systems. Students explore electrical fundamentals, control theory, sensing and actuation technologies, programmable logic controllers (PLCs), and open/closed-loop control strategies. The course is the foundational entry point for the Energy Management and Controls Technology (ETM) program under Florida's Statewide Course Numbering System (SCNS), classified within the Engineering Technologies > Mechanics, Fluids & Heat taxonomy. Hands-on laboratory activities accompany all lecture topics, giving students direct experience with controls hardware, wiring, and software representative of industry-leading brands.

Students completing this course will be prepared to enter the building automation and industrial controls field as entry-level technicians, or to continue into advanced ETM coursework covering HVAC systems, BAS integration, and programmable control applications.

Learning Outcomes

Required Outcomes

Upon successful completion of this course, students will be able to:

• Apply electrical safety practices in lab environments, including lockout/tagout (LOTO) procedures and compliance with relevant electrical codes.
• Use fundamental electrical laws (Ohm's Law, Kirchhoff's Laws) to analyze and troubleshoot AC and DC control circuits.
• Identify, wire, and test common input devices (sensors, switches, thermostats) and output devices (relays, contactors, actuators, motors).
• Read and interpret electrical schematic diagrams and ladder logic diagrams used in industrial and building control systems.
• Distinguish between open-loop and closed-loop control systems and explain the role of feedback in process control.
• Describe the basic architecture and operation of a Programmable Logic Controller (PLC), including inputs, outputs, the processor, and the program scan cycle.
• Use standard test equipment (multimeters, volt-ohm meters, amp probes) to measure voltage, current, resistance, and continuity in control circuits.
• Explain the principles of PID (Proportional-Integral-Derivative) control, including feedback, setpoints, and error correction.

Optional Outcomes

The following outcomes may be covered at the discretion of the instructor or institution:

• Write and modify basic PLC ladder logic programs, including contacts, coils, timers, and counters.
• Interface a PLC with sensors and actuators to implement a simple automated control sequence.
• Identify components and communication pathways in a basic Building Automation System (BAS).
• Apply Boolean algebra and logic diagrams to analyze digital control logic.
• Describe the role of Human-Machine Interfaces (HMIs) in monitoring and operating automated systems.
• Identify energy efficiency considerations related to automated HVAC and mechanical system controls.

Major Topics

Required Topics

1. Electrical Safety and Lab Practices — Personal protective equipment (PPE), LOTO procedures, NFPA 70E awareness, safe wiring practices.
2. DC and AC Electrical Fundamentals — Voltage, current, resistance, power; series, parallel, and combination circuits; Ohm's Law; capacitance and inductance basics; transformers.
3. Control Circuit Components — Manual and automatic switches, pushbuttons, limit switches, float switches, pressure switches, relays, contactors, and solenoids.
4. Sensors and Input Devices — Temperature sensors (thermistors, RTDs, thermocouples), proximity sensors, photoelectric sensors, level sensors, and pressure transducers.
5. Output and Actuating Devices — Motors (single-phase and three-phase), motor starters, drives, control valves, and damper actuators.
6. Schematic and Ladder Diagram Interpretation — Reading and tracing electrical schematics; introduction to ladder logic notation; control circuit tracing and documentation.
7. Open-Loop vs. Closed-Loop Control — System definitions, feedback principles, setpoints, process variables, error signals, and basic control loop operation.
8. Introduction to Programmable Logic Controllers (PLCs) — PLC architecture (CPU, I/O modules, power supply, programming device); program scan cycle; basic programming with contacts, coils, timers, and counters.
9. PID Control Fundamentals — Proportional, integral, and derivative actions; tuning concepts; applications in temperature, pressure, and flow control.
10. Test Equipment and Troubleshooting — Use of digital multimeters, clamp meters, and continuity testers; systematic troubleshooting methods for control circuits.

Optional Topics

• Basic PLC Programming Lab — Connecting to a PLC, downloading programs, monitoring I/O status, basic ladder logic modification.
• Human-Machine Interfaces (HMIs) — Overview of operator interface panels; display configuration; alarm management basics.
• Building Automation System (BAS) Overview — BAS architecture, DDC (Direct Digital Control) controllers, communication protocols (BACnet, Modbus), and integration concepts.
• Motor Speed Control — Variable Frequency Drives (VFDs); speed-torque relationships; energy savings in fan and pump applications.
• Pneumatic and Hydraulic Control Fundamentals — Fluid power principles as applied to control actuators; pneumatic controllers and positioners.
• Energy Management and Controls Integration — Introduction to energy efficiency strategies using automated controls; scheduling, setback, and trending in BAS environments.

Resources & Tools

• Textbook: Fundamentals of Industrial Controls and Automation (Lonnie L. Smith) or equivalent instructor-selected text covering electricity, control components, and PLC fundamentals.
• Lab Equipment: AC/DC electrical training workstations; multimeters, clamp meters, and continuity testers; PLC training kits (Allen-Bradley/Rockwell, Siemens, or equivalent); relay and contactor demonstration panels.
• Software: PLC programming software (e.g., Rockwell Studio 5000 / RSLogix 500, Siemens TIA Portal, or equivalent); building automation simulation or configuration tools as available.
• Standards References: NFPA 70 (National Electrical Code); NFPA 70E (Electrical Safety in the Workplace); ANSI/ISA standards for instrumentation and control.
• Florida SCNS: Course profile available at flscns.fldoe.org.

Career Pathways

Successful completion of ETM 1600C prepares students for entry-level roles in building automation and industrial controls, and supports progression into the full Energy Management and Controls Technology A.S. degree or Advanced Manufacturing & Automation Technology A.S. degree at participating Florida colleges.

• Building Automation Technician — Install, commission, and maintain DDC/BAS systems in commercial buildings.
• Industrial Controls Technician — Operate, maintain, and troubleshoot automated manufacturing control systems.
• HVAC Controls Specialist — Service and program electronic controls for commercial HVAC and refrigeration systems.
• Automation Control Specialist/Technician — Work with PLCs, HMIs, and sensors in manufacturing, food production, and distribution.
• Electro-Mechanical Technician — Support automated equipment maintenance across manufacturing, logistics, and utilities industries.
• Energy Management Technician — Monitor and optimize building systems for energy efficiency using automated controls platforms.

Central Florida's proximity to aerospace, defense, logistics, manufacturing, and theme park industries creates strong regional demand for controls and automation technicians. Graduates may also pursue certifications from organizations such as MSSC (Manufacturing Skill Standards Council), NICET, or vendor-specific credentials (e.g., Rockwell Automation, Siemens).

Special Information

Laboratory Component: The "C" suffix in ETM 1600C designates a combined lecture and laboratory course that meets in the same place at the same time, per Florida SCNS convention. Students should expect hands-on wiring, measurement, and controls exercises as an integral part of the course grade.

Grade Requirement: A grade of C or better is required to satisfy program requirements for the Energy Management and Controls Technology A.S. degree and related certificate programs at Florida colleges, including Valencia College.

Certification Preparation: Course content aligns with foundational knowledge areas for the MSSC Certified Production Technician (CPT) credential and entry-level preparation for NICET (National Institute for Certification in Engineering Technologies) examinations in fire alarm and building systems. Students holding the MSSC CPT certification may be eligible for advanced standing credit toward related A.S. degree programs at participating Florida colleges.

Industry Alignment: Where available, instruction incorporates controls devices and software representative of leading industry brands encountered in Florida's commercial building, manufacturing, and industrial sectors.