A conveyor that is switched on for the first time with a full load can damage the belt, the chain or the drive in seconds. The commissioning sequence exists to find problems while the energy is low.
Key takeaways
- Start with a visual and manual check, not with power.
- Run no-load before loaded, and low speed before full speed.
- Test the safety circuits before production.
- Record the baseline current, noise and temperature.
Step 1: visual and mechanical check
Check that all guards are fitted, all bolts are tight, all tools are removed and the conveyor path is clear. Check the belt or chain tension and the take-up position. Check that the drive is free to rotate by hand.
Confirm that the direction of rotation is correct. A conveyor that runs backwards on first start can damage a take-up or a transfer.
Step 2: manual rotation
Rotate the drive by hand or with a bar for at least one full revolution. Listen for rubbing, clicking or tight spots. Check that the belt or chain follows the pulleys or sprockets. If it does not, stop and correct before applying power.
Step 3: no-load run
Start the conveyor at low speed, with no load. Run for 10 minutes and check the tracking, the noise, the vibration and the motor current. Increase to full speed and run for 30 minutes. Check the bearing temperatures and the drive temperature.
Record the current at no load. It is the baseline for future maintenance; a rising no-load current indicates a bearing or alignment problem.
| Step | Duration | Check |
|---|---|---|
| Manual rotation | 1 revolution | Free rotation, no rubbing |
| No-load low speed | 10 min | Tracking, noise |
| No-load full speed | 30 min | Current, temperature |
| Safety test | — | E-stop, guards, interlocks |
| Loaded run | 2–4 h | Tracking, current, product |
| Performance | 1 shift | Rate, quality, uptime |
Step 4: safety tests
Test every emergency stop, every guard interlock and every safety sensor. The conveyor must stop within the specified time and must not restart until the fault is reset. Test the start warning and the audible alarm if fitted.
Record the test results. A safety test that is not recorded is a test that did not happen.
Step 5: loaded run
Load the conveyor gradually, starting with a few units and increasing to full load. Check the tracking, the current and the product position. Run for at least two hours, or one full shift for a critical line. Watch for product damage, jams and accumulation issues.
Check the drive current at full load and compare it with the design. A current that is 20% above the design indicates excessive friction, a wrong drive setting or a mechanical problem.
Step 6: performance verification
Run the line at the specified rate for one shift and record the output, the quality and the downtime. Compare with the design. If the line does not reach rate, identify the bottleneck before handing over. A line that is handed over below rate becomes a problem for the customer and the supplier.
Train the operators and the maintenance team during this step. The training should cover the start-up, the shutdown, the safety devices, the daily checks and the fault response.
Frequently asked questions
How long does commissioning take?
For a simple conveyor, one day. For a complete line, one to two weeks, including the loaded run and training.
What if the line does not reach rate?
Identify the bottleneck with a cycle-time study before changing the conveyor. The conveyor may not be the cause.
Should the customer sign off before the loaded run?
No. The acceptance should be after the loaded run and the performance verification, not after the no-load run.
For the electrical checks before commissioning, see our VFD settings guide. For the mechanical checks, see installation.
