Senior-level automation/ Control systems engineer (HVAC)

Job Title: Senior Engineer Motors, Controls & PLC Software (HVAC)

Location: Bethlehem, PA

Onsite/ Hybrid/ Remote: Onsite/Hybrid at Bethlehem (There is a flexibility of Remote and sometime need to be in Bethlehem. Some Travel between Bethlehem & Texas may also be needed)

Role Summary:-

The Senior Engineer Motors, Controls & PLC Software (HVAC) is responsible for the design, development, programming, testing, and commissioning of motor control systems and PLC-based control software for HVAC equipment and systems. This role plays a key part in delivering reliable, energy efficient, and compliant HVAC control solutions across commercial and industrial applications.

Key Responsibilities

• Control Systems & PLC Software
• Design, develop, and maintain PLC software for HVAC systems including chillers, AHUs, FCUs, pumps, and compressors
• Develop control logic for temperature, pressure, flow, humidity, and energy optimization
• Program and troubleshoot PLCs (e.g., Siemens, Rockwell/Allen Bradley, Schneider, or equivalent)
• Implement communication protocols such as Modbus, BACnet, LonWorks, Profibus, Profinet, and Ethernet/IP
• Support integration with BMS/EMS
• Motors & Drives
• Design and validate motor control strategies for AC/DC motors, EC motors, VFDs, and soft starters
• Select and specify motors, drives, and protection devices based on application requirements
• Optimize motor performance for energy efficiency, reliability, and compliance with HVAC standards
• Troubleshoot motor and drive-related field issues
• Controls & Hardware
• Design control panel architectures, I/O mapping, wiring schematics, and control hardware layouts
• Review and approve electrical drawings, BOMs, and technical documentation
• Ensure compliance with applicable standards (IEC, UL, IS, NEC, CE, etc.)
• Testing & Commissioning
• Perform software testing, FAT, SAT, and on-site commissioning
• Diagnose and resolve system-level issues during testing and field deployment
• Support root cause analysis and corrective actions
• Collaboration & Leadership
• Work closely with mechanical, electrical, firmware, and system engineering teams
• Provide technical guidance and mentoring to junior engineers
• Interface with customers, suppliers, and cross-functional stakeholders

Required Qualifications

• Bachelor s or master s degree in electrical engineering, Electronics, Mechatronics, or related field
• 7 12 years of experience in HVAC controls, motor systems, or industrial automation
• Strong hands-on experience with PLC programming and debugging
• Solid understanding of motor control theory, VFDs, and HVAC system operation
• Experience with HVAC control strategies and energy optimization

Technical Skills

• PLC Programming: Ladder Logic, Function Block, Structured Text
• Motors & Drives: Induction motors, BLDC/EC motors, VFD tuning
• HVAC Controls: PID tuning, sequencing, alarms, safety interlocks
• Communication: BACnet, Modbus RTU/TCP, LonWorks, CAN, Ethernet
• Tools: PLC IDEs, HMI/SCADA tools, simulation and testing tools

Preferred Qualifications

• Experience with embedded control systems or hybrid PLC embedded architectures
• Exposure to global HVAC standards and certification processes
• Experience with cybersecurity concepts for industrial control systems
• Prior experience in product development lifecycle for HVAC equipment

Soft Skills

• Strong analytical and problem-solving skills
• Ability to work independently and in cross-functional teams
• Clear communication and technical documentation skills

Customer-focused mindset with attention to quality and reliability