Foundry & Die Casting Machine Electronics Repair
Induction furnace inverters, die casting machine controllers, IGBT modules, PLCs, and robot drive repair for India's foundry and die casting industry — from Bühler DAK controllers and Inductotherm VIP power supplies to Siemens SINAMICS drives and ABB robot controllers.
A failed inverter or controller in a foundry halts melting, casting, and finishing — costing lakhs per hour in lost production. Synchronics repairs induction furnace inverters, die casting controllers, IGBT modules, PLCs, and robot drives at the component level — getting your melt and casting lines back to full capacity.
Foundries and die casting plants rely on high-power electronics operating in extreme conditions — induction furnace inverters handling megawatts of power, die casting machine controllers coordinating precise shot profiles, IGBT modules switching at high frequency under thermal stress, and PLCs orchestrating automated moulding lines. Synchronics has 32+ years of experience repairing electronics across the entire foundry and die casting workflow, from Inductotherm and ABP induction furnace power supplies to Bühler and Toshiba die casting controllers, Siemens SINAMICS drives, and ABB robot controllers. We serve all major foundry clusters including Rajkot, Ahmedabad, Pune, Coimbatore, Kolhapur, Belgaum, Ludhiana, Jalandhar, Howrah, and Bengaluru.
Diagnosis Guide
Common Foundry & Die Casting Machine Electronics Problems We Fix
Experiencing any of these symptoms? Our engineers have diagnosed and repaired thousands of these faults.
Induction Furnace Inverter Failure
Furnace trips on overcurrent, no melting power, inverter alarm, reduced power output
IGBT module degradation from thermal cycling, DC bus capacitor ageing, gate driver optocoupler failure, cooling system blockage
Die Casting Controller Fault
Machine in error state, shot cycle interrupted, inconsistent shot parameters, HMI blank
Controller board failure from vibration, hydraulic oil contamination, power surge, communication bus fault
IGBT Module Short Circuit
Inverter trips immediately on start, fuse blown, earth fault alarm, reduced furnace capacity
Thermal fatigue from repeated melt cycles, gate driver timing drift, insufficient cooling, voltage transients from mains
PLC / Moulding Line Stoppage
Automated moulding line halted, PLC in stop mode, I/O fault, safety circuit tripped
Sand dust ingress, vibration-induced connector failure, analog input card drift, power supply degradation
Shot Monitoring System Error
No real-time shot data, pressure/velocity readings invalid, quality rejection rate increase
Sensor interface board failure, ADC drift from temperature extremes, cable damage from heat radiation, connector corrosion
Robot Controller / Drive Trip
Robot stopped mid-cycle, servo fault alarm, teach pendant communication error, axis following error
Servo amplifier IGBT failure, encoder feedback cable damage from heat, capacitor ageing in DC bus, fan failure
How It Works
Our Foundry & Die Casting Electronics Repair Process
A systematic, schematic-driven repair process — from receipt to dispatch.
Heavy-Duty Intake & Inspection
Foundry electronics arrive with metal dust, slag residue, and heat damage. Each board is cleaned, photographed, and logged in our ERP with full fault history from the operator.
Thermal Damage Assessment
PCBs inspected for heat-related degradation — discoloured solder joints, cracked traces, delamination, and burnt components common in furnace and die casting environments.
OEM-Referenced Diagnosis
Fault diagnosis using OEM schematics and test procedures. Inverter boards tested with simulated load. Controllers verified against original operating parameters.
Component-Level Repair
Failed IGBTs, capacitors, gate drivers, and ICs replaced with genuine or OEM-equivalent parts. High-temperature solder used for boards returning to furnace environments.
Power & Load Testing
Inverter boards tested under simulated load conditions. Controller boards verified with full I/O simulation. Extended burn-in at elevated temperature confirms thermal reliability.
Documentation & Dispatch
6-month warranty certificate, detailed service report with root-cause analysis, and repair photographs provided. Boards returned in ESD-safe, heat-resistant packaging.
Thorough Inspection
What We Inspect in Every Foundry & Die Casting Board
Every unit goes through a comprehensive inspection checklist before and after repair.
Induction Furnace Inverter
Die Casting Controller
IGBT / Thyristor Module
PLC & Motion Controller
Shot Monitoring Electronics
Power Supply & Environment
The Synchronics Advantage
Why Choose Us for Foundry & Die Casting Machine Electronics Repair
Multi-OEM Foundry Expertise
We repair electronics across all major foundry and die casting OEMs — Bühler, Toshiba/Shibaura, Inductotherm, ABP Induction, Siemens, and ABB — giving foundries and die casters a single-source repair partner for every machine on the shop floor.
High-Power Inverter Specialists
Induction furnace inverters demand expertise in high-power IGBT modules, DC bus capacitors, and gate driver circuits operating at extreme power levels. Our engineers have repaired thousands of inverter boards across Inductotherm, ABP, and other furnace OEMs.
Foundry Belt Logistics
Courier pickup and rapid return from all major foundry and die casting clusters — Rajkot, Ahmedabad, Pune, Coimbatore, Kolhapur, Belgaum, Ludhiana, Jalandhar, Howrah, and Bengaluru. 48-hour standard turnaround after receipt at our Vadodara facility.
Troubleshooting
Common Foundry & Die Casting Electronics Faults We Resolve
Seeing one of these error codes? We diagnose and repair the root cause.
Inverter overcurrent or IGBT short-circuit detected in induction furnace
IGBT module failure from thermal fatigue, gate driver timing drift, DC bus voltage transient, cooling blockage
Die casting machine controller error, DAK or TOSJACS fault
Controller board failure, EEPROM corruption, hydraulic valve feedback error, communication bus fault
DC bus overvoltage or undervoltage alarm on inverter or drive
Capacitor bank degradation, precharge circuit failure, mains voltage fluctuation, braking resistor fault
PLC in stop mode or I/O module fault on moulding line
I/O card failure from sand dust ingress, power supply degradation, safety circuit trip, analog input drift
Robot servo drive fault or axis following error during casting extraction
Servo amplifier IGBT failure, encoder cable damage from radiant heat, DC bus capacitor ageing, motor brake fault
Melt temperature or furnace monitoring sensor failure alarm
Thermocouple interface board failure, cold junction compensation drift, ADC reference error, connector heat damage
Foundry and die casting electronics faults are often linked to extreme heat exposure, metal dust contamination, and high-power thermal cycling. Contact us with your board model, fault description, and operating environment for expert assessment.
Industries Served
Where Foundry & Die Casting Machine Electronicss Are Used
Ferrous Foundries
Induction furnace inverters, melt monitoring boards, moulding line PLCs, pouring system controllers
Non-Ferrous (Aluminium/Zinc)
Holding furnace controllers, degassing unit electronics, die casting machine controllers, trim press drives
High-Pressure Die Casting
Bühler/Toshiba machine controllers, shot monitoring electronics, spray robot drives, extraction robot controllers
Low-Pressure Die Casting
Pressurisation system controllers, tilt-pour controllers, mould temperature regulators, cooling circuit electronics
Investment Casting
Wax injection machine controllers, autoclave control boards, shell drying line PLCs, vacuum furnace inverters
Sand Casting (Automated)
Automated moulding line PLCs, sand mixer controllers, shakeout vibrator drives, core shooter electronics
Trusted Brands
Brands We Service
Component-level repair for all major manufacturers
FAQ
Frequently Asked Questions
Yes. We repair Inductotherm VIP power supply boards, IGBT inverter modules, melt monitoring electronics, and control interface boards, as well as ABP Induction medium-frequency inverter boards, furnace power supply IGBT modules, and cooling system controller boards. Our high-power testing rig simulates actual furnace load conditions during verification.
Yes. We repair Bühler Carat and Evolution series DAK controller boards, real-time shot monitoring electronics, and hydraulic servo valve driver boards, as well as Toshiba/Shibaura DC series TOSJACS controllers and servo pump drives. All repaired boards are tested with full I/O simulation before dispatch.
Foundry boards receive a thorough cleaning on intake to remove metal dust, slag particles, and heat-related deposits. We assess thermal damage including cracked traces, delaminated layers, and heat-discoloured solder joints. High-temperature solder is used for joints on boards returning to furnace-side locations, and our service report includes root-cause analysis.
Standard turnaround is 48 hours for most inverter and controller boards after receipt at our Vadodara facility. IGBT module replacements with matched devices are included in this timeline. For critical furnace-down situations, we offer emergency priority service with expedited diagnosis and repair.
Yes. We have established logistics networks covering all major foundry and die casting clusters in India — Rajkot, Ahmedabad, Pune, Coimbatore, Kolhapur, Belgaum, Ludhiana, Jalandhar, Howrah, and Bengaluru. We offer courier pickup and rapid return service to minimise your production downtime.
Foundry & Die Casting Electronics Repair Across India
Synchronics is India's trusted partner for industrial electronics repair in the foundry and die casting sector. Our 32+ years of experience covers every critical system — induction furnace inverters (Inductotherm VIP, ABP medium-frequency), die casting machine controllers (Bühler DAK, Toshiba TOSJACS), IGBT and thyristor power modules, PLCs and motion controllers (Siemens S7-1500, SIMOTION), drives (Siemens SINAMICS, ABB ACS880), and robot controllers (ABB IRB, DCS 800 DC drives) used in finishing and extraction.
We serve all major foundry and die casting clusters in India: Gujarat (Rajkot, Ahmedabad, Vadodara), Maharashtra (Pune, Kolhapur), Karnataka (Belgaum, Bengaluru), Tamil Nadu (Coimbatore), Punjab (Ludhiana, Jalandhar), and West Bengal (Howrah). Every repaired board carries a 6-month warranty, a detailed service report with root-cause analysis, and is returned in ESD-safe packaging designed to protect against transit damage.
Get Your Equipment
Back in Action — Fast
Send us your faulty industrial electronics. Our engineers will diagnose it and provide a detailed quote within 24 hours — with no obligation to proceed.
Free Evaluation
No obligation
48hr Turnaround
Fastest in India
6-Month Warranty
Every repair
No Fix, No Charge
Zero risk policy
Pan-India Pickup
Doorstep service