Senior Controls Support Engineer at Operio Group

Lower Moreland Township, Pennsylvania, United States -

Full Time

Start Date

Immediate

Expiry Date

26 May, 26

Salary

135000.0

Posted On

25 Feb, 26

Experience

5 year(s) or above

Remote Job

Yes

Telecommute

Yes

Sponsor Visa

Skills

Tier 3 Technical Escalation, Remote Access Tools, PLC Code Debugging, RSLogix 500/5000, FactoryTalk View, Servo Drive Configuration, VFD Configuration, Legacy System Obsolescence, Electrical Schematics Editing, Bill Of Materials Management, Software Backup Management, AutoCAD Electrical, Industrial Networking, 480V 3-Phase Troubleshooting, Kinetix, PowerFlex

Industry

Wholesale Chemical and Allied Products

Description

Job Summary We are seeking a highly experienced Senior Controls Support Engineer to join our headquarters team. This role is designed for a seasoned automation professional—ideally a former Field Service Engineer or Systems Integrator—who is looking to transition away from heavy travel into a stable, high-impact technical support role. In this position, you will serve as the primary technical anchor for our installed base of machinery. You will take ownership of high-level troubleshooting, legacy system obsolescence, and remote support, acting as a critical bridge between our R&D design team and field operations. You will rely on your ability to reverse-engineer solutions, troubleshoot complex electrical/software issues, and mentor junior staff. This is a Full-Time position, on-site at our Huntingdon Valley, PA location. Travel time: Less than 15% Duties and Responsibilities Technical Support & Troubleshooting Serve as the Tier 3 technical escalation point for critical machine-down situations, utilizing remote access tools (Ewon, Netbiter) to diagnose root causes without deploying to the site. Analyze and debug live PLC code (RSLogix 500/5000) and HMI applications (FactoryTalk View) to distinguish between software logic errors, electrical faults, or mechanical failures. Guide on-site technicians and junior engineers through complex diagnostic procedures via video/phone, including multimeter checks, servo drive parameter updates, and VFD configuration. Legacy Systems & Obsolescence Management Lead engineering efforts for legacy equipment, including identifying modern replacements for obsolete components (amplifiers, drives, HMIs) and validating new solutions. Update electrical schematics and Bill of Materials (BOMs) to reflect retrofit changes and ensure accurate documentation for future service. Manage the archival and organization of software backups and disaster recovery images for a diverse range of custom production machinery. Requirements and Qualifications Education & Experience Bachelor’s degree in Electrical Engineering, Mechatronics, or related field; OR equivalent hands-on professional experience. 7–10+ years of experience in industrial automation, specifically as a Field Service Engineer, Controls Engineer, or Systems Integrator. Proven experience troubleshooting custom machinery in a production environment. Technical Skills Allen Bradley/Rockwell Automation Expert: High-level proficiency in RSLogix 500, Studio 5000, and FactoryTalk View ME/SE. Must be able to read and troubleshoot existing complex ladder logic. AutoCAD Electrical Proficiency: Demonstrated expertise in creating, editing, and updating detailed electrical schematics of equipment and panels. Must be capable of modifying existing drawings for retrofits and ensuring documentation accurately reflects the "as-built" state of the equipment. Industrial Networking: Strong working knowledge of IP addressing, subnetting, and configuring industrial remote access gateways (VPNs, Ewons, etc.). Electrical Diagnostics: Ability to read and interpret complex electrical schematics and troubleshoot 480V 3-phase and 24VDC control circuits. Hardware Knowledge: Familiarity with Servo Drives (Kinetix/PowerFlex), VFDs, instrumentation (Load Cells, Encoders), and legacy PC-to-PLC communications. Key Competencies Crisis Management: Ability to remain calm and analytical under pressure while dealing with urgent customer demands. The "Generalist" Mindset: Comfortable working on machines you did not design and navigating systems with partial or missing documentation. Communication: Strong verbal and written communication skills, with the ability to explain technical concepts to non-technical stakeholders. Benefits: Join a Team That Really Cares - Everyone is friendly, collaborative and driven. We are a family business and we care about each other so because of this, you will always be pushed to become the best you can be. Real Work-Life Balance - 22 days' vacation and 40 hours sick time (pro-rated based on hire date) plus 8 federal holidays. Salary - $120,000 - $135,000 per year based on experience.

Responsibilities

This role serves as the primary technical anchor for installed machinery, acting as the Tier 3 escalation point for critical machine-down situations using remote tools to diagnose issues. Responsibilities include leading legacy system obsolescence efforts, updating documentation, and mentoring junior staff.