Machine Start-Up Failures — Warranty Defect or Installation & Commissioning Error?

Initial installation (first power-on)

Few situations create more tension between buyer and supplier than this:

“The machine will not start.”

Start-up failures happen at one of three stages:

Initial installation (first power-on)
First production trial
After relocation or shutdown period

When a new roll forming machine fails to start, the immediate question becomes:

Is this a manufacturing defect?
Or an installation / commissioning issue?
Or an electrical supply problem?
Or an operator configuration error?

This guide explains:

The most common causes of start-up failures
How to diagnose them step-by-step
When warranty applies
When responsibility shifts to installation or site conditions
How to protect your warranty claim

What Is a “Start-Up Failure”?

A start-up failure can include:

Machine will not power on
PLC does not boot
Servo drives in alarm
Motor will not rotate
Hydraulic pump does not engage
Emergency stop fault remains active
Repeated electrical trips
Control system stuck in safety lock

It is critical to identify whether this is:

A complete electrical failure
A safety circuit issue
A configuration problem
A mechanical jam
Or genuine component defect

Most Common Causes of Start-Up Failure

1. Incorrect Electrical Supply

The #1 cause of start-up failure in new machines is incorrect power supply.

Common issues:

Wrong voltage (e.g., 380V supplied to 415V system)
Wrong frequency (50Hz vs 60Hz)
Phase imbalance
Incorrect phase rotation
Undersized breaker
No neutral where required

Symptoms:

PLC does not boot
Servo drive over/under-voltage alarm
Immediate breaker trip

In most cases, this is an installation issue — not manufacturing defect.

2. Emergency Stop or Safety Circuit Fault

Modern roll forming machines include:

E-stop loop
Guard door interlocks
Light curtains (if fitted)
Safety relays

If safety loop is not properly closed:

Machine will not enable
Drives remain disabled

Common causes:

Loose wiring
Miswired safety relay
Emergency stop engaged
Guard switch not aligned

Often mistaken for machine defect.

3. Incorrect PLC Configuration

During installation or shipping:

PLC may require reinitialization
Communication settings may need confirmation
Encoder reference may require reset

Improper configuration may prevent start-up.

If parameters were altered without authorization, warranty disputes arise.

4. Hydraulic System Not Primed

If hydraulic system:

Not filled correctly
Air not purged
Oil level low
Pump rotation incorrect

Hydraulic motor may:

Fail to engage
Overheat
Trigger pressure alarms

Incorrect pump rotation due to phase reversal is common.

5. Mechanical Jam Before First Run

During shipping:

Shafts may shift
Couplings may loosen
Debris may enter line
Rollers may contact if improperly secured

If mechanical resistance exists:

Motor may not rotate
Drive trips immediately

Mechanical inspection required before blaming electrical system.

6. Incorrect Motor Wiring

Incorrect motor wiring can cause:

Overcurrent trip
Reverse rotation
Inability to reach torque

This often occurs during site wiring — not factory build.

7. Low Voltage Under Load

Some facilities show correct voltage at idle — but drop under load.

Symptoms:

Machine powers on
Motor attempts to start
Voltage drops
Drive trips

Voltage drop can mimic motor defect.

When Start-Up Failure Is a Warranty Issue

Warranty likely applies if:

Internal wiring fault in control panel
Defective PLC or drive unit
Faulty transformer
Incorrect internal component specification
Factory wiring error
Internal short circuit

If electrical supply matches specification and failure originates inside panel, manufacturer responsibility increases.

When Warranty May Be Rejected

Warranty may be denied if:

Electrical supply incorrect
Machine improperly wired onsite
Safety system modified
PLC parameters altered
Generator power used without approval
Hydraulic oil not filled per manual

Most warranty agreements exclude damage from improper installation.

Structured Start-Up Failure Diagnosis Checklist

Before filing warranty claim, complete this structured review:

Step 1: Verify Electrical Supply

Measure:

Phase-to-phase voltage
Phase-to-ground voltage
Voltage under load
Frequency

Confirm matches machine specification exactly.

Step 2: Check Phase Rotation

Ensure correct motor direction before full load.

Step 3: Inspect Safety Loop

Confirm:

All E-stops reset
Guard switches aligned
Safety relay active
No loose safety wiring

Step 4: Check Hydraulic System

Confirm:

Oil filled to correct level
Pump primed
No air in system
Pressure set per manual

Step 5: Inspect Mechanical Freedom

Manually rotate shafts (if safe to do so) to ensure no binding.

Step 6: Review PLC Alarm Codes

Document exact alarm messages.

Never report “machine not working” without alarm code details.

Real Case Example

A new structural roll forming machine would not start.

Buyer claimed electrical panel defect.

Investigation revealed:

Facility supplying 360V instead of required 415V
Voltage dropped to 330V under load
Servo drive under-voltage fault

After correcting transformer supply, machine operated normally.

Warranty claim rejected.

Second case:

Roofing machine PLC failed to boot on first power-on.

Supply voltage confirmed correct.

Inspection revealed:

Internal 24V power supply defective from factory

Component replaced under warranty.

Machine operated normally.

Warranty claim approved.

Signs It Is Likely Installation Issue

Machine worked during factory test
Electrical alarms inconsistent
Multiple drives showing undervoltage
Breaker trips immediately
Problems started after relocation

These usually indicate site-related issue.

Signs It May Be Manufacturing Fault

Internal panel wiring incorrect
Same fault persists with verified power supply
Component failure inside sealed control cabinet
Factory test report inconsistent with delivered configuration

These may indicate supplier responsibility.

Protecting Yourself During Start-Up

Before first power-on:

Confirm voltage & frequency in writing
Hire qualified industrial electrician
Verify grounding & phase balance
Follow commissioning procedure strictly
Document all readings
Keep factory test video and reports

Proper documentation protects warranty rights.

Frequently Asked Questions

Is start-up failure usually a manufacturing defect?

No. Most cases are electrical supply or installation issues.

Can incorrect voltage prevent machine from starting?

Yes — and may damage drives if not corrected.

Should machine be tested before shipment?

Yes. Always request factory acceptance test (FAT) documentation.

Does using a generator affect start-up?

Yes. Unstable generator power can prevent drives from enabling.

Who is responsible for site wiring?

Typically the buyer unless installation is included in contract.

What is the most common start-up mistake?

Incorrect phase rotation and undervoltage supply.

Final Conclusion

Machine start-up failures are stressful — but they are rarely random.

Most start-up problems are caused by:

Incorrect electrical supply
Safety circuit configuration
Hydraulic setup errors
Improper installation
Parameter misconfiguration

True manufacturing defects do occur — but they must be proven through structured diagnosis.

Without documented electrical verification, warranty claims are difficult to defend.

With proper installation records and alarm logs, responsibility becomes clear.