Principal PLC Controls Engineer Job Berkeley area,California USA,Engineering

Position: Staff / Principal PLC Controls Engineer

Staff / Principal PLC Controls Engineer – Test & Integration Role Overview

We are looking for a highly skilled Staff or Principal-level PLC Controls Engineer to manage PLC programming, system integration, and the commissioning of sophisticated test platforms within our high-volume production facility.

Context for the Position

Our organization is currently expanding to achieve a 225-unit build capacity, necessitating a comprehensive upgrade to our test-stand infrastructure and control systems. While our current PLC framework is operational, we are shifting specific control logic from the PLC to dedicated product controllers, which requires establishing robust communication interfaces between these systems. This is an optimization and integration initiative rather than a greenfield development project.

We need a seasoned expert to navigate the existing CODESYS and Structured Text environment, refine the logic, and implement necessary communication protocols independently. Additionally, you will play a key role in validating updated test stands—covering everything from instrumentation and signal scaling to I/O and control-panel integrity—to ensure full production readiness.

Your Responsibilities

Create, refine, and maintain PLC software utilizing CODESYS and Structured Text to ensure optimal system performance.
Analyze and interpret established control architectures with minimal supervision to drive project progress.
Determine which segments of existing PLC logic should be decommissioned, adjusted, or migrated to product controllers.
Establish seamless communication pathways between the PLC and product controllers to improve overall system efficiency.
Incorporate product controllers into both legacy and newly upgraded test-stand configurations.
Adjust proven PLC operations while maintaining the integrity and reliability of existing system performance.
Diagnose and resolve issues related to PLC logic, I/O, instrumentation, sensors, wiring, and control-panel hardware.
Validate that all instrumentation is correctly interfaced with the PLC to ensure accurate signal scaling and output.
Provide expert electrical support to help the team achieve successful system integration and commissioning.
Lead the commissioning of test stands to guarantee full operational readiness before production units arrive.
Collaborate across electrical, mechanical, and systems departments to foster a cohesive environment for resolving integration challenges.
Act as the primary technical authority for controls during the integration, commissioning, and production-readiness phases.
Rapidly identify technical bottlenecks and independently execute effective, long-term solutions.
Contribute to the enhancement of controls architecture to bolster test-system reliability and manufacturing throughput.
Maintain comprehensive documentation of all PLC modifications, system upgrades, and commissioning outcomes.

Technical Environment

CODESYS
Structured Text (ST)
PLC programming and controls architecture
PLC-to-product-controller communication
Product controllers
Industrial I/O
Sensors and instrumentation
Control panels and electrical systems
Automated test stands
System integration and commissioning
High-volume manufacturing equipment

Required Qualifications

Extensive experience in a Staff, Principal, or equivalent senior-level PLC/Controls engineering capacity.
Proven hands-on expertise in the development and modification of complex PLC programs.
Advanced proficiency in Structured Text programming.
Professional background using CODESYS or similar IEC 61131-3 environments with the capability to operate independently.
Demonstrated success in navigating and modifying legacy PLC codebases without significant oversight.
Experience architecting communication interfaces between PLCs and external product controllers.
Deep understanding of PLC architecture, including I/O, instrumentation, sensors, and control systems.
Strong electrical troubleshooting capabilities, specifically regarding wiring, pinouts, control panels, and PLC I/O.
Experience managing system integration, commissioning, or automated test equipment projects.
Ability to resolve complex technical issues spanning both PLC software and physical electrical hardware.
Capacity to work autonomously and make critical technical decisions with limited supervision.
Excellent interpersonal skills to facilitate effective cross-functional collaboration.

Preferred Qualifications

Experience with industrial PLC platforms such as Rockwell/Allen-Bradley or Siemens.
Familiarity with various industrial communication protocols.
Background in integrating embedded or product controllers into PLC-based systems.
Experience optimizing existing PLC architectures rather than building systems from scratch.
Experience with automated test stands, laboratory equipment, or production-grade test systems.
Experience supporting high-volume manufacturing environments.
Ability to read and interpret complex electrical schematics.
Experience with instrumentation scaling, signal…