PLC Programming & Troubleshooting
Control-Core develops, edits, and troubleshoots PLC logic for Allen-Bradley and Rockwell environments, including legacy systems that need better structure, more stable performance, or a modernization path.
Whether the issue is nuisance downtime, undocumented logic, or a process that no longer behaves predictably, the goal is to restore clarity and control.
- New logic development
- Edits and expansions to existing programs
- Fault isolation and diagnostic support
- Legacy PLC upgrades and migrations
- Logic cleanup and standardization
- Startup and commissioning support
HMI & SCADA Development
Operator interfaces should help people make decisions quickly, not bury them in clutter. Control-Core develops HMI and SCADA solutions that improve visibility, streamline alarms, present process context clearly, and support local or remote operation.
- New HMI screen development
- SCADA visualization and process overviews
- Alarm rationalization and display improvements
- Remote access integration
- Interface modernization projects
- Operator training and documentation support
System Integration
Control-Core integrates the pieces that make automation systems work as one coordinated environment — instrumentation, variable frequency drives, PLCs, networking, panels, field devices, and supporting electrical components.
- Instrumentation integration and calibration
- Drive configuration and coordination (VFDs)
- PLC and network integration
- Signal mapping and I/O documentation
- Startup and functional checkout
- Retrofit coordination on mixed equipment
Electrical & Controls Services
Automation performance depends on electrical execution just as much as programming. Control-Core supports panel work, field wiring, MCC-related tasks, and industrial controls support so the physical side of the system matches the logic behind it.
- Panel builds and modifications
- Field wiring support and terminations
- MCC work and motor control support
- Device replacement and verification
- Control circuit troubleshooting
- Industrial electrical support aligned with PLC layer
Diagnostics & Emergency Support
When a system goes down, the priority is fast, disciplined troubleshooting that gets to the real cause instead of chasing symptoms. Control-Core provides rapid diagnostics, root cause analysis, and recovery support for urgent automation and electrical issues.
- Emergency troubleshooting (on-site and remote)
- Fault tracing and signal verification
- Root cause analysis and reporting
- Process recovery support
- Follow-up recommendations to prevent recurrence
- System documentation updates post-repair
Preventive Maintenance & Optimization
Some of the most expensive failures start as small issues that go unchecked. Control-Core provides preventive maintenance and optimization support designed to reduce avoidable downtime and keep systems performing consistently.
- Scheduled controls review and inspection
- Alarm and trend review for early detection
- Performance tuning and loop optimization
- Documentation updates and version control
- Preventive maintenance planning and scheduling
- Reliability-focused improvement recommendations
Panel Building
Control-Core designs and builds custom control panels from the ground up — wired to spec, built to last, and ready to integrate with the automation system it's supporting. Every panel is built with maintainability in mind, not just to get it out the door.
- Custom enclosure design and component layout
- DIN rail assembly — breakers, relays, terminal blocks, I/O modules
- VFD, soft starter, and motor control wiring
- PLC and I/O panel integration
- Point-to-point wiring from schematics or designed in-house
- UL-compliant builds and proper wire management
- Factory acceptance testing before delivery or installation
Panel Servicing
Existing panels deteriorate — loose connections, failed components, outdated layouts, and undocumented modifications add up over time. Control-Core provides hands-on panel servicing to bring existing equipment back to a reliable, safe, and documented state.
- Panel inspection and condition assessment
- Loose connection tightening and terminal block repair
- Failed or aged component replacement
- Wiring cleanup and re-labeling
- As-built documentation and redlines
- Overheating and thermal imaging inspection
- Upgrades to improve safety, code compliance, or capacity
