Controls Technician

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 preventive maintenance on MCCs, panels, disconnects, motors, drives, and transformers.

• Conduct infrared thermography of electrical and mechanical equipment. Document findings and create corrective work orders in the CMMS.

• Support maintaining critical electrical and automation spare parts, and support autonomous maintenance and 5S.

Mechanical Support

• Diagnose and communicate mechanical issues that affect controls performance.

• Troubleshoot hydraulic and pneumatic systems. Perform basic mechanical tasks, including bearing installation, shaft alignment, lubrication, rigging, small equipment installation, and air compressor support.

Production Support & Reliability

• Respond to equipment breakdowns and restore production safely and efficiently. Coach maintenance technicians on electrical and controls troubleshooting.

• Lead or participate in root cause analysis of recurring failures, record findings in the CMMS, and use maintenance data and KPIs to reduce downtime, repeat failures, and cost.

• Support installation, commissioning, and startup of new equipment and reliability improvement projects.

Perform other tasks as instructed by supervision.

MINIMUM QUALIFICATIONS:

To perform the job successfully, an individual must be able to perform each essential duty satisfactorily. The requirements listed below are representative of the knowledge, skill, and/or ability required. Reasonable accommodation may be made to enable individuals with disabilities to perform the essential functions.

Education and/or Experience:

Associate degree in electrical, electronics, or industrial automation technology, technical diploma, completed apprenticeship, or equivalent experience. 3 to 5 years of industrial controls and electrical troubleshooting experience preferred. Experience with PLCs, HMIs, VFDs, and industrial networks required. Experience with the PLC and drive platforms used at the hiring location preferred.

Language Skills:

Ability to read and interpret safety rules, OEM manuals, operating and maintenance instructions, and procedure manuals. Ability to write work order records, program change records, and root cause findings. Ability to present information and respond to questions from employees and managers.

Mathematical Skills:

Ability to calculate proportions, percentages, area, circumference, and volume in all units of measure. Ability to apply basic algebra and electrical formulas, including Ohm's law, power, and three-phase calculations.

Reasoning Ability:

Ability to define problems, collect data, establish facts, and draw valid conclusions. Ability to interpret technical instructions in written, oral, diagram, or schedule form and solve practical problems where only limited standardization exists.

Computer Skills:

Working knowledge of PLC programming software (such as Siemens STEP 7 / TIA Portal or Rockwell Studio 5000) and drive configuration software. Ability to use the site CMMS for work orders and parts. Proficient in Microsoft Office, including basic data analysis in Excel.

Certificates, Licenses, Registrations:

Desirable: NFPA 70E training, Level I infrared thermography, and PLC, drive, or robot manufacturer training. Required after hire: company certifications for powered industrial trucks, overhead cranes, and mobile equipment.

Other Skills and Abilities:

Blueprint and electrical schematic reading, including American and European (IEC) style prints. Ability to troubleshoot mechanical, hydraulic, and pneumatic systems. Ability to prioritize work, manage time, communicate clearly, and make sound decisions under production pressure.

Other Qualifications:

Willingness to learn and apply multiple job-related skills, train others, and work in a group environment.

EQUIPMENT/MATERIALS/TOOLS USED:

A broad range of equipment is used to maintain steel pipe manufacturing equipment. The following list is general and not all inclusive: computer with PLC, HMI, and drive software; programming cables and network adapters; digital multimeter, clamp meter, and insulation tester; infrared camera and loop calibrator; electrical hand and power tools; conduit benders; measuring and calibration tools; forklift; and overhead crane.

PHYSICAL/ENVIRONMENTAL REQUIREMENTS:

While performing the duties of this job, the employee is regularly required to use hands to finger, handle, or feel and talk or hear. The employee is frequently required to stand; walk; reach with hands and arms and stoop, kneel, crouch, or crawl. The employee is occasionally required to climb or balance. The employee must regularly lift and /or move up to 10 pounds, frequently lift and/or move up to 25 pounds and occasionally lift and/or move up to 50 pounds. Specific vision abilities required by this job include close vision, distance vision, color vision, depth perception and ability to adjust focus.

All candidates are required to complete a background check and pre-employment physical and drug testing.