Senior PLC Controls Engineer – Test & Integration Lead

Mach10 Solutions; Berkeley (CA); On-site; USD 120,000 - 160,000; Full time

Job summary

Mach10 Solutions seeks a Staff/Principal PLC Controls Engineer to lead PLC software development, integration, and commissioning for high-volume test stands in a production environment.

You will migrate logic to product controllers, implement robust PLC-to-controller communication, and validate instrumentation and I/O across legacy and upgraded platforms. The role requires autonomy and strong cross-functional collaboration.

Qualifications

• Extensive experience in a Staff/Principal level PLC/Controls engineering role.
• Proven hands-on development and modification of complex PLC programs.
• Advanced Structured Text programming.
• Experience with CODESYS or IEC 61131-3 environments and independent work.
• Experience modifying legacy PLC codebases.
• Architecting communication interfaces between PLCs and external product controllers.
• Strong understanding of PLC architecture including I/O, sensors, and control systems.
• Electrical troubleshooting: wiring, pinouts, control panels, I/O.
• Experience with system integration, commissioning, or automated test equipment projects.
• Autonomy and decisive technical decision-making.
• Cross-functional collaboration.

Responsibilities

• Create and maintain PLC software with CODESYS/ST.
• Analyze control architectures with minimal supervision.
• Migrate PLC logic to product controllers where appropriate.
• Establish PLC-to-product-controller communication pathways.
• Integrate product controllers into legacy and upgraded test stands.
• Adjust PLC operations while preserving system reliability.
• Diagnose issues in PLC logic, I/O, instrumentation, wiring, and panels.
• Validate instrumentation interfacing with PLC for accurate signal scaling.
• Provide electrical support for system integration and commissioning.
• Lead test-stand commissioning to ensure production readiness.
• Collaborate across electrical, mechanical, and systems teams.
• Serve as the controls authority during integration and production readiness.
• Identify bottlenecks and implement long-term solutions.
• Enhance controls architecture to improve reliability and throughput.
• Document all PLC modifications and commissioning results.

Skills

Senior PLC/Controls

Structured Text

CODESYS IEC61131-3

PLC debugging

PLC-to-controller comms

Electrical troubleshooting

Autonomy

Cross-functional collaboration

Tools

Beckhoff

Allen-Bradley

Siemens

Solid Edge

Siemens NX

CATIA

Creo

SolidWorks

AutoCAD

Job description

Mach10 Solutions seeks a Staff/Principal PLC Controls Engineer to lead PLC software development, integration, and commissioning for high-volume test stands in a production environment.

You will migrate logic to product controllers, implement robust PLC-to-controller communication, and validate instrumentation and I/O across legacy and upgraded platforms. The role requires autonomy and strong cross-functional collaboration.