How to Buy Refurbished PLCs, HMIs, and VFDs Without Risking Downtime

In modern manufacturing, a single hour of unplanned downtime can cost $10,000 or more—and replacing an entire control system can quickly reach seven figures. As lead times stretch and budgets tighten, more facilities are turning to refurbished PLCs, HMIs, and VFDs to keep operations running.

When refurbished equipment is sourced from a qualified partner, it is not a shortcut—it’s a strategic advantage. Professionally refurbished automation components can deliver OEM-level performance, faster availability, and significant cost savings. The key is knowing how to separate truly refurbished equipment from high-risk used hardware.

1. Know the Difference Between “Refurbished” and “Used”

True refurbishment is a documented restoration process—not cosmetic cleanup or repackaging. Professionally refurbished automation hardware is returned to original performance standards and validated under operating conditions.

At Chief Automation, refurbishment means every unit is inspected, repaired to OEM specifications, and tested under load. Skilled technicians evaluate electrical, mechanical, and functional performance using certified test benches. Wear components such as capacitors, relays, and fuses are replaced as needed, firmware is updated to stable revisions, and devices are run under load to confirm thermal stability, response time, and accuracy.

Typical refurbished equipment includes:

Siemens TP700 Comfort Panels with calibrated touchscreens and verified backlight brightness
ABB ACS550 VFDs load-tested for torque accuracy and ramp performance
Mitsubishi MR-J2S servo amplifiers verified for encoder feedback and output stability

Every unit undergoes full I/O and communication testing—not just a power-on check—ensuring real-world readiness.

2. Demand Verifiable Testing Documentation

Reputable refurbishers provide proof, not promises. Before purchasing, request documentation that shows how and where the equipment was tested.

Professional validation should include:

Power integrity testing: Voltage regulation, startup current, and phase balance
I/O verification: Digital and analog input/output accuracy
Communication testing: EtherNet/IP, Modbus, PROFIBUS, and other network protocols
Environmental screening: Thermal and vibration testing to expose latent faults

At Chief, every refurbished PLC, HMI, and drive includes serial-numbered test reports and traceable inspection logs—supporting ISO compliance and maintenance audits.

3. Warranty Coverage Is a Reliability Signal

Warranty length and scope separate true refurbishment programs from resale operations. Chief backs most refurbished products with a full 12-month warranty, matching coverage offered on new surplus equipment.

This includes critical control and motion hardware such as:

Schneider Electric ATV320 drives validated for torque response and network reliability
Yaskawa GA800 VFDs re-certified for IGBT health and harmonic control
FANUC A06B servo amplifiers tested for encoder synchronization and braking performance

“As-is” or lightly tested components may appear cheaper upfront but often lead to repeat failures, emergency replacements, and higher total cost of ownership.

4. Confirm Firmware and System Compatibility Before Installation

Firmware mismatch is one of the most common causes of startup failures when replacing automation hardware. Incorrect revisions can trigger communication errors, lost configurations, or controller recognition issues.

Chief's technicians verify firmware compatibility across PLCs, HMIs, and drives before shipment. Whether installing a PanelView Plus HMI, or Siemens SINAMICS drive, firmware revisions are aligned to ensure immediate system integration.

When required, Chief can also recommend compatible firmware updates to eliminate commissioning delays.

5. Packaging Indicates Process Discipline

Professional refurbishment extends beyond testing to how equipment is prepared for delivery. Proper packaging protects sensitive electronics and reflects process discipline.

Every Chief-refurbished unit is:

Secured in ESD-safe materials with anti-static protection
Clearly labeled with part number, firmware version, and serial ID
Shipped in impact-resistant, moisture-protected packaging

Each item includes QC tags and tamper seals verifying final inspection, allowing maintenance teams to install and document parts with confidence.

6. Reduce Costs While Supporting Sustainability Goals

Refurbished automation hardware isn’t just economical—it’s environmentally responsible. Re-certifying PLCs, HMIs, and VFDs reduces electronic waste while extending the life of high-value industrial assets.

Many facilities implement a hybrid strategy: new surplus equipment for mission-critical spares and refurbished units for maintenance and secondary systems. This approach minimizes lead times, lowers capital spend, and improves overall maintenance ROI.

7. Why Manufacturers Partner With Industrial Automation Co.

Chief Automation has built a trusted, multi-brand refurbishment and sourcing program designed to support both legacy and modern automation systems. Our capabilities include:

In-house and partner lab testing across leading automation platforms
Certified technicians trained on Siemens, ABB, Mitsubishi, FANUC, Schneider, and Yaskawa systems
1-year warranty coverage with responsive technical support
Rapid global shipping, including discontinued and hard-to-find models

Final Thoughts — and Your Next Step

Refurbished PLCs, HMIs, and VFDs are not a compromise when they’re properly restored, tested, and warrantied. In many cases, they deliver OEM-level performance faster—and at up to half the cost of new equipment.

If you’re facing downtime risk, long lead times, or discontinued hardware, contact Chief Automation for a compatibility check or same-day availability review. Our team will help you source the right solution—without the wait or the risk.