Electrical Repairs for Roll Forming Machines — Fast, Accurate, and Fully Certified

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 We Fix On-Site:

• Motor failures

• VFD faults

• Encoder/sensor failures

• Safety circuit issues

• PLC faults

• Panel wiring problems

• Cable damage

• Hydraulic/electrical interlock issues

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]