Electrical Control System

Engineering & Automation

UL 508A Automation Experts

With more than 40 years of expertise, Cope Controls specializes in the engineering, optimization, and maintenance of electrical control systems and equipment. As a certified UL 508A integrator of electrical control panels, we are equipped to design and integrate robust control systems tailored to your needs. We serve a diverse range of sectors including semiconductor, metal processing, tube and pipe mills, robotics and assembly lines, water and wastewater management, food and beverage production, and testing and measurement industries.

What we do

Engineering Services

We offer a full spectrum of engineering services:

  • System integration
  • Instrumentation selection and system design
  • PLC, VFD, HMI, and safety relay programming
  • Motion control dimensioning and axis sizing
  • Electrical, pneumatic, vacuum, and hydraulic system design
  • Component selection, BOM, conduit schedule, and electrical schematic generation
  • Safety risk assessment and mitigation for machine controls
  • Project management

Field Services

We offer a number of field services to our customers:

  • Machinery and equipment startups
  • Electrical troubleshooting and diagnostics
  • PLC, VFD, HMI, and safety relay programming
  • Safety circuit troubleshooting
  • Used machinery and equipment evaluation

Custom Control Panel Integration

We design, select components, generate schematics, and integrate automation control systems to your specifications. When desired, we ensure UL 508A-compliant solutions. We are happy to work from your drawings or preferred components for tailored results.

Main Control Cabinets

A Main Control Cabinet (MCC) will usually include the brains of the system. Most interconnects on a machine are wired back to this panel. Typically, but not always, the main power feed is connected to this panel, where the appropriate branch circuit protection is applied. The MCC may contain a PLC, drives, motor starters, contactors, and safety control relays. Control circuit power often originates here through the use of control transformers or switching power supplies. In most cases, the MCC will include a nameplate with date of manufacture, FLA, short-circuit protection, SCCR calculation, and electrical drawing reference name.

Remote I/O Panels

Remote I/O Panels typically include terminal blocks, relays, and other components that interface with field wiring such as transducers, solenoids, etc. For high density I/O panels, sometimes the system designer will opt for a local Remote I/O control rack with direct communication to the PLC via a communications protocol such as Ethernet. This can eliminate high density wire runs and significantly reduce the number of interconnection cables needed between equipment sections. All that is needed is an Ethernet cable and branch power input fed from the MCC (or elsewhere).

Operator Consoles

Our Operator Consoles are expertly crafted to provide intuitive interfaces for seamless operator interaction. They feature pushbuttons, E-stops, selector switches, dials, digital readouts, and HMIs, tailored to your needs. These consoles ensure ergonomic control, reliable performance, and smooth integration with your control systems.

Junction Boxes

Junction Boxes are a simple, but necessary part of a control system. They usually include terminal blocks for ease of wiring. This is where signals get split and/or combined. For example, a number of field sensors may get wired to a junction box where they are combined via terminal blocks into a single multi-conductor cable. This allows for one cable pull instead of several small cables, simplifying the installation and reducing cost for conduit runs.

VFD Panels

Our Variable Frequency Drive (VFD) Panels are expertly designed to control motor speed and torque, optimizing energy efficiency and performance. These custom solutions ensure seamless integration with your control systems, enhancing operational flexibility and reliability for various industrial and commercial applications.

DOL Starter Panels

Direct On-Line (DOL) Starter Panels provide a robust and straightforward solution for starting and protecting electric motors. DOL Starter Panels deliver reliable performance, incorporating high-quality components to ensure safe and efficient motor operation across diverse industrial environments.

EPO Panels

Our Emergency Power Off (EPO) Panels are critical for ensuring safety in urgent situations. These panels enable rapid shutdown of power systems, protecting personnel and equipment. They are tailored to meet stringent safety standards and integrate seamlessly with your control infrastructure.

Lighting Control Panels

Lighting Control Panels offer efficient and customizable management of lighting systems for commercial and industrial spaces. These panels integrate advanced controls to optimize energy usage, enhance user comfort, and ensure reliable operation, tailored to your specific lighting requirements.

why we do it

We’ve been there

We understand what it takes to apply coherent, efficient, and reliable industrial automation systems. We know that our systems must be extremely dependable and we achieve this by using sound engineering principles. It's simply not possible to support an ever growing number of installations without a high level of reliability. With over a decade of industrial experience and a very strong passion for automation, we have got what it takes to support your needs!

Coherent

We take complex systems and simplify them using sound engineering principles.

Reliable

We engineer systems to operate for a 10-20+ year lifespan.

Cost-Effective

We are a small business with low overhead and an outstanding passion for automation.

Contact Information

2616 Mill Race Rd, Frederick, MD, 21701

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