By Dovydas Kersys · Chapter 47 of 58 in Machine Commissioning.
Before you begin: Follow the machine documentation, risk assessment, site procedures and lockout/tagout requirements. Commissioning can expose personnel to electrical energy, stored pressure and unexpected motion. Never defeat a safety function merely to make a test easier. Examples and diagrams are generic and must be checked against the actual machine.
Extended running reveals heat-related faults, loose connections, marginal sensors, network instability and timing drift that short tests miss.
Why this matters during commissioning
Many components change behavior as temperatures rise: VFDs, motors, cabinets, bearings, hydraulic oil and process sensors.
Commissioning procedure
- Run at representative production load for an agreed duration.
- Monitor cabinet temperature, motor current, drive temperature, fluid temperature and other critical values.
- Inspect for loosening, leaks, vibration or abnormal odor.
- Review alarm/event history for intermittent faults.
- Repeat performance checks after thermal stabilization.
Common failure patterns
- Panel cooling not sufficient with doors closed.
- Proximity sensor drifts when hot.
- Hydraulic oil heats and changes actuator speed.
- Motor current grows because mechanical alignment changes with temperature.
Evidence to record
- Measured value and test point
- Expected value / expected state
- Observed value / observed state
- Pass/fail result and any deviation
- Name/date or responsible person where required
FIELD RULE: A machine proven only while cold has not been proven for a production shift.
Continue the series
- Previous chapter: Rate and Performance Testing: Commissioning Guide
- Next chapter: Power-Loss and Recovery Testing: Commissioning Guide
- Browse all Machine Commissioning chapters
Adapted from Machine Commissioning for Maintenance and Automation Technicians, by Dovydas Kersys. © 2026 Dovydas Kersys. Featured cover image is an AI-generated editorial illustration.