Sr Electrical Controls Engineer

Sr Electrical Controls Engineer Location: Western North Carolina Region Engagement Type: Contract / 1099 Preferred Duration: Long-Term Contract with Rolling Renewal Periods Industry: Advanced Manufacturing Client: Confidential Tier-One Manufacturing Customer Role Overview CAC is supporting a confidential tier-one manufacturer with a production line upgrade and installation project at an active manufacturing facility in Western North Carolina. This is a hands‑on controls engineering role supporting a live production environment. The site has a strong Rockwell ControlLogix base with motion control and servo‑driven line equipment. The current project scope includes new Siemens S7 content being added as part of a production line upgrade and installation. The right contractor will be comfortable working across both Siemens and Rockwell platforms, supporting commissioning and startup activities on the plant floor, troubleshooting production issues, and leaving behind clean documentation for the site team. This opportunity is well suited for a senior controls engineer who has experience with real production line installs, Siemens programming, Rockwell troubleshooting, motion control, drives, SCADA interfaces, and plant‑floor commissioning. Key Responsibilities Lead Siemens S7 controls work for a production line upgrade and installation, including program development, hardware configuration, testing, and commissioning. Support integration of new Siemens controls content with the existing Rockwell ControlLogix platform. Read, troubleshoot, and modify ControlLogix / Studio 5000 code where the upgraded line interfaces with existing equipment. Configure, troubleshoot, and tune VFDs and servo drives, including PowerFlex, Yaskawa, and Rockwell Kinetix platforms. Support drive parameters, motion profiles, homing logic, synchronization logic, fault recovery, and startup troubleshooting. Work hands‑on through FAT, installation, startup, commissioning, SAT, and production ramp‑up. Interface with iFix SCADA where the upgraded line connects to existing HMI, alarming, and trending systems. Mark up and update electrical and controls drawings in AutoCAD Electrical to reflect field changes and as‑built conditions. Troubleshoot live production issues during startup and ramp‑up while coordinating with site engineering, maintenance, and operations teams. Provide clean handoff documentation so the plant team can support the system after commissioning. Required Qualifications 7+ years of hands‑on industrial controls engineering experience. Experience supporting at least one full production line installation, major upgrade, or commissioning effort from design through startup. Strong Siemens S7 programming experience using TIA Portal and/or Classic STEP 7. Real production deployment experience with Siemens systems, not just minor maintenance edits. Working knowledge of Rockwell ControlLogix and Studio 5000, including the ability to navigate, troubleshoot, and modify existing code. Experience configuring and troubleshooting VFDs, with PowerFlex experience strongly preferred. Commissioning and startup experience in an active plant‑floor environment. FAT and SAT experience. Ability to work independently on a customer site with limited hand‑holding. Strong troubleshooting, documentation, and professional communication skills. Ability to operate as a 1099 contractor, LLC, sole proprietor, or willingness to establish the proper business structure. Ability to meet required insurance levels under the applicable contract agreement. Local, regional, or willing to commute weekly to the project site at own cost. Preferred Qualifications Servo motion control experience, especially Rockwell Kinetix or Yaskawa servo systems. iFix SCADA experience. AutoCAD Electrical experience for redlines, markups, and as‑built updates. Experience in fiber, cabling, extrusion, web handling, continuous manufacturing, or similar high‑volume production environments. Prior experience working as a contractor under another integrator or supplier's MSA. Familiarity with contractor insurance, LLC structure, professional services agreements, indemnity language, and customer‑site expectations. Ideal Candidate Profile A strong candidate for this role has supported a real Siemens line installation or major upgrade, not just small maintenance edits to an existing program. The ideal contractor should be able to explain how they structured an S7 program, how they handled motion faults, how they recovered from startup issues, and what lessons they learned from previous commissioning work. They should also be comfortable opening Studio 5000 to trace signals, review legacy logic, and understand how new equipment ties into existing Rockwell‑controlled assets. This role is best suited for someone who treats contract work professionally. That means clear communication, organized documentation, weekly updates, clean handoffs, and a strong understanding of customer‑site expectations. Site and Personality Fit The right person will be self‑directed, calm under pressure, and comfortable working in an active manufacturing environment. They must be able to manage communication between CAC, the customer, and plant stakeholders without creating confusion or unnecessary escalation. Startup work can be demanding. The ideal candidate should bring a steady, methodical troubleshooting approach and remain focused when production issues arise. They should document as they go, keep redlines organized, maintain clean program structure, and leave behind a system the plant team can support after commissioning. Why This Opportunity Stands Out Work on a real production line upgrade at a major manufacturing customer. Gain exposure to a mixed Siemens and Rockwell controls environment. Support motion control, drives, SCADA interfaces, and commissioning activities. Engage in meaningful plant‑floor troubleshooting and startup work. Long‑term contract potential with rolling renewal periods. Opportunity to work through CAC on a high‑value controls engineering engagement. Engagement Notes This role is intended for an experienced contractor who can operate with professionalism and independence on a customer site. The selected contractor will be expected to follow all site safety requirements, maintain clear communication, support project execution, and represent CAC professionally throughout the assignment. #J-18808-Ljbffr