Overhead Crane Controls Engineer / Technician

Controls & Automation Consultants; Austin (TX); On-site; USD 80,000 - 100,000; Full time

Job summary

Controls & Automation Consultants is looking for an Overhead Crane Controls Engineer / Technician located in Austin, Texas. This hands-on role involves designing and troubleshooting crane systems, utilizing expertise with Siemens S7 PLC programming. The ideal candidate should have 5+ years of experience in industrial controls and familiarity with HMI systems and safety devices. The position may require substantial time on-site during commissioning and startup phases and offers a dynamic industrial environment.

Qualifications

• 5+ years of experience in industrial controls or automation.
• Hands-on experience with Siemens S7 PLC programming.
• Strong understanding of electrical systems and instrumentation.

Responsibilities

• Perform PLC and HMI programming for overhead crane systems.
• Troubleshoot electrical, controls, and communication issues.
• Support commissioning activities including startup and functional testing.

Skills

Siemens S7 PLC programming

Troubleshooting

HMI/SCADA development

Understanding of safety-rated systems

Education

5+ years of experience in industrial controls or automation

Tools

Siemens TIA Portal

HMI systems (Siemens WinCC)

Variable Frequency Drives (VFDs)

Job description

Overhead Crane Controls Engineer / Technician

Position Overview

We are seeking a skilled Contract Controls Engineer / Technician to support the design, programming, commissioning, and troubleshooting of overhead crane systems in industrial environments. This role is hands‑on and field‑focused, working with PLCs, HMIs, drives, and safety systems to ensure reliable and safe crane operation.

The ideal candidate will have experience with Siemens SIMATIC S7 platforms, including failsafe (F) systems, and a strong understanding of motion control and industrial safety as it relates to crane operations.

Key Responsibilities

• Perform PLC and HMI programming for overhead crane systems using Siemens S7 (TIA Portal / Step 7)
• Develop and modify safety logic using S7 F-systems and Step 7 Safety Advanced
• Configure and commission VFDs and motion control systems for hoist, trolley, and bridge travel
• Execute loop checks, I/O verification, and point‑to‑point testing of field devices
• Support commissioning activities including startup, functional testing, and system validation
• Troubleshoot electrical, controls, and communication issues in real‑time during commissioning and operations
• Implement and validate safety functions including E‑stops, limit switches, overload protection, and anti‑collision systems
• Work with HMI/SCADA systems to develop operator interfaces, alarms, and diagnostics
• Collaborate with mechanical, electrical, and operations teams to ensure system performance and reliability
• Document system changes, test results, and commissioning activities

Key Systems & Equipment

• Overhead bridge cranes, gantry cranes, and hoist systems
• HMI systems (Siemens WinCC or equivalent)
• Variable Frequency Drives (VFDs) and motor control systems
• Industrial communication protocols (PROFINET, PROFIBUS, Ethernet/IP as applicable)
• Safety devices including light curtains, safety relays, encoders, and limit switches
• Important Aspects of the Role

Functional Safety

• Strong understanding of safety‑rated systems (SIL / Performance Level concepts)
• Experience implementing and validating failsafe logic in S7 F‑systems
• Ability to design and troubleshoot safety circuits for crane operations
• Understanding of coordinated motion between hoist, trolley, and bridge
• Experience with acceleration/deceleration tuning to minimize load swing
• Familiarity with positioning systems and encoder feedback
• Experience with crane‑to‑crane anti‑collision systems
• Implementation of travel limits, zoning, and restricted areas
• Integration of sensors for position and proximity detection
• Comfortable working in heavy industrial environments (manufacturing, steel, logistics, etc.)
• Ability to support long shifts during commissioning and startup phases
• Strong troubleshooting mindset under real‑time operational pressure

Qualifications

• 5+ years of experience in industrial controls or automation
• Hands‑on experience with Siemens S7 PLC programming (TIA Portal / Step 7)
• Experience with S7 F‑systems and Safety Advanced programming preferred
• Background in crane systems, material handling, or heavy industrial equipment strongly preferred
• Experience with HMI/SCADA development and integration
• Strong understanding of electrical systems, instrumentation, and control panels
• Ability to read and interpret electrical schematics and control drawings

Preferred Experience

• Commissioning of overhead or gantry crane systems
• Integration of crane systems into plant‑wide controls or MES systems
• Experience with multi‑crane coordination and safety zoning
• Familiarity with industry standards related to crane safety and operation
• Field‑based role with onsite commissioning and support activities
• Travel may be required depending on project location
• Work performed in industrial settings with adherence to site safety protocols

Additional Notes

• Candidates should be capable of working independently while collaborating with cross‑functional teams
• Strong communication skills are essential for coordinating with clients and internal teams
• Flexibility to support accelerated schedules during critical project phases