Site Acceptance Test (SAT) Checklist for Roll Forming Machines — Commissioning Procedures and Logs

Introduction — What Site Acceptance Testing (SAT) Is

A Site Acceptance Test (SAT) is the final verification stage of a roll forming machine after it has been installed at the customer’s factory.

While a Factory Acceptance Test (FAT) verifies that the machine works at the manufacturer’s facility, SAT confirms that the machine operates correctly in the real production environment.

SAT verifies several key areas:

• installation quality
• electrical and mechanical connections
• PLC control performance
• safety systems
• production accuracy.

This stage is critical because many issues only appear once the machine is installed at the final production location.

Objectives of a Roll Forming SAT

The main objectives of SAT are to confirm that:

• the machine was installed correctly
• the PLC and HMI operate correctly in the plant network
• mechanical systems function under real load conditions
• production quality meets specification.

Successful SAT completion means the machine is ready for normal production.

Preparing for Site Acceptance Testing

Before performing SAT, several preparation steps must be completed.

Important preparation tasks include:

• machine installation completed
• electrical power connected
• compressed air and hydraulics available
• network communication established
• safety systems installed.

Engineers should also confirm that all FAT documentation is available.

SAT Documentation

SAT should be documented carefully.

Typical records include:

• installation inspection results
• commissioning notes
• PLC test logs
• production test results.

These documents confirm that the machine meets contractual performance requirements.

Visual Installation Inspection

The first SAT step is a physical inspection of the machine installation.

Technicians should verify:

• machine frame alignment
• anchor bolts secured
• forming stands correctly positioned
• shear assembly installed correctly
• stacker alignment.

Mechanical misalignment can affect product quality and machine reliability.

Electrical Installation Verification

Electrical systems must be inspected before powering the machine.

Checks include:

• proper grounding connections
• correct voltage supply
• control cabinet wiring
• motor connections
• sensor wiring.

Incorrect electrical installation can cause immediate equipment damage.

Control Cabinet Inspection

The electrical control cabinet should be inspected carefully.

Important checks include:

• PLC modules correctly installed
• communication cables connected
• cabinet cooling systems operational
• wiring properly labeled.

Clean cabinet installation helps prevent electrical noise problems.

Power System Testing

Before operating the machine, engineers should test the power system.

Typical tests include:

• verifying main power voltage
• testing control power supplies
• confirming correct phase rotation.

Incorrect phase rotation can cause motors to run in reverse direction.

PLC Communication Verification

After powering the system, the PLC communication network should be tested.

Checks include:

• PLC communication with HMI
• PLC communication with drives
• PLC communication with remote systems.

Reliable communication is essential for machine operation.

HMI Operation Testing

The operator interface should be tested to ensure correct operation.

Typical tests include:

• start and stop commands
• recipe entry and selection
• alarm display and reset
• production counters.

Operators must be able to control the machine easily.

Safety System Verification

Safety systems must be verified before running production material.

Typical tests include:

• emergency stop activation
• guard door switches
• safety relay functionality
• safety light curtain operation if installed.

The machine must stop immediately when safety devices activate.

Hydraulic System Testing

Hydraulic systems power many roll forming components such as shears and punches.

Important checks include:

• hydraulic pressure levels
• oil temperature
• pump operation
• valve response.

Leaks or pressure instability must be corrected before production.

Pneumatic System Verification

Machines using pneumatic actuators require compressed air systems.

Tests include:

• air pressure stability
• valve operation
• cylinder movement.

Proper pneumatic operation ensures reliable machine functions.

Sensor Verification

Sensors must operate correctly under real production conditions.

Typical sensors include:

• proximity sensors
• photoelectric sensors
• encoder systems
• limit switches.

Engineers should verify that each sensor provides reliable signals.

Encoder Calibration

Encoders measure strip movement and determine panel length.

SAT tests include:

• verifying encoder pulse signals
• confirming direction detection
• verifying scaling factors.

Incorrect encoder calibration will cause inaccurate panel lengths.

Line Speed Testing

The roll forming line must operate at the specified production speed.

Engineers should gradually increase line speed while monitoring:

• motor load
• vibration levels
• encoder accuracy.

This confirms stable machine operation.

Punch System Verification

If the machine includes punching operations, engineers must test:

• punch timing accuracy
• punch tool alignment
• safety interlocks.

Accurate punching is critical for product quality.

Shear Cutting Verification

The cutting system must produce accurate panel lengths.

Tests include:

• verifying cut timing
• measuring panel length
• checking blade alignment.

Multiple panels should be measured to confirm repeatability.

Stacker Operation Testing

The stacker system must handle panels without causing jams.

Typical tests include:

• panel detection sensors
• panel counting accuracy
• bundle drop sequence.

The stacker should operate smoothly at full production speed.

Alarm System Testing

The alarm system should be tested by simulating fault conditions.

Typical alarms include:

• hydraulic pressure low
• encoder failure
• stacker jam
• drive faults.

Alarms must display correctly on the HMI.

Fault Recovery Testing

After a fault occurs, operators must be able to recover the machine safely.

Typical recovery tests include:

• resetting alarms
• restarting production
• verifying system stability.

The machine should return to operation without requiring complex procedures.

Production Trial Runs

Once the system passes functional tests, production trials should begin.

Engineers should run several production cycles and monitor:

• product quality
• panel length accuracy
• punching accuracy
• stacker operation.

This confirms the machine is ready for production.

Operator Training

SAT often includes training for the customer’s operators and maintenance staff.

Training topics may include:

• HMI operation
• alarm handling
• routine maintenance.

Proper training helps prevent operational errors.

Commissioning Logs

During SAT, engineers should record detailed commissioning logs.

Typical log entries include:

• date and time of tests
• machine settings
• observed issues
• corrective actions.

These records help track machine performance.

Final SAT Approval

After testing is complete, both the machine supplier and the customer review the results.

SAT approval typically includes:

• signed acceptance documents
• confirmation that machine specifications are met.

Once approved, the machine enters normal production.

Benefits of a Thorough SAT

A detailed SAT provides several advantages.

These include:

• reliable machine startup
• early detection of installation issues
• improved product quality
• reduced downtime during early production.

SAT ensures that the machine performs correctly in the real operating environment.

FAQ — Site Acceptance Testing

What is the difference between FAT and SAT?

FAT occurs at the manufacturer’s facility, while SAT takes place after the machine is installed at the customer’s factory.

Why is SAT necessary?

Some issues only appear after installation in the real production environment.

What systems are tested during SAT?

Mechanical systems, PLC controls, safety systems, sensors, drives, and production performance.

Who participates in SAT?

Typically the machine supplier, customer engineers, and commissioning technicians.

How long does SAT usually take?

SAT duration depends on machine complexity but may take several days.

What happens after SAT approval?

The machine is officially accepted and enters normal production operation.