PLC Repair Service — Programmable Logic Controllers
Flexa Systems is a Lewisville, Texas industrial automation repair and parts company providing component-level PLC repair service for all major brands — Allen-Bradley ControlLogix, Siemens S7, Mitsubishi MELSEC, Omron, Schneider Modicon. CPU, I/O modules, communication cards, power supplies — program always preserved. Free diagnostic, 2-year warranty, 5–30 day turnaround. Refurbished and brand-new units are also available from stock. Nationwide mail-in industrial controller and programmable controller repair services — all 50 states.
PLC Brands We Repair & Stock
Select your PLC brand for model-specific repair information and pricing
Allen-Bradley PLCs
Full repair for the complete Allen-Bradley PLC family — including discontinued SLC 500 and PLC-5 systems with program preservation.
View ControlLogix RepairSIMATIC S7 Series
CPU, I/O, communication module repair for Siemens S7 and legacy S5 PLC systems.
View S7-1500 RepairMELSEC Series
CPU and I/O module repair for the complete Mitsubishi MELSEC PLC family.
View Mitsubishi RepairSysmac Series
Full component-level repair for Omron Sysmac PLCs including discontinued CS and CJ series.
View Omron RepairPACSystems & Series 90
CPU, I/O, and power supply repair for GE Fanuc PACSystems and legacy Series 90 PLCs.
View GE Fanuc RepairAll Other Brands
We repair all PLC brands. If it controls automation, we repair it. All brands and models accepted.
Get a QuoteWhy Repair Instead of Replace?
The numbers make the decision easy
Cost Savings
vs. new PLC + engineering cost
Day Turnaround
vs. 8–24 weeks for legacy models
Preserved
ladder logic backed up on every repair
PLCs Repaired
SLC 500, PLC-5, S5, Series 90
PLC repair at Flexa Systems costs 30–60% less than buying a new controller plus reprogramming, with a 5–30 day standard turnaround and 24–72 hour rush service. Every repair preserves your ladder logic and program, carries a 2-year parts and labor warranty, and includes a free diagnostic evaluation — you approve a firm written quote before any work begins.
How Much Does PLC Repair Cost?
Most PLC repairs cost $350–$1,500 depending on the module type and fault — typically 30–60% less than a new controller once you add engineering and reprogramming time. Every job starts with a free diagnostic evaluation and a firm written quote.
| Component | Typical Repair Cost | New Replacement + Engineering | Savings |
|---|---|---|---|
| Power supply module | $300 – $600 | $800 – $2,500 | 50–70% |
| I/O module | $350 – $700 | $600 – $3,000 | 40–75% |
| CPU module (program preserved) | $500 – $1,500 | $2,000 – $8,000 + reprogramming | 60–80% |
| Communication module | $400 – $900 | $900 – $3,500 | 50–70% |
| Legacy PLC (SLC 500, PLC-5, S5) | $500 – $1,800 | often unavailable — full migration $15,000+ | 90%+ |
Program & Data Recovery
A failed CPU doesn't have to mean a lost program. We recover ladder logic from flash memory and battery-backed RAM on Allen-Bradley SLC 500, PLC-5 and MicroLogix processors, and Siemens S5/S7 CPUs — even when the original programmer is long gone and no offline copy exists. Every repair starts with a full program backup before any component work begins, and ends with the program restored and verified on the bench.
Legacy Platforms We Support
Discontinued doesn't mean unrepairable. We routinely repair controllers the OEM abandoned years ago:
- Allen-Bradley PLC-5, SLC 500, MicroLogix 1000/1200/1500
- Siemens SIMATIC S5 (90U–155U) and early S7-300/400
- GE Fanuc Series 90-30 and 90-70
- Texas Instruments / Siemens TI505
- Omron C200H / C500 series
- Modicon 984 and Quantum
Repair vs. Replace — Side by Side
| Component-Level Repair | New Replacement | |
|---|---|---|
| Cost | 30–60% less than new | Full price + engineering time |
| Lead time | 5–30 business days (rush 24–72hr) | 6–24 weeks for many catalog numbers |
| Warranty | 2 years parts & labor | Typically 1 year OEM |
| Program & configuration | Preserved — plug back in and run | Reprogramming and commissioning required |
| Obsolete models | Fully supported | Often unavailable — forced migration |
How PLC Repair Works
Simple 4-step process — ship us the PLC, get it back repaired with a 2-year warranty
Free Diagnostic
Full control system analysis: CPU, I/O, power supply, communication modules. No charge, no obligation.
Written Quote
Detailed fault diagnosis report specifying what failed and what we'll replace. Approve before any work starts.
Circuit Board Repair
Our PLC technicians perform circuit board repair at component level. PLC program and ladder logic backed up and preserved before work begins.
Function Test
Comprehensive I/O simulation and control panel testing. Program restored and verified before shipping.
Nationwide PLC Repair — Based in Lewisville, TX
Located in the Dallas-Fort Worth metro, Flexa Systems repairs PLCs for customers across all 50 states via our mail-in program. Ship us your PLC, we repair it, ship it back. Local drop-off available for DFW customers.
PLC Products In Stock
Tested, refurbished PLC units available for immediate purchase or exchange. All units carry our 2-year warranty.
Ready to Get Your PLC Repaired?
Free diagnostic evaluation, no obligation. All brands and models accepted. Program always preserved. Rush service available.
PLC Repair — Frequently Asked Questions
Answers to the most common questions about our programmable logic controller repair service
What PLC brands do you repair?
We repair all major PLC brands including Allen-Bradley ControlLogix, CompactLogix, SLC 500, and PLC-5; Siemens S7 and S5; Mitsubishi MELSEC; Omron Sysmac; GE Fanuc PACSystems; Schneider Modicon; ABB AC500; Beckhoff; and all other brands.
Can you preserve my PLC program during repair?
Yes. We back up and preserve the PLC program — including ladder logic, function block diagrams, and configuration — before any repair work begins. Your program is restored and verified after repair.
Do you repair discontinued PLCs like the Allen-Bradley SLC 500?
Yes. We specialize in repairing discontinued and legacy PLCs including Allen-Bradley SLC 500, PLC-5, MicroLogix, Siemens S5, and GE Fanuc Series 90. Repair is often the only option when replacement units are unavailable.
How long does PLC repair take?
Standard PLC repair turnaround at Flexa Systems is 5–30 days. Rush service with 24–72 hour turnaround is available for critical production equipment.
Where can I find PLC repair near Dallas or Lewisville TX?
Flexa Systems provides PLC repair in Lewisville, TX — part of the Dallas-Fort Worth metro. DFW and Dallas-area customers can drop off equipment directly. Nationwide mail-in also available with free return shipping on completed repairs.
How does fast PLC repair minimize production downtime?
We begin free diagnostic evaluation within 24–48 hours of receiving your PLC. Rush 24–72hr repair is available for production-critical situations. We preserve your existing program so no reprogramming is needed — getting your original PLC back is faster and cheaper than sourcing a replacement and reconfiguring it from scratch.
Do you perform firmware updates or PLC reprogramming as part of the repair?
Yes. We can update firmware as part of the repair when a firmware issue is identified, or when the customer requests it. Your existing ladder logic, function block diagrams, and configuration are preserved and verified after any firmware update.