Modern roll forming machines rely heavily on electrical systems — PLCs, encoders, VFDs, sensors, safety circuits, and interlocks — to produce accurate roofing panels, purlins, decking, flashings, and structural components.

When any of these electrical systems fail, the machine will:

• Stop driving material

• Produce incorrect lengths

• Refuse to cut

• Lose synchronization

• Trip motors or VFDs

• Create costly downtime

Below are the 12 most common electrical problems in roll forming factories worldwide — and exactly how to diagnose and fix them. Each section includes:

✔ Causes
✔ Symptoms
✔ Fix
✔ How Machine Matcher technicians handle it

1. Faulty Encoders

Causes

• Broken or loose encoder coupling

• Damaged encoder cable

• Electrical noise

• Oil/dust contamination

• Encoder disk wear

• Incorrect alignment

Symptoms

• Wrong cut length

• Flying saw misalignment

• Punching in the wrong place

• VFD speed not matching motor speed

• PLC showing unstable pulses

Fix

• Clean encoder

• Realign coupling

• Replace cable

• Add shielding

• Replace encoder if pulses drop out

How Machine Matcher Handles It

We perform encoder signal quality tests, replace defective components, recalibrate scaling, and verify synchronization with VFD/servo systems.

2. Incorrect VFD Parameter Settings

Causes

• Parameter resets

• Wrong motor data

• Incorrect torque or accel/decel values

• Faulty V/Hz curve

• Overly aggressive current limits

Symptoms

• Machine won’t drive under load

• Wrong line speed

• Overcurrent trips

• Slow or unstable motor

Fix

• Re-enter motor nameplate data

• Tune torque boost and accel ramps

• Fix scaling issues

• Save parameters to EEPROM

Machine Matcher Approach

Full VFD audit, parameter backup, and torque tuning to restore perfect motor performance.

3. Sensor Delays Causing Miscuts

Causes

• Dirty lenses

• Incorrect alignment

• Loose brackets

• Bad 24V power supply

• Electrical noise

Symptoms

• Cuts too early / too late

• Missed cuts

• Random stops

• Jittering or flickering sensor inputs

Fix

• Clean/replace sensor

• Tighten and realign

• Upgrade to noise-resistant models

• Stabilize 24V supply

Technician Method

We test sensor switching time in PLC monitor mode, align sensors, and replace unstable units.

4. Loose Terminals

Causes

• Vibration

• Heat cycles

• Poor installation

• Ageing wiring

Symptoms

• Random machine stops

• Intermittent sensor or motor faults

• Overheating connectors

• Burning smell in cabinet

Fix

• Tighten every terminal

• Replace burnt connectors

• Add vibration-resistant ferrules

Machine Matcher Practice

Full panel tightening + thermal imaging to detect hotspots.

5. Overloaded Motors

Causes

• Roll tooling too tight

• Excessive material thickness

• Jammed forming pass

• Incorrect VFD torque limits

• Failing bearings

Symptoms

• Motor running hot

• VFD current spikes

• Motor stalls under load

• Slow production speed

Fix

• Loosen roll gaps

• Tune VFD torque boost

• Replace bearings

• Improve lubrication

Technician Approach

Measure motor current under load, identify mechanical resistance, correct torque settings.

6. Damaged Control Wiring

Causes

• Metal shaving contamination

• Pinched cables

• Ageing insulation

• Heat damage near drives

Symptoms

• PLC losing inputs

• Intermittent cut/punch

• Unstable encoder signals

• Short circuits or blown fuses

Fix

• Replace wiring

• Install proper cable routing

• Add conduit or cable trays

How We Handle It

We trace wiring faults, perform continuity testing, and rebuild damaged sections for long-term reliability.

7. Grounding Issues

Causes

• Poor machine grounding

• Multiple ground points

• Loose earth connection

• High harmonic environment

Symptoms

• Electrical noise

• PLC resets

• Encoder dropping pulses

• VFD instability

• Sensor flicker

Fix

• Install single-point grounding

• Replace loose or corroded grounding straps

• Add harmonic filters

Machine Matcher Action

We test earth resistance, correct grounding architecture, and eliminate noise sources.

8. Emergency Stop Faults

Causes

• Worn E-stop buttons

• Loose safety relay terminals

• Faulty guard switches

• Bypassed safety circuits

• Dual-channel mismatch

Symptoms

• Machine won’t start

• E-stop fault on HMI

• Machine restarts unexpectedly (dangerous)

Fix

• Replace faulty E-stop devices

• Test safety relay

• Realign guard switches

• Rebuild wiring

Technician Process

Full E-stop compliance audit + stop-time measurement.

9. PLC Input/Output Failures

Causes

• Faulty input cards

• Overloaded outputs

• Water/oil ingress

• Electrical noise

• Damaged backplane

Symptoms

• Random machine stops

• Punch/shear not activating

• Sensor readings missing

• PLC I/O error messages

Fix

• Replace I/O cards

• Rewire to clean terminals

• Improve cabinet ventilation

Machine Matcher Method

We use PLC diagnostics, scan cycles, and oscilloscope readings to identify faulty I/O channels.

10. Hydraulic Solenoid Wiring Faults

Causes

• Broken wires at solenoid coils

• Loose connectors

• Bad cable shielding

• Low coil voltage

• Wrong polarity (on DC systems)

Symptoms

• Punch not firing

• Shear not cutting

• Slow cylinder response

• Valve chattering or buzzing

Fix

• Replace coil wiring

• Tighten connectors

• Replace solenoid if burnt

• Ensure 24V DC stability

Technician Process

We test coil current draw, inspect wiring, and verify PLC output logic to each valve.

11. Cable Wear and Tear

Causes

• Drag chains

• Chain lubrication overspray

• Heat from VFDs

• Sharp tray edges

• Mechanical vibration

Symptoms

• Flickering sensors

• Intermittent motor faults

• Encoder pulse loss

• Safety devices failing sporadically

Fix

• Replace worn cables

• Re-route away from heat and moving parts

• Install proper cable tracks

How We Handle It

We inspect entire cable harness paths, replace damaged runs, and upgrade cable protection.

12. Power Supply Mismatch (50Hz vs 60Hz)

Causes

• Imported machines not converted

• Wrong transformer tap

• Incorrect VFD frequency settings

• Underpowered supply

Symptoms

• Overheating motors

• Incorrect line speed

• VFD tripping

• Slow punching or cutting

• Servo errors

Fix

• Adjust VFD base frequency

• Reconfigure PLC logic

• Install correct transformer

• Replace incompatible motors

Technician Approach

We verify every device’s rated frequency, correct settings, and ensure matched power distribution.

Conclusion

Electrical problems are the leading cause of downtime in roll forming factories — but with the right diagnostics, maintenance, and preventive practices, nearly all of them are fixable before they cause production stoppages.

Machine Matcher provides certified electrical technicians worldwide to diagnose, repair, and optimize every electrical system in roll forming equipment.

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.

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Phone: +44 20 335 56554

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Phone: +1 407 559 7948

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Email: [email protected]