Senior Controls and Automation Technician

Senior Controls and Automation Technician

Austin, Texas, United States

• Develop and refine PLC logic, HMI screens, alarms, interlocks, and automation sequences to improve safety, uptime, and usability.
• Create and maintain controls documentation: I/O lists, wiring and network diagrams, configuration baselines, commissioning checklists, and service/SOP procedures.
• Diagnose controls-related failures using logs, fault codes, instrumentation, and structured troubleshooting (power, I/O, comms, motion, safety).
• Integrate, test, and validate sensors, actuators, drives, VFDs/servos, pneumatics/hydraulics interfaces, and safety systems (E-stops, light curtains, safety relays, STO).
• Perform root cause analysis (RCA) and implement corrective actions; document findings and prevent recurrence.
• Follow configuration control and change management practices (ECO/ECN) for field updates and validated releases.
• Collaborate with mechanical, electrical, software, and field teams to standardize architectures and implement reliability improvements.
• Support operator/technician training and develop clear diagnostic guides and troubleshooting playbooks.
• Commission, troubleshoot, and support automated industrial equipment in factory and field environments.

• 4+ years supporting, troubleshooting, or commissioning industrial automation or electromechanical systems in production, field service, construction, robotics, or similar environments.
• Demonstrated hands-on controls troubleshooting across electrical systems: 24
  
  VDC controls, sensors, relays/contractors, VFDs/servos, encoders, and basic instrumentation.
• Experience with at least one PLC platform (or equivalent controls environment):
  Beckhoff/TwinCAT, Rockwell Studio 5000, Siemens TIA Portal, Codesys, or similar.
• Working knowledge of common industrial communications/networking (e.g., Ether Net/IP, Profinet, EtherCAT, Modbus TCP/RTU) and basic network troubleshooting.
• Ability to read and interpret electrical schematics and troubleshoot from drawings and update documentation with guidance.
• Willingness to work in dynamic, field-like environments and travel as needed for commissioning/support.
• Strong safety mindset and ability to follow structured troubleshooting and verification practices.

• Motion control experience (servo tuning, homing strategies, basic performance optimization).
• Functional safety familiarity (risk assessment concepts, safety circuits, ISO 13849 / IEC 61508 awareness).
• Experience with power quality issues, grounding/noise mitigation, generators, and field power distribution.
• Experience supporting hydraulic systems from a controls perspective (instrumentation, interlocks, HPU integration).
• Scripting or automation skills (Python, Bash) and familiarity with data logging/diagnostics.
• Experience with large-format robotics, gantry/CNC-like systems, or complex multi-subsystem industrial machines.
• Experience creating commissioning checklists, test procedures, and training materials for technicians/operators.