Controls Engineer

Job Description

Job Description

Job Title: Senior Controls Engineer

Job Description

This Senior Controls Engineer role focuses on designing and programming custom control systems for highly automated industrial machines. You will create PLC and HMI programs, commission equipment, and perform runoffs that meet customer requirements. The position involves translating customer specifications into robust electrical designs for machine controls and safety circuits, while collaborating closely with software controls technicians, mechanical engineering, and electrical teams to deliver reliable, high-performance automation solutions.

Responsibilities

• Design and program sophisticated industrial control systems from concept through startup, including front-to-back PLC and HMI development.
• Create, configure, and debug PLC and HMI programs to control highly automated machinery and ensure reliable performance.
• Simulate, test, and debug control systems in-house prior to deployment, ensuring they meet functional and safety requirements.
• Commission equipment and perform runoffs to verify that systems meet customer specifications and performance expectations.
• Design electrical controls, including hardware specification, panel layouts, and wiring diagrams, using tools such as AutoCAD.
• Develop and implement electrical and software interfaces for machine tools, robots, and automated loaders.
• Design and implement machine and automation safety circuits, including emergency stops, safety guarding, and related safety functions.
• Commission and tune frequency and servo drives, including servo and AC motors, to achieve required motion performance.
• Design and implement industrial communication and I/O networks using technologies such as Profibus DP, Profinet, Ethernet/IP, DeviceNet, and remote I/O.
• Support the software controls technicians, mechanical engineering, and electrical departments throughout the project lifecycle.
• Startup systems at end-user facilities, including on-site testing, troubleshooting, and optimization of control systems.
• Provide ongoing technical support for installed systems via phone or on-site visits, resolving issues and implementing improvements.
• Identify and define the best technical solutions and strategies to meet customer automation and motion control requirements.
• Participate in project proposals and technical discussions with sales engineers and customers, contributing to solution design and scope definition.
• Design and author control software to customer specifications so that hardware systems properly control motion control equipment and related automation.
• Program and support PLC systems using platforms such as Allen-Bradley RSLogix and Siemens S7.
• Program and support HMI systems using platforms such as FactoryTalk and Siemens WinCC flexible.
• Apply machine safety requirements and standards, including relevant ISO and industry guidelines, to control system designs.
• Work with machine vision systems, integrating vision solutions into automated equipment where required.
• Maintain clear documentation for control software, electrical designs, safety circuits, and network configurations.
• Use Microsoft Office and other productivity tools to prepare technical documentation, reports, and project communications.

Essential Skills

• Strong proficiency in PLC programming, including full lifecycle development (design, programming, troubleshooting, and debugging) with platforms such as Allen-Bradley RSLogix and Siemens S7.
• Proficiency in HMI programming, including experience with FactoryTalk and Siemens WinCC flexible or similar platforms.
• Demonstrated experience designing and programming custom control systems for highly automated machines.
• Hands-on experience with industrial electrical design, including control panels, wiring, and hardware specification.
• Ability to design and debug electrical and software interfaces for machine tools and robot or automated loaders.
• Experience designing and implementing machine and automation safety circuits, including emergency stops and safety guarding.
• Experience commissioning and tuning frequency drives and servo drives, including servo and AC motors.
• Ability to design and implement industrial communication and I/O networks such as Profibus DP, Profinet, Ethernet/IP, DeviceNet, and remote I/O.
• Proficiency with AutoCAD for creating and modifying electrical schematics and control drawings.
• Strong understanding of advanced software and machine control engineering principles.
• Experience with Allen-Bradley PLCs and HMIs and/or Siemens PLCs and HMIs.
• Experience with industrial networking and various communication protocols including Ethernet, DeviceNet, and remote I/O systems.
• Working knowledge of machine vision systems and their integration into automated equipment.
• Knowledge of machine safety requirements and the application of relevant ISO and industry standards.
• General knowledge of AC/DC power, motors, drives and motion control, industrial controls, pneumatic valves, and sensors.
• Knowledge of NEC and NFPA 79 requirements as they relate to industrial control systems.
• Knowledge of automation controls and risk assessments in an industrial environment.
• Strong oral and written communication skills to collaborate effectively with internal teams and customers.
• Ability to support projects from concept through startup, including on-site commissioning and technical support.

Additional Skills & Qualifications

• Bachelor’s degree in electrical engineering, computer science, or a related field; an Associate of Applied Science degree or equivalent experience is also considered.
• At least 5 years of industrial controls design and software experience.
• Proven industrial electrical design experience and troubleshooting skills in both electrical circuitry and PLC systems.
• Robot programming experience with Fanuc RJ series controls and ABB robots.
• Robotics experience with platforms such as ABB, Fanuc, or IAI.
• Experience with vision systems such as Cognex or Keyence.
• Experience applying machine safety requirements using ISO standards and related industry guidelines.
• Competency with Microsoft Office applications for documentation, reporting, and communication.
• Familiarity with commonly used concepts, practices, and procedures in machine control design.
• Experience with Siemens PLCs and HMIs in addition to Allen-Bradley platforms.
• Comfort working in a collaborative, cross-functional engineering environment with mechanical, electrical, and software teams.

Work Environment

You will work as part of a small, highly engaged engineering team that manages automation projects from initial concept through final startup. The environment offers exposure to the entire project lifecycle, including design, programming, testing, commissioning, and on-site support at customer facilities. Work is primarily performed in an office and shop setting using tools such as AutoCAD, PLC and HMI development software, and standard engineering productivity applications. Some travel, typically ranging from approximately 5% to 25% depending on project requirements, is expected for on-site startups, commissioning, and customer support.

This is a Contract to Hire position based out of Rochester, NY.

The pay range for this position is $40.00 - $50.00/hr.

Individual compensation offered for this position within this range will depend on many factors, including qualifications, skills, relevant experience, job knowledge, geographic location, internal equity, and other pertinent job-related factors.

Eligibility requirements apply to some benefits and may depend on your job classification and length of employment. Benefits are subject to change and may be subject to specific elections, plan, or program terms. If eligible, the benefits available for this temporary role may include the following: • Medical, dental & vision • Critical Illness, Accident, and Hospital • 401(k) Retirement Plan – Pre-tax and Roth post-tax contributions available • Life Insurance (Voluntary Life & AD&D for the employee and dependents) • Short and long-term disability • Health Spending Account (HSA) • Transportation benefits • Employee Assistance Program • Time Off/Leave (PTO, Vacation or Sick Leave)

This is a fully onsite position in Rochester,NY.

This position is anticipated to close on Aug 28, 2026.

About Actalent

Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 20,000 consultants and 5,000 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. We are proud to be an Engineering News-Record (ENR) Top 500 Design Firm for our engineering design services and a ClearlyRated Best of Staffing® winner for both client and talent service.

The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.

If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing process due to a disability, please email View email address on ziprecruiter.com for other accommodation options.

San Francisco Fair Chance Ordinance: Pursuant to the San Francisco Fair Chance Ordinance, for all positions located in the city and county of San Francisco, we will consider for employment qualified applicants with arrest and conviction records.

Massachusetts Lie Detector: It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability.

Use of Artificial Intelligence (AI): We may use Artificial Intelligence (AI) to support parts of our hiring process, including sourcing, screening, and evaluating candidates. AI helps assess applications and qualifications, but final decisions are made by our hiring team. By applying, you acknowledge and agree that your application may be reviewed using AI tools.