Components that stand out to us

In industrial electronics, there are hundreds of thousands of components in operation every day. Each plays a specific role in keeping machines, production lines, and processes running smoothly. Some components, however, stand out because of their reliability, their widespread use, and the technical attention they require over time. 

Below, we highlight five components that continue to make a significant impact in industrial environments, and explain why proper maintenance and refurbishment are essential to extend their lifespan.

The Siemens S7 200 CPU 224 is a compact and affordable PLC that has been widely used in machines performing relatively simple automation tasks . Although production ended several years ago and the unit is now in the phase out stage, it remains active in countless installations. 

Technically, the CPU 224 is robust. However, like many electronic devices, it contains components that are sensitive to ageing. The capacitors in the power supply section gradually degrade due to prolonged thermal and electrical stress. If not replaced in time, this degradation can cause internal damage that may render the entire PLC unusable. With timely overhaul and preventive capacitor replacement, this PLC can continue operating reliably for many years. Preventive refurbishment within ten years is strongly recommended, even if the device appears to function normally. 

Industrial PCs are often described as the brains of a machine, and the Sinumerik PCU 50 is a clear example of that role . Widely used in CNC machines and other industrial applications, this industrial PC remains popular despite being produced between 2000 and 2006. 

The most common issue in the PCU 50 lies in the motherboard, specifically in the ball grid array connections. Temperature fluctuations during operation cause expansion and contraction. Over time, the adhesive that secures the BGA loosens, resulting in connection loss between the chip and the board. When this happens, the device stops functioning.Professional refurbishment restores these connections, allowing the PC to return to reliable service. Maintaining stable operating conditions and temperature control helps extend the lifespan of this unit. 

Human machine interfaces are exposed to demanding factory conditions. The Siemens OP7 series is frequently installed on the exterior of machines, where it encounters impact, temperature changes, moisture, and contamination. 

Over time, common wear points include the membrane keypad, backlight, casing, and capacitors within the communication circuit. After approximately ten years, capacitor replacement becomes essential to prevent unexpected failures. The positive aspect is that OP7 units can often be restored to near new condition through professional refurbishment. Preventive refurbishment every ten years is advisable, particularly for units operating continuously or in harsh environments. 

The Lenze 9300 series consists of intelligent drives controlling motors in a wide range of machines. Produced between 2004 and 2019, many units are now reaching a stage where servicing becomes critical. 

These drives handle significant power loads, which places stress on internal components. Optocouplers are particularly vulnerable due to LED ageing and reduced phototransistor sensitivity after prolonged operation. Severe degradation can even create safety risks if not addressed in time. During refurbishment, high stress components are replaced, internal memory is renewed and reprogrammed, and cooling fans are swapped for new ones. Proper cooling and stable ambient temperature significantly extend the lifespan of the 9300 series. 

Precision is critical in weighing applications, whether measuring grams in food production or tonnes at a weighbridge. The Siwarex M weighing modules are designed for extremely accurate measurements and have remained in demand for many years. 

Because of their precision, these modules are sensitive to environmental conditions. Dust or moisture can influence readings. During refurbishment, the analogue to digital converter is replaced and the module is tested using a dedicated precision test system developed specifically for this device. Keeping the system clean and free from contamination is essential to ensure long term accuracy. 

What these five components have in common is longevity. All were produced over long periods and remain widely installed in industrial environments. They are reliable by design, but like all electronics, they are subject to ageing and wear. Refurbishment plays a crucial role in extending their service life. By replacing wear prone components, restoring electrical connections, renewing internal memory, and conducting dedicated testing, professional refurbishment ensures continued reliability without the need for complete system replacement. In an era where supply chain stability, cost control, and sustainability are increasingly important, extending the life of proven industrial components is both a technical and strategic advantage.