Controls Technician

The Controls Technician installs, maintains, troubleshoots, and improves industrial control systems, electrical systems, and automation equipment used in steel pipe production. Uses PLC, HMI, drive, and robot software to diagnose faults, make approved program changes, and maintain backups. Supports production and maintenance teams during breakdowns, preventive and predictive maintenance, and equipment commissioning, and diagnoses mechanical issues that affect controls performance.

include the following: (Other duties may be assigned, including but not limited to cross training and housekeeping.)

• Follow all safety rules, including LOTO, electrical safe work practices (NFPA 70E), confined space, fall protection, and hazard communication. Stop work when conditions are unsafe.
• Operate forklifts, overhead cranes, and mobile equipment after completing company certification.

• Go online with PLCs to monitor I/O, logic, interlocks, alarms, and parameters. Diagnose faults and identify root causes.
• Modify PLC logic, timers, interlocks, and parameters only as authorized, following the site change and approval process.
• Troubleshoot HMI/SCADA systems, industrial networks (such as PROFINET, PROFIBUS, and Ether Net/IP), and PLC field devices, including 2-wire and 3-wire sensors.
• Maintain current backups of PLC, HMI, drive, and robot programs, and document all changes.
• Support SCADA, MES, and SPC data collection from plant equipment.

• Troubleshoot, commission, and replace AC and DC drives. Set and verify parameters, backup and restore configurations, and apply open-loop and closed-loop control.
• Troubleshoot encoders, braking resistors, and solid-state power devices such as SCRs and soft starters.
• Troubleshoot industrial robots, including alarms, I/O, interlocks, and robot-to-PLC communication, where applicable.

• Troubleshoot control and power circuits from 24 VDC through 480 VAC, including relay logic, motor starters (across-the-line and wye-delta), safety circuits, sensors, and control panels, using a DMM, clamp meter, and insulation tester.
• Troubleshoot and maintain AC and DC motors and generators.
• Specify, install, and modify motor circuits, power distribution, lighting, conduit, and wiring in accordance with the NEC.
• Troubleshoot and calibrate instrumentation, including transmitters and 4-20 mA loops. Check and document the calibration of production welding equipment.
• Develop electrical and controls expertise on at least five pieces of major production equipment.

• Perform electrical and controls preventive maintenance on MCCs, panels, disconnects, motors, drives, and transformers.
• Conduct infrared thermography of electrical and mechanical equipment. Document findings and create corrective work orders in the CMMS.
• Support maintaining critical electrical and automation spare parts, and support autonomous maintenance and 5S.

• Diagnose and communicate mechanical issues that affect controls performance.
• Troubleshoot hydraulic and pneumatic systems. Perform basic mechanical tasks, including bearing installation, shaft alignment, lubrication, rigging, small equipment installation, and air compressor support.

• Respond to equipment breakdowns and restore production safely and efficiently. Coach maintenance technicians on electrical and controls troubleshooting.
• Lead or participate in root cause analysis of recurring failures, record findings in the CMMS, and use maintenance data and KPIs to reduce downtime, repeat failures, and cost.
• Support installation, commissioning, and startup of new equipment and reliability improvement projects.

Perform other tasks as instructed by supervision.

To perform the job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.

Associate degree in electrical, electronics, or industrial automation technology, technical diploma, completed apprenticeship, or equivalent experience. 3 to 5 years of industrial controls and electrical troubleshooting experience preferred. Experience with PLCs, HMIs, VFDs, and industrial networks required. Experience with the PLC and drive…