Controls Technician

Job Description

Job Description

The Controls Technician installs, maintains, troubleshoots, and improves industrial control systems, electrical systems, and automation equipment used in steel pipe production. Uses PLC, HMI, drive, and robot software to diagnose faults, make approved program changes, and maintain backups. Supports production and maintenance teams during breakdowns, preventive and predictive maintenance, and equipment commissioning, and diagnoses mechanical issues that affect controls performance.

ESSENTIAL FUNCTIONS/RESPONSIBILITIES:   include the following: (Other duties may be assigned, including but not limited to cross training and housekeeping.)

Safety

• Follow all safety rules, including LOTO, electrical safe work practices (NFPA 70E), confined space, fall protection, and hazard communication. Stop work when conditions are unsafe.

• Operate forklifts, overhead cranes, and mobile equipment after completing company certification.

PLC / Automation

• Go online with PLCs to monitor I/O, logic, interlocks, alarms, and parameters. Diagnose faults and identify root causes.

• Modify PLC logic, timers, interlocks, and parameters only as authorized, following the site change and approval process.

• Troubleshoot HMI/SCADA systems, industrial networks (such as PROFINET, PROFIBUS, and EtherNet/IP), and PLC field devices, including 2-wire and 3-wire sensors.

• Maintain current backups of PLC, HMI, drive, and robot programs, and document all changes.

• Support SCADA, MES, and SPC data collection from plant equipment.

Drives & Robotics

• Troubleshoot, commission, and replace AC and DC drives. Set and verify parameters, backup and restore configurations, and apply open-loop and closed-loop control.

• Troubleshoot encoders, braking resistors, and solid-state power devices such as SCRs and soft starters.

• Troubleshoot industrial robots, including alarms, I/O, interlocks, and robot-to-PLC communication, where applicable.

Electrical Maintenance

• Troubleshoot control and power circuits from 24 VDC through 480 VAC, including relay logic, motor starters (across-the-line and wye-delta), safety circuits, sensors, and control panels, using a DMM, clamp meter, and insulation tester.

• Troubleshoot and maintain AC and DC motors and generators.

• Specify, install, and modify motor circuits, power distribution, lighting, conduit, and wiring in accordance with the NEC.

• Troubleshoot and calibrate instrumentation, including transmitters and 4-20 mA loops. Check and document the calibration of production welding equipment.

• Develop electrical and controls expertise on at least five pieces of major production equipment.

Preventive & Predictive Maintenance

• Perform electrical and controls