When buying a new roll forming machine — whether from a local manufacturer or an overseas supplier — the electrical system is the most important part of the build. A machine can have perfect rollers, strong frames, and good hydraulics, but if the electrical panel is poorly designed, you will experience:

• Random machine stops

• Unsafe operation

• VFD trips

• Incorrect cut lengths

• Electrical noise

• Sensor failures

• Overheating

• Difficult maintenance

• Compliance issues (CE, UL, UKCA)

The problem? Many suppliers provide the bare minimum electrical configuration unless you specify exactly what you require.

This blog gives you a practical, ready-to-send checklist that tells your electrician or supplier exactly what your roll forming line must include.

You can literally copy and paste it into your order email.

Why This Matters

Factories lose thousands each year due to machines that are shipped with:

• Under-rated breakers

• Cheap sensors

• Weak control power supplies

• Incorrect grounding

• No surge protection

• Unprotected motors

• Unsafe E-stop circuits

• Missing documentation

By telling your supplier what you want up front, you ensure:

✓ Safer operation
✓ Longer machine life
✓ Faster troubleshooting
✓ Better performance
✓ Lower scrap rate
✓ Full electrical compliance

What to Send to Your Electrician / Supplier

Below is the exact message you can send:

Copy & Paste This Into Your Email:

“For this new roll forming line we want:
• Lockable main disconnect with door interlock
• Main MCCB sized to site fault level
• Type 2 surge protector on incoming supply
• Phase-loss / phase-sequence relay
• Individual MCBs or motor-protective breakers for each motor and the hydraulic unit
• Separate breaker feeding 24VDC control supply with fused outputs for PLC, I/O, sensors, encoders
• RCD/GFCI for panel service outlets
• Category 3/4 E-stop circuit with safety relay
• Safety interlocks on main guards and cabinet door
• Proper earth bar and full bonding of frame, guards, motors, and panel door
• Panel drawings updated to match final wiring”

Breakdown of Each Requirement (And Why It’s Critical)

Below is the explanation behind each requirement — useful for educating factory owners, operators, and suppliers.

1. Lockable Main Disconnect With Door Interlock

Prevents the machine from being powered while the panel is open.
Required for: Safety, CE, UKCA, UL, OSHA compliance.

2. MCCB Sized to Site Fault Level

If the machine’s breaker cannot handle your factory’s available fault current, it may not trip during a fault — creating a fire risk.

Factories with strong 3-phase supply MUST request this.

3. Type 2 Surge Protector

Protects against:

• Lightning

• Grid instability

• Nearby welders/compressors

Stops VFDs and PLCs from burning out.

4. Phase-Loss / Phase-Sequence Relay

Prevents:

• Reverse motor rotation

• Motor overheating

• VFD faults

• Hydraulic pump damage

Essential for machines shipped internationally.

5. Separate Motor Breakers

Each motor (main drive, hydraulic pump, decoiler, etc.) must have its own breaker or motor-protective device.

Benefits:

• Better overload protection

• Easy fault isolation

• Safer maintenance

6. Protected 24VDC Control Supply

The heart of your machine.

Needs:

• Dedicated breaker

• Fused outputs

• Clean grounding

Prevents “mystery faults” like:

• Sensor flicker

• Encoder pulse loss

• PLC resets

7. RCD/GFCI for Service Outlet

Protects maintenance engineers using tools near the panel.

Often forgotten by OEMs.

8. Category 3/4 E-Stop Circuit With Safety Relay

Stops machine immediately and safely.
Dual-channel and monitored.

Prevents:

• Unsafe restart

• Guard bypassing

• False safety resets

Required by all major standards.

9. Safety Interlocks on Guards & Cabinet Door

Ensures machine cannot run unless:

• Guards are closed

• Panel door is locked

Reduces injury risk dramatically.

10. Proper Earth Bar & Frame Bonding

Correct grounding prevents:

• Electrical noise

• Encoder instability

• PLC glitches

• Electric shock hazards

Most imported machines do this incorrectly.

11. Updated Panel Drawings

If the drawings don’t match the build, maintenance becomes nearly impossible.

Technicians need:

• Updated schematics

• Terminal layout

• I/O list

• VFD/servo parameters

Machine Matcher provides these in every job.

When to Send This List

Send it to your supplier before the machine is built, ideally at the quote or design stage.
If buying used machines, send it to your electrician during refurbishment.

This ensures:

• Correct panel build

• Electrical compliance

• No surprise costs

• Fast troubleshooting

• Safer long-term operation

Machine Matcher CTA — Electrical Panel Review & Compliance Service

Machine Matcher provides:

• Full electrical panel inspection

• Compliance check (CE / UKCA / OSHA / UL)

• Safety relay & interlock testing

• Breaker & grounding verification

• Wiring quality audit

• Sensor & encoder evaluation

• VFD/PLC electrical assessment

• Rebuild or upgrade recommendations

• Written report and photos

• 24/7 global technical support

Send this checklist to your supplier — and let Machine Matcher make sure your machine is built safely, correctly, and ready for long-term high-speed production.

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]