Controls Engineer

Federal Mfg•New Freedom, PA

34d•Onsite

About The Position

The Controls Engineer is responsible for the design, programming, implementation, and support of automated control systems for manufacturing and industrial applications. This role involves developing and maintaining control system designs, schematics, and bills of materials, including flow diagrams, panel layouts, and termination diagrams. The engineer will also code, test, and debug PLC, HMI, and Motion Control programs, and provide technical support for Factory Acceptance Tests (FATs), on-site installation, and after-sales support, including troubleshooting in the field and over the phone. Collaboration with panel shop technicians is essential to ensure control panels and electrical systems meet quality standards, applicable codes, and customer requirements. The role also includes handling component selection, specification, and vendor quotations, writing validation and design specification documentation, and participating in cross-functional teams for continuous improvement initiatives related to control systems and automation processes. Hands-on hardware/software integration and troubleshooting of control systems are key aspects of this position.

Requirements

BS in Engineering (Electrical, Computer, or Mechanical Engineering preferred)
5+ years of Controls Engineering experience
Strong PLC programming skills (Allen Bradley/Rockwell, Keyence, Panasonic, others)
Proficient in RsLogix/Studio5000, AutoCAD, FactoryTalk View
Proficient in Ladder Logic & Structured Text
Strong Mechanical Aptitude
Experience with designing and implementing process controls on high-speed machinery including open loop and closed loop controls, rotary and linear indexing mechanisms with servo, stepper, and VFD motors and drives, pneumatic and electric actuators.
Strong oral and written communication skills
Knowledge of NEC, UL, NEMA, CE, NFPA 79, 21CFR Part 11, and relevant ISO/EN standard
Familiarity of industrial communication protocols such as Modbus RTU, Ethernet/IP, TCP/IP, Serial, etc.

Nice To Haves

Experience with Vision Systems (e.g. Cognex) a plus

Responsibilities

Develop and maintain control system designs, schematics, and bills of materials that include flow diagrams, panel layouts, termination diagrams.
Code, test, and debug/troubleshoot PLC & HMI & Motion Control programs.
Provide technical support for FATs, on-site installation, and after-sales support (troubleshooting both in field and over the phone).
Work with panel shop technicians to ensure that assembly, wiring, installation, and operation of control panels and electrical systems conform to quality standards, applicable codes, and customer requirements.
Handle component selection & specification and vendor quotations.
Write validation and design specification documentation as required.
Travel up to 20% to customer sites.
Participate in cross-functional teams to support continuous improvement initiatives related to control systems and automation processes.
Being hands-on with hardware/software integration and troubleshooting of control systems.