Senior Controls Engineer – High-Power Automation

Actalent; Birmingham (AL); On-site; USD 120,000 - 160,000; Full time

Benefits offered by this job

Medical insurance

Dental insurance

Vision insurance

401(k)

Job summary

Actalent in Birmingham, AL seeks a Senior Controls Engineer to design, develop, and implement advanced control systems for high-power electrical equipment and integrated energy systems. You will own BOMs, program PLC/CODESYS, and work in Linux environments while collaborating across mechanical, electrical, and manufacturing teams.

The role emphasizes scalable solutions, documentation, mentoring, and adherence to engineering standards in a fully onsite setting in Birmingham, AL.

Qualifications

• Bachelor's degree in Electrical Engineering, Controls Engineering, or a related field.
• 7+ years of experience in industrial controls, automation, or power systems engineering.
• Demonstrated experience programming and supporting PLC platforms.
• Hands-on experience with CODESYS environments for control system development.
• Strong experience with Linux-based systems, including application development, scripting, and system integration.
• Direct experience designing and supporting high-power electrical systems, including integration with inverters or variable frequency drives.
• Proven ability to develop and manage BOMs, electrical schematics, and control panel designs.
• Strong troubleshooting skills across electrical systems, controls software, and integrated systems.
• Experience with PLC programming, automation, and controls engineering in industrial environments.
• Proficiency in electrical design for control systems, including I/O selection, wiring, and panel layout.
• Experience with control systems design and development from concept through commissioning.
• Ability to work with structured text (ST) code or similar IEC 61131-3 programming languages.
• Experience integrating and troubleshooting industrial communication protocols such as Modbus.
• Ability to collaborate effectively in cross-functional engineering teams and communicate technical information clearly.

Responsibilities

• Design and develop control systems for high-power applications, including overall system architecture, control strategies, and detailed design deliverables.
• Own and develop complete bills of materials (BOMs), I/O lists, wiring diagrams, and panel layouts to support production and field deployment.
• Ensure control system designs are manufacturable, serviceable, and aligned with internal standards and best practices.
• Develop, program, and maintain control software across multiple platforms, including traditional PLC environments, CODESYS-based systems, and Linux-based control applications.
• Integrate control systems with inverters, drives, and other power electronics to ensure proper operation, communication, and protection strategies.
• Configure and commission variable frequency drives and inverter systems, including development of parameter sets, communication interfaces, and control logic for stable and efficient operation.
• Collaborate closely with mechanical, electrical, and manufacturing teams to ensure seamless product development and execution.
• Actively participate in design reviews, providing technical input, identifying risks, and proposing mitigation strategies early in the design process.
• Support testing, validation, and commissioning activities, including prototype builds, factory acceptance testing (FAT), and field commissioning.
• Troubleshoot system issues across hardware and software domains, diagnosing root causes and implementing timely and effective resolutions.
• Develop and maintain technical documentation such as control narratives, functional specifications, software documentation, and commissioning procedures.
• Ensure consistency, clarity, and completeness across all technical deliverables and documentation.
• Mentor junior engineers by providing guidance, code and design reviews, and knowledge sharing in controls and automation.
• Contribute to the development and continuous improvement of engineering standards, templates, and best practices within the organization.

Skills

PLC programming

CODESYS

Linux based systems

Electrical power systems

System integration

Troubleshooting

Cross-functional collaboration

Hardware design

Project leadership

Documentation

Control narratives

Mentoring

Education

Bachelor's degree in Electrical Engineering/Controls

Tools

Danfoss drives

BOM management

I/O wiring diagrams

Job description

Actalent in Birmingham, AL seeks a Senior Controls Engineer to design, develop, and implement advanced control systems for high-power electrical equipment and integrated energy systems. You will own BOMs, program PLC/CODESYS, and work in Linux environments while collaborating across mechanical, electrical, and manufacturing teams.

The role emphasizes scalable solutions, documentation, mentoring, and adherence to engineering standards in a fully onsite setting in Birmingham, AL.