Senior Controls Engineer

Senior Controls Engineer

The Senior Controls Engineer designs, develops, and implements advanced control systems that support high-power electrical equipment and integrated energy systems. This role spans both hardware and software, including control and power panel design, ownership of bills of materials (BOMs), PLC and CODESYS programming, and work within Linux-based control environments. The engineer leads and contributes to controls and automation initiatives, driving standardized, scalable solutions across product lines while promoting a culture of accountability, clear communication, and team-first execution.

Responsibilities

• Design and develop control systems for high-power applications, including overall system architecture, control strategies, and detailed design deliverables.
• Own and develop complete bills of materials (BOMs), I/O lists, wiring diagrams, and panel layouts to support production and field deployment.
• Ensure control system designs are manufacturable, serviceable, and aligned with internal standards and best practices.
• Develop, program, and maintain control software across multiple platforms, including traditional PLC environments, CODESYS-based systems, and Linux-based control applications.
• Integrate control systems with inverters, drives, and other power electronics to ensure proper operation, communication, and protection strategies.
• Configure and commission variable frequency drives and inverter systems, including development of parameter sets, communication interfaces, and control logic for stable and efficient operation.
• Collaborate closely with mechanical, electrical, and manufacturing teams to ensure seamless product development and execution.
• Actively participate in design reviews, providing technical input, identifying risks, and proposing mitigation strategies early in the design process.
• Support testing, validation, and commissioning activities, including prototype builds, factory acceptance testing (FAT), and field commissioning.
• Troubleshoot system issues across hardware and software domains, diagnosing root causes and implementing timely and effective resolutions.
• Develop and maintain technical documentation such as control narratives, functional specifications, software documentation, and commissioning procedures.
• Ensure consistency, clarity, and completeness across all technical deliverables and documentation.
• Mentor junior engineers by providing guidance, code and design reviews, and knowledge sharing in controls and automation.
• Contribute to the development and continuous improvement of engineering standards, templates, and best practices within the organization.

Essential Skills

• Bachelor's degree in Electrical Engineering, Controls Engineering, or a related field.
• 7+ years of experience in industrial controls, automation, or power systems engineering.
• Demonstrated experience programming and supporting PLC platforms.
• Hands-on experience with CODESYS environments for control system development.
• Strong experience with Linux-based systems, including application development, scripting, and system integration.
• Direct experience designing and supporting high-power electrical systems, including integration with inverters or variable frequency drives.
• Proven ability to develop and manage BOMs, electrical schematics, and control panel designs.
• Strong troubleshooting skills across electrical systems, controls software, and integrated systems.
• Experience with PLC programming, automation, and controls engineering in industrial environments.
• Proficiency in electrical design for control systems, including I/O selection, wiring, and panel layout.
• Experience with control systems design and development from concept through commissioning.
• Ability to work with structured text (ST) code or similar IEC 61131-3 programming languages.
• Experience integrating and troubleshooting industrial communication protocols such as Modbus.
• Ability to collaborate effectively in cross-functional engineering teams and communicate technical information clearly.

Additional Skills & Qualifications

• Experience with Danfoss drives and inverter systems or equivalent platforms.
• Experience with industrial communication protocols such as Modbus, CAN, Ethernet/IP, and TCP/IP.
• Familiarity with power systems concepts including motor control, protection schemes, and energy systems.
• Experience supporting commissioning in field environments such as marine, industrial, oil and gas, or similar sectors.
• Exposure to embedded systems or edge-device software architecture.
• Experience with embedded systems development and integration in control applications.
• Ability to develop clear control narratives, functional specifications, and commissioning procedures.
• Experience participating in and contributing to design reviews, risk assessments, and design-for-manufacturability activities.
• Interest in mentoring junior engineers and contributing to a culture of continuous improvement in standards and best practices.

Work Environment

The Senior Controls Engineer works in a…