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2 Year Warranty on ALL products

What to Know Before Buying Refurbished PLCs, HMIs, and VFDs

by Bryan Hellman



In industrial automation, downtime costs thousands per hour — and replacing entire control systems can cost millions. That’s why many facilities turn to refurbished automation parts as a smart, budget-conscious alternative. When sourced from the right partner, refurbished drives, PLCs, and HMIs deliver the same reliability and performance as new OEM equipment — often faster, and at a fraction of the cost.

But “refurbished” can mean very different things depending on who’s doing the work. Understanding what defines a professionally refurbished product versus a risky used one can protect both your uptime and your bottom line.

1. Define “Refurbished”

True refurbishment isn’t about cleaning or repackaging — it’s a controlled process of restoring equipment to original factory performance standards. At Industrial Automation Co., refurbished = inspected, repaired to OEM spec, and tested under operational load.

Every component goes through electrical, mechanical, and functional evaluation by skilled technicians using certified test benches. Capacitors, relays, fuses, and high-wear components are replaced as needed; firmware is updated to stable versions; and devices are run under load to verify thermal stability and I/O response. Common refurbished items include:

Each of these parts undergoes more than just basic power-on testing — IAC verifies analog inputs, digital I/O, and communication ports to ensure full functionality under real-world conditions.

2. Ask for Testing Documentation

Professional refurbishers provide proof. Before purchasing, request detailed test documentation that shows the component has been validated under load and in temperature-controlled environments. A credible partner should verify:

  • Power integrity: Voltage regulation, startup current draw, and phase balance.
  • I/O verification: Digital and analog input/output performance, ensuring no channel drift or loss.
  • Communication validation: Network interfaces (EtherNet/IP, Modbus, PROFIBUS, etc.) tested for reliable data exchange.
  • Environmental testing: Thermal cycling and vibration simulations to reveal hidden stress faults.

These reports not only prove quality but also support traceability for ISO or internal maintenance audits. When you buy from IAC, every refurbished drive or PLC is backed by serial-numbered test data and a traceable inspection log.

3. Warranty Confidence

Warranty coverage separates true refurbishers from secondhand resellers. IAC backs most refurbished items with a full 24-month warranty — the same duration we offer on new surplus equipment. This policy reflects our confidence in the restoration and testing process.

That includes critical motion and control hardware such as:

Cheaper, “as-is” listings from unauthorized sellers may look appealing, but they often skip component replacement or safety verification — leading to costly secondary failures. A documented warranty is your proof of both reliability and accountability.

4. Firmware & Compatibility

One of the most overlooked risks in buying automation hardware is firmware mismatch. Installing a PLC, HMI, or drive with the wrong firmware revision can cause communication errors, lost configuration files, or compatibility issues with existing controllers.

IAC technicians ensure firmware levels are compatible with your installed base. Whether it’s a PanelView Plus HMI, Allen-Bradley CompactLogix processor, or Siemens SINAMICS drive, we confirm controller and drive revisions align so your system recognizes the replacement immediately.

Need to synchronize PLC and HMI versions? IAC provides version verification and can recommend compatible firmware updates to prevent integration errors during commissioning.

5. Packaging & Presentation Matter

Professional refurbishment is as much about presentation as performance. Proper packaging signals attention to detail — and helps ensure the part arrives installation-ready. Every IAC-refurbished item is:

  • Packed in ESD-safe bags and anti-static foam to prevent electrostatic discharge damage.
  • Clearly labeled with part number, firmware version, and serial ID for traceability.
  • Protected in impact-resistant cartons with moisture barriers for long-term shelf storage.

Each item includes tamper seals and QC tags verifying inspection and final testing completion. This ensures your maintenance team can identify, install, and document refurbished assets confidently.

6. The Environmental and Economic Edge

Choosing refurbished parts isn’t just a financial decision — it’s a sustainable one. Every re-certified drive, PLC, or HMI keeps electronic waste out of landfills and extends the lifespan of valuable industrial hardware. By leveraging IAC’s refurb and surplus inventory, plants reduce both lead-time stress and environmental impact without compromising uptime.

Many facilities strategically combine refurbished and surplus stock to achieve optimal balance: new surplus parts for mission-critical backups, refurbished for routine maintenance and lower-risk areas. This hybrid strategy maximizes ROI across your maintenance budget.

7. Why Partner With IAC?

Industrial Automation Co. has spent years building one of the most trusted refurbishment and sourcing programs in the industry. Our process includes:

  • In-house and partner lab testing for multi-brand drives, PLCs, and HMIs.
  • Certified technicians trained on Allen-Bradley, Siemens, ABB, Mitsubishi, FANUC, Schneider, and Yaskawa systems.
  • Two-year warranty coverage and responsive technical support.
  • Rapid global shipping from stocked inventory — including discontinued models.

From the Allen-Bradley PowerFlex family to ABB ACS drives and Yaskawa servo systems, IAC helps manufacturers keep legacy equipment running strong while protecting budgets.

Final Thoughts

Refurbished automation equipment is not a compromise — it’s a smart, strategic advantage. With proper testing, documentation, and warranty coverage, refurbished PLCs, HMIs, and drives perform every bit as reliably as new OEM parts, often arriving faster and at half the cost.

For engineers and maintenance managers seeking dependable legacy replacements, IAC offers tested, warrantied, and ready-to-ship components to keep your plant running — without the wait or the risk.

Ask us for help with your project today

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