Senior Controls Support Engineer

Duties and Responsibilities

• 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.
• 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.

About Operio Group

Launched in 2022 from the seeds of LFA Machines and Vivion Inc, Operio was conceived from the simple idea that our customers don't need a machine or an ingredient, they need to make a product. With the addition of CCS Index Stokes, Elizabeth Tooling and Elizabeth Tablet Presses, and Scheu & Kniss, we are combining over 100 years of experience and expertise in machinery and ingredients to provide our customers with the excellent support and quality they need to fulfill their goals. We do this thanks to our team, that keeps our core values at the center of every process, every interaction, and every goal.

Department

Engineering

Locations

Huntingdon Valley, PA

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.