‘Ghost Machines’ and Rogue Components: A Repair Security Wake-Up Call
A recent investigation reported by Reuters uncovered a serious security risk that should concern anyone involved in the operation and maintenance of critical electronics and infrastructure security. Several Chinese-manufactured solar inverters, used globally to manage and convert renewable energy sources, contained undocumented communication devices. These “ghost machines” can allow unauthorised remote access to a device, posing an alarming cybersecurity risk. While the headline has largely focused on energy infrastructure and national security, there’s another side to this story, one that directly impacts the future of secure electronics repair. These revelations underscore the pressing need for repair professionals, technicians, and facility managers to take repair security seriously. If you don’t know exactly what’s inside your electronics before and after repair, you could be compromising entire systems.
According to this article published by Reuters, U.S energy researchers discovered undocumented cellular radios inside these inverters, components not listed in the documentation, not disclosed by the manufacturer, and not verified by integrators. These rogue modules weren’t just sitting harmlessly; they had the potential to “phone home,” enabling someone outside of the organisation to monitor, control, or disrupt the device. But it’s not just about solar power. Inverter-style controllers are widely used in manufacturing, energy, transportation, and beyond. If one category of electronics can include unknown components, so can others. This creates a new category of threat, malicious or unintended vulnerabilities introduced at the hardware level. And here’s the difficult truth: most third-party repair operations are not equipped to detect this. Traditional repair methods focus on functionality, not forensic security.
This is where forward-thinking electronics professionals need to pivot. Bringing diagnostics and repair in-house isn’t just a matter of cost, it’s about control, traceability, and trust. One of the most powerful tools available for this shift is the BoardMaster from ABI Electronics. Rather than outsourcing critical diagnostics to unverified third parties, This diagnostic tool allows organisations to test, diagnose, and repair PCBs internally. It doesn’t require full circuit diagrams to be effective, making it especially useful in situations where original documentation is missing or incomplete, exactly the kind of scenario where hidden components could slip by unnoticed.
Additionally, when third-party or OEM repairs are required, the BoardMaster’s Advanced Matrix Scanner and Multiple Instrument Station modules allow for precise forensic analysis beyond functionality testing. The software allows for automatic circuit board data capture and comparison before and after a repair. This comparison doesn’t just confirm that the board is working, it verifies that it hasn’t been altered in ways that introduce risk. A discrepancy in the automatic data analysis can indicate the addition of a new, potentially unauthorised component, or a behaviour change that warrants further inspection. By using signature comparisons, facilities can effectively “fingerprint” their equipment and maintain verified custody over their electronics. If the post-repair board doesn’t match its original state, it doesn’t go back into service but instead goes for further scrutiny.
The solar inverter case is a warning signal, not an isolated incident. With increasing global reliance on electronic infrastructure, repair professionals must ask: Who do you trust to handle your electronics? And how do you verify that trust? Regulatory bodies are beginning to pay attention, but until systemic change comes, organisations must take ownership of their own hardware security. By operating their own circuit board repair solutions, companies can dramatically reduce their reliance on opaque third-party services and increase the reliability and integrity of their own systems.
In sectors like defence, energy, healthcare, and manufacturing, the cost of an unnoticed rogue component could be catastrophic. We have recently seen how tampered walkie-talkies became deadly weapons through the interception of a foreign state. Ensuring that repair doesn’t become a way to infiltrate security risks is the next frontier when advocating for the right to repair. Tools, like ABI’s BoardMaster, don’t just make repair easier, they make it safer, more transparent, and future-proof. As we move forward in a world where electronics underpin everything from our power grids to our public safety systems, it’s clear that secure repair isn’t optional, it’s mission-critical!
