PLC Systems Integration Architect (CODESYS/ST)

Torrey Holistics; Berkeley (CA); On-site; USD 140,000 - 190,000; Full time

Job summary

Torrey Holistics in Berkeley, CA seeks a Senior PLC/Controls Engineer to refactor and modernize PLC-based control systems for high-volume manufacturing. You will move critical logic to product controllers, design robust PLC-to-controller communications, and ensure integration of updated test stands and instrumentation ahead of production units.

You will troubleshoot both software and hardware, collaborate across electrical, mechanical, systems, and manufacturing teams, and own the controls

Qualifications

• Senior-level PLC/controls engineering experience (Staff, Principal, or equivalent).
• Extensive hands-on PLC programming and modification experience.
• Expertise in Structured Text.
• Professional work in CODESYS or IEC 61131-3 environment, with ability to contribute in CODESYS.
• Proven ability to enter, understand, and independently modify an existing PLC codebase.
• Experience implementing communications between PLCs and external or product controllers.
• Deep understanding of PLC architecture, I/O, instrumentation, sensors, and control systems.
• Strong electrical troubleshooting across wiring, pinouts, control panels, sensors, and PLC I/O.
• Background in system integration, commissioning, or automated test equipment.
• Fluency troubleshooting across both PLC software and physical hardware.
• Self-directed decision-maker with excellent cross-functional communication.

Responsibilities

• Develop, modify, debug, and sustain PLC applications using CODESYS and ST.
• Understand existing controls architecture with minimal direction.
• Decide what logic remains on PLC vs migrates to product controllers.
• Design PLC-to-product-controller communications and related logic.
• Integrate product controllers into current and upgraded test stands.
• Troubleshoot PLC logic, I/O, instrumentation, sensors, wiring, and panel issues.
• Verify instrumentation connections, signal scaling, and output accuracy.
• Provide hands-on electrical troubleshooting during integration and commissioning.
• Commission updated test stands and validate functionality ahead of production units.
• Act as controls SME across integration, commissioning, and production readiness.

Skills

CODESYS

Structured Text

PLC programming

Electrical troubleshooting

Systems integration

Cross-functional communication

Tools

Beckhoff

Allen-Bradley

Siemens

Job description

PLC Systems Integration Architect (CODESYS/ST)

A day in this role

You start by reviewing the latest test-stand updates: sensors are wired, I/O is mapped, and instrumentation is ready for validation. Before lunch, you dive into an existing CODESYS Structured Text codebase, tracing control logic to decide what stays on the PLC and what must transition to the product controller. In the afternoon, you stand up robust PLC-to-controller communications, scale signals correctly, and commission a station so it is production-ready. Along the way, you partner with electrical, mechanical, systems, and manufacturing colleagues to resolve integration issues quickly and decisively.

Why this matters now

We are scaling toward a 225-unit build rate while modernizing test-stand infrastructure and the controls architecture. The PLC system is functional, but too much logic lives in the PLC today. Your mission is to refactor that footprint, move targeted functionality into product controllers, and ensure bulletproof communications between the PLC and those controllers. This is not a ground-up build; you will step into working code and make it better, faster, and production-hardened.

What you will own

• Develop, modify, debug, and sustain PLC applications using CODESYS and Structured Text (ST).
• Rapidly understand an existing controls architecture and codebase with minimal direction.
• Decide what logic remains on the PLC, what is removed, and what migrates to product controllers.
• Design and implement PLC-to-product-controller communications and related control logic.
• Integrate product controllers into current and upgraded automated test stands.
• Preserve proven behaviors while refactoring or removing legacy logic.
• Troubleshoot PLC logic, I/O, instrumentation, sensors, wiring, pinouts, and control-panel issues.
• Verify that instrumentation is properly connected and that signals read, scale, and output correctly.
• Provide hands-on electrical troubleshooting during integration and commissioning.
• Commission updated test stands and validate functionality ahead of production units.
• Act as the controls SME across integration, commissioning, and production readiness.
• Identify root causes quickly and implement durable fixes independently.
• Improve controls architecture, test-system reliability, and throughput.
• Document code changes, system updates, troubleshooting steps, and commissioning results.

Technical environment

CODESYSStructured Text (ST)PLC programming and controls architecturePLC-to-product-controller communicationProduct controllersIndustrial I/OSensors and instrumentationControl panels and electrical systemsAutomated test standsSystem integration and commissioningHigh-volume manufacturing equipment

Required qualifications

• Senior-level PLC/controls engineering experience (Staff, Principal, or equivalent).
• Extensive hands-on PLC programming and modification experience.
• Expertise in Structured Text.
• Professional work in CODESYS or a comparable IEC 61131-3 environment, with the ability to contribute directly in CODESYS.
• Proven ability to enter, understand, and independently modify an existing PLC codebase.
• Experience implementing communications between PLCs and external or product controllers.
• Deep understanding of PLC architecture, I/O, instrumentation, sensors, and control systems.
• Strong electrical troubleshooting across wiring, pinouts, control panels, sensors, and PLC I/O.
• Background in system integration, commissioning, or automated test equipment.
• Fluency troubleshooting across both PLC software and physical hardware.
• Self-directed decision-maker with excellent cross-functional communication.

Preferred qualifications

• Rockwell/Allen-Bradley, Siemens, or other industrial PLC platforms.
• Industrial communication protocols.
• Integrating embedded or product controllers with PLC-based systems.
• Modifying established PLC architectures (vs exclusively greenfield builds).
• Automated test stands, laboratory equipment, or production test systems.
• High-volume manufacturing support.
• Ability to read and interpret electrical schematics.
• Instrumentation scaling, signal validation, and I/O commissioning.

Screening prompts (be ready to discuss)

• CODESYS and ST depth: hands-on scope, percent of work in ST, and examples.
• Experience inheriting and improving an existing PLC codebase with minimal guidance.
• Shifting functionality from PLC to a separate or embedded controller: approach and lessons.
• Designing PLC-to-external-controller communications: platforms and protocols you used.
• Automated test-stand responsibilities and commissioning achievements.
• Debugging mis-wired or mis-scaled sensors and verifying proper PLC communications.
• Examples of troubleshooting both PLC code and the physical electrical system.
• Operating as a controls SME, driving issues to closure in production environments.

Broader proficiencies

PLC Troubleshooting SkillsElectrical SchematicsSingle and Three Phase Power120/208/240/480 Voltage SystemsIndustrial Robot ProgrammingDesign for Assembly (DFA)PLC Programming ExperienceSCADA ExperienceElectrical / Electronic SystemsHigh Voltage SystemsEquipment Installation & WiringAccess Control SystemsAerospace ManufacturingMachines and technologies you will useVariable Frequency Drives (VFD)CAD Software (Solid Edge, Siemens NX, Catia, Pro-E / Creo, NX CAD (Siemens), Solidworks, Onshape, Autodesk Inventor, AutoCAD)Programmable Logic Controller (PLC) (Beckoff, Allen Bradley, Fanuc, Schneider Electric, Mitsubishi, Modicon, Omron, B&R Industrial Automation, Siemens, Panasonic, Sigmatek)Vision SystemServo MotorsIndustrial Robot

How we define success

Success looks like taking ownership immediately, transitioning selected PLC functionality to product controllers, implementing reliable PLC-to-controller communications, integrating upgraded test stands, and validating instrumentation and electrical systems ahead of production units. With a 225-unit build rate in sight, your work directly boosts test capacity, production readiness, and manufacturing reliability.