Sr Electrical Controls Engineer
Listed on 2026-06-21
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Engineering
Automation & Mechatronics Engineer, Systems Engineer
Sr Electrical Controls Engineer
Location: Western North Carolina Region
Engagement Type: Contract / 1099 Preferred
Duration: Long-Term Contract with Rolling Renewal Periods
Industry: Advanced Manufacturing
Client: Confidential Tier-One Manufacturing Customer
Role OverviewCAC is supporting a confidential tier-one manufacturer with a production line upgrade and installation project at an active manufacturing facility in Western North Carolina.
This is a hands‑on controls engineering role supporting a live production environment. The site has a strong Rockwell Control Logix base with motion control and servo‑driven line equipment. The current project scope includes new Siemens S7 content being added as part of a production line upgrade and installation.
The right contractor will be comfortable working across both Siemens and Rockwell platforms, supporting commissioning and startup activities on the plant floor, troubleshooting production issues, and leaving behind clean documentation for the site team.
This opportunity is well suited for a senior controls engineer who has experience with real production line installs, Siemens programming, Rockwell troubleshooting, motion control, drives, SCADA interfaces, and plant‑floor commissioning.
Key Responsibilities- Lead Siemens S7 controls work for a production line upgrade and installation, including program development, hardware configuration, testing, and commissioning.
- Support integration of new Siemens controls content with the existing Rockwell Control Logix platform.
- Read, troubleshoot, and modify Control Logix / Studio 5000 code where the upgraded line interfaces with existing equipment.
- Configure, troubleshoot, and tune VFDs and servo drives, including Power Flex, Yaskawa, and Rockwell Kinetix platforms.
- Support drive parameters, motion profiles, homing logic, synchronization logic, fault recovery, and startup troubleshooting.
- Work hands‑on through FAT, installation, startup, commissioning, SAT, and production ramp‑up.
- Interface with iFix SCADA where the upgraded line connects to existing HMI, alarming, and trending systems.
- Mark up and update electrical and controls drawings in AutoCAD Electrical to reflect field changes and as‑built conditions.
- Troubleshoot live production issues during startup and ramp‑up while coordinating with site engineering, maintenance, and operations teams.
- Provide clean handoff documentation so the plant team can support the system after commissioning.
- 7+ years of hands‑on industrial controls engineering experience.
- Experience supporting at least one full production line installation, major upgrade, or commissioning effort from design through startup.
- Strong Siemens S7 programming experience using TIA Portal and/or Classic STEP 7.
- Real production deployment experience with Siemens systems, not just minor maintenance edits.
- Working knowledge of Rockwell Control Logix and Studio 5000, including the ability to navigate, troubleshoot, and modify existing code.
- Experience configuring and troubleshooting VFDs, with Power Flex experience strongly preferred.
- Commissioning and startup experience in an active plant‑floor environment.
- FAT and SAT experience.
- Ability to work independently on a customer site with limited hand‑holding.
- Strong troubleshooting, documentation, and professional communication skills.
- Ability to operate as a 1099 contractor, LLC, sole proprietor, or willingness to establish the proper business structure.
- Ability to meet required insurance levels under the applicable contract agreement.
- Local, regional, or willing to commute weekly to the project site at own cost.
- Servo motion control experience, especially Rockwell Kinetix or Yaskawa servo systems.
- iFix SCADA experience.
- AutoCAD Electrical experience for redlines, markups, and as‑built updates.
- Experience in fiber, cabling, extrusion, web handling, continuous manufacturing, or similar high‑volume production environments.
- Prior experience working as a contractor under another integrator or supplier's MSA.
- Familiarity with contractor insurance, LLC structure, professional services agreements, indemnity language, and customer‑site…
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