Sr. Controls Engineer

Core Group; Birmingham (AL); On-site; USD 110,000 - 150,000; Full time

Job summary

Core Group is seeking a Senior Controls Engineer in Birmingham, AL to lead design and deployment of advanced control systems for high-power electrical equipment. You will develop scalable control software, create electrical documentation, and collaborate across engineering disciplines to ensure reliability.

The role requires PLC/CODESYS expertise, Linux-based control work, and hands-on experience with VFDs, drives, and power electronics.

Qualifications

• Bachelor's degree in Electrical Engineering or a related technical discipline.
• 7+ years of experience in industrial controls, automation, or power systems.
• Hands-on PLC programming with CODESYS environments.
• Experience with Linux-based control software and scripting.
• Experience with high-power electrical systems including VFDs, inverters, and drives.

Responsibilities

• Architect and develop advanced control systems for high-power applications, defining architecture and specifications.
• Create BOMs, I/O lists, wiring diagrams, schematics, and control panel layouts for manufacturability.
• Program and sustain control software across PLC, CODESYS, and Linux-based platforms.
• Integrate controls with inverters, VFDs, power electronics, and related components.
• Configure and commission VFD and inverter systems, developing parameters and interfaces.
• Develop control and protection strategies for safe, efficient operation.
• Collaborate with electrical, mechanical, manufacturing, and field teams throughout product development.
• Participate in design reviews to mitigate risks and improve performance.
• Support prototype assembly, FAT, validation, and field commissioning.

Skills

PLC programming

CODESYS environments

Linux-based systems

Control panel design

Electrical systems

Education

Bachelor's degree in Electrical Engineering (or related)

Tools

Danfoss drives

Inverter platforms

Job description

We are seeking an accomplished Senior Controls Engineer to spearhead the design, development, and deployment of sophisticated control systems for high-power electrical equipment and integrated energy solutions. This pivotal role requires a blend of controls engineering expertise, electrical design proficiency, and software development skills. The ideal candidate will bring hands‑on experience with PLC/CODESYS programming, Linux‑based control systems, control panel design, VFDs/inverters, and high-power electrical systems. Serving as a key technical resource, the Senior Controls Engineer will develop scalable and standardized control solutions, collaborating closely with electrical, mechanical, manufacturing, and field teams to ensure optimal system performance and reliability.

Responsibilities

• Architect and develop advanced control systems for high-power electrical applications, including defining system architecture, control strategies, and engineering specifications.
• Create and maintain essential documentation such as Bills of Materials (BOMs), I/O lists, wiring diagrams, electrical schematics, and control panel layouts, ensuring manufacturability, serviceability, and scalability.
• Program, develop, and sustain control software across diverse platforms, including traditional PLC environments, CODESYS‑based systems, and Linux‑based control applications.
• Integrate controls with inverters, variable frequency drives (VFDs), power electronics, and related electrical components.
• Configure and commission VFD and inverter systems, focusing on parameter development, communication interfaces, and control logic implementation.
• Develop control and protection strategies to ensure stable, efficient, and safe system operation.
• Collaborate across disciplines—electrical, mechanical, manufacturing, and others—throughout the product development lifecycle.
• Engage in engineering and design reviews to mitigate technical risks and enhance system performance.
• Support prototype assembly, system testing, Factory Acceptance Testing (FAT), validation, and field commissioning activities.
• Troubleshoot complex issues involving electrical hardware, controls software, communication protocols, and integrated systems.
• Prepare comprehensive technical documentation, including control narratives, functional specifications, software manuals, and commissioning procedures.
• Mentor junior engineers and contribute to the development of engineering standards, templates, and best practices for controls engineering.

Requirements

• Bachelor's degree in Electrical Engineering, Controls Engineering, or a related technical discipline.
• Minimum of 7 years of experience in industrial controls, automation, power systems engineering, or through similar fields.
• Proven hands‑on expertise with PLC programming and CODESYS environments.
• Strong experience working with Linux‑based systems, including software development, scripting, and system integration.
• Demonstrated experience supporting high-power electrical systems, including VFDs, inverters, drives, and related power electronics.
• Ability to develop and manage electrical schematics, wiring diagrams, I/O lists, BOMs, and control panel layouts.
• Robust troubleshooting skills for electrical hardware, software, and integrated systems.
• Excellent communication skills, with the ability to work effectively across multiple engineering teams.
• Preferred: experience with Danfoss drives and inverter platforms, knowledge of communication protocols such as Modbus, CAN, Ethernet/IP, TCP/IP, and familiarity with power systems concepts—including motor controls, electrical protection schemes, drives, and energy systems.
• Field commissioning experience within industrial, marine, oil and gas, energy, or similar environments is advantageous.
• Exposure to embedded systems or edge‑device software architecture is a plus.