Electrical faults are one of the most common causes of downtime in roll forming production. When a machine loses motor power, starts misreading encoder values, or suffers a panel wiring failure, production can stop instantly — costing thousands per hour.

Machine Matcher provides fast, professional, OEM-independent electrical repair services for all brands of roll forming equipment. From minor cable repairs to full panel rewiring, our technicians diagnose problems quickly and restore your line to safe, accurate operation.

Below is a complete overview of the electrical repair services we provide.

1. Motor Replacement (Main Drive, Hydraulic, Decoiler & Conveyor Motors)

A failed motor can shut down an entire line. Common causes include:

Phase imbalance
Overheating
Bearing failure
Undersized cables
Voltage spikes
Incorrect overload settings

Our Motor Replacement Service Includes:

Motor testing & diagnosis
Removing old motor safely
Installing new motor
Shaft alignment & coupling checks
Setting overloads & motor breakers
Testing rotation, torque, and current draw
Updating panel labelling & documentation

We handle AC induction motors, servo motors, hydraulic pump motors, brake motors, and VFD-driven units.

2. Encoder, Sensor & VFD Replacement

Electrical accuracy depends on clean signals from sensors and encoders. When these fail, production becomes inaccurate or stops entirely.

We replace:

Rotary encoders (incremental & absolute)
Proximity sensors
Photoelectric sensors
Pneumatic sensors
VFD (Variable Frequency Drive) units
Servo drives
Safety sensors and interlocks

Our service includes:

Diagnosis of root cause
Wiring verification
Parameter setup for new VFDs
Encoder calibration
Sensor alignment
Testing with live production
Documentation update

We ensure the machine returns to accurate and safe operation.

3. Rewiring Sections of the Deep Panel

Old machines frequently suffer from:

Brittle insulation
Burnt wires
Loose terminals
Overloaded breakers
Poor-quality cables
DIY modifications

Our rewiring service includes:

Removing damaged or unsafe wiring
Installing new industrial-grade cables
Re-terminating and ferruling all ends
Replacing DIN rail components as required
Tidying the panel for easier maintenance
Updating all circuit labels
Providing post-repair electrical drawings

This instantly improves reliability and safety.

4. Cable Repairs (Electrical & Encoder Cables)

Damaged cables can cause:

Random stops
Incorrect length cutting
Misalignment
VFD trips
Intermittent faults

We repair & replace:

Motor power cables
Encoder cables (shielded)
PLC signal cables
Sensor cables
Hydraulic unit wiring
Decoiler control cables
Communication cables (CAN, Modbus, Ethernet, Profibus)

We also ensure correct shielding & grounding to eliminate noise issues.

5. PLC Card Replacement (I/O Modules, CPUs, Communication Cards)

When PLC modules fail, the machine will experience:

Dead sensor inputs
Solenoid valves not firing
Random alarms
No machine movement
Incorrect punching sequence

Our service includes:

Identifying faulty PLC module
Installing replacement card (any brand)
Reconfiguring the system
Restoring or backing up machine programs
Testing each input/output point
Full diagnostic report

We support Siemens, Delta, Omron, Mitsubishi, Allen-Bradley, Fuji, Schneider, Weintek, and more.

6. Control Panel Rewiring & Component Replacement

Many imported machines come with:

Weak wiring
Cheap breakers
Incorrect grounding
Missing labels
Unsafe E-stop circuits

Our technicians can completely restore electrical reliability.

Control Panel Repairs Include:

Replacing breakers, relays & contactors
Installing new terminal blocks
Rewiring 24V circuits
Strengthening grounding & bonding
Replacing safety relays
Cleaning, reorganizing, and relabeling panel
Installing surge protectors
Updating wiring schematics

This creates a safe, compliant, and serviceable electrical system.

7. Emergency On-Site Electrical Repair

When your roll forming line fails, every hour of downtime costs money. Machine Matcher offers:

Rapid On-Site Support

UK, USA, Middle East & global coverage
24/7 callout availability
Same-day or next-day visits in many regions

What You Receive:

Full inspection report
List of root causes
Repair actions completed
Recommendations to prevent recurrence

Your machine returns to production quickly and safely.

Why Use Machine Matcher for Electrical Repairs?

✔ Specialists in roll forming machines only
✔ Fast diagnosis — minimal downtime
✔ Works with all brands, models & PLC types
✔ OEM-independent (we fix anything)
✔ Transparent pricing & documentation
✔ Highly skilled technicians around the world
✔ 24/7 remote support team
✔ Emergency site visits

Machine Matcher now offers full electrical technician services for roll forming machines — including diagnostics, rewiring, testing, encoder calibration, PLC programming, electrical audits, and preventive maintenance.
We support all machine types and all global regions.
Contact us today for immediate technical assistance or to schedule a full electrical inspection at your factory.

Looking for the right roll forming machine or expert guidance on your next project? Machine Matcher is here to help. Our global team provides 24/7 technical support, expert advice, and guidance on machine selection, setup, and maintenance—ensuring your operations run smoothly from day one.

With team members based worldwide—including the UK, USA, Middle East, and beyond—we are equipped to assist buyers across the globe. Whether you’re sourcing a single machine or upgrading an entire production line, our experts are ready to provide tailored solutions and support every step of the way.

Get in touch now and let Machine Matcher help you find the perfect roll forming machine for your business.

United Kingdom (Main Office)
Phone: +44 20 335 56554

United States
Phone: +1 407 559 7948

Mobile / WhatsApp: +44 7816 972935

Email: [email protected]