We had a conversation recently with a plant manager who was in a tough spot. His critical Medium Voltage Variable Frequency Drive had failed catastrophically and he had no good alternatives. He’d gotten quotes for a new drive with at least 22 weeks lead time. When we told him we had a refurbished drive in stock that we could ship in five days, we could hear the skepticism in his voice. “Refurbished? You mean used? I don’t know. We need something reliable. We can’t have this thing failing again in six months.”
We get it. We hear this all the time. “Refurbished” sounds like a euphemism for “old and questionable.” It sounds like you’re settling for second-best because you can’t afford first-best. But after 35 years in this industry, we can tell you that’s not how it works—at least not when refurbishment is done right. Let us explain why some of the smartest facility managers and engineers we know are choosing refurbished medium voltage drives over new ones, even when budget isn’t the issue.
What “Refurbished” Actually Means:
There’s a huge difference between “refurbished by EMA” and “some used drive we pulled out of a facility and wiped the dust off.”
When we refurbish a medium voltage drive, here’s what actually happens:
Complete Inspection: All elements of that drive are tested. We’re not just looking at it—we’re testing it. Power cells, control boards, cooling fans, contactors, etc.
Component Replacement: Anything that’s worn, marginal, or at risk of failure gets replaced with new. This includes:
- All electrolytic capacitors (even if they test okay—if they’re over 5 years old, they’re getting replaced)
- This include board-level capacitors
- Any semiconductors that don’t test within specifications
Cleaning and Refurbishment:
- Heat sinks cleaned
- All connections cleaned and torqued to spec
- Contamination removed
- Enclosure cleaned and repainted if needed
- Damaged or worn mechanical parts replaced
Testing: This is the big one. Every refurbished drive goes through a full load test to make sure you’re getting a drive that operates as it should. That’s not “used.” That’s refurbished
The Math That Makes CFOs Smile
Let’s talk numbers, because this is where refurbished drives become really attractive. Note: These numbers are simply an example, there are many factors that determine the price of a new or refurbished drive: manufacturer, options, age, availability, etc.
Typical pricing comparison for a 2000 HP, 4160V drive:
New Drive:
- Equipment cost: $310,000
- Shipping: $8,000
- Installation and Startup: $55,000
- Lead time: 18-26 weeks
- Warranty: 1 year (with manufacturer exclusions)
- Total initial cost: $373,000
EMA Refurbished Drive:
- Equipment cost: $125,000
- Shipping: $8,000
- Installation and startup: $55,000
- Lead time: 1-2 weeks (or immediate if in stock)
- Warranty: 1 year comprehensive (backed by EMA, not the manufacturer)
- Total initial cost: $188,000
Savings: $185,000
But wait, it gets better. Let’s factor in the lead time impact.
If you’re down and waiting for that new drive:
- 20 weeks at $50,000/week in lost production = $1,000,000
- Emergency rental drive while waiting: $75,000
- Total downtime cost: $1,075,000
If you get the refurbished drive in stock:
- 1 week downtime for installation = $50,000
- No rental needed
- Total downtime cost: $50,000
Total project cost comparison:
New Drive Path: $373,000 + $1,075,000 = $1,448,000
Refurbished Drive Path: $188,000 + $50,000 = $238,000
Actual savings: $1,210,000
Now, I know not every situation is an emergency replacement. But even on planned installations, that cost savings is real money you can spend somewhere else.
The Lead Time Problem:
Post-COVID, supply chains got wrecked. They’ve improved somewhat, but lead times for new medium voltage drives are still brutal:
- Standard drives: 18-26 weeks
- Anything custom or high-power: 30-40 weeks
- Special features or certifications: Add another 8-12 weeks
We’ve seen quotes with 52-week lead times!
Meanwhile, your drive doesn’t care about supply chain issues. When it fails, it fails, and your production stops.
This is where refurbished drives become not just attractive, but essential. We maintain inventory of the most common drive types specifically for this reason:
- Siemens/Robicon Perfect Harmony (various sizes)
- Toshiba T300MV2
- TMEIC Dura-Bilt 5i
- ABB ACS2000
- And others
Lead time? Usually 1-2 weeks. Sometimes same-day if we have it in stock and ready to go.
The Reliability Question:
Okay, here’s what everyone really wants to know: “Is a refurbished drive as reliable as a new drive?”
The answer is yes—and sometimes it’s more reliable. Let me explain why.
Infant Mortality Is Real: In reliability engineering, there’s a concept called the “bathtub curve.” Equipment has three phases:
- Infant mortality period: High failure rate as manufacturing defects reveal themselves
- Useful life period: Low, stable failure rate
- Wear-out period: Increasing failures as components age
Many new drives are in phase 1. They haven’t proven themselves yet. Manufacturing defects, quality control issues, assembly problems—all of these show up early.
Refurbished drives are in phase 2. They’ve already survived the infant mortality period. Any early-life problems have already been found and fixed. The components most likely to fail with age (capacitors, fans, contactors) get replaced during refurbishment. So the drive isn’t just in phase 2 of the bathtub curve—it’s in phase 2 with fresh components.
Warranty:
This is where the “new is better” assumption really falls apart.
New Drive Manufacturer Warranty (Typical):
- Duration: 12-18 months
- What’s covered: Defects in materials and workmanship
- What’s NOT covered:
- Damage from “improper installation” (very broad definition)
- Damage from “environmental factors” (dust, heat, humidity)
- Damage from “improper maintenance”
- Damage from “power quality issues”
- Components that show “signs of overheating” (even if it’s a manufacturing defect)
- Labor for diagnosis or repair
- Consequential damages
We’ve seen manufacturers deny warranty claims because there was dust in the drive. Not excessive dust, Just… dust; in an industrial environment!
EMA Refurbished Drive Warranty:
- Duration: 12 months comprehensive
- What’s covered: Everything
- Backed by EMA, not a manufacturer
- No “gotcha” clauses about dust or installation
- We come fix it if there’s a problem, period
Why can we offer a better warranty? Because we control the quality. We know exactly what condition every component is in because we personally tested it. And we have the parts and expertise in-house to fix any issue that comes up.
When you call a manufacturer with a warranty claim, you’re dealing with call centers, bureaucracy, and fine print. When you call us, you’re talking to the people who refurbished your drive. We want it to work because our reputation depends on it.
Let’s Talk About YOUR Drive Needs
Whether you’re dealing with a failed drive emergency, planning future installations, or just want to understand your options, we should talk.
At EMA, we’ve been refurbishing medium voltage drives for over 15 years. We’ve refurbished medium voltage variable frequency drives of most major manufacturers and models. We know what fails, what lasts, and what makes the difference between a drive that runs for 20 years and one that gives you problems.
No One Anywhere Knows More About Medium Voltage Drives Than We Do.
We’re not pushing refurbished because it’s cheaper for us. We recommend refurbished when it’s the right solution for your situation. Sometimes that’s a refurbished drive. Sometimes it’s new. Sometimes it’s a hybrid approach.
What we can promise:
- Honest assessment of what makes sense for your application
- Proper refurbishment by people who’ve been doing this for decades
- Real inventory—when we say we have it in stock, we actually have it
- Comprehensive warranty backed by our reputation
- Support that doesn’t disappear after the sale
Whether you need:
- Emergency replacement of a failed drive
- Planned equipment for new or retrofit installations
- Assessment of whether refurbished makes sense for your application
- Parts and support for existing drives
- Someone to give you straight talk about your options
…we can help.
Give us a call at 770-448-4644, shoot us an email at info@emainc.net, or use the chat feature on our website.
Let’s figure out the smartest solution for your facility—whether that’s refurbished, new, or something in between.
Because at the end of the day, it’s not about new versus refurbished. It’s about getting reliable equipment that keeps your facility running without breaking the bank.