PLC Programmer Specialist

Salary: $100,000 – $150,000 per year

About the role

We are seeking a hands-on PLC programmer and controls expert to program, commission, fault-find and improve fully automatic and semi-automatic parking systems.

This is a national role based in Port Melbourne but will include international projects.

The need is for a highly accomplished programmer who can connect to a PLC, navigate an unfamiliar program, understand how the machine operates and identify exactly why a movement or sequence has stopped. You must be able to distinguish between a software fault, missing input, electrical problem, safety interlock, drive issue, communications failure and mechanical or hydraulic fault.

This is not a design-only, documentation-only or project-management position. The successful applicant must demonstrate hands-on, practical machine-control programming and fault-finding ability—not simple familiarity with PLC terminology or experience resetting faults from an HMI. The role covers existing installations, new commissioning, control-system upgrades and the development of new PLC and HMI software.

Key responsibilities

• PLC programming and machine-sequence development: Develop, modify and troubleshoot PLC programs using Siemens TIA Portal and Beckhoff TwinCAT. Write and maintain ladder logic, Structured Text and Siemens SCL, including function blocks, equipment state machines, interlocks, timers, alarm handling and diagnostic functions.

• Develop new programs from functional specifications, as well as understand and improve existing third-party programs through authorised access. Create clear, maintainable software for parking, retrieval, platform movement, equipment positioning and fault recovery.

• PLC-based fault finding: Trace faults through the complete control chain and identify the active sequence state, the condition preventing progression and the origin of that condition. Use cross-references, online monitoring, watch tables, diagnostic buffers, traces and event history to establish the cause before changing software or replacing components.

• Electrical, drive, hydraulic and mechanical diagnosis: Read electrical schematics and trace control circuits, including supplies, fuses, relays, contactors, sensors, limit switches, solenoids and drive interfaces. Diagnose motor and VFD faults, encoder and referencing problems, position-feedback discrepancies, communications failures and equipment that does not respond to a valid command.

• For semi-automatic systems, investigate the relationship between PLC outputs, hydraulic pumps, valve commands, cylinders, mechanical locks and position feedback. Work with the mechanical and electrical service teams to identify the actual cause and verify the repair.

• Safety, recovery and commissioning: Understand the separation between normal PLC commands, safety permissions, safe torque off and actual machine movement. Diagnose emergency-stop circuits, door interlocks, safety scanners, light curtains and safety-controller faults without bypassing protective functions.

• Commission and test normal operation, rejected or interrupted sequences, missing feedback, communication loss and restart after power interruption. Develop controlled recovery procedures that re-establish the machine's actual condition before automatic operation resumes.

• HMI, communications and diagnostics: Develop and improve HMIs so technicians can identify the current machine state, missing permissives, equipment faults and required recovery actions. Troubleshoot EtherCAT, PROFINET and controller-to-controller communications.

• Provide on-site and authorised remote support to Carcram technicians. Explain findings clearly, develop repeatable troubleshooting procedures and assist with technical training.

• Maintain controlled PLC/HMI backups, software revisions, I/O schedules, electrical drawings, parameter records and commissioning reports. Identify obsolete controls and develop suitable upgrade or retrofit proposals.

About you

• Proven hands-on PLC programming: Siemens S7 using TIA Portal and Beckhoff using TwinCAT.

• Practical machine-logic diagnosis: Ability to navigate an unfamiliar program, locate the correct function-block instance, identify the current state and trace a missing permissive back to its source.

• Strong ladder logic and Structured Text/SCL skills, including state machines, function blocks, interlocks, communications handshakes, alarms and recovery logic.

• Industrial electrical and motion-control knowledge: Ability to interpret schematics and investigate field I/O, sensors, relays, contactors, VFDs, encoders and positioning systems.

• Safe, evidence-based working methods: Ability to preserve fault information, distinguish symptoms from causes, control software changes and validate the machine before returning it to service.

• Relevant electrical, controls, automation or mechatronics qualifications are expected, supported by practical experience.

• Current driver's licence, willingness to travel interstate and availability for agreed commissioning or breakdown-support requirements.

• Experience with automated parking, car stackers, automated warehousing, storage and retrieval systems, AGVs, conveyors, lifts, pallet-handling equipment or other coordinated machinery is highly regarded.