Thousands of roll forming machines worldwide are still running on electrical panels that are 10, 20, or even 30 years old. While the mechanical tooling may still produce good profiles, the electrical systems often become dangerous, unstable, and impossible to troubleshoot.

A complete rewire restores:

• Safety

• Accuracy

• Reliability

• Production speed

• Compliance

• Value of the machine

This guide explains when a rewire is needed, the benefits, the complete step-by-step process, and why Machine Matcher’s rewiring specialists deliver the highest standard of electrical restoration.

1. When a Rewire Is Needed

A full rewire is recommended when any of the following conditions exist:

✔ Electrical panel is over 10–15 years old

Components degrade, insulation cracks, and terminals loosen.

✔ Machine experiences frequent electrical faults

Especially intermittent problems.

✔ Machine was imported with the wrong voltage/frequency

(60 Hz machine running in a 50 Hz region, or vice versa)

✔ Machine still uses obsolete or unsupported PLC/VFD hardware

✔ Panel has been modified repeatedly by different electricians

Creating unsafe or undocumented wiring.

✔ Machine requires increased speed, precision, or automation

New drives and sensors need modern wiring.

✔ Safety compliance requirements have changed

OSHA, CE, and UKCA standards require updated circuits and safety relays.

2. Key Signs Your Roll Forming Machine Needs Rewiring

Electrical issues always show early warning signs. If you see any of the following, a rewire is overdue:

1. Overheating Electrical Panel

Causes include:

• Loose terminals

• Undersized wiring

• Blocked ventilation

• Failing VFD or contactor

2. Burning or “hot metal” smell

Often indicates:

• Short circuits

• Melting insulation

• Overloaded cables

• Failing relays

3. Unstable or inconsistent machine behavior

Examples:

• Random stops

• Sensor flickering

• Wrong cut lengths

• Motor won’t start

• Machine restarts unexpectedly

4. High electrical noise

Symptoms:

• PLC resets

• Encoder pulse loss

• VFD instability

5. Visible wiring damage

• Brittleness

• Cracked insulation

• Exposed copper

• Charring

6. Corrosion or moisture inside panel

Especially in coastal or humid regions.

7. Outdated parts no longer available

Obsolete PLCs and drives cannot be repaired.

3. Benefits of a Full Machine Rewire

Rewiring isn’t just “repairing old cables” — it transforms an unreliable machine into a modern, safe, high-performance system.

1. Massive Improvement in Reliability

Stable wiring eliminates:

• Random sensor faults

• Flickering inputs

• VFD resets

• Voltage drops

2. Increased Production Accuracy

New wiring ensures:

• Accurate encoder pulses

• Fast, stable sensors

• Reliable cut/punch timing

3. Safety Compliance Upgrades

Rewire includes:

• New safety relay

• Dual-channel E-stop

• Guard interlocks

• STO (Safe Torque Off) where applicable

4. Higher Machine Speed

Modern VFDs, servos, and wiring support faster forming speeds without losing stability.

5. Lower Fire & Shock Risk

Replacing degraded insulation and overheated components eliminates major hazards.

6. Easier Future Maintenance

New wiring comes with:

• Cable labels

• Documentation

• Updated diagrams

• Logical structure

Technicians can diagnose faults quickly — reducing downtime.

7. Increased Machine Value

A fully rewired machine is worth 30–60% more on the used market.

4. Step-by-Step Rewire Process (Machine Matcher Standard)

Below is the exact process our technicians use globally.

Step 1 — Full Electrical Assessment

We test:

• Voltage levels

• Panel temperature

• Insulation resistance

• Load currents

• Wiring condition

• Grounding

• Sensor/encoder performance

• VFD/servo status

Step 2 — Strip Out Old Wiring

We safely remove:

• Old cables

• Obsolete relays

• Burnt connectors

• Dangerous modifications

• Unsupported PLCs/VFDs

Step 3 — Install New Control Devices

We typically upgrade to:

• Siemens / Delta / Mitsubishi PLC

• Modern HMI

• New VFDs

• New power supplies

• New safety relays

• New terminals

• New fuses and circuit breakers

Step 4 — Install New Panel Wiring

All wiring is:

• Labelled

• Routed cleanly

• Secured against vibration

• Heat-rated

• Shielded where required

• Installed according to UL/CE/UKCA wiring practices

Step 5 — Install New Sensors & Encoder Wiring

We check and replace:

• Proximity sensors

• Photoelectric sensors

• Encoder cables

• Limit switches

• Guard interlocks

Stable sensors = stable production.

Step 6 — Rebuild Safety System

We upgrade:

• E-stop circuit (dual channel)

• Guard locking switches

• Emergency rope pull (for long lines)

• STO circuits for drives

Step 7 — Reprogram PLC Logic

Includes:

• New auto/stop sequence

• Cut length algorithm

• Punch timing

• Flying saw sync

• Error handling

• Safety logic

Step 8 — Before/After Electrical Test

Before Rewire — Typical Problems Found:

• High panel temperature

• Voltage drop of 2–5V on control circuits

• Unstable encoder signals

• VFD torque fluctuation

• Sensor chatter

• Irregular PLC scan cycles

After Rewire — Verified Improvements:

• Zero electrical noise

• Stable 24V control supply

• Perfect encoder pulses

• Balanced motor loads

• Zero flicker on PLC inputs

• Faster, safer cut/punch cycles

We provide a full Machine Matcher Electrical Test Report.

5. Compliance Upgrades (UL / CE / UKCA)

A rewire brings your machine up to modern safety and compliance requirements.

We upgrade:

• Cable rating

• Circuit protection

• Safety relay category

• Grounding and bonding

• Warning labels

• Electrical documentation

• STO compliance (where required)

Machine Matcher technicians ensure your machine meets the electrical safety requirements of your region.

6. Dangers of Outdated Wiring

Old wiring is one of the most dangerous parts of any factory.

❌ Fire risk from overheated cables

❌ Unexpected machine restarts

❌ Flying saw or shear malfunction

❌ Inaccurate cut length

❌ Sensor failure causing misfeeds

❌ Insulation breakdown leading to shocks

❌ VFD/PLC damage from surges

❌ Stopped production with no clear fault

These risks grow every year as insulation continues to degrade.

7. Why Machine Matcher’s Rewiring Specialists Are Required

Our technicians specialize only in roll forming and metal fabrication electrical systems — unlike general electricians.

Machine Matcher provides:

• Certified industrial electricians

• Global on-site service

• PLC + VFD experts

• Encoder & sensor calibration specialists

• Full wiring diagram creation

• 24/7 remote support

• Guaranteed workmanship

• OEM-independent solutions

We rewire machines from:

• The USA

• Europe

• Turkey

• India

• South Korea

• Taiwan

…and ensure they work flawlessly in your environment.

Machine Matcher CTA — Book a Full Machine Rewire & Electrical Test

For complete rewiring, diagnostics, upgrades, and certification:

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]