Digital Power Controls Engineer

LayerZero Power Systems, Inc.; Raleigh (NC); On-site; USD 120,000 - 170,000; Full time

Benefits offered by this job

Competitive pay with performance

100% company-paid medical, dental, and

401(k) with company match

4 weeks PTO, 10 holidays, 2 floating

Job summary

LayerZero Power Systems, Inc. seeks a skilled Digital Power Controls Engineer to develop embedded firmware for advanced AC/DC and DC/DC power conversion systems.

You will design, implement, test, and optimize real-time control algorithms, including monitoring, protection, and safety functions, across modular power architectures. The role requires hands-on work with MCU/DSP platforms, PWM/ADC timing, and closed-loop control, and offers opportunities to influence system-level performance and

Qualifications

• Bachelor's degree in Electrical/Computer Engineering or related field.
• 510+ years of embedded firmware development experience.
• Demonstrated hands-on experience implementing or tuning closed-loop digital control for a power converter, inverter, rectifier, or comparable power-electronics system.
• Strong proficiency in C/C++ for embedded systems development.
• Experience with microcontrollers, DSPs, ARM-based processors, or real-time embedded platforms.
• Practical understanding of PWM switching, ADC sampling, real-time control-loop timing, and digital control implementation.
• Experience debugging embedded control systems integrated with hardware and validating performance through instrumentation.

Responsibilities

• Embedded Firmware Development: real-time control for AC/DC and DC/DC power conversion stages.
• Design and optimize control algorithms for converters, inverters, rectifiers, and related systems.
• Develop firmware using real-time embedded architectures and MCU/DSP platforms.
• Support firmware verification, validation, debugging, and performance optimization.
• Develop and tune digital control algorithms for switching power converters (current, DC-bus voltage, power, transient response).
• Implement real-time control functions using MCU/DSP peripherals (ADC sampling, PWM, interrupts, timing).
• Analyze converter dynamics and stability (compensator design, bandwidth, phase margin).
• Support hardware bring-up and validation using test equipment and automated systems.
• Collaborate with design leads to validate performance against models and measured hardware.
• Develop safety state machines, fault protection coordination, and restart interlocks.
• Support parallel operation, module coordination, and current/power sharing.
• Implement droop regulation on AC and DC.
• Develop and maintain Modbus interfaces and other protocols (CAN, Ethernet, TCP/IP, RS-485, UART, SPI, I2C).
• Assist integration with HMI, supervisory controllers, and cloud interfaces.
• Participate in design reviews and create test procedures and documentation.

Skills

Embedded firmware development

Real-time control

C/C++

Microcontrollers/DSPs/ARM

RTOS

Power electronics fundamentals

Control-loop design

Education

Bachelor's degree in Electrical Engineering, Computer Engineering, Computer Science, or related field

Tools

ARM-based processors

DSPs

PWM/ADC timing

Job description

About us

LayerZero Power Systems, Inc. is a leader in power management products for mission and process critical applications. Our customer base is comprised of companies in the computer service provider (on-line commerce, streaming, hosting, etc.), semiconductor manufacturing and financial sectors. LayerZero provides innovative products to ensure user safety and ultimate reliability of computers, servers, communication gear, and other critical equipment. LayerZero manufactures best-in-class products representing high-end solutions. LayerZero Power Systems is on a trajectory of sustained growth, with a loyal base of existing Fortune 100 customers and an expanding portfolio of new customers.

Role Overview

We are seeking a skilled Digital Power Controls Engineer to develop embedded firmware for advanced power conversion systems and energy infrastructure products. This role will be responsible for designing, implementing, testing, and optimizing real-time control algorithms for AC/DC power conversion systems while supporting system monitoring, communications, protection, and safety functions.

Key Responsibilities

• Embedded Firmware Development: Develop embedded firmware for real-time control of AC/DC and DC/DC power conversion stages.
• Design, implement, and optimize control algorithms for power converters, inverters, rectifiers, and related systems.
• Develop firmware using real-time embedded architectures and microcontroller/DSP platforms.
• Support firmware verification, validation, debugging, and performance optimization activities.
• Digital Power Control and Converter Implementation: Develop, implement, and tune closed-loop digital control algorithms for switching power converters, including current regulation, DC-bus voltage regulation, power control, and transient response.
• Implement and validate real-time control functions using MCU/DSP peripherals, including synchronized ADC sampling, PWM generation, interrupt-driven execution, and deterministic control-loop timing.
• Analyze converter dynamics and control-loop stability, including compensator design, bandwidth, phase margin, and response to input and load disturbances.
• Support converter hardware bring-up and control validation using oscilloscopes, voltage and current probes, programmable power sources, electronic loads, and automated test systems as appropriate.
• Collaborate with the Power Electronics Design Lead to validate control performance against power-stage models, simulation results, and measured hardware behavior.
• Monitoring, Protection & Safety: Develop converter state machines, including startup, precharge coordination, enable/disable sequencing, fault handling, controlled shutdown, and restart interlocks.
• Implement firmware-based fault detection and protection coordination including overcurrent, overvoltage, undervoltage, overtemperature and other system-level safety and protection requirements.
• Implement fault monitoring. Develop safety permissives and protection coordination strategies in collaboration with the Power Electronics Design Lead.
• Support parallel operation of converter modules, including module coordination, current or power sharing, DC-bus regulation, and fault response as applicable to the product architecture.
• Implement droop regulation on both AC and DC.
• Communications & System Integration: Develop and maintain Modbus communication interfaces for telemetry, configuration, diagnostics, alarms, and event logging.
• Support integration of additional communication protocols such as CAN, Ethernet, TCP/IP, RS-485, UART, SPI, and I²C.
• Partner with system, controls, and software engineers to ensure seamless product integration.
• Support HMI, supervisory controller, and cloud connectivity interfaces.
• Product Development & Design Reviews: Participate in system architecture discussions and firmware design reviews.
• Develop firmware requirements, design documentation, and test procedures.
• Support prototype bring-up, hardware integration, and product qualification activities.
• Contribute to root-cause analysis and corrective actions for field and manufacturing issues.

Required Qualifications

• Bachelor's degree in Electrical Engineering, Computer Engineering, Computer Science, or related field.
• 510+ years of embedded firmware development experience.
• Demonstrated hands-on experience implementing or tuning closed-loop digital control for a power converter, inverter, rectifier, or comparable power-electronics system.
• Strong proficiency in C/C++ for embedded systems development.
• Experience with microcontrollers, DSPs, ARM-based processors, or real-time embedded platforms.
• Practical understanding of PWM switching, ADC sampling, real-time control-loop timing, and digital control implementation.
• Experience debugging embedded control systems integrated with physical hardware and validating performance through instrumented testing.
• Working knowledge of control-loop stability, compensator design, and converter transient response.
• Knowledge of: Digital control systems, Power electronics fundamentals, Real-time operating systems (RTOS), Embedded communications protocols, Fault management and protection systems, Control loop design and implementation.

Preferred Qualifications

• Experience with three-phase active rectifiers, high-voltage DC links, or bidirectional AC/DC and DC/DC conversion.
• Experience with parallel converter operation, current sharing, and modular power-conversion architectures.
• Experience with hardware-in-the-loop (HIL) testing, automated control validation, and model-based development.
• Experience with DSP-based digital power controllers or MCU platforms equipped with high-resolution PWM and synchronized ADC peripherals.
• Experience with MATLAB/Simulink, code generation tools, and model-based design.
• Familiarity with UL, IEC, IEEE, and functional safety standards.

Key Competencies

• Embedded Firmware Development
• Real-Time Control Systems
• AC/DC Power Conversion
• Digital Power Electronics Control
• Fault Detection & Protection
• Modbus Communications
• System Integration
• Firmware Verification & Validation
• Root Cause Analysis
• Cross-Functional Collaboration

What We Offer

• Competitive pay with performance incentives
• 100% company-paid medical, dental, and vision
• 401(k) with company match
• 4 weeks PTO, 10 paid holidays, and 2 floating holidays

Why You Will Love Working with Us

Impact: Develop your skills and expertise in a rapidly growing industry, with your work directly influencing the success of mission‑critical projects.

Innovation: Immerse yourself in an environment that celebrates forward‑thinking and continuous improvement.

Collaborative spirit: Work closely with engineers, marketers, and other professionals to bring ideas to life.

Grow with us: We are committed to your personal and professional development, offering endless opportunities to improve your skills and advance your career.

At LayerZero, we are proud to be an Equal Opportunity Employer. We welcome and celebrate diversity, and we are committed to creating an inclusive environment for all employees.