Field Service Controls Engineer - Web Handling & Drives

Field Service Controls Engineer – Web Handling & Drives

We are seeking an experienced Field Service Controls Engineer to provide hands-on technical support, troubleshooting, commissioning, and startup assistance for industrial automation systems, variable frequency drives, and web-handling equipment in customer production environments.

The ideal candidate has strong experience troubleshooting Rockwell Automation control systems, PowerFlex drives, PLC programming, HMI applications, electrical controls, and industrial networks. Experience with winding systems, tension control, dancer systems, load cells, or other web-handling applications is strongly preferred.

This position requires advanced diagnostic ability, professional customer communication, and the ability to independently troubleshoot complex equipment issues in active manufacturing environments.

Key Responsibilities

• Provide onsite field service support for industrial automation systems, control equipment, variable frequency drives, and manufacturing machinery.
• Troubleshoot Rockwell Automation platforms, including Studio 5000, Logix Designer, ControlLogix, and CompactLogix.
• Diagnose PLC logic, ladder logic, control sequences, input/output signals, interlocks, alarms, and machine-operation issues.
• Troubleshoot and support FactoryTalk View SE and FactoryTalk View ME applications, operator interfaces, alarms, and HMI communications.
• Configure, commission, and troubleshoot PowerFlex variable frequency drives, including PowerFlex 525, PowerFlex 753, and PowerFlex 755 drives.
• Read and interpret electrical schematics, control drawings, machine documentation, and field-wiring diagrams.
• Perform electrical diagnostics and motor diagnostics, including motor testing, megger testing, encoder verification, analog signal troubleshooting, and control-panel inspection.
• Troubleshoot industrial Ethernet networks, EtherNet/IP communications, IP addressing, managed and unmanaged switches, and device connectivity.
• Diagnose web-handling systems and tension-control applications, including winders, unwinds, driven rolls, sectional drives, dancer systems, and load-cell feedback systems.
• Support open-loop tension control and closed-loop tension control strategies, including taper tension, dancer-position control, load-cell control, and cascade control.
• Tune and troubleshoot PID control loops, including gain adjustment, loop instability, oscillation, integral windup, and feedback issues.
• Calibrate and troubleshoot load cells, amplifiers, signal-conditioning equipment, and tension-feedback scaling.
• Perform equipment commissioning, machine startup, system validation, and corrective troubleshooting at customer sites.
• Communicate technical findings clearly to customers, operators, maintenance teams, engineering personnel, and internal stakeholders.
• Prepare accurate field-service reports documenting equipment conditions, diagnostic steps, corrective actions, root causes, and recommended follow-up work.
• Work independently in customer facilities while maintaining professional, safe, and responsive service.
• Follow applicable electrical safety procedures, customer-site requirements, and industrial safety standards.

Required Qualifications

• Associate degree or higher in Electrical Technology, Controls Engineering, Automation Engineering, or a related technical discipline, or equivalent hands-on experience.
• At least three years of experience in industrial automation, field service, controls engineering, equipment commissioning, drives, or manufacturing support.
• Hands-on experience troubleshooting Rockwell Automation PLC systems, including ControlLogix or CompactLogix.
• Working knowledge of Studio 5000, Logix Designer, ladder logic programming, and PLC troubleshooting.
• Experience commissioning or troubleshooting PowerFlex variable frequency drives or similar industrial drive systems.
• Ability to read electrical schematics, control drawings, and field-wiring documentation.
• Experience troubleshooting electrical controls, motors, encoders, analog signals, sensors, and industrial control panels.
• Working knowledge of industrial Ethernet networks and EtherNet/IP communications.
• Strong analytical, troubleshooting, technical documentation, and customer-service skills.
• Ability to identify root causes and resolve complex electrical, controls, communications, and machine-performance issues.
• Ability to work independently in active manufacturing and customer production environments.
• Ability to travel to customer facilities as required.

Preferred Qualifications

• Experience with PowerFlex 525, PowerFlex 753, and PowerFlex 755 drives.
• Experience with FactoryTalk View SE or FactoryTalk View ME.
• Experience with web handling, converting, printing, coating, laminating, paper, film, foil, textile, or similar continuous-process equipment.
• Knowledge of center winders, center unwinds, surface winders, driven rolls, and sectional drive systems.
• Experience with dancer-position control, load-cell tension control, taper tension, and cascade-control applications.
• Experience calibrating load cells, signal conditioners, and tension-control amplifiers.
• Knowledge of PID loop tuning, gain adjustment, integral windup, derivative filtering, and loop-stability troubleshooting.
• Familiarity with Function Block Diagram, Structured Text, or Sequential Function Chart programming.
• Previous field-service, commissioning, startup, or customer-site troubleshooting experience.
• Experience performing root-cause analysis, machine optimization, controls upgrades, or system retrofits.
• Familiarity with motor control systems, feedback devices, encoders, torque control, speed regulation, and drive synchronization.

Work Environment

This position involves working in active manufacturing environments and may require travel, extended periods onsite, and occasional support outside standard business hours depending on customer production needs. The role may involve working near operating machinery, electrical control panels, production equipment, motors, drives, and industrial processes while following all required safety procedures.

Field Service Controls Engineer, industrial automation systems, variable frequency drives, web-handling equipment, Rockwell Automation control systems, PowerFlex drives, PLC programming, HMI applications, electrical controls, industrial networks, winding systems, tension control, dancer systems, load cells, web-handling applications, manufacturing environments, field service support, Studio 5000, Logix Designer, ControlLogix, CompactLogix, PLC logic, FactoryTalk View SE, FactoryTalk View ME, PowerFlex variable frequency drives, PowerFlex 525, PowerFlex 753, PowerFlex 755, electrical schematics, electrical diagnostics, megger testing, industrial Ethernet networks, EtherNet/IP communications, web-handling systems, tension-control applications, open-loop tension control, closed-loop tension control, PID control loops, load cells, field-service reports, industrial safety standards, Electrical Technology, Controls Engineering, Automation Engineering, industrial automation, ladder logic programming, industrial drive systems, industrial control panels, customer-service skills, continuous-process equipment, center winders, center unwinds, Function Block Diagram, Structured Text, Sequential Function Chart, root-cause analysis