Controls Engineer

Wunderlich-Malec Engineering (WM) is a 100% employee-owned ESOP and one of the largest and most well-established engineering companies in the United States. When you join WM you become part of a company that is 100% employee-owned with 40+ years of industry history, an ENR (Engineering News Record) Top 500 firm, and rated as a top System Integrator Giant.

About the role

This position is responsible for electrical/controls engineering on large-scale projects. Project requirements involve control system design from scratch (hardware/software/network), electrical panel design and power calculations, risk assessment, component selection and configuration, control system programming, and control system installation/commissioning.

Responsibilities

• Be organized, technically competent, and have effective oral and written communications; experienced in working in a multi-disciplined environment and interfacing with engineers, designers, and drafters.
• Responsible for system design from a blank sheet of paper to create concepts of electrical/control/system components based on project requirements.
• Perform design via drafting software (AutoCAD preferred).
• Provide input and system modifications as needed for system integration with other project disciplines.
• Interface with facility design to optimize panel location, minimizing voltage drop and designing a more efficient system hardware layout.
• Manage vendor scope to verify safety, functionality, and all contract requirements are satisfied.
• Ensure design complies with local or government agency design/implementation codes in addition to client codes/standards.
• Analyze system design for hazard analysis development and mitigation.
• Design and analyze safety-critical parts within a control system.
• Design redundant mitigations in systems to increase safety and reliability.
• Design systems with complex motion and integration from automated systems.
• Develop documents of system configuration and design, including:
  • Description of operation
  • Detailed control system design description
  • Panel assembly drawings and schematics
  • Termination drawings
  • Network layout
  • System implementation/acceptance test plans
  • System routine maintenance/job plans
• Perform system design calculations/analysis, including:
  • Short circuit protection
  • Harmonics
  • Noise reduction/cancellation
  • Power consumption
  • Load flow
  • Protective relay/circuit design
  • Ground fault monitoring
  • Safety system implementation (SIL/PL rating knowledge preferred)
• Design, develop, and implement DCS/PLC control system (logic software) to meet process requirements, including understanding and implementing client design standards for software systems.
• Understand control system components and instrumentation to properly design software interface/control to achieve system functionality.
• Develop documents detailing control/software configuration and design, including:
  • Theory/Description of operation
  • Detailed control system design description
  • Software design plan
  • Detailed software implementation/description
  • System implementation/acceptance test plans
• Design, troubleshoot, and implement code for the following programming languages:
  • Ladder logic (required)
  • C++ (preferred)
  • Visual Basic (preferred)
  • Structured text (required)
• Perform processor loading calculations, scan time analysis, input/output response timing analysis, control system network delays analysis, and program task/code block priorities/timing management/interface.
• Design efficient code (not processor-resource-heavy) while maintaining minimalist implementation to facilitate future modifications and client understanding post-turnover, including documentation and tools to assist with program understanding and troubleshooting.
• Diagnose control system issues during troubleshooting to determine root cause (e.g., trending, system analysis, test logic).
• Minimize secondary faults within logic by programming “smart” diagnostics that determine root cause and minimize further effects from initial faults.
• Assist with initial start-up, debug integrated systems, and develop system documentation.
• Work on automation and control system integration projects for clients in industries such as entertainment and manufacturing.
• Act as technical lead on projects and guide lower-level engineers, technicians, and contractors.
• Work “off” shifts as needed during installation/commissioning to support the project.

Requirements

• Bachelor’s degree in Electrical Engineering (degrees in other disciplines may be acceptable if work experience is directly related to electrical engineering; disciplines outside electrical/controls will not be considered).
• 5+ years of experience covering most responsibilities listed above.
• Preferred experience in ASTM standards, attractions industry, safety engineering, instrumentation, components, and logic programming.
• Experience with AutoCAD is desired.

Skills

• Knowledge of contract documents and specifications.
• Ability to collect field data and accurately record findings.
• Proficiency in system design functions.
• Planning, customer focus, timely decision-making, informing, organizing, priority setting, and problem-solving.
• Experience working with hardware/software from major industrial manufacturers (e.g., Allen-Bradley, Siemens).
• Experience with Ethernet-based distributed remote I/O systems.
• Proficiency in Microsoft Windows and Office environments.
• Knowledge of ride system design for attractions involving guests is preferred.

Travel

Ability to travel up to 30% (10% is typical, with variation depending on project).

Physical Demands

• Seeing, color perception, hearing, listening, clear speech.
• Dexterity in hands, driving, lifting, climbing.
• Ability to mount and dismount equipment, pushing, and pulling.

Working Conditions

• Expected on client location 5 days a week.
• Standard office environment, on-site office environment, and diverse industrial/construction environments.
• Frequent PC usage, copy machines, phones.

Benefits

Wunderlich-Malec offers a comprehensive employee-owner benefit package for full-time employees, which may include:

• Medical, dental, and vision insurance.
• Basic and supplemental life and AD&D insurance.
• Long-term disability and voluntary short-term disability.
• Healthcare and dependent care flexible spending accounts.
• Health savings account.
• Paid time off (PTO) and paid holidays.
• Tuition reimbursement.
• Referral bonus program.
• 401(k)/Profit sharing.
• 100% ESOP (Employee Stock Ownership Plan).
• Employee Assistance Program.
• Will preparation resources.
• Worldwide travel assistance.