Senior Controls Engineer

Valknut • Nashville, TN

2d • Onsite

About The Position

Step into a high-impact senior engineering role where your expertise in industrial controls will directly shape complex automation projects for leading manufacturing clients. This contract position offers the opportunity to own critical control system deliverables, solve challenging technical problems, and work with modern PLC, motion, and safety technologies in a fast-paced environment. About the Role: As a Senior Controls Engineer, you will take the technical lead on the design, development, and commissioning of industrial control systems for a range of automation projects. You will be responsible for delivering robust, safe, and maintainable solutions that meet client specifications, support production efficiency, and comply with relevant standards. Working closely with project teams and customer stakeholders, you will provide senior-level troubleshooting support and ensure systems perform reliably in real-world operations.

Requirements

• Strong hands-on experience in PLC programming and troubleshooting with major platforms such as Allen-Bradley ControlLogix/CompactLogix and Siemens S7/TIA Portal.
• Proven background in motion control, including configuration and tuning of VFDs, servo drives, and integration of robotic systems in automated machinery.
• Solid experience with instrumentation and process control, including selection, integration, and PID loop tuning for temperature, pressure, flow, and level applications.
• Demonstrated capability in HMI/SCADA development, configuration, and deployment using tools such as FactoryTalk View, Ignition, or WinCC.
• Practical expertise in machine safety systems design, including risk assessment, safety circuits, and application of relevant safety standards (e.g. IEC/ISO).
• Track record of leading commissioning activities, troubleshooting complex control issues, and stabilizing systems in production environments.
• Ability to interpret and work from electrical schematics, P&IDs, and functional specifications, and to translate requirements into control strategies.
• Strong communication skills with the ability to interface directly with clients, vendors, and multidisciplinary engineering teams.

Nice To Haves

• Experience with industrial networking and communication protocols (EtherNet/IP, Profinet, Modbus, OPC UA).
• Familiarity with data collection, historian systems, and basic integration with MES or ERP platforms.
• Exposure to batch or continuous process industries such as food & beverage, chemicals, automotive, or packaging.
• Experience with version control, change management, and structured development methodologies for control systems.
• Ability to mentor junior engineers and provide technical guidance on best practices in controls and automation.

Responsibilities

• Design, program, and debug PLC-based control systems using platforms such as Allen-Bradley and Siemens for new and existing automation equipment.
• Configure and commission motion control solutions including VFDs, servo drives, and robotic systems to achieve precise, repeatable machine performance.
• Specify, integrate, and calibrate instrumentation and process control devices (sensors, actuators, transmitters) and perform PID tuning for stable process operation.
• Develop, configure, and test HMI/SCADA applications (e.g. FactoryTalk, Ignition, WinCC) including screens, tags, alarms, and data logging.
• Lead on-site startup, commissioning, and acceptance testing, diagnosing and resolving control system issues under time-critical conditions.
• Design and implement machine safety systems, including safety PLC logic, interlocks, and emergency stop circuits, aligned with SIL/PL requirements and risk assessments.
• Produce detailed control system documentation, including functional specifications, I/O lists, wiring diagrams, and operating procedures.
• Collaborate with mechanical, electrical, and process engineering teams to align control strategies with overall machine and process design.

What This Job Offers

• Job Type: Full-time
• Career Level: Senior