Sr. Electrical Controls Engineer

Applied Controls is seeking a Sr. Electrical Design & Controls Engineer to support the design, programming, integration, and commissioning of custom automation, robotics, vision, and industrial control systems. This position is responsible for electrical system design, controls programming, hardware selection, documentation development, and startup support throughout the project lifecycle.

The ideal candidate combines strong electrical design skills with hands-on controls engineering experience and is capable of taking ownership of both electrical and controls deliverables for automation projects. Prior department leadership experience is a plus.

Electrical Design & Documentation
• Develop electrical schematics, panel layouts, wiring diagrams, and documentation packages using EPLAN.
• Design industrial control systems including PLCs, HMIs, motion control systems, robotic systems, machine safety systems, and industrial networking.
• Create electrical bills of materials (BOMs) and support component procurement activities.
• Select and specify electrical components.
• Generate manufacturing documentation packages for panel fabrication, machine assembly, installation, and customer deliverables.
• Maintain and improve company electrical design standards and best practices.

Controls Engineering
• Develop PLC, HMI, and motion control software for custom automation systems.
• Configure industrial communication networks including Ethernet/IP, Profinet, Modbus TCP, and other industrial protocols.
• Support robotic integration and communication with control systems.
• Troubleshoot software, communication, and hardware-related issues during system development and deployment.
• Develop reusable software standards and programming methodologies.

Project Execution
• Participate in project kickoff meetings and technical design reviews.
• Collaborate with mechanical engineers, project managers, programmers, technicians, and customers throughout project execution.
• Review customer specifications and ensure compliance with project requirements.
• Support technical evaluations during quoting and proposal development.

Manufacturing, Testing & Commissioning
• Support panel fabrication and machine assembly teams during system build.
• Perform electrical checkout and system verification.
• Lead or support FAT, SAT, startup, and commissioning activities.
• Troubleshoot and resolve issues during installation and startup.

Safety & Compliance
• Design machine safety systems in accordance with applicable standards and customer requirements.
• Support risk assessments and machine safety reviews.

• Associate's or Bachelor's degree in Electrical Engineering, Electrical Engineering Technology, Mechatronics, Automation Engineering, or related field.
• 5+ years of experience designing and programming industrial automation systems.
• Experience creating electrical schematics and documentation using EPLAN.
• Experience programming PLC and HMI systems.
• Strong troubleshooting and problem-solving skills.
• Ability to manage multiple projects simultaneously.
• Strong written and verbal communication skills.

• Experience with Siemens TIA Portal, S7 PLCs, WinCC HMIs, Profinet Networks, and Siemens Motion Control.
• Experience integrating robotic systems.
• Experience with machine vision systems.
• Experience with machine safety design and implementation.
• Experience supporting customer startups and commissioning activities.

• Prior department leadership experience is a plus.

• Takes ownership of projects from concept through commissioning.
• Comfortable working independently while collaborating across disciplines.
• Strong attention to detail and documentation quality.
• Customer-focused with a commitment to delivering reliable automation solutions.
• Hands-on mindset with willingness to assist in troubleshooting and startup activities.
• Continuously seeks opportunities to improve processes, standards, and technical capabilities.