Senior Controls Engineer FAT/CSV Lead for Large Automation

Vulcan-Elements; Durham (NC); On-site; USD 110,000 - 150,000; Full time

Job summary

Vulcan Elements in Durham, NC seeks a Sr. Controls Engineer (FAT/CSV) to lead automation acceptance for a large facility expansion. You will own FAT/SAT protocols, author acceptance tests, and coordinate live commissioning across multi-vendors.

The role requires deep expertise in Siemens and AllenBradley/Rockwell PLCs/HMIs, robotics, vision systems, and industrial networks, plus travel up to 50% during test campaigns.

Qualifications

• Bachelor’s or Master’s degree in electrical engineering, Automation Engineering, Mechatronics, or related field.
• 7+ years of direct industrial automation and controls engineering experience.
• Hands-on experience programming and commissioning Siemens and AllenBradley/Rockwell PLCs and HMIs.
• Multi-vendor acceptance campaign management with disciplined change control and punch-item triage.
• Deep understanding of servos, VFDs, high-speed conveyors, robotic cells, and automated material handling systems.
• Proficiency with Ethernet/IP, Profinet, EtherCAT, OPCUA, Modbus, serial, and similar industrial communication standards.

Responsibilities

• Lead hands-on programming, debugging, and commissioning of Siemens and AllenBradley/Rockwell PLCs and HMIs.
• Develop, modify, and maintain PLC code structures, HMI screens, safety circuits, device mapping, and networking configurations.
• Own FAT/SAT campaign: author standardized acceptance protocols and manage the program-wide punch list.
• Review vendor electrical schematics, controls architectures, and PLC/HMI logic for acceptance campaigns.
• Drive integration of robotics, vision systems, AGVs, conveyors, and motion control systems.
• Configure and troubleshoot PLC/HMI communications with MES/SCADA; develop SCADA tags and data acquisition.

Skills

Industrial automation expertise

PLC programming

HMI/SCADA experience

Robotics & vision systems

Industrial networks

Education

BSc/MSc in electrical/automation/mechatronics

Tools

Siemens PLCs

AllenBradley/Rockwell PLCs

HMI platforms

Ignition/FactoryTalk/Wonderware

Python/C++ for automation

Job description

Vulcan Elements in Durham, NC seeks a Sr. Controls Engineer (FAT/CSV) to lead automation acceptance for a large facility expansion. You will own FAT/SAT protocols, author acceptance tests, and coordinate live commissioning across multi-vendors.

The role requires deep expertise in Siemens and AllenBradley/Rockwell PLCs/HMIs, robotics, vision systems, and industrial networks, plus travel up to 50% during test campaigns.