MCC & Motor Control Engineering Support
From phone troubleshooting to complete facility modernization, our team of veteran engineers provides the expertise you need to keep your motor control systems running at peak performance.
Comprehensive Engineering Services
Whether you need immediate troubleshooting or a complete facility upgrade, we have the expertise to solve your motor control challenges.
Phone Troubleshooting
Get immediate expert guidance for MCC issues. Our engineers diagnose problems, walk you through solutions, and help you avoid costly downtime.
- Real-time diagnostics
- Step-by-step repair guidance
- Parts identification & sourcing
Complete Site Surveys
Our field engineers perform comprehensive facility assessments, documenting every MCC, identifying issues, and creating detailed modernization roadmaps.
- Full equipment inventory
- Obsolescence risk analysis
- Upgrade recommendations & budgets
Retrofit & Modernization
Transform aging MCCs into modern, efficient systems with minimal downtime. We engineer solutions that fit your existing infrastructure and budget.
- VFD & soft starter integration
- Smart overloads & metering
- Industrial networking & PLCs
Common MCC Retrofit & Upgrade Projects
From energy efficiency to obsolescence mitigation, we handle the full spectrum of motor control modernization.
Variable Frequency Drive (VFD) Installation
Why: Energy savings, speed control, reduced mechanical stress
Replace across-the-line starters with VFDs to achieve 20-50% energy savings on pumps, fans, and conveyors. Soft acceleration reduces mechanical wear and extends equipment life.
Typical Applications:
- • HVAC fans & pumps (variable load)
- • Conveyor systems (adjustable speed)
- • Compressors (demand matching)
Soft Starter Upgrades
Why: Eliminate inrush current, reduce electrical stress
Replace mechanical starters with electronic soft starts for motors that don't need speed control. Reduces voltage sags, mechanical shock, and extends motor life by 30-50%.
Typical Applications:
- • Large pumps (water hammer prevention)
- • Compressors (torque limiting)
- • Centrifugal loads (belt protection)
Electronic Overload Relay Replacement
Why: Precise protection, diagnostics, communication
Replace aging thermal overloads with solid-state relays offering trip history, ground fault detection, and Ethernet/IP communication for real-time motor monitoring.
Key Benefits:
- • ±1% accuracy vs ±10% thermal
- • Ground fault protection (50mA-20A)
- • Trip logs & predictive maintenance
Industrial Networking & Automation
Why: Remote monitoring, SCADA integration, Industry 4.0
Add Ethernet/IP, Modbus, or Profinet communication modules to legacy MCCs. Integrate with PLCs, HMIs, and cloud-based monitoring platforms for complete visibility.
Common Integrations:
- • Allen-Bradley ControlLogix PLCs
- • Siemens S7-1500 controllers
- • Cloud IoT platforms (AWS, Azure)
Power Metering & Energy Management
Why: Cost reduction, utility compliance, sustainability
Install power meters and energy monitoring modules to track consumption per motor/load. Identify inefficiencies, optimize run schedules, and reduce utility demand charges.
Measurable Results:
- • 15-30% reduction in energy costs
- • Utility rebate qualification
- • ISO 50001 compliance
Arc Flash Reduction & Safety Upgrades
Why: Worker safety, NFPA 70E compliance
Retrofit arc flash mitigation systems, zone-selective interlocking, and maintenance mode switches to reduce incident energy levels and protect personnel during maintenance.
Safety Enhancements:
- • Arc flash sensors & relays
- • Racking interlocks
- • IR windows for thermal scans
Why Retrofit Instead of Replace?
A complete MCC replacement can cost $100,000+ and require weeks of downtime. Retrofitting existing buckets delivers 70-90% of the benefits at a fraction of the cost and disruption.
Cost Savings: 50-80% vs. New
Retrofit buckets for $5,000-$15,000 vs. $50,000-$200,000 for new MCC sections. Use existing infrastructure and bus work.
Minimal Downtime
Swap buckets during scheduled maintenance windows. No facility-wide shutdowns or major electrical work.
Phased Approach
Upgrade critical buckets first, spread costs over multiple budget cycles. Address worst problems immediately.
Typical Retrofit ROI Timeline
Average Project Payback: 18-36 months through energy savings, reduced labor, and avoided equipment failures.
Need Expert Guidance on Your MCC Retrofit?
Our engineering team provides comprehensive support—from phone troubleshooting to complete facility modernization. We'll help you choose the right approach for your budget and timeline.
Engineering Team That Knows MCC Backwards & Forward
Our engineers have collectively solved thousands of motor control problems across every major brand and application. When you call us, you're getting decades of hands-on experience.
What Sets Us Apart
Cross-Brand Expertise
We work with Square D, Siemens, GE, Allen-Bradley, Cutler Hammer, Westinghouse, and more. No "brand loyalty," we recommend what's best for your application.
Field-Tested Solutions
Every retrofit design comes from real-world projects. We know what works, what fails, and how to avoid common pitfalls.
Parts Availability
With 40,000+ sq ft of surplus inventory, we can source hard-to-find components that OEMs say are obsolete. Keep systems running longer.
Fast Response
Emergency support available. We understand downtime costs thousands per hour. Our engineers prioritize urgent troubleshooting calls.
Ready to Modernize Your Motor Control?
Start with a free consultation. Our engineers will assess your needs and recommend the most cost-effective path forward.
Available Mon-Fri 7AM-3PM EDT • Emergency support available