Controls Engineer – PLC Automation
BlackStar Cary $70,000 - $85,000/year
Position Overview
We are seeking a Controls Engineer – Vehicle Wash Systems to support the design, programming, commissioning, and troubleshooting of automated vehicle wash equipment. This role blends PLC-based controls engineering with strong mechanical system understanding, including pumps, conveyors, spray assemblies, and drive mechanisms.
The ideal candidate is hands-on, technically versatile, and comfortable working across electrical, mechanical, and software systems in both office and field environments.
Key Responsibilities- Design, program, modify, and troubleshoot PLC and HMI systems for automated vehicle wash equipment
- Support system projects from engineering design through installation and commissioning
- Perform field troubleshooting and startup support, including occasional overnight travel to customer sites
- Diagnose system issues with a strong focus on mechanical root-cause analysis, as well as controls/electrical logic
- Create and update AutoCAD drawings, including mechanical layouts, schematics, wiring diagrams, and control documentation
- Interpret mechanical and electrical prints to ensure proper system integration and operation
- Collaborate with project managers to align designs with technical requirements, budget, and timelines
- Support continuous improvement initiatives focused on reliability, maintainability, and system performance
- Assist with BOM development, technical quotes, and equipment upgrade recommendations
- Provide technical input for sales engineering and jobsite evaluations when required
- 3–5+ years of experience in industrial automation, controls engineering, or electro-mechanical equipment environments
- Strong mechanical aptitude with hands-on troubleshooting of pumps, conveyors, spray systems, or similar equipment
- Proven experience with PLC programming and industrial controls troubleshooting
- Experience with HMI development, modification, and debugging
- Ability to read and interpret mechanical drawings, electrical schematics, and wiring diagrams
- Proficiency in AutoCAD (or similar CAD tools) for mechanical and electrical documentation
- Experience supporting equipment commissioning, field service, or on-site startup activities
- Strong analytical and problem-solving skills in complex systems
- Allen-Bradley, Siemens, or Mitsubishi PLC platforms
- OEM machinery, material handling, packaging, manufacturing automation, or fluid handling systems
- Vehicle wash systems or similar wash/rinse automation equipment
- Experience working across engineering, service, and field operations teams
- Full-time, on-site role based in Cary, Illinois
- Candidates ideally located within commuting distance of Cary, IL, or the surrounding Northwest Chicago suburbs
- Occasional travel required for customer site support and system startups
- Hands-on role involving both office engineering work and field service support
Travel: ~20% (occasional overnight field support, approx. once per month)
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