Field Service Engineer - Web Handling & Tension Control

Field Service Engineer – Web Handling & Tension Control

Responsibilities

• Provide hands-on field service support for industrial automation, controls systems, variable frequency drives, and manufacturing equipment in customer production environments.
• Troubleshoot, configure, and support Rockwell Automation platforms, including Studio 5000, Logix Designer, ControlLogix, and CompactLogix.
• Perform diagnostics and adjustments for PLC programming, ladder logic, HMI systems, FactoryTalk View SE / ME, alarm handling, and operator interface issues.
• Configure, troubleshoot, and commission PowerFlex variable frequency drives, including PowerFlex 525, PowerFlex 753, and PowerFlex 755 drives.
• Support industrial networks, including IP addressing, switch configuration, EtherNet/IP communication, and basic network diagnostics.
• Troubleshoot tension control systems, including open-loop taper tension, closed-loop feedback, dancer-position control, load cell control, and cascade control.
• Diagnose and tune center winder, center unwind, surface winder, driven roll, web handling, and sectional drive applications.
• Perform PID loop tuning, including proportional gain adjustment, integral windup correction, derivative filtering, and loop oscillation troubleshooting.
• Read and interpret electrical schematics, control drawings, machine documentation, and field wiring diagrams to resolve equipment issues.
• Complete motor and electrical diagnostics, including motor testing, megger testing, encoder verification, analog signal wiring, and electrical panel troubleshooting.
• Communicate technical findings clearly with customers and prepare accurate, professional field service reports.

Qualifications

• Associate degree or higher in Electrical Technology, Controls Engineering, Automation Engineering, or a related technical field; equivalent hands-on experience may be considered.
• 2+ years of hands-on field service experience in industrial automation, controls, drives, or manufacturing equipment support.
• Experience with Rockwell Automation platforms, including Studio 5000, Logix Designer, ControlLogix, and CompactLogix.
• Working knowledge of PLC programming languages, including ladder logic; experience with FBD, SFC, or structured text is a plus.
• Experience configuring and troubleshooting PowerFlex variable frequency drives, especially PowerFlex 525, 753, and 755 series.
• Familiarity with FactoryTalk View SE / ME, HMI troubleshooting, alarm handling, and operator interface support.
• Knowledge of industrial networks, including IP addressing, switch configuration, EtherNet/IP communication, and basic network diagnostics.
• Understanding of tension control theory, including open-loop taper tension, closed-loop feedback, dancer-position control, load cell control, and cascade control.
• Experience with load cells, signal conditioning, amplifier calibration, K-factor geometry, and tension feedback scaling.
• Experience with dancer roll systems, including position feedback, speed trim, torque feedback, pneumatic dancer systems, and loop stability.
• Ability to troubleshoot center winder, center unwind, surface winder, driven roll, web handling, and sectional drive applications.
• Knowledge of PID loop tuning, including proportional gain, integral windup, derivative filtering, and loop oscillation troubleshooting.
• Ability to read and interpret electrical schematics, control drawings, machine documentation, and field wiring diagrams.
• Experience with motor testing, megger testing, encoder verification, analog signal wiring, and electrical panel troubleshooting.
• Strong customer communication skills with the ability to write professional field reports and explain technical issues clearly.
• Valid driver’s license and ability to travel up to 75%.
• Ability to pass required background check and drug screening.
• Authorization to work in the applicable jurisdiction.

Preferred Experience

• Experience with FactoryTalk Historian, FactoryTalk AssetCentre, or industrial data logging systems.
• Experience with DriveTools SP or Connected Components Workbench.
• Experience with Kinetix servo drives and basic axis configuration.
• Experience supporting wire and cable lines, including pay-off, capstan, accumulator, take-up, line speed synchronization, and tension control.
• Experience with paper and converting equipment, including unwind/rewind stands, nip control, tension zones, and web guiding.
• Experience with plastics extrusion lines, haul-off systems, pelletizers, winders, unwinders, melt pressure coordination, and product diameter control.
• Experience with textile equipment, including warpers, knitting machines, stenter frames, creel tensioning, and fabric tension control.
• Experience using CMMS or service ticketing platforms such as SAP, ServiceMax, or similar systems.
• Knowledge of safety circuit commissioning, safety relays, STO wiring, and machine safety practices.

Important Bold Keywords

hands-on field service support, industrial automation, controls systems, variable frequency drives, manufacturing equipment, Rockwell Automation, Studio 5000, Logix Designer, ControlLogix, CompactLogix, PLC programming, ladder logic, HMI systems, FactoryTalk View SE / ME, PowerFlex variable frequency drives, PowerFlex 525, PowerFlex 753, PowerFlex 755, industrial networks, IP addressing, switch configuration, EtherNet/IP communication, tension control systems, open-loop taper tension, closed-loop feedback, dancer-position control, load cell control, cascade control, center winder, center unwind, surface winder, driven roll, web handling, sectional drive, PID loop tuning, electrical schematics, control drawings, motor testing, megger testing, encoder verification, analog signal wiring, electrical panel troubleshooting, field service reports, Electrical Technology, Controls Engineering, Automation Engineering, FBD, SFC, structured text, load cells, signal conditioning, amplifier calibration, K-factor geometry, tension feedback scaling, dancer roll systems, FactoryTalk Historian, FactoryTalk AssetCentre, industrial data logging systems, DriveTools SP, Connected Components Workbench, Kinetix servo drives, wire and cable lines, paper and converting equipment, plastics extrusion lines, textile equipment, CMMS, service ticketing platforms, SAP, ServiceMax, safety circuit commissioning, safety relays, STO wiring, machine safety practices