Lead Controls Engineer – Industrial Automation & Systems

Vulcan Elements

Benson (NC)

On-site

USD 110,000 - 150,000

Full time

7 days ago

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Job summary

Vulcan Elements is seeking a Controls Engineer to own controls execution for the magnet equipment portfolio within a massive 1 million square foot facility expansion. You will oversee cradle-to-grave design review, FAT witness, site commissioning, and sustaining support, including hands-on implementation and domestic travel up to 50% during test campaigns.

This leadership role requires technical expertise in industrial automation and will begin in Durham, NC, with relocation to Benson, NC after

Qualifications

Bachelor's or Master's degree in electrical engineering, Automation Engineering, Mechatronics, or related field with 3+ years of direct industrial automation and controls engineering experience.
Strong hands-on experience programming and commissioning Siemens and Allen-Bradley/Rockwell PLCs and HMIs.
Deep understanding of servos, VFDs, high-speed conveyors, robotic cells, and automated material handling systems.
Proficiency with Ethernet/IP, Profinet, EtherCAT, OPCUA, and similar industrial communication standards.
Analogue loop fundamentals, gas analyzer integration (O2, pressure, flow), loop tuning, and literacy to read and validate safety-rated circuits and safety PLCs.

Responsibilities

PLC Programming & Commissioning: Execute hands-on programming, debugging, and commissioning of Siemens and Allen-Bradley/Rockwell PLCs and HMIs for new and existing automation equipment.
Advanced Automation & System Integration: Drive the integration and commissioning of robotics, conveyors, and motion control systems—including servos and VFDs—to enable seamless material flow and high reliability production operations.
SCADA/MES Connectivity: Configure and maintain communications between PLCs/HMIs and SCADA/Batch systems. Support tag mapping, alarming, and data acquisition to the site SCADA platform as required.
Vendor Technical Support & FATs: Review vendor electrical schematics, controls architectures, and PLC/HMI logic. Participate in FATs and SATs to ensure full compliance with functional and safety requirements.
Troubleshooting & Technical Escalation: Serve as the first-line, hands-on responder for diagnosing complex automation issues involving networks, motion systems, instrumentation, and industrial communication protocols.