Sr. Controls Engineer

Core Group Resources is seeking a Senior Controls Engineer to design, develop, and deploy advanced control systems for high-power electrical equipment and integrated energy solutions. The role is onsite in Birmingham, AL and focuses on building reliable PLC/CODESYS and Linux-based controls, commissioning power electronics, and supporting end-to-end integration from design reviews through field validation.

This position combines controls architecture, software development, documentation, troubleshooting, and mentoring. You will work across disciplines including electrical, mechanical, and manufacturing partners to deliver stable, efficient, and safe system operation.

Responsibilities

• Architect and develop advanced control systems for high-power electrical applications, including system architecture, control strategies, and engineering specifications.
• Create and maintain documentation such as Bills of Materials (BOMs), I/O lists, wiring diagrams, electrical schematics, and control panel layouts to support manufacturability, serviceability, and scalability.
• Program and sustain control software across platforms, including PLC environments, CODESYS-based systems, and Linux-based control applications.
• Integrate controls with inverters, VFDs (variable frequency drives), power electronics, and related electrical components.
• Configure and commission VFD and inverter systems, including parameter development, communication interfaces, and control logic implementation.
• Develop control and protection strategies to ensure stable, efficient, and safe system operation.
• Collaborate with multiple engineering disciplines throughout the product development lifecycle (electrical, mechanical, manufacturing, and others).
• Participate in engineering and design reviews to mitigate technical risk and improve 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.
• Produce comprehensive technical documentation, including control narratives, functional specifications, software manuals, and commissioning procedures.
• Mentor junior engineers and contribute to engineering standards, templates, and controls best practices.

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 related fields.
• Hands-on expertise with PLC programming and CODESYS environments.
• Strong Linux-based experience, including software development, scripting, and system integration.
• Proven 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.
• Strong troubleshooting capability for electrical hardware, software, and integrated systems.
• Excellent communication skills and 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; familiarity with power systems concepts including motor controls, electrical protection schemes, drives, and energy systems.
• Advantageous: field commissioning experience in industrial, marine, oil and gas, energy, or similar environments.
• Plus: exposure to embedded systems or edge-device software architecture.

Technologies

• PLC
• CODESYS
• Linux
• VFDs
• Inverters
• Danfoss drives
• Modbus
• CAN
• Ethernet/IP
• TCP/IP