Most roll forming machines imported from China use a minimal breaker configuration. Everything is grouped onto too few circuits, often with one oversized MCB feeding the entire machine. This reduces cost for the manufacturer, but it creates major problems for the factory:

• One small fault shuts down the whole machine

• Troubleshooting is difficult

• Safety is reduced

• Motors run without proper protection

• Sensors and PLCs share noisy circuits

• Breakers fail prematurely

• Fault isolation becomes impossible

• Risk of fire or cable damage increases

A modern roll forming line should use segregated breakers that protect each subsystem independently and make fault-finding 10x faster.

Below is the proper configuration every roll forming machine should have.

1. Separate Breakers for Every Major Motor

Every major motor should have its own MCB or motor-protective breaker, never a shared one.

Motors that MUST have their own breaker:

• Main roll former drive motor / VFD

• Hydraulic power pack motor

• Decoiler motor (expansion motor or pinch-roll motor)

• Stacker motors

• Run-out conveyor motors

• Lube pump / coolant pump (if fitted)

Why it matters

• A single motor fault shouldn’t stop the entire machine

• Overloads should trip only the affected circuit

• Motor wiring is protected individually

• Maintenance becomes safer and easier

• Prevents a bad motor from destroying a VFD

Chinese OEMs often run 2–5 motors from one breaker — unacceptable for modern standards.

2. Use Motor-Protective Breakers or Breaker + Overload Relay

Proper motor protection requires:

Option A — Motor-Protective Breaker (MPB)

These provide:

• Overload protection

• Phase-loss protection

• Short-circuit protection

• Adjustable thermal settings

Option B — MCB + Overload Relay

A traditional approach, still acceptable:

• MCB handles short-circuit

• Overload relay protects against heating and current overload

Why this is required

• Motors last longer

• Trips happen before equipment damage

• VFDs and hydraulic systems remain safe

• Reduces panel overheating

Without proper motor protection, a jam or phase problem can burn the motor windings within seconds.

3. A Dedicated Breaker for the Control Power Supply

This is one of the most important upgrades you can make.

The 24VDC power supply or control transformer should have its own small MCB.

After the 24V supply, each device group must also have its own fuse or fused terminal:

Protected individually:

• PLC CPU + HMI

• PLC I/O modules

• Encoders

• Sensors (grouped by zone)

• Safety relays (if 24V)

Why this matters

• A short on a single sensor won’t kill the entire PLC

• Encoders stay stable

• Control voltage remains clean

• Better troubleshooting: one fuse blows = one fault found

• Prevents VFD noise from affecting the PLC

Many Chinese machines use one PLC fuse for everything — a major risk.

4. MCB for Panel Outlets / Service Sockets

If the cabinet includes a plug socket for engineers (110/120V or 230V):

• It MUST have its own breaker

• It MUST have its own RCD/GFCI

Why

• Protects maintenance engineers

• Prevents tripping the entire line if a tool short-circuits

• Required under UK, US, EU, AUS safety standards

This is one of the most overlooked panel components.

5. Breakers for Safety Circuits (Where Appropriate)

Your safety system may require dedicated low-current breakers for:

• E-stop safety relay supply

• Light curtains

• Safety scanners

• Guard interlocks

But important note:

Safety circuits must remain safety-rated.
This simply isolates them so the entire panel doesn't trip over a non-critical issue.

Benefits

• A minor sensor short doesn’t shut down the whole machine

• Safety circuits remain independent and reliable

• Troubleshooting becomes easier

Summary — The Correct Breaker Layout Every Roll Former Should Have

A proper panel must include:

If your machine does not have this configuration, it is not up to modern standards.

Machine Matcher CTA — Electrical Panel Upgrade & Breaker Segregation Service

Machine Matcher can upgrade any roll forming machine to proper, safe, modern panel standards:

• Breaker segregation

• Motor-protective breaker installation

• Control-power rewire

• Safety circuit upgrades

• 24VDC distribution redesign

• Full panel rewiring

• Short-circuit and fault-level compliance

• VFD/PLC protection

• Full electrical audit with report

Protect your machine. Protect your technicians. Protect your production.
Upgrade your breaker layout with Machine Matcher.

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]