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

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:

1. Initial installation (first power-on)

2. First production trial

3. 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:

1. Confirm voltage & frequency in writing

2. Hire qualified industrial electrician

3. Verify grounding & phase balance

4. Follow commissioning procedure strictly

5. Document all readings

6. 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.