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The average salary range is between $ 48,417 and $ 106,314 year , with the average salary hovering around $ 61,564 year .
A Senior Controls Engineer needed to design, develop, program, test, and commission industrial control systems for a variety of automation projects. This role is responsible for PLC and HMI development, instrumentation configuration, system testing, startup support, and customer training while serving as the technical lead on automation projects.
Key Responsibilities
Design and develop industrial control system architectures and communication networks.
Collaborate with project managers, estimators, customers, and stakeholders to define project scope and system functionality.
Review and interpret P&IDs, electrical drawings, and technical documentation.
Develop Bills of Materials (BOMs), I/O lists, and control panel requirements.
Program PLCs using Ladder Logic, Function Block, Structured Text, and other IEC programming languages.
Design and develop Human Machine Interface (HMI) applications.
Create hardware and software test plans and simulation logic for system validation.
Serve as the technical lead on automation projects, including PLC and HMI template development.
Support installation teams during system implementation and commissioning.
Perform startup, commissioning, and validation of industrial control systems.
Troubleshoot hardware, software, networking, and instrumentation issues during startup and operation.
Develop customer training materials and provide operator and maintenance training.
Coordinate with equipment manufacturers and software vendors to resolve technical issues.
Respond to field service calls as needed to troubleshoot and resolve system issues.
Mentor and train junior controls engineers and automation specialists.
Required Qualifications
Bachelor's degree in Electrical Engineering, Computer Engineering, Mechatronics Engineering, or a related engineering discipline, or equivalent industrial controls experience.
Minimum of 5 years of industrial controls or systems integration experience in manufacturing, engineering, or industrial automation.
Minimum of 5 years of PLC programming experience.
Strong experience programming Allen-Bradley/Rockwell Automation PLCs.
Proficiency with:
Ladder Logic
Function Block
Structured Text
Experience developing HMI/SCADA applications.
Working knowledge of EtherNet/IP and industrial networking.
Experience with instrumentation, control panel design, and industrial process control systems.
Strong troubleshooting, commissioning, and startup experience.
Excellent communication and customer-facing skills.
Preferred Qualifications
Experience with AutoCAD or Autodesk design software.
Experience leading automation projects from design through commissioning.
Familiarity with additional PLC platforms such as Siemens, Schneider Electric, or Emerson is a plus.
Benefits
Competitive compensation and benefits package, including:
Medical, Dental, and Vision Insurance
Flexible Spending Accounts (FSA)
Generous Paid Time Off (PTO)
401(k) with Company Match
Employee Stock Ownership Plan (ESOP)
Professional development and training opportunities
Company-sponsored employee appreciation and team events
Excellent opportunities for career growth within a leading industrial automation organization
