Controls Engineer

The Controls Engineer is a mid-level technical role responsible for designing, programming, testing, and commissioning industrial automation systems. This includes PLC and HMI programming, developing control panel schematics, selecting hardware, and performing field troubleshooting. The role works under the guidance of a Senior Controls Engineer and collaborates with cross-functional teams to deliver safe, compliant, and reliable automation solutions. This position is intended for engineers building technical depth and progressing toward greater autonomy.

• Assist in creating schematics, panel layouts, wiring diagrams, and documentation using AutoCAD Electrical.
• Help develop PLC and HMI programs (e.g., Rockwell Studio 5000, Siemens TIA Portal) including logic, tags, and basic screen layouts.
• Support hardware selection (sensors, relays, VFDs, safety components).
• Ensure designs meet NEC, UL, safety, and customer standards under senior review.

• Develop and test PLC/HMI code for standard automation systems, including alarms, interlocks, and UI configurations.
• Assist with installation, wiring checks, hardware integration, and I/O validation.
• Troubleshoot issues involving communication, wiring, and software logic.
• Participate in FAT/SAT testing and document results.

• Prepare I/O lists, BOMs, wiring diagrams, manuals, and control narratives following company standards.
• Maintain revision histories and follow document control processes.
• Participate in design and safety reviews.

• Coordinate tasks with Senior Controls Engineers, project managers, and mechanical/electrical teams.
• Provide timely updates on progress, risks, and issues.
• Support team knowledge-sharing, cross-training, and improvement initiatives.

• Bachelor’s degree in Electrical Engineering, Mechatronics, or related field.

• 2–5 years of hands-on controls engineering experience with PLC/HMI systems.
• Field experience with commissioning, I/O checkout, troubleshooting, and working with technicians/electricians.

• Proficiency with PLC/HMI software (Rockwell, Siemens, etc.).
• Working knowledge of AutoCAD Electrical.
• Familiarity with industrial networking (Ethernet/IP, Profinet, Modbus).
• Strong attention to detail, problem-solving skills, and documentation discipline.
• Ability to read and interpret electrical schematics and loop diagrams.
• Willingness to travel frequently for commissioning and support.

• OSHA 10/30, LOTO, or similar safety training.
• Vendor training for Rockwell, Siemens, or VFDs.
• Functional safety or safeguarding training (e.g., TÜV).
• Familiarity with NFPA 70E.

• Reports to: Controls Manager and Senior Controls Engineer
• Direct Reports: None

• Based at ASI Direct Office: 25 West Park Circle, Birmingham, AL 35211
• Frequent travel required for commissioning, troubleshooting, and field support.

• Work alternates between office (design, programming, documentation) and industrial field settings (testing, commissioning, troubleshooting).
• Field environments may involve noise, dust, heat, tight spaces, and heavy machinery.
• PPE required as applicable (glasses, boots, ear protection, etc.).
• Travel may involve overnight stays, multi-day trips, and short-notice assignments.

• Complete engineering tasks on schedule and to quality standards.
• Demonstrate ownership, problem-solving, and continuous improvement.
• Participate in team collaboration, knowledge sharing, and cross-functional meetings.

• No responsibility for managing, supervising, or reviewing other employees.

• Cannot make final decisions on safety-critical or code-related designs; these require senior approval.

• Not responsible for leading project schedules, budgets, or primary customer communication.

Responsibilities may adjust as the engineer grows in skill and experience.

The role involves handling sensitive technical and customer information. All materials must be kept confidential in accordance with ASI policy and applicable NDAs. Unauthorized disclosure is prohibited.