ecc-automation day tank enclosure back door

PLCs In Automation Control

Hard-wired electronic control versus full automation

Yesterday is the time for PLCs in electronic control

The industrial world has significantly advanced by leveraging computer power for automation today. However, some still opine that electronic controls for industrial-mechanical applications should remain “hard-wired.” They believe that harvesting the power of programmable logic controllers (PLCs) and integrated, expandable automation control related to its use should not be employed when it comes to certain types of machinery and equipment. This argument primarily comes from those experienced with traditional control systems. They are used to working with dials, buttons, and analog readout instruments. Unfamiliar with the power of a fully automated PLC solution and HMI readout, they stress simplicity. Yet, the growing demand for complex processes in turn requires modern automation technology that can handle them. The PLC-based solution for automation control, well-tested now over time, provides numerous benefits in terms of innovation, risk management, and increased efficiency.

Simpler paths to let the PLC centrally handle complexity

A more traditional electronic control system, unable to rely on the central processing power of a PLC, can require far more materials and work. More relays, controllers, and readout instrumentation can be required to handle industrial projects. For example, a data center requiring day tank control to supply diesel fuel backup generators would require significant more relays without a PLC. Without a PLC-based automation control for this system, a constant readout of remaining fuel would also require many more controllers. These additional electronic components and wiring increase the physical complexity. The impact in terms of higher costs of labor would be felt, from the stages of design and building up through the maintenance of the system.

One could make a strong case that if a PLC programmer’s logic is not sound, then yes, the ability to oversee and interact with the system could be a detriment when compared to a simpler hard-wired control process. Again, modern computing and the time-tested expertise behind advanced logic now offers enough PLC hardware and software to make this argument null.

PLC-based electronic control provides the ability to solve most any challenge to automating a process with the right components. One such advantage is making additions and upgrades to an industrial process. A new piece of equipment can be wired into the existing system. The programmable logic controller can be reprogrammed for its accommodation of the new modality.

Modern facilities now controlled through PLCs

If there is a modern industrial or commercial building facility, it is controlled by a PLC through the building management system (BMS). Equipment and machinery, wired one way or another to accomplish whatever process is necessary, is most likely integrated into that BMS.

Once mastered, the PLC’s human machine interface or HMI, allows field engineers to work smarter with more efficiency including Inputs and Outputs for alarm triggers and any kind of level readouts required, such as pressure of an operating steam boiler or fuel tank transfer process. The amount of time troubleshooting can be greatly reduced through programming sequences of operation that help isolate and readily identify the problem. Making the case for PLCs starts with demonstrating how much easier automation control becomes when the controller handles what is complex so the person in charge can focus on other priorities.


Electrical Wiring for Automation Controls

veins and arteries for electronic controls

If Programmable Logic Controllers are the brains of an automated control panel, and power sources are the heart, then electrical wiring would be the veins and arteries. And no matter the size of a project here at Electronic Control Corporation, we use tons of it. The need for scaling as we employ larger projects as well as multiple projects, while still maintaining the highest quality demands an automated high-volume widget capable of keeping our operations in optimal health as we flex to meet growing customer demands.

The Komax Kappa 320 for Automated Cutting and Stripping of Wires

Komax Kappa 320 - Electrical Wiring - ECC-Automation

The Kappa 320 Automated Cut and Strip Machine by Komax

ECC-Automation has procured the flexible, ultra-fast Komax Kappa 320 cut and strip wiring machine. This cutting and stripping machine offers the latest in high-range processing, and quick set-up for simple to harder electrical wiring materials. The controls are user-friendly and provide for great flexibility, allowing the operator to set-up job runs in no time.

A quick look at some features we like:

Electrical Wiring Sizes

This fully automated cut and strip machine we use for our electronic control panels allows for wire sizes from 0.05mm to 10mm2.

Inkjet marking

From Komax provided TopWin software, wiring can be custom-marked. This provides a tremendous advantage for electronic controller projects that require any unique identification on the wiring of a control panel.


Intuitive touch screen and software

TopTouch and TopWin, respectively, for seamless machine communications

Sensors like the optical cable detector

For quick job setup and significant reduction of material loss from cutting by early detection of stripping errors

As part of ECC-Automation commitment to producing state-of-the-art electronic controls, we continue to invest in equipment and operational assets that yield the quality and durability, regardless of the volume required. Our recent procurement of this cutting edge cut and strip wiring machine is now an integral part of keeping our operations running smoothly at an optimal level.

If you would like to learn more our approach to designing and manufacturing electronic control panels, including our wiring capabilities, give us a call today.

ecc-automation facility USA

New Control Panel Design and Manufacturing Facility for ECC Automation

ecc-automation facility USA

ECC-Automation’s new facility in Westminster, MD USA

Electronic Control Corp has now expanded into a larger control panel design and manufacturing facility, located in Westminster, Maryland USA. The company relocated to accommodate increasing demands of existing and future design project and manufacturing production requirements. All design, engineering, fabrication and quality testing of their electronic control panels & components now happens here. Once the completed electronic control systems are approved, they are shipped out of the new location to the project site for installation.


New equipment for electronic control design & manufacturing

As part of their commitment to the highest standards for electronic control manufacturing, Electronic Control Corporation continues to invest in modern technology and equipment. For example, building high quality electronic controls requires an unfathomable amount of wiring. Assuring a control panel is built with speed and volume, while maintain the highest quality requires a wiring machine to meet the demand. So ECC recently procured a brand new Komax Kappa 320 Cut and Strip machine to use in their new manufacturing space. The Kappa 320 cuts to length and strips the ends with extreme precision. This Cadillac of a cut and strip machine automatically ink-labels the wiring as well – for specific identification requirements of a project.

“Our Komax wiring machine gives us peace of mind knowing that every wire is stripped perfectly and is always the correct length. Production time goes down and quality goes up because issues like conductor strands being nicked, or a wire being cut too short are issues of the past.” ~Bradley Keck, Communications Engineer

Other areas of the facility include offices with the latest computer systems and software for designing electronic control systems, as well as developing the logic for programmable logic controllers.

Electronic Control Corp manufactures every system to exceed expectations

ECC Automation engineers work closely with clients to make sure their design fulfills every requirement, prior to product assembly. Once assembled, every control panel undergoes extensive quality control evaluation and testing procedures. Their goal: provide the highest quality electronic control systems to exceed expectations – 100+% customer satisfaction. As part of this goal, they have now expanded into a new control panel design and manufacturing facility. The growing company has procured state-of-the-art equipment and technology, continuing to offer the best automation control systems. Learn more here at and contact Electronic Control Corp today, so they can hear more about your automation control challenges.