Direct Digital Control Fundamentals: Sensors and Actuators

This introductory course establishes the core technical foundation required for modern commercial building automation and direct digital control (DDC) systems. Students examine the operating characteristics of analog and binary input/output devices, including temperature, humidity, pressure, and flow sensors, along with electronic damper actuators and control valves. Instruction emphasizes practical electrical safety, standard instrumentation signal ranges such as $4\text{--}20\text{ mA}$ and $0\text{--}10\text{ VDC}$, resistive circuit analysis, and mechanical field installation practices. Through structured laboratory exercises and systematic diagnostic scenarios, technicians learn to wire controllers, measure process variables, calibrate field hardware, and verify transducer scaling. Additional topics explore open- and closed-loop control architectures, basic two-position logic, and proportional-integral response concepts. By the conclusion of the course, participants will possess the practical proficiency to install, troubleshoot, and commission fundamental field-level control loops without reliance on vendor-specific proprietary tools.

InstructorJacob Calhoun

Course outline

Lectures, virtual labs, and graded assignments — completed in your browser.

01Lesson 1: Introduction to DDC Architecture and Control Loopslecture

02Lesson 2: Control Power, Signal Wiring, and Grounding Standardslecture

03Lesson 3: Binary Inputs and Outputs: Switches, Relays, and Status Monitoringlecture

04Hands-on Lab: Hands-On Lab: Binary Circuit Wiring, Interposing Relays, and Circuit Verificationlab

05Lesson 5: Analog Inputs: Thermistors, RTDs, and Resistive Measurementlecture

06Lesson 6: Analog Inputs: Active Transducers ($0\text{--}10\text{ V}$ and $4\text{--}20\text{ mA}$)lecture

07Lesson 7: Analog Outputs: Modulating Signals, Impedance, and Range Scalinglecture

08Hands-on Lab: Hands-On Lab: Analog Transducer Calibration, Signal Troubleshooting, and Scaling Verificationlab

09Lesson 9: Damper Actuators: Mechanical Linkages, Torque Sizing, and Fail-Safe Actionslecture

10Lesson 10: Control Valves: Body Styles, Characteristic Curves, Flow Coefficients ($C_v$), and Stroke Setuplecture

11Hands-on Lab: Hands-On Lab: Valve and Damper Actuator Mounting, Wiring, and Operational Stroke Testinglab

12Lesson 12: Loop Dynamics: Floating Control, Proportional Action, and Loop Stability Basicslecture

13Lesson 13: System Diagnostics: Troubleshooting Sensor Drift, Signal Attenuation, and Wiring Faultslecture

14Capstone Service Project: Comprehensive Field Device Checkout, Calibration, and Loop Commissioningassignment

Syllabus

["Week 1: Lesson 1: Introduction to DDC Architecture and Control Loops", "Week 2: Lesson 2: Control Power, Signal Wiring, and Grounding Standards", "Week 3: Lesson 3: Binary Inputs and Outputs: Switches, Relays, and Status Monitoring", "Week 4: Hands-on Lab: Hands-On Lab: Binary Circuit Wiring, Interposing Relays, and Circuit Verification", "Week 5: Lesson 5: Analog Inputs: Thermistors, RTDs, and Resistive Measurement", "Week 6: Lesson 6: Analog Inputs: Active Transducers ($0\\text{--}10\\text{ V}$ and $4\\text{--}20\\text{ mA}$)", "Week 7: Lesson 7: Analog Outputs: Modulating Signals, Impedance, and Range Scaling", "Week 8: Hands-on Lab: Hands-On Lab: Analog Transducer Calibration, Signal Troubleshooting, and Scaling Verification", "Week 9: Lesson 9: Damper Actuators: Mechanical Linkages, Torque Sizing, and Fail-Safe Actions", "Week 10: Lesson 10: Control Valves: Body Styles, Characteristic Curves, Flow Coefficients ($C_v$), and Stroke Setup", "Week 11: Hands-on Lab: Hands-On Lab: Valve and Damper Actuator Mounting, Wiring, and Operational Stroke Testing", "Week 12: Lesson 12: Loop Dynamics: Floating Control, Proportional Action, and Loop Stability Basics", "Week 13: Lesson 13: System Diagnostics: Troubleshooting Sensor Drift, Signal Attenuation, and Wiring Faults", "Week 14: Capstone Service Project: Comprehensive Field Device Checkout, Calibration, and Loop Commissioning"]