Senior Controls Support Engineer

Operio Group • Lower Moreland Township, PA

2d • $120,000 - $135,000 • Onsite

About The Position

We are seeking a highly experienced Senior Controls Support Engineer to join our headquarters team. This role is designed for a seasoned automation professional—ideally a former Field Service Engineer or Systems Integrator—who is looking to transition away from heavy travel into a stable, high-impact technical support role.
In this position, you will serve as the primary technical anchor for our installed base of machinery. You will take ownership of high-level troubleshooting, legacy system obsolescence, and remote support, acting as a critical bridge between our R&D design team and field operations. You will rely on your ability to reverse-engineer solutions, troubleshoot complex electrical/software issues, and mentor junior staff.
This is a Full-Time position, on-site at our Huntingdon Valley, PA location.
Travel time: Less than 15%

Requirements

• 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.
• 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.
• 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.

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.

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.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level