Dry Runs and Single-Cycle Tests: Commissioning Guide

By Dovydas Kersys · Chapter 43 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.

Dry runs reduce risk by testing motion and sequence logic without product, process pressure, heat or other full production conditions when the machine design allows it.

Why this matters during commissioning

A dry run separates automation problems from product/process problems and makes observation easier.

Commissioning procedure

Define which utilities or process conditions can be safely omitted or simulated.
Run manual motions first.
Run single-cycle/step mode and watch each transition.
Confirm sensors are triggered by real mechanics or approved simulation.
Verify stop, pause and fault behavior.
Record cycle timing and abnormal noises/interference.

Common failure patterns

Simulation bits left enabled for production.
Dry run hides a product-presence interlock that later blocks automatic mode.
Mechanism clears when empty but collides with actual product.
Single-cycle mode bypasses timing used in automatic mode.

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: Dry-run success is a prerequisite for production testing, not proof of production readiness.

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