Safety risks

  • Thorough product overhaul repairs

  • Washing & cleaning of each module before repair

  • Preventive exchange of all components subject to ageing or wear

  • Exchange of all components that are identified as weak points and thus constitute a safety risk for the machine and its operators

  • Exclusive use of new components authorised by the manufacturer or legislator

Safety risks – BVS Industrie-Elektronik

Proven quality instead of improvised risk

As a repair service provider for CNC, PLC and robot automation technology and electronics for renewable energies we are often asked to assess damage. During this process, we have repeatedly encountered improper repairs, which are often caused by the use of reproductions of safety-relevant components, such as power packs, transformers and relays. This often results in blatant safety risks that cannot even be counteracted with a repair. If these risks can be resolved then we will complete the repair for you. However, if the safety of the module cannot be restored by a repair and the risk of damage or injury due to previous interventions is too high, we will reject the repair as a matter of principle.

Exclusive use of new components authorised by the manufacturer or legislator during repairs and the use of more than 100 original test stands for all manufacturers ensure that BVS can guarantee the complete fault-free function of the module. By completing simulations under actual conditions and tests with a full load applied, it is also ensured that modules will withstand rigorous daily operation. 
Play it safe and appoint us as your reliable partner, to minimise the risk of another malfunction relating to the operating licence, health and safety and service life of the machine.

Examples of incorrect repairs from our photo library

You can't? No way!

The maintenance of this hand-held operating device was literally an "extraordinary" achievement. The proper functioning of the inner safety-relevant switching element is endangered by the broken housing!


Components are often glued in place instead of soldered. This approach is faster and cheaper. However, components attached in this way are not safe. A perfect connection cannot be guaranteed.

Art instead of quality

Every now and then, very simple solutions are found for very complex tasks. As nice as these solutions are, they are not permissible and pose a hazard to humans and the machine.


The housing, key foils and switching matrix have been perforated when fastening the screws. The intended function of individual keys can therefore no longer be guaranteed. The protection class is also no longer guaranteed.

Faulty insulation

Cables have been installed incorrectly, generating pressure points so that the cable isolation has subsequently worn through. The danger to humans and the machine increases and a failure is likely.

Loose connection

As the component has not been soldered correctly this will result in a loose connection. The component can then not be implemented reliably, the risk of consequential damage to other components increases uncontrollably and the safety of the machine operators is not guaranteed.

Uncleaned soldering points

Soldering points that have not been cleaned will damage the surface of the circuit board. Predictable production can thus no longer be guaranteed and the probability of consequential damage to other components and danger for machine operators increases.

Manual wiring

The following provides an example of a manually wired, non-original replacement part. If connections are not secured, contact will be lost. The machine is likely to fail.

Negligent bridging

Grossly negligent approach by bridging the faulty basic material.