Controls Technician

1. Overview

1.1. The Controls Technician plays a key role in the design, installation, support, and maintenance of industrial control systems. While working under the leadership of the Electrical Manager, this is a specialized position that functions independently from general electrical technicians. The Controls Technician is focused on PLCs, HMIs, VFDs, sensor integration, and control system testing—ensuring automation systems function reliably and safely across all ASI projects.

2. Key Responsibilities

2.1. Control Panel Assembly

2.1.1. Build and wire custom control panels from schematics and layout diagrams.

2.1.2. Install PLCs, I/O modules, safety relays, VFDs, terminal blocks, and other control devices.

2.1.3. Conduct continuity and quality checks prior to panel shipment or install.

2.2. Field Control Wiring

2.2.1. Run and terminate control wiring for industrial equipment, sensors, and automation systems.

2.2.2. Verify connections to field devices (proximity switches, encoders, solenoids, etc.) match documentation.

2.2.3. Collaborate with electrical installers and mechanical teams during system builds.

2.3. System Commissioning Support

2.3.1. Assist in startup, loop checks, and I/O verification for new systems.

2.3.2. Provide real-time technical support to Controls Engineers during functional testing.

2.3.3. Make field wiring adjustments or minor program edits under supervision.

2.4. Troubleshooting and Diagnostics

2.4.1. Identify and resolve faults related to control wiring, device failures, or signal loss.

2.4.2. Use diagnostic tools like multimeters, PLC software, and HMI tools to isolate problems.

2.4.3. Assist in correcting control-related field issues and restore system functionality quickly.

2.5. PLC and HMI Assistance

2.5.1. Upload/download control logic to devices from engineering-approved code.

2.5.2. Modify minor logic elements or HMI screens (e.g., timers, labels) when permitted.

2.5.3. Provide basic field-side support for controls configuration and firmware management.

2.6. Preventive Maintenance

2.6.1. Perform regular inspections of control systems, including wiring integrity, terminal tightness, and labeling.

2.6.2. Replace aging components as needed and document all activities performed.

2.6.3. Flag any critical system degradation to engineers or the Electrical Manager immediately.

2.7. Documentation and As-Builts

2.7.1. Mark up wiring diagrams and schematics with any field modifications.

2.7.2. Assist with generating accurate as-built drawings and file submissions post-project.

2.7.3. Maintain project folders and share documentation with the appropriate project lead.

2.8. Control System Safety Compliance

2.8.1. Ensure all work meets NEC, NFPA 70E, UL508A, and OSHA safety standards.

2.8.2. Identify unsafe conditions or system designs that may pose risks during operation.

2.8.3. Participate in safety walkthroughs and toolbox talks as needed.

2.9. Tool, Inventory, and Workspace Maintenance

2.9.1. Maintain hand tools, testing equipment, and labeling devices in clean working condition.

2.9.2. Track commonly used components and notify the team when restocking is needed.

2.9.3. Keep panel build areas and field job sites clean and organized.

2.10. Team Collaboration and Communication

2.10.1. Work independently and with engineers, project managers, and electricians to meet deadlines.

2.10.2. Provide clear, concise updates to project leads and escalate issues when necessary

2.10.3. Offer suggestions for improving build quality, device selection, or system layout.

3. Requirements

3.1. Education

3.1.1. Associate degree in Industrial Engineering, Mechanical Engineering, Instrumentation, Electrical Technology, or equivalent field preferred.

3.2. Experience

3.2.1. 2–4 years of experience in controls assembly, wiring, or commissioning in an industrial environment.

3.2.2. Prior hands-on work with PLCs, HMIs, or VFDs in shop or field environments.

3.3. Required Skills

3.3.1. Electrical Drawing and Schematic Interpretation

3.3.1.1. Must be able to read and interpret detailed control schematics, panel layout diagrams, I/O lists, and wiring schedules.

3.3.1.2. Understands electrical symbols, wiring standards, and circuit logic including ladder diagrams.

3.3.1.3. Applies schematics accurately during panel builds, field terminations, and troubleshooting.

3.3.1.4. Can identify discrepancies between drawings and actual builds and communicate them effectively for resolution.

3.3.2. PLC and HMI System Familiarity

3.3.2.1. Has hands-on experience with common PLC platforms such as Allen-Bradley (RSLogix/Studio 5000), Siemens (TIA Portal), or Omron (CX-One).

3.3.2.2. Understands the structure and purpose of PLC logic and basic HMI screen navigation.

3.3.2.3. Capable of assisting with uploading/downloading programs and performing basic changes (e.g., timers, counters, fault resets) under guidance.

3.3.2.4. Able to recognize and diagnose common I/O or communication faults within PLC-based systems.

3.3.3. Control Panel Wiring and Standards Compliance

3.3.3.1. Proficient in terminating wires using proper stripping, crimping, and labeling techniques.

3.3.3.2. Routes and bundles wires neatly in control enclosures to meet UL508A, NEC, and internal panel build standards.

3.3.3.3. Able to identify components like power supplies, contactors, overloads, and relays and wire them correctly per schematic.

3.3.3.4. Uses appropriate wire sizes, fuse ratings, and breaker selections based on application.

3.3.4. Technical Tool Proficiency

3.3.4.1. Skilled in using diagnostic and installation tools including:

3.3.4.2. Multimeters (voltage, continuity, resistance checks)

3.3.4.3. Cable testers and signal tracers

3.3.4.4. Wire strippers, ferrule crimpers, torque drivers, and labeling machines

3.3.4.5. Laptops with PLC software and HMI editors for field commissioning

3.3.4.6. Maintains tool condition and uses them safely and correctly.

3.3.5. Safety Awareness and Field Adaptability

3.3.5.1. Fully understands lockout/tagout (LOTO) procedures and energized system protocols.

3.3.5.2. Comfortable working in variable conditions (e.g., hot/cold environments, elevated platforms, confined spaces).

3.3.5.3. Maintains calm and professionalism under pressure, especially when troubleshooting on-site during tight project timelines.

3.3.5.4. Adapts quickly to changes in project scope, layout, or device selection without compromising safety or quality.

3.4. Certifications

3.4.1. OSHA 10/30 certification preferred.

3.4.2. UL508A panel wiring or NFPA 70E safety training is a plus.

3.4.3. Manufacturer certifications in VFDs, PLC programming, or HMI software are preferred.

3.5. Preferred

3.5.1. Familiarity with industrial networking (EtherNet/IP, Modbus TCP) and communication wiring.

3.5.2. Experience assisting in machine control logic testing or safety system validation.

4. Reporting Structure

4.1. Reports to

4.1.1. Electrical Manager

5. Location

5.1. Position is primarily at ASI Direct Office and occasional travel to job sites and client facilities for system installs and service work.

5.2. ASI Direct Office

5.2.1. 25 West Park Circle

Birmingham, AL 35211

6. Work Environment

6.1. Combination of shop floor, control panel assembly area, and on-site job environments. May involve standing for long periods, working in confined spaces, or around energized systems. PPE required.

7. Performance Expectations

7.1. Panel Builds and Field Wiring – Precision, Quality, and Timeliness

7.1.1. Complete control panel builds that meet all mechanical, electrical, and functional specifications.

7.1.2. Ensure proper labeling, wire routing, torque settings, and device placement inside enclosures.

7.1.3. Deliver work that requires little to no rework or correction by engineers or inspectors.

7.1.4. Execute field wiring efficiently while maintaining high standards for neatness, correct routing, and protection of cables.

7.1.5. Complete all assignments within established project timelines and communicate proactively if delays occur.

7.2. Responsive Troubleshooting and Documentation of Issues

7.2.1. Respond immediately to issues during installation, commissioning, or post-install support.

7.2.2. Use systematic diagnostic methods to identify root causes of faults (e.g., I/O errors, communication failures, blown fuses).

7.2.3. Perform repairs or escalate appropriately depending on the complexity and scope.

7.2.4. Maintain thorough written records of what occurred, what was done to fix it, and what recommendations were made.

7.2.5. Use issue tracking systems (if implemented) or project logs to ensure transparency and traceability of problems and fixes.

7.3. Compliance with Safety and Quality Standards

7.3.1. Follow all OSHA, NEC, and company-specific safety procedures without exception.

7.3.2. Demonstrate consistent use of PPE (e.g., gloves, glasses, hard hats, lockout tags) in shop and field environments.

7.3.3. Pass safety audits and quality control inspections with minimal corrections or citations.

7.3.4. Build panels and systems that meet UL508A and NFPA70E guidelines, or other standards specified by customers or engineering.

7.3.5. Identify potential compliance gaps and recommend solutions before they become violations.

7.4. Team Collaboration and Control System Reliability

7.4.1. Support engineers, electricians, and mechanical techs by proactively communicating needs, risks, and changes in system status.

7.4.2. Offer clear, professional updates during meetings, status calls, or field check-ins.

7.4.3. Help ensure systems are wired and installed in ways that reduce future maintenance and troubleshooting issues.

7.4.4. Provide feedback to engineers on how real-world installs can be improved in future designs.

7.4.5. Represent the Controls team with professionalism and competence in front of clients during on-site work.

8. Responsibilities to Avoid

8.1. Administrative and Office-Based Duties

8.1.1. The Controls Technician role is focused on hands-on technical execution in the field and on the floor—not on clerical, coordination, or project administration tasks. These responsibilities are outside the scope of this role and should be delegated to appropriate support staff or project managers.

8.1.2. Quoting and Estimating

8.1.2.1. Controls Technicians are not responsible for generating cost estimates, customer quotes, or pricing sheets.

8.1.2.2. All quote creation should be handled by sales staff, project managers, or engineering leads with access to cost data and customer contracts.

8.1.2.3. If material lists or labor time inputs are needed, the technician may provide technical details—but should not finalize or distribute quotes.

8.1.3. Procurement and Ordering

8.1.3.1. Technicians are not expected to source, select, or order parts from vendors unless specifically instructed by an engineer or manager.

8.1.3.2. While they may notify the team of low inventory or missing parts, actual ordering must be done by purchasing staff or designated personnel.

8.1.4. Scheduling and Customer Coordination

8.1.4.1. Controls Technicians are not responsible for scheduling site visits, coordinating job timelines, or communicating delivery dates to customers.

8.1.4.2. These tasks belong to project managers or team leads who oversee the broader scope and timeline of each job.

8.1.5. Office Documentation or Report Drafting

8.1.5.1. Technicians should not be required to write formal reports, job proposals, or customer-facing documentation beyond their daily logs or field notes.

8.1.5.2. Detailed report writing, proposals, or commissioning reports should be handled by engineering or project leadership.

8.2. Programming or Engineering Design Ownership

8.2.1. While Controls Technicians often work with PLCs and HMIs, they are not responsible for core programming or engineering design decisions. Their role is to support implementation, troubleshooting, and basic edits—not to independently create or manage software logic.

8.2.2. PLC/HMI Program Development

8.2.2.1. Technicians should not be tasked with developing full control system logic or writing original ladder logic/function block/HMI code from scratch.

8.2.2.2. All control strategies, process sequences, interlocks, and safety logic must be designed, approved, and owned by a qualified Controls Engineer.

8.2.3. Control Architecture Design

8.2.3.1. Controls Technicians should not make final decisions on PLC hardware, I/O allocation, safety relays, or network topology.

8.2.3.2. These decisions require a deeper understanding of system requirements, safety compliance, and integration considerations.

8.2.3.3. Technicians may offer suggestions or field-based insights, but the engineer retains authority and responsibility for final system design.

8.2.4. Independent Software Modifications Without Approval

8.2.4.1. While minor logic edits (e.g., timer adjustments or tag edits) may be made with approval, unsupervised programming changes are prohibited.

8.2.4.2. All code changes must be reviewed and tested under controlled conditions to avoid unexpected equipment behavior or safety risks.

9. Compensation or Salary Range (optional)

9.1. Salary Range

9.1.1. $50,000 - $70,000

9.2. Benefits

9.2.1. 401(k) with Matching

9.2.2. Health, Vision, and Hearing Insurance

9.2.3. Paid Time Off

9.2.4. Flexible Schedule

10. Notes

10.1. Role Flexibility

10.1.1. Evolving Responsibilities with Business Growth

10.1.1.1. The Controls Technician position is designed to meet the current needs of the company’s control systems division. However, as ASI grows—expanding its client base, integrating new technologies, or increasing project complexity—the scope of this role may expand.

10.1.1.2. Technicians may be asked to support more advanced commissioning activities, mentor junior team members, or assist in the standardization of control panel builds.

10.1.1.3. The company may introduce new platforms (e.g., new PLC brands, motion control systems, IIoT integration) that require the technician to learn and adapt.

10.1.2. Willingness to Support Cross-Functional Projects

10.1.2.1. While the Controls Technician is a specialized role, there may be occasional overlap with related areas like mechanical, electrical, or IT systems.

10.1.2.2. The technician may be called upon to assist with the physical integration of systems, cable management, or basic troubleshooting that spans multiple disciplines.

10.1.2.3. Collaboration across teams is expected, and flexibility in roles is encouraged to meet deadlines and client expectations.

10.1.3. Participation in Continuous Improvement

10.1.3.1. Technicians are encouraged to identify inefficiencies, inconsistencies, or technical limitations in daily workflows or designs and communicate suggestions for improvement.

10.1.3.2. Feedback on panel layouts, device selections, wire routing, or testing procedures is valued and may influence future standards or design guidelines.

10.1.3.3. As internal processes evolve (e.g., digital documentation, inventory tracking, panel templates), Controls Technicians should be prepared to adopt new systems and provide input on usability.

10.1.4. Training and Upskilling

10.1.4.1. To remain effective and competitive, Controls Technicians are expected to grow their skillsets through company-sponsored or self-directed learning.

10.1.4.2. Training may include vendor certifications, electrical safety refreshers, or emerging technologies like IIoT and Industry 4.0 tools.

10.1.4.3. Demonstrated growth may lead to expanded responsibilities, project leadership, or advancement opportunities within the controls department.

10.2. Confidentiality

10.2.1. Protection of Company Intellectual Property

10.2.1.1. Controls Technicians regularly work with confidential wiring diagrams, logic files, device configurations, and integration documents that represent proprietary company know-how.

10.2.1.2. These materials are not to be shared, copied, or discussed outside the organization unless authorized.

10.2.1.3. This includes screenshots of PLC programs, vendor pricing, project timelines, or any materials labeled “Confidential” or “Internal Use Only.”

10.2.2. Client Information Sensitivity

10.2.2.1. In some cases, technicians may work at client sites or with client-owned equipment that contains sensitive or competitive information.

10.2.2.2. Technicians must not photograph, share, or comment on any client systems, machinery, or facility layouts without explicit permission.

10.2.2.3. Confidentiality extends to conversations, access credentials, or data that may be encountered during project execution.

10.2.3. Secure Handling of Data and Devices

10.2.3.1. If issued a company laptop, USB drive, or software license, the technician is expected to follow IT security policies.

10.2.3.2. This includes using strong passwords, avoiding unauthorized downloads, and reporting lost or compromised devices immediately.

10.2.3.3. Any backups of PLC/HMI programs must be stored in designated project folders with appropriate permissions and naming conventions.

10.2.4. Professional Discretion

10.2.4.1. Technicians are expected to demonstrate discretion when discussing internal processes, personnel matters, or operational challenges.

10.2.4.2. Refrain from discussing project issues or company challenges with vendors or customers unless directed.

10.2.4.3. Maintain a professional demeanor in all internal and external communications, protecting the company’s reputation and trust.

Job Type: Full-time

Pay: $50,000.00 - $70,000.00 per year

Benefits:

• 401(k)
• 401(k) matching
• Dental insurance
• Flexible schedule
• Health insurance
• Paid time off
• Relocation assistance
• Retirement plan
• Vision insurance

Work Location: In person

Salary : $50,000 - $70,000