Automation and Controls Integration

Course Description

ETM2605C — Automation and Controls Integration is a 3-credit, lab-enhanced course within the Florida Statewide Course Numbering System (SCNS) taxonomy of Engineering Technologies > Mechanics Fluids Heat. This course provides students with the knowledge and hands-on skills required to integrate programmable logic controllers (PLCs), human-machine interfaces (HMIs), supervisory control and data acquisition (SCADA) systems, variable frequency drives (VFDs), sensors, and other automation components into cohesive, functional industrial control systems. Emphasis is placed on system architecture design, industrial communication protocols, hands-on configuration, testing, and fault diagnosis. Students apply learned concepts in lab exercises that simulate real-world industrial automation environments.

Learning Outcomes

Required Outcomes

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

• Design and implement integrated automation systems combining PLCs, HMIs, SCADA software, and VFDs into a unified control architecture.
• Program and configure PLC ladder logic, function block diagrams, and structured text for discrete and analog I/O control applications.
• Configure and commission Human-Machine Interface (HMI) screens including alarm displays, trend graphs, and process visualization.
• Install, configure, and troubleshoot Variable Frequency Drives (VFDs) for AC motor speed and torque control in industrial applications.
• Apply industrial communication protocols such as Modbus RTU, Ethernet/IP, and OPC to connect automation components.
• Perform system-level troubleshooting including fault detection, diagnostics, and resolution strategies across integrated control systems.
• Follow safe work practices including Lockout/Tagout (LOTO) procedures, NFPA 70E electrical safety standards, and proper use of PPE.
• Read and interpret electrical schematics, wiring diagrams, and control panel documentation associated with automation systems.

Optional Outcomes

The following outcomes may be covered depending on institutional resources and instructional focus:

• Develop basic SCADA applications using industry software such as FactoryTalk, Ignition, or WonderWare for supervisory monitoring and data logging.
• Integrate Industrial Internet of Things (IIoT) devices and data acquisition systems into an existing control architecture.
• Apply the Purdue Model of industrial network segmentation including VLAN and firewall configurations for cybersecurity.
• Design and test a telemetry subsystem using wireless (900 MHz, 2.4 GHz) and serial (RS-232, RS-485) communications media.
• Demonstrate proficiency with motion control systems and servo drive integration in an automation context.

Major Topics

Required Topics

• PLC Fundamentals and Programming — Ladder logic, discrete and analog I/O, timers, counters, and data handling instructions; platforms such as Allen-Bradley MicroLogix, CompactLogix, or equivalent.
• HMI Design and Configuration — Creating operator screens, alarm management, trending, and process animation using HMI development software.
• SCADA Systems Overview — Architecture of SCADA systems, RTUs, historian databases, alarm management, and integration with PLCs and field devices.
• Variable Frequency Drives (VFDs) — Operating principles, installation, parameter configuration, two-wire and three-wire control methods, and AC motor speed/torque regulation.
• Industrial Communication Protocols — Modbus RTU/ASCII, Ethernet/IP, DeviceNet, OPC; device-level bus structures and network configuration.
• Sensors and Transducers — Selection and application of proximity sensors, photoelectric sensors, pressure transducers, flow meters, and temperature sensors in control loops.
• Control Panel Wiring and Documentation — Reading and interpreting electrical schematics; wiring discrete and analog I/O modules; enclosure standards (NEMA).
• System Integration and Commissioning — Connecting PLCs, HMIs, VFDs, and sensors into a complete system; site acceptance testing (SAT); documentation.
• Troubleshooting and Fault Diagnosis — Systematic fault detection, PLC diagnostics, HMI-based fault monitoring, and corrective maintenance procedures.
• Industrial Safety — OSHA regulations, NFPA 70E, Lockout/Tagout, arc flash awareness, and safe work practices in industrial automation environments.

Optional Topics

• SCADA Software Applications — Hands-on development using FactoryTalk View, Ignition, or WonderWare SCADA platforms.
• IIoT and Industry 4.0 Concepts — Edge computing, cloud-based monitoring, and smart sensor integration.
• Industrial Network Security — Purdue Model, VLAN segmentation, firewall configuration, and cybersecurity best practices for OT environments.
• Motion Control Systems — Servo drives, stepper motors, and motion programming basics.
• Wireless and Telemetry Systems — Design and deployment of wireless SCADA links using 900 MHz, 2.4 GHz, and 5 GHz technologies.
• Process Control Loops — PID controller theory and tuning; closed-loop control integration with PLC analog modules.

Resources & Tools

• PLC Software: Rockwell Automation Studio 5000 / RSLogix 500, or equivalent (AutomationDirect Do-more, Siemens TIA Portal)
• HMI/SCADA Software: FactoryTalk View, Ignition (Inductive Automation), or WonderWare
• Lab Equipment: PLC trainer stations, VFD test panels, AC motor loads, analog and discrete I/O modules, HMI touch panels
• Communication Tools: Ethernet switches, serial converters (RS-232/RS-485), OPC server software
• Test Instruments: Digital multimeters, clamp ammeters, signal generators, oscilloscopes
• Reference Standards: NFPA 70 (NEC), NFPA 70E, OSHA 1910.147 (LOTO), ISA-95 Automation Hierarchy
• Textbooks/References: Instructor-selected automation and controls textbooks aligned to current PLC and SCADA platforms

Career Pathways

Completion of ETM2605C prepares students for employment and advancement in the following roles:

• Automation Technician — Installing, programming, and maintaining PLC-based control systems in manufacturing or process industries.
• Controls Technician / Controls Electrician — Wiring, commissioning, and troubleshooting industrial control panels and field devices.
• SCADA/HMI Operator or Technician — Monitoring and supporting supervisory control systems in utilities, water/wastewater, or oil and gas facilities.
• Industrial Maintenance Technician — Performing preventive and corrective maintenance on automated production equipment.
• Systems Integration Specialist — Designing and deploying integrated automation solutions for industrial clients.
• Field Service Engineer (entry-level) — Supporting automation system installations and upgrades at customer facilities.

This course applies toward the A.S. in Engineering Technology and related certificate programs at Florida state colleges. Graduates are well-positioned for careers in manufacturing, process industries, utilities, building automation, and aerospace.

Special Information

Certification Preparation

Content covered in ETM2605C aligns with preparation for the following industry-recognized credentials:

• NCCCO / NOCTI — Industrial Controls and Automation assessments
• Rockwell Automation Certified Technician (RA) — RSLogix / Studio 5000 platform certification pathway
• ISA Certified Automation Professional (CAP) — Foundation-level competencies in automation system lifecycle
• OSHA 10 General Industry — Safety credential commonly required in industrial employment

Students completing this course as part of a degree or certificate program in Engineering Technology are encouraged to pursue these credentials to enhance employability in Florida's growing advanced manufacturing and industrial automation sectors.