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PLC & Control System Repair

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Home > Repair > PLC Repair Service

A malfunctioning PLC (Programmable Logic Controller) or control system disrupts your entire production line. At ROC Industrial, we have a deep understanding of industrial control systems, and we know how critical your PLC is. We specialize in PLC and control system repair services for all major manufacturers, including Allen-Bradley, Siemens, Schneider Electric, ABB and GE Fanuc (now Emmerson). Our expert repair team proudly offers a reliable, cost-effective alternative to replacement for customers across the entire United States. Please give us a call or fill out our repair form to see how easy our process is!

ISO 9001:2015 Certified Quality

Our certified process ensures consistent quality and reliable repairs every time.

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2-Year Repair Warranty

We stand behind our repairs with an extensive 2-year warranty on parts and labor for your peace of mind.

Fast Turnaround Time

Our efficient process and large parts inventory help minimize your operational downtime.

Expert Component-Level Repair

We find and replace individual failed components, offering a more affordable and effective repair than full replacement.

Free, No-Obligation Quote

Send us your item for a free evaluation and receive a detailed repair quote with no commitment required.

What is a PLC and Why is it Important?

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A PLC, or Programmable Logic Controller, is a specialized industrial computer used to automate processes. It's the "brain" of many automated systems, controlling everything from simple machines to complex manufacturing lines. PLCs receive input signals from sensors, switches, and other devices, process the information based on a programmed set of instructions (the "logic"), and then send output signals to control actuators, motors, valves, and other equipment.

Top PLC Manufacturers We Repair

We service PLCs and related control system components from all major brands. Below is a list of some common brands we repair:

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Common PLC & Control System Problems We Solve

PLC Repair Process:

  • The repair process for every PLC begins with a careful visual inspection to identify any obvious physical damage, corrosion, or component issues upon arrival. The PLC (including CPU, power supply, and any relevant modules sent) is then thoroughly cleaned to remove dust and contaminants.

  • Our technicians utilize specialized diagnostic equipment, including PLC test racks, programming software (like Studio 5000, TIA Portal, GX Works), multimeters, and oscilloscopes. We meticulously test the power supply module for correct output voltages, the CPU for processing errors and memory integrity, all I/O modules for proper input signal detection and output switching (testing relays, optoisolators, transistors), and communication ports for reliable data transfer. Common failure components like capacitors and relays are thoroughly checked.

  • Identified faulty components are replaced by our skilled technicians using high-quality parts and professional soldering methods. We also proactively address components known to be potential failure points based on the specific PLC model.

  • Following repair, the PLC system is rigorously tested. We load test programs, cycle inputs and outputs, verify communication protocols, and check battery backup functionality to ensure the entire system operates according to specifications. The unit is then final cleaned, reassembled, and prepared for secure shipment back to you, covered by our comprehensive warranty.

A properly functioning PLC is vital for:

  • Automation: Automating repetitive tasks, reducing human intervention.

  • Flexibility: Easily reprogrammed to adapt to changing process requirements.

  • Reliability: Designed for harsh industrial environments.

  • Safety: Implementing safety interlocks and emergency stop functions.

  • Efficiency: Optimizing processes for maximum productivity.

Key Functions of a PLC

Sequential Control

Executing a series of operations in a predefined order.

Logic Operations

Making decisions based on logical conditions (AND, OR, NOT).

Communication

Communicating with other devices, such as HMIs, SCADA systems, and other PLCs (using protocols like Ethernet/IP, Modbus, Profibus, Profinet, etc.).

Timing and Counting

Performing tasks based on time intervals or the number of events.

Data Handling

Processing and manipulating data from sensors and other sources.

Process Control

PID loops

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Get Your PLC Repaired Quickly!

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Contact ROC Industrial for a free quote on expert PLC and control system repair services.

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